ISAB ENERGY IGCC NEW HYDROGEN PLANT. Gasification Technologies Council Conference San Francisco, CA - October 2007

Transcription

1 / ISAB ENERGY IGCC NEW HYDROGEN PLANT Gasification Technologies Council Conference San Francisco, CA - October 2007

2 ISAB ENERGY IGCC NEW HYDROGEN PLANT Authors: Gianluca Rospo (ISAB Energy) Rosa Maria Domenichini (Foster Wheeler Italiana) Silvio Arienti (Foster Wheeler Italiana) Paolo Cotone (Foster Wheeler Italiana) Presented by Rosa Maria Domenichini Technical Director Foster Wheeler Italiana Power Division 2007 Gasification Technologies Conference, th October 2007 San Francisco 2

3 A G E N D A Scope of the Project Comparison of Options Existing IGCC plant New Gasifier Revamping of Existing Facilities New IGCC Performances Plot Plan Project Execution Plan 2007 Gasification Technologies Conference, th October 2007 San Francisco 3

4 Scope of the Project Production of 20,000 Nm 3 /h for Euro-grade automotive fuels Three options for ERG: 1. Refinery revamping new steam reformer 2. Purchase H 2 from external suppliers new steam reformer 3. ISAB Energy IGCC revamping third gasifier + H 2 plant ONE OPTION 2007 Gasification Technologies Conference, th October 2007 San Francisco 4

5 Option Comparison Bases: ERG Financial/ economic parameters and natural gas/ hydrocarbon products price forecast /t Steam Reform er Third Gasifier Fixed Costs Variable Costs Higher capex for IGCC: +30% Lower opex for IGCC: -20% Marginally lower H 2 price for third gasifier option 1900 /t (0.17 /Nm 3 ) 2007 Gasification Technologies Conference, th October 2007 San Francisco 5

6 Option Comparison Forecast to 2020: the third gasifier advantages become higher /t Steam Reformer Third Gasifier 2007 Gasification Technologies Conference, th October 2007 San Francisco 6

7 Additional benefits for IGCC/refinery: - Reduction of fuel oil production Option Comparison - Increase of deasphalted oil production - Increase of IGCC overall availability With consequent increase of light products 30,000 MWh per year Crude Topping Vacuum Visbreaker Gasoline Vacuum Flash DAO Gofiner FCC Desulphurization and Hydrogenation Gasoil Deasphalting Asphalt IGCC 2007 Gasification Technologies Conference, th October 2007 San Francisco 7

8 Existing IGCC plant 2007 Gasification Technologies Conference, th October 2007 San Francisco 8

9 Existing IGCC plant Kellogg deasphalting unit Feed: asphalt 132 t/h sulphur 6%wt Two quench-type GE gasifiers MDEA based AGR for H 2 S removal Oxygen Claus SRU + TGT Two power train (GT+HRSG+ST) based on GT Ansaldo/Siemens V94.2K IGCC power output: 560 MWe 2007 Gasification Technologies Conference, th October 2007 San Francisco 9

10 Existing IGCC plant - Availability ISAB Energy IGCC - Availability % Percentage % 90.00% 80.00% 70.00% 86.47% 91.21% 96.34% % 88.67% 92.30% Availability on syngas Availability on syngas and gasoil 60.00% 50.00% Year Excellent operating results from the first year of commercial operation 2007 Gasification Technologies Conference, th October 2007 San Francisco 10

11 New Gasifier Target: 20,000 Nm 3 /h of H 2 at constant IGCC power output: 560 MWe Gasification capacity increase +5.4% i.e t/h of asphalt Two alternatives: 1. New gasifier same size as the existing ones 2. New gasifier sized for 18 t/h of asphalt 2007 Gasification Technologies Conference, th October 2007 San Francisco 11

12 Revamping of Existing Facilities FI Hydrogen FIRST FIC HYDROGEN PRODUCTION (UNIT 3800) Offgas to Postfiring SECOND GASIFIFICATION SYNGAS TREATMENT & CONDITIONING LINE (UNIT 3300) NEW CONTROL VALVE EXPANDER (UNIT 3300) Dry Syngas to GTs COMBINED CYCLE (UNIT 4000) Power Output THIRD Existing gasification feed storage is adequate for the future operating conditions Utilities and infrastructure are able to operate in the future configuration Flare system is adequate Control and safety shutdown systems with the same philosophy and integrated with the existing facilities 2007 Gasification Technologies Conference, th October 2007 San Francisco 12

13 Revamping of Existing Facilities FI Hydrogen Third Gasification Train FIRST SECOND GASIFIFICATION SYNGAS TREATMENT & CONDITIONING LINE (UNIT 3300) FIC HYDROGEN PRODUCTION (UNIT 3800) NEW CONTROL VALVE Offgas to Postfiring Dry Syngas to GTs EXPANDER (UNIT 3300) COMBINED CYCLE (UNIT 4000) Power Output THIRD New facilities: Gasifier sized for 18 t/h Charge oil pump Syngas scrubber Start-up quench water pumps and sump for start-up/shutdown Grey water/soot water exchanger Ancillaries dedicated to third gasification line 2007 Gasification Technologies Conference, th October 2007 San Francisco 13

