RTI Warm Syngas Cleanup Technology Demonstration
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1 RTI Warm Syngas Cleanup Technology Demonstration 8 th International Freiberg Conference on IGCC & XtL Technologies June 13, 2016 David L. Denton (speaker), Raghubir Gupta, Markus Lesemann, and Brian Turk RTI International is a registered trademark and a trade name of Research Triangle Institute. 1 RTI International is a registered trademark and a trade name of Research Triangle Institute.
2 What Is RTI International? RTI is an independent, nonprofit institute that provides research, development, and technical services to government and commercial clients worldwide. Our mission is to improve the human condition by turning knowledge into practice. 2
3 RTI and Its Energy Technology Focus RTI International Energy Technology Division Turning Knowledge Into Practice 3 One of the world s leading research organizations 4,150 staff Work in 75 countries 3,680 Active projects Scientific staff Highly qualified, tremendous breadth $831.5 million Research budget
4 RTI Warm Syngas Cleanup Technology Platform RTI PILOT PLANT TEST UNITS AT EASTMAN COAL GASIFICATION PLANT Regenerable ZnO sorbents Sulfur Transport reactor Hg adsorbents (disposable) As adsorbents (disposable) Direct Sulfur Recovery Process Regenerable NH 3 /HCN adsorbents Se adsorbents (disposable) HCl adsorbents (disposable) Regenerable CO 2 sorbents PRE-COMMERCIAL DEMO PROJECT w/cc UNDERWAY AT TAMPA ELECTRIC SITE RTI has developed a platform of warm syngas cleanup technologies: Increase efficiency and lower costs Operate at ºC Pressure independent Effective for all forms of sulfur Fully compatible with all CO 2 capture Flexible modular approach enables specific syngas purity needs to be met Systems tested on actual coal-based syngas Warm desulfurization process (WDP) now tested through pre-commercial scale 4
5 RTI Warm Gas Desulfurization Process (WDP) Enables high removal of total sulfur (>99.9%) from syngas at temperatures as high as 650 C. A unique process technology based on dual transport reactor loops (similar to FCC reactor designs) and on the development of a highly active, attrition-resistant sorbent. REGENERATED SORBENT RAW SYNGAS C ADSORBER (REACTOR) CLEAN SYNGAS N 2 /O 2 (Air) C REGENERATOR (REACTOR) SO 2 / N 2 TO SULFUR RECOVERY REGENERATED SORBENT TO ADSORBER MIXING ZONE RTI Warm Gas Desulfurization Process (WDP) RTI Proprietary Desulfurization Sorbent R&D 100 Award Unique highly-dispersed nanostructures Developed in long-term cooperation with Clariant (~100 tons to date) Covered by extensive US & International patents, including several recent improvements 5
6 Successful WDP Scale-up from Lab to Large-Scale Pre-Commercial Testing Invention (2001) Proprietary RTI sorbent High attrition resistance Lab/bench testing ( ) RTI International, NC Concept proven & modeled Pilot testing ( ) Eastman Chemical Co., TN >3000 hr coal-based syngas Pre-Commercial Syngas Cleanup & CO 2 Capture ( ) Tampa Electric Co., Polk 1 IGCC Plant, FL 50-MW e scale, >3500 hr with coal/petcoke-based syngas 6 Over 6500 hours of combined pilot and pre-commercial scale testing of WDP!
7 RTI WDP 50-MW e Pre-Commercial Demonstration Testing Project Demonstration Project Team Role CO 2 Capture Desulfurization System RTI Project management; technology developer Tampa Electric (TEC) Host site, feed, utilities, operations support Shaw Group, AMEC Engineering (Shaw - FEED, AMEC - EPC) CH2M Hill Owner s engineer BASF Technology (amdea ) for CO 2 capture WGS Reactors Clariant DOE/NETL Supply of sulfur sorbent & WGS catalysts Funding agency; project consultation Eastman Chemical Development partner; early tech support Project Detail: Combined syngas cleanup / water-gas-shift / carbon capture demonstration DOE ARRA funding to support the design, construction, and operation 50 MW e equivalent scale - 20% slipstream from TECO Polk 1 IGCC unit; captures > 90% of CO 2 7
8 Overall Objective for WDP Pre-Commercial Operational Testing The overall objective of this project was to mitigate the technical risks associated with the scale up and integration of the warm syngas cleaning and carbon dioxide (CO 2 ) capture technologies, enabling subsequent commercial demonstration. 8
9 Integration of Syngas Cleaning and Carbon Capture Systems at Tampa Electric Company Polk 1 IGCC Site WDP Sweet WGS Reactors Syngas Cooling amdea CO 2 Recovery Air Air Separation Oxygen Coal/Petcoke GE Gasifier (~400 psig) Slag Syngas Cooling Char Syngas Diluent (N 2 ) Pre-Commercial Project Scope Extraction Air Scrubbers COS Hydrolysis Process Condensate Syngas Cooling 8% H 2 O Regenerator Gas MDEA Reheat/ Humidify Clean Fuel Gas Currently vented, but could be sequestered or used or recycled Sulfuric Acid Plant Acid Gas Sulfuric Acid 9 Raw Syngas ~ 128 Mwe (122 Mwe) Process Clean 20% slipstream test (~50 MW e ) enables direct Water commercial Fuel scale-up Gas from this pre-commercial scale. The WDP test facility cleans ~2MMscfh (~70,000 Nm3/hr) of raw syngas from the TEC gasifier. ~
