First Year of Operational Experience with the Negishi IGCC

Transcription

1 First Year of Operational Experience with the Negishi IGCC Gasification Technologies 2004 October 3-6, 2004 JW Marriott Hotel Washington, DC Makoto Yamaguchi Group Manager IPP Group Negishi Refinery Nippon Petroleum Refining Company, LTD.

2 NOC/NPRC Your Choice of Energy Comprehensive Energy Supply System LPG Refining Lubricant oil Electric power Petrochemical Coal LNG New energy

3 Contents 1. Introduction 2. Outline of Negishi IGCC 3. Commissioning 4. Commercial Operation 5. Conclusions

4 1.Introduction(1) Profile of NOC Group Total 1,217kBPSD = 25% of domestic capacity Osaka Marifu Mizushima Toyama Kainan Muroran Sendai Yokohama Negishi 340kBPSD

5 1.Introduction(1) Negishi is Located in Yokohama City 30km Distance from Tokyo Metropolis Negishi 340kBPSD

6 1.Introduction(2) Background Why did NOC enter the IPP Business? (IPP = Independent Power Producer) Why did NOC adopted the IGCC?

7 1.Introduction(2) Background Why did NOC enter the IPP Business? Changes of Oil Demand Structure Deregulation of Electric Power Market

8 1.Introduction(2) Background Why did NOC enter the IPP Business? Changes of Oil Demand Structure - Heavy Oil Demand Decreasing Light Oil Demand Increasing Imbalance between Supply and Demand Imported Crude Oil Heavier - NOC has adopted Bottom Upgrading Plants - What s Next?

9 1.Introduction(2) Background Why did NOC enter the IPP Business? Changes of Oil Demand Structure Deregulation of Electric Power Market In 1995, Electricity Power Industry Law was Revised. Any Company was Allowed to enter the IPP business.

10 1.Introduction(2) Background Why did NOC enter the IPP Business? Changes of Oil Demand Structure Deregulation of Electric Power Market Utilizing Surplus Heavy Oil New Source of Income Taking Advantage of Existing Infrastructure and Expertise on Power Plants

11 1.Introduction(2) Background Why did NOC adopted the IGCC? Strict Environment Regulations City Government has not Allowed to Combust the Fuel Heavier than Jet or Kerosene Higher Efficiency

12 2.Outline of Negishi IGCC Process Block Diagram VR CEU Gasifier Scrubber LTGC Black Water Gray Water NH3 Water O2 Pre-WWT ASU COS/ HCN WWT Steam N2 Syngas NH3 Scrubber SWS Sea Stack HRSG GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

13 2.Outline of Negishi IGCC Process Block Diagram VR CEU Gasifier Scrubber LTGC Black Water Gray Water NH3 Water O2 Pre-WWT ASU COS/ HCN WWT Steam N2 Syngas NH3 Scrubber SWS Sea Stack HRSG GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

14 2.Outline of Negishi IGCC Process Block Diagram VR CEU Gasifier Scrubber LTGC Black Water Gray Water NH3 Water O2 Pre-WWT ASU COS/ HCN WWT Steam N2 Syngas NH3 Scrubber SWS Sea Stack HRSG GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

15 2.Outline of Negishi IGCC Process Block Diagram VR CEU Gasifier Scrubber LTGC Black Water Gray Water NH3 Water O2 Pre-WWT ASU COS/ HCN WWT Steam N2 Syngas NH3 Scrubber SWS Sea Stack HRSG GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

16 2.Outline of Negishi IGCC Process Block Diagram VR CEU Gasifier Scrubber LTGC Black Water Gray Water NH3 Water O2 Pre-WWT ASU COS/ HCN WWT Steam N2 Syngas NH3 Scrubber SWS Sea Stack HRSG GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

17 2.Outline of Negishi IGCC Process Block Diagram VR CEU Gasifier Scrubber LTGC Black Water Gray Water NH3 Water O2 Pre-WWT ASU COS/ HCN WWT Steam N2 Syngas NH3 Scrubber SWS Sea Stack HRSG GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