14 Revamping of Existing Facilities FI Hydrogen Third Gasification Train FIRST SECOND GASIFIFICATION SYNGAS TREATMENT & CONDITIONING LINE (UNIT 3300) FIC HYDROGEN PRODUCTION (UNIT 3800) NEW CONTROL VALVE Offgas to Postfiring Dry Syngas to GTs EXPANDER (UNIT 3300) COMBINED CYCLE (UNIT 4000) Power Output THIRD Impact on existing facilities: Revamping of the burner cooling water pumps to assure proper cooling of the three gasifiers burners New high pressure naphtha pump New emergency demiwater diesel pump to cool the quench ring of the new gasifier in case of electric power failure 2007 Gasification Technologies Conference, th October 2007 San Francisco 14

15 Revamping of Existing Facilities FI Hydrogen Hydrogen Plant FIRST SECOND GASIFIFICATION SYNGAS TREATMENT & CONDITIONING LINE (UNIT 3300) FIC HYDROGEN PRODUCTION (UNIT 3800) NEW CONTROL VALVE Offgas to Postfiring Dry Syngas to GTs EXPANDER (UNIT 3300) COMBINED CYCLE (UNIT 4000) Power Output THIRD New facilities: Clean syngas scrubber for MDEA solvent entertainment abatement Membrane section for hydrogen enrichment (approx. 50% syngas) PSA section for 20,000 Nm 3 /h hydrogen production Control valve to regulate the syngas fed to hydrogen plant 2007 Gasification Technologies Conference, th October 2007 San Francisco 15

16 Revamping of Existing Facilities FI Hydrogen Syngas treatment FIRST SECOND GASIFIFICATION SYNGAS TREATMENT & CONDITIONING LINE (UNIT 3300) FIC HYDROGEN PRODUCTION (UNIT 3800) NEW CONTROL VALVE Offgas to Postfiring Dry Syngas to GTs EXPANDER (UNIT 3300) COMBINED CYCLE (UNIT 4000) Power Output THIRD New facilities: Condensate return pump dedicated to the new scrubber; existing pumps acting as spare also for third gasifier Existing facilities: The existing facilities for syngas cooling, COS hydrolysis, syngas saturation and expansion are suitable 2007 Gasification Technologies Conference, th October 2007 San Francisco 16

17 Revamping Existing Facilities FI Hydrogen Combined Cycle FIRST SECOND GASIFIFICATION SYNGAS TREATMENT & CONDITIONING LINE (UNIT 3300) FIC HYDROGEN PRODUCTION (UNIT 3800) NEW CONTROL VALVE Offgas to Postfiring Dry Syngas to GTs EXPANDER (UNIT 3300) COMBINED CYCLE (UNIT 4000) Power Output THIRD Impact on existing facilities: Different H 2 /CO ratio of syngas fed to GTs. Ansaldo Energia confirmed existing burners suitability with minor impacts on performance and emissions New facilities: Two new post-firing burners able to burn either syngas or PSA offgas 2007 Gasification Technologies Conference, th October 2007 San Francisco 17

18 New IGCC performances EXPECTED PERFORMANCES OF THE IGCC PLANT Existing IGCC Revamped IGCC Feedstock t/h Oxygen consumption Nm 3 /h 102, ,800 Gross power output MW Combined cycle consumption MW Net power output MW Process and utility consumption MW Net IGCC power MW Hydrogen production Nm 3 /h 0 20,000 New solvent proposed in the AGR maintains constant SO 2 emissions NOx, CO and particulate emissions are not expected to increase in future operating conditions (GTs and post-firing systems at constant loads) 2007 Gasification Technologies Conference, th October 2007 San Francisco 18

19 Plot Plan 1 st TRAIN (Gasifier + scrubber + aux) 2 nd TRAIN (Gasifier + scrubber + aux) NEW TRAIN (Gasifier + scrubber + aux) NEW CHARGE OIL PUMP NEW HYDROGEN PLANT (Membrane + PSA) Third gasifier located in a new area far from the existing gasifier due to constructability reasons Charge oil pump located close to the existing ones Hydrogen plant located within the syngas cooling, saturation and expansion area 2007 Gasification Technologies Conference, th October 2007 San Francisco 19

20 Project Execution Plan Fast track strategy with overlap of the permitting, basic design and detailed engineering phases to optimise the overall project schedule Mechanical, instrument and electrical modifications designed and implemented in the general IGCC complex turnaround previously planned in May 2007 Construction phase is planned to start in early 2008 Hydrogen unit is planned to be mechanically complete by the end of 2008 Gasification unit is planned to be ready for commissioning activities in 4Q/ Gasification Technologies Conference, th October 2007 San Francisco 20

21 For any question: Gasification Technologies Conference, th October 2007 San Francisco 21

22 / THANK YOU