Transcript Diapositiva 1 - Power Generatio

Conference on Clean Coal and Carbon
Capture and Storage Technologies
2nd and 3rd December, 2013 at Trichy (India)
IGCC: Towards zero emissions power plants
Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain
1
Index
1. The ELCOGAS company
2. Puertollano IGCC power plant
3. Future of IGCC technology
4. ELCOGAS R&D investment plan
5. Conclusions
2
Index
1. The ELCOGAS company
2. Puertollano IGCC power plant
3. Future of IGCC technology
4. ELCOGAS R&D investment plan
5. Conclusions
3
The ELCOGAS company
ELCOGAS is an Spanish
company established in April
1992 to undertake the planning,
construction, management and
operation of a 335 MWeISO IGCC
plant located in Puertollano
(Spain)
Hidrocantábrico
Explotación de
Centrales SAU
4,32%
Siemens Project
Ventures GmbH
2,53%
Enel, SpA
4,32%
Krupp Koppers
GmbH
0,04%
Hidroeléctrica del
Cantábrico, S.A.
4,32%
Endesa
Generación, S.A.
40,99%
Iberdrola
Generación, S.A.
12,00%
Shareholders
Electricité de
France
International, S.A.
31,48%
Puertollano
Puertollano IGCC Plant
REPSOL refinery
ENCASUR (open cast coal mine)
4
Index
1. The ELCOGAS company
2. Puertollano IGCC power plant
3. Future of IGCC technology
4. ELCOGAS R&D investment plan
5. Conclusions
5
Description of the Puertollano IGCC process
Flue gas to stack
Combined
cycle
Steam
Heat Recovery
Steam
Generator
G
STEAM TURBINE
135MWISO
HP Steam
Gasification
Coal
MP Steam
PetCoke
Limestone
Condenser
Hot combustion gas
Cooling tower
HP Boiler
Coal
preparation
MP Boiler
Coal - N2
Gasifier
Raw Gas
Filtration
Water
to treatment
Quench Gas
Air
N2
O2
Slag
Sulfur
removal
Water
wash
O2
Tail
Gas
Claus Gas
Clean
Syngas
G
GAS TURBINE
200 MWISO
Sulfur recovery
Fly ash
Sulfur
(recovery of 99.8%)
ASU
Air Separation Unit
Waste N2
Compressed air
6
General view of the Puertollano IGCC plant
Air separation unit
Gasifier
Fuel
preparation
Laboratory and
water treatment
Clean-up of
gas
Combined
cycle
CO2 capture
7
Description of the Puertollano IGCC process
Fuel design values
Fuel design is a mixture 50/50 of coal/coke which now is 45/55. Moreover some tests with
biomass were undertaken (meat bone meal, grape seed meal, olive oil waste).
Moisture (%w)
Ash (%w)
C (%w)
H (%w)
N (%w)
O (%w)
S (%w)
LHV (MJ/kg)
COAL
PET COKE
FUEL MIX
(50:50)
11.8
41.10
36.27
2.48
0.81
6.62
0.93
13.10
7.00
0.26
82.21
3.11
1.90
0.02
5.50
31.99
9.40
20.68
59.21
2.80
1.36
3.32
3.21
22.55
With those fuels at 50:50, the whole plant
demonstrated a gross efficiency of 47.2%
and a net efficiency of 42%, under
acceptance tests in 2000 year
Syngas composition
RAW GAS
CLEAN GAS
Real average
Design
CO (%)
59.26
61.25
CO (%)
59.30
60.51
H2 (%)
21.44
22.33
H2 (%)
21.95
22.08
CO2 (%)
2.84
3.70
CO2 (%)
2.41
3.87
N2 (%)
13.32
10.50
N2 (%)
14.76
12.5
Ar (%)
0.90
1.02
Ar (%)
1.18
1.03
H2S (%)
0.81
1.01
H2S (ppmv)
3
6
COS (%)
0.19
0.17
COS (ppmv)
9
6
23
38
HCN (ppmv)
-
3
HCN (ppmv)
Real average
Design
8
Operational data: Annual energy production
IGCC, NGCC and Total yearly production
2.500
NGCC GWh
IGCC GWh
265
1,417
251
259
1.130
1,623
327
312
1.150
1,389
1,698
263
1,489
277
1,462
421
452
1.293
1,550
1.129
301
1,171
1,803
1,744
622
GWh
1.500
1,672
1.371
1,533
321
1,712
343
1,938
2.000
0
1.166
1.358
1.435
1.527
1.162
1.595
1.391
911
9
335
500
743
752
836
1.000
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
year
1st 5 years: Learning curve
2003: Major overhaul Gas Turbine findings
2004 & 2005: Gas turbine main generation transformer isolation fault
2006: Gas turbine major overhaul & candle fly ash filters crisis
2007 & 2008: ASU WN2 compressor coupling fault and repair MAN TURBO
2010: No operation due to non-profitable electricity price (30-40 days).