18 2.Outline of Negishi IGCC Process Block Diagram VR Gasifier Scrubber LTGC ASU COS/ HCN Scrubber CEU Pre-WWT SWS NH3 Water O2 WWT Steam N2 Stack HRSG All Single Train Syngas No cushion Volume Tanks or No Gas HoldersNH3 Black Water Gray Water Sea GT ST G AGR AGE SRU TGT TEPCO Stack Incinerator Sulfur

19 3.Commissioning(1) Schedule Oct Nov Dec Jan Feb Mar Apr May Jun CCU ASU SRU Gasification IGCC Kerosene External Acid Gas First Syngas Production ; Feb.6 First Syngas to GT ; Mar.3 Commercial Operation Start ; Jun.30

20 3.Commissioning(1) Schedule 9 Months Oct Nov Dec Jan Feb Mar Apr May Jun CCU ASU SRU Gasification IGCC Kerosene External Acid Gas First Syngas Production ; Feb.6 First Syngas to GT ; Mar.3 Commercial Operation Start ; Jun.30

21 3.Commissioning(2) Performance and Topics(1) Process Specifications were Achieved CCU (Combined Cycle Unit) 431 MW (gross) 342 MW (net) Gasification (Asphalt=) 2,000 MTPD SRU (Sulfur Recovery Unit) 130 MTPD ASU (Air Separation Unit) (O2 Production=) 2,300 MTPD

22 3.Commissioning(2) Performance and Topics(2) Environment Requirements were Achieved O2 NOx SOx Particulate CCU 16% <2.6ppm <2.0ppm <1.4mg/Nm3 SRU 8% <20ppm <90ppm <6.7mg/Nm3 WWT (to Sea) COD T-N SS (Waste Water Treatment) 8mg/L 5mg/L 10mg/L

23 3.Commissioning(2) Very Close to Residential Area N IGCC Flare Stack IGCC Area Railway & Highway Negishi Refinery Residential Area

24 3.Commissioning(2) Very Close to Residential Area Flaring - Advance Notice to Nearby Residents Unpleasant Noise - Added Laggings and Sound Insulation Walls - Improved ASU Blow Silencer - Added Roofs to ASU Compressor Houses

25 3.Commissioning(2) Performance and Topics(3) Auto Control Systems were Satisfied - Daily Operation include Load Change with No Flaring - Gas Turbine Fuel Switch - Stabilizing Frequency Variation - Shut-down System

26 3.Commissioning(2) Performance and Topics(3) Operational Pattern Power Supply 342MW Daytime on Weekdays Nighttime & Holidays 262MW 80MW/30min. 6:30 7:00 23:00 23:30

27 3.Commissioning(2) Performance and Topics(3) Daily Load Change with No Flaring 80MW Syngas Flow Rate Net Power Syngas Pressure 25min. 0.1MPa

28 4.Commercial Operation(1) Frequency Disturbance Influence By 1,116MW Power Plant Trip at 3:11 Jul.9, 2004 Frequency 50Hz 71.3MW 0.48Hz 361.7MW Power (Gross) 290.4MW Flaring beyond 3.35MPa 0.35MPa Syngas Pressure 3.20MPa min.

29 4.Commercial Operation(2) Availability (% of Year) (Jun ~Jun ) Planned Outage Unplanned Outage Forced Outage Rate Availability (=On-Stream) Gasification 14.7% Power 13.3% Gasifier Continuous Operation ; Max. 94 days (Scheduled Feed Injector Replacement)

30 4.Commercial Operation(2) Unplanned Outage Details (% of Year) ASU Main Air Compressor Trouble ASU Other Troubles Gasifier Feed Injector Replacements Gasification Other Trouble CCU Troubles Gasification Unplanned Outage Total 9.9% %

31 4.Commercial Operation(3) ASU Main Air Compressor Trouble Third Stage Impeller was Cracked

32 4.Commercial Operation(4) Remained Issues Feed Injector - Middle Tip Fusion - Verification of New Type FI Life Amine (MDEA) Formic Acid Formation - Unexpected Formation in AGE - Formation Speed is Higher than Expected

33 5.Conclusions On-Schedule Commercial Operation Achieved High Performance and Controllability Continue to Improve Operability and Availability Continue to Make Efforts to Resolve Remained Issues