10 RTI Warm Gas Cleanup (WDP) Pre-Commercial Testing Project Performance WDP Unit Construction was achieved on schedule and under budget. ~600,000 total construction and operation labor hours with no injury other than a few minor first aids. Unit performed as expected, replicating previous lab and pilot scale performance. RTI WDP unit consistently reduced inlet total sulfur from as high as 14,000 ppmv (40% over design level) to ~10-20 ppmv or less (~99.9% removal). Clean syngas exiting the activated amine (amdea ) carbon capture block was consistently <0.5 ppmv (as low as 100 ppbv, ~99.999% total S removal). Microreactor testing of the cleaned syngas (post-amdea ) with commercial Fischer-Tropsch (Fe- and Co-based) and methanol catalysts showed no significant signs of catalyst deactivation after several hundred hours of testing. 10
11 RTI Warm Gas Cleanup (WDP) Pre-Commercial Testing Project Performance WDP Unit Sorbent attrition rate was better (lower) than design expectations. Sorbent sulfur capacity was steady - no significant deactivation was observed. WDP unit was successfully operated both below and above its design syngas feed rate and design sulfur feed rate. RTI achieved >3,500 total syngas operation hours on WDP, >2,000 hrs on WDP+aMDEA, and ~700 total integrated hours on WDP+WGS+aMDEA by the end of testing. WDP availability at the end of testing was as high as 93% and identified design improvements should enable availabilities in the high 90 s% for future commercial units. RTI is now in discussions with potential partners to offer the technology (via license) and sorbent (via sale) commercially later this year. 11 DOE/RTI/TEC/Clariant Team
12 Pre-commercial Demonstration Test Plant Results: Consistently High Total Sulfur Removal (H 2 S and COS) Four months of WDP operations H 2 S Removal (inlet H 2 S = 10,000-12,000 ppmv) COS Removal (inlet COS = ppmv) Note: Gaps are due to periods of syngas outages 12
13 Comparison of Technologies for Syngas Sulfur Removal and CO 2 Capture Characteristics Rectisol Selexol RTI + amdea Capture Mechanism Physical absorption Physical absorption Solid adsorbent + chemical absorption Pressure Dependent? Yes Yes No (for S removal) COS Hydrolysis Needed? No Yes (most applications) No Operating Temperature -40 F to -80 F 30 F to 100 F Sulfur Removal < 0.1 ppmv H 2 S + COS < a few ppmv H 2 S + COS S removal: > 600 F CO 2 capture: ~110 F ~ ppmv H 2 S + COS (< 0.1 ppmv w/guard bed) CO 2 Capture 97-99% 90-99% > 97% Relative Efficiency w/co 2 Capture Relative Capital Costs < X% (due to refrigeration) > Y (pressure dependent) X% Can be up to 10% higher Y 20-50% lower 13
14 RTI WDP Provides Significantly Lower Capex and Opex! Techno-Economic Analysis (TEA): Coal to Methanol Case (2 x 300-MW equiv Shell-type solids-fed gasifiers with Shenhua Mix or PRB coal) CAPEX reduced ~50% RTI WDP improves economics for all carbon capture options, but best when coupled with activated amine. OPEX reduced >50% Rectisol Base Case RTI WDP + Rectisol RTI WDP + Selexol RTI WDP + amdea Rectisol Base Case RTI WDP + RTI WDP + RTI WDP + Rectisol Selexol amdea 14 Technology used in RTI Demo Plant Non-labor, non-feedstock operating costs NOTES: Cost savings are across the entire block from raw warm syngas exiting the gasifier through cleaned syngas feed to the methanol conversion step, including the sulfur recovery unit. These analyses do not include additional benefits to the entire plant that might occur from overall efficiency savings.
15 WDP Economic Benefits for IGCC Power Generation Cases (2 x 300 MW e Shell-type gasifiers w/prb or Shenhua Mix coal) Note: The capex savings shown here are for the entire syngas cleanup block, but do not include additional savings for the overall IGCC due to improved efficiency. The overall IGCC capex savings can more than offset all WDP cleanup capital costs for IGCC w/o carbon capture or for IGCC with a warm carbon capture process. RTI WDP reduces AGR CAPEX 100% 79% Single-Stage Selexol RTI WDP RTI WDP reduces AGR CAPEX 100% 67% CAPEX and OPEX are for AGR + WGS + LTGC + SRU blocks IGCC w/o Carbon Capture IGCC with 90% Carbon Capture RTI WDP reduces AGR OPEX* 100% RTI WDP Single-Stage Selexol -500% RTI WDP reduces AGR OPEX* 100% 55% * Non-labor, nonfeedstock OPEX 15 Dual-Stage Selexol RTI WDP + amdea Dual-Stage Selexol RTI WDP + amdea
16 Benefits of RTI WDP Technology Rectisol and Selexol (solvent-based sorbent systems that operate at subambient temperatures) dominate the current coal-to-chemicals/fuels markets. RTI WDP is a unique differentiated warm-temperature, solid-sorbent based syngas cleanup system that simultaneously offers: Lower capital costs (20-50% less), Lower non-labor, non-feedstock operating costs (up to % less), Improved overall process efficiency (up to 10+% better), Improved process flexibility by decoupling sulfur removal and CO 2 capture, and A capable and economic syngas cleanup option for all applications: CC = Carbon Capture 16
17 Summary 17 RTI s warm syngas cleanup technology offers opportunities to both improve efficiency and significantly reduce capex/opex costs of gasification for