2011: 100,000 EOH Major Overhaul
2012: 1,498 hours in stand-by due to regulatory restrictions. (3,969 in 2013)
9
Operational data: Emissions 2012
Natural gas (mg/Nm 3 at 6% O2 dry)
EEC 88/609
EU Directive 2001/80/EEC
ELCOGAS Environmental Permit
EU Directive 2010/75/EU DEI
ELCOGAS 2012 average
350
292
300
Natural gas (NGCC)
250 250
250
200
155,3
150
125
100
50
29
29
13
0
SO2
NI
4
6,7
NOx
4
4
NI 0,4
Particles
Coal gas (mg/Nm 3 at 6% O2 dry)
700
650
EU Directive 88/609/EEC
EU Directive 2001/80/EEC
ELCOGAS Environmental Permit
EU Directive 2010/75/EEC
ELCOGAS 2012 average
600
Coal gas (IGCC)
500
500
400
400
300
300
200
200
200 200
111
100
50
20
5
20
0
SO2
NOx
ELCOGAS power plant emissions in NGCC & IGCC modes
0,4
Particles
10
Operational data: Variable costs 2012
Fuel mode
Fuel
Consume
(GJP C S)
Production
(GWh)
Heat rate
(GJP C S/GWh)
Fuel cost
(€/GJP C S)
GT
Natural gas
59.987
2,891
20.748
10,46
216,98
216,98
NGCC
Natural gas
249.495
22,154
11.262
10,46
117,77
117,77
NGCC + ASU
Natural gas
1.854.675
155,148
11.954
10,46
125,01
125,01
Natural gas
351.147
10.522
10,46
110,03
Coal
67.459
2.021
3,49
7,05
Petocke
195.947
5.871
1,98
11,61
NG auxiliar
consumption
257.700
260
10,46
2,71
Coal
2.536.891
2.555
3,49
8,91
Petocke
7.368.734
7.422
1,98
14,67
NGCC+ASU+
Gasifier
(by flare)
IGCC
33,373
992,811
Partial cost Total cost
(€/MWh)
(€/MWh)
128,69
26,30
Note: Net energy variable costs (average 2012)
11
Index
1. The ELCOGAS company
2. Puertollano IGCC power plant
3. Future of IGCC technology
4. ELCOGAS R&D investment plan
5. Conclusions
12
Future of IGCC technology
•
•
•
Multi-fuel (coal, biomass, wastes)
Multi-product (H2, electricity, liquid fuels, chemicals)
CO2 capture and storage
COAL + BIOMASS + WASTES
COMBINED
CYCLE
GASIFICATION
GAS
XtL
CLEAN UP
Alternative Fuel &
Chemicals
Potential demonstrating of
new process with synthesis
gas partial flow.
CO + H2O
CO2 + H2
H2/CO2 SEPARATION
H2
CO2
Future of IGCC technology
H2 Production by coal gasification
GASIFICATION
SECONDARY
PRODUCTION H2:
WATER-GAS
REACTION
PREPARATION
CO2 CAPTURE &
H2PURIFICATION
PROCESS
CO2
H2
Step 1: Syngas production from Gasification
Carbon compound + O2 + H2O
400-1600ºC
10-40 bar
CO + H2 + Impurities
Step 2:Conditioning fly ash removal, particles and sulphur comp.
 Fly ash
Step 3: “Shifting” or water-gas reaction
CO + H2O
 Char
CO2 + H2
 Cl CN-
Step 4: H2 and CO2 separation
H2
&
CO2
H2 production from fossil fuels involves CO2
generation  To talk about “clean” H2 it is required
to consider CCS
 SH2
 COS
 CO2
 N2 …
Index
1. The ELCOGAS company
2. Puertollano IGCC power plant
3. Future of IGCC technology
4. ELCOGAS R&D investment plan
5. Conclusions
15
ELCOGAS R&D investment plan
PUERTOLLANO IGCC ACTIVITIES:
 Based on the opportunity that an IGCC plant represents
 Can be relevant in:
•
climate change mitigation
•
energy supply reliability
In 2007 a R&D investment plan was elaborated and results are yearly reported to
Spanish authorities for evaluation. Its 6 master research lines are:
CO2 emission
reduction in
utilization of
fossil fuels
H2 production
by
gasification
of fossil fuels
Diversification
of raw fuels
and products
Other
environment
improvements
IGCC
process
optimization
Dissemination
of
results
ELCOGAS R&D investment plan
Dissemination of results
• Forum participations. CO2, H2, and sustainability associations and Technological Platforms.
European and Spanish. Coordinating working groups in Technological Spanish Platforms.
• Participation in conferences, seminars, congresses.
• Consulting services. Germany, China, Chile
• Attending and promoting technical visits. Generally international visits.
ELCOGAS R&D investment plan
Optimization of IGCC process
Oriented to improve availability & costs
Elimination of membrane
water leakages at reaction
chamber
Test materials
Ceramic filters
Gasifier materials/Syngas corrosion
processes
ELCOGAS R&D investment plan
Other environmental improvements
• Liquid wastes reduction (Zero Liquid Discharges).
Installation of a new liquid waste treatment plant
(evaporation – crystallization).
•Improvements in the dry dedusting system.
Overview of the new ZLD plant
•Improvements in Sulphur Recovery plant.
In progress several modifications to improve availability
and to reduce S emissions.
•Optimization of additives parameters.
Internal research for improve the quality of subproducts
•Emissions reduction during start up and other
transitory situations.
Overview of the test rig for mercury
and carbonyls analysis
ELCOGAS R&D investment plan
Diversification of raw fuels and products
•Project FECUNDUS (RFCS-CT-2010-00009, 2010-2013)
Selection of biomass and undertake real co-gasification test (2
and 4 % in weight of biomass) for asset its influence in CO2
capture process.
•Project PIIBE (ESP-CENIT).
To impulse biofuels technologies in Spain. ELCOGAS has
coordinated the subproject about biodiesel from gasification by
real co-gasification 10% of biomass and syngas characterization
(F-T process in laboratory).
Pre-selected
biomasses
•Meat and Bone Meal (MBM) co-gasification test (2001)
•Possibility to install a pilot plant in IGCC of Puertollano to
develop process to obtain gasoline / diesel from syngas
•Availability to undertake tests of gasification of different fuels at
large scale to help in design of new IGCC plants
Biomass yard
ELCOGAS R&D investment plan
Diversification of raw fuels and products
Biomass selection criteria:
Critical parameter for biomass
selection was the behavior on
the ELCOGAS grinding system
Size
< 25 mm
Humidity < 12 %
Price
< 150 €/t
Availability in large quantities
LOAD DURING 8% ORUJILLO CO-GASIFICATION TEST
gasifer load (%)
100
90
15
40
1 -2 %
1,572.8
800.3
30
4%
652.1
154
6%
395.8
64.4
8%
383.9
46
10%
656.6
62
Oil olive
waste
(Orujillo)
2%
218.1
106
4%
409.3
153.5
Grape
Seed
Meal
2%
179.3
127
4%
425.7
119.5
TOTAL
4,986.9
1,647.7
Oct - Nov 2012
Oct. 2012
Nov - Dec 2012
20
40.000
% Orujillo
10
20.000
20/06/2009 16:48
20/06/2009 7:12
Load during 8% olive oil waste
co-gasification test
20/06/2009 12:00
20/06/2009 2:24
19/06/2009 21:36
19/06/2009 16:48
19/06/2009 7:12
19/06/2009 12:00
19/06/2009 2:24
18/06/2009 21:36
18/06/2009 16:48
18/06/2009 7:12
18/06/2009 12:00
18/06/2009 2:24
17/06/2009 21:36
17/06/2009 16:48
17/06/2009 7:12
17/06/2009 12:00
17/06/2009 2:24
16/06/2009 21:36
16/06/2009 16:48
16/06/2009 7:12
16/06/2009 12:00
16/06/2009 2:24
15/06/2009 21:36
15/06/2009 16:48
0
15/06/2009 7:12
0
15/06/2009 12:00
Nov - Dec 2011
60.000
H2 clean gas (%)
15/06/2009 2:24
Sept. 2009
100.000
80.000
14/06/2009 21:36
Jun. 2009
CO clean gas (%)
14/06/2009 16:48
Mar. 2009
120.000
50
93.3
Oil olive
waste
(Orujillo)
140.000
60
1%-4,5%
2007- 2009
2008
70
14/06/2009 7:12
2001
Meat
Bone &
Meal
Biomass
(t)
160.000
clean gas flow (%)
14/06/2009 12:00
Biomass
type
80
Test
Duration
(h)
%
Test
Month/Year
180.000
Nm3/h
Battery of Biomass co-gasification tests
Biomass
dosage
ratio (%wt)
200.000
ELCOGAS R&D investment plan
H2 production and CO2 emission reduction
Clean H2 production by gasification of fuels

Collaboration in several projects (HYDROSEP (UE-RFCS) and SPHERA (ESPCENIT)

H2 production optimization using the CO2-H2 Pilot Plant

Possibility to collaborate with The National Center for Hydrogen “CNH2”
(SPAIN)
CO2 Emission reduction
IGCC Efficiency Optimization
•
Analysis of viability to improve efficiency based on Critical Assessment of
Puertollano IGCC design.
•
Auxiliary consumption optimization. New revision
•
Development of tools to improve efficiency. Supervision on line of main (120)
equipment efficiency. Installed and in tests
•
Integration optimization. Improvement of controls to adjust heat & mass
balances in real operation
And
CO2 capture for CCS with IGCC
ELCOGAS R&D investment plan – Line CO2
PSE-CO2 project
TARGETS
To demonstrate the feasibility of capture of CO2 and production of H2 in an
IGCC that uses solid fossil fuels and wastes as main feedstock.
To obtain economic data enough to scale it to the full Puertollano IGCC
capacity in synthetic gas production.
PARTICIPANTS & BUDGET
ELCOGAS – UCLM – Ciemat – INCAR CSIC
14.5 M€ (initially 18.5 M€)
COORDINATED
Project of pilot plant in an existing IGCC of Puertollano (pre-combustion technology) is part
of a Spanish national initiative, “Advanced technologies of CO2 conversion, capture
and storage” and it is coordinated with other related projects:
Project # 2 is to explore oxyfuel combustion to be applied in the construction of a pilot plant
(20-30 MW) to be built in El Bierzo, NW of Spain. CIUDEN
Project # 3 is to study and regulate geological storage in Spain. IGME
Project # 4 is to study public awareness of CCS technologies. CIEMAT
23
ELCOGAS R&D investment plan – Line CO2
Puertollano IGCC power plant and pilot plant location
PRENFLO Gasifier
Coal
preparation
New CO2
capture pilot
plant
ASU
Sulphur
Recovery
Combined
Cycle
CO2 capture & H2 production
Pilot plant
Recycle compressor
COAL + COKE
GASIFICATION
Raw
gas
Syngas
FILTRATION
SYSTEM
COMBINED
CYCLE
PURIFICATION
&
DESULPHURATION
2%
2%
H2 rich gas
SWEET
SOUR
Flow
(Nm3/h)
3,610
4,006
P
(bar)
19.8
23.6
T (ºC)
126
138
% CO2
60.45
53.72
% H2
21.95
19.57
% H2O
0.29
10.40
% H2S
0
0.70
Pure H2 (2 t/d)
% COS
0
0.11
99.99% H2 @ 15 bar
37.5 % CO2
50.0 % H2
3.0 % CO
CO2 +H2S (1.44%)
100 t/d
Raw H2 (80% of purity)
IP STEAM
SHIFTING REACTORS
SWEET /SOUR
CO + H2O → CO2 + H2
CO2 & H2
separation
(Chemical, aMDEA)
40%
HYDROGEN
PURIFICATION
(PSA)
Tail gas
1.3 bar
25
CO2 capture & H2 production
Pilot plant
 Installation unique in the world: 14 MWt precombustion technology integrated in an existing
IGCC.
PSA adsorbers
CO2 absorber
 3 step process: shifting unit, CO2/H2 separation
by chemical absorption, and H2 purification by
PSA. All technology used is commercial.
 100 t/d of CO2 are captured and 2 t/d of pure
H2 are produced
Control room
CO2 stripper
 In service since October 2010. Operation is
intermittent, linked to official Research projects,
collaborations and internal research
campaigns.
 1,017 hours of operation accumulated.
 Cost of construction (equipment & services):
13.5 Million €
WGS reactors
Consejería de Educación, Ciencia y
Cultura
 No storage is foreseen
26
CO2 capture & H2 production
Conclusions
1) The carbon capture pilot Project has been a success: first of its kind in the
world, >90% capture rate achieved and CO2 capture cost can be <30 €/t
2) Commercial technology at any scale is available: the singularity comes
from “integration in a existing IGCC plant”
3) Tests carried out show room for improvement in operating conditions and
optimization of energy balance.
4) Carbon capture cost estimations come from figures of a real project.
5) From now on, the pilot is being used for internal research
6) But it is also open for international research projects and for other kinds of
collaboration
CO2 capture & H2 production
Results and learning
CO2 capture in IGCC plants
 With SWEET catalyst
Fuel
preparation
Filtration
and wet
scrubbing
Gasification
 With SOUR catalyst
Fuel
preparation
Desulphurization
and sulphur
recovery
Unit of CO2
capture
S
Filtration
and wet
scrubbing
Gasification
Combined
cycle
CO2
Unit of CO2
capture
Combined
cycle
CO2 + H2S (1.5%)
Based on our CO2 capture pilot plant, we have scaled the cost of a CO2 capture unit at
scale 1:1 about 350 M€. Approximately, it represents the cost of the desulphurization and
sulphur recovery units in an IGCC w/o CO2 capture.
By installing an IGCC with CO2 acid capture to store or use CO2 together with ~1.5% H2S,
the investment costs are similar to those w/o CO2 capture. And the only penalty is the
decreasing efficiency:
From 42
and from 50
33% currently
44% near future
28
Index
1. The ELCOGAS company
2. Puertollano IGCC power plant
3. Future of IGCC technology
4. ELCOGAS R&D investment plan
5. Conclusions
29
Conclusions
IPCC  Unless greenhouse gas
emissions are cut by 50-80% by 2050
(especially CO2), the impact of global
warming can be disastrous.
World energy demand  Expect
to be doubled by 2050.
We must act fast using a
portfolio of solutions
(energy efficiency
improvement, renewables
& CCS) to reduce CO2
emissions in the required
massive scale
IGCC technology can contribute to this aim because:
 Existing
IGCC plants are an opportunity to develop cleaner electricity with
fossil fuels, so next IGCC generation must learn from them
 IGCC
is a promising technology with the minimum variable costs and the
best environmental performance and it can be adapted to multifuel and
polygeneration
 Main burden for IGCC technology deployment is high investment requires a
long term regulatory frame
30
Conference on Clean Coal and Carbon
Capture and Storage Technologies
2nd and 3rd December, 2013 at Trichy (India)
IGCC: Towards zero emissions power plants
Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain
THANK YOU FOR YOUR ATTENTION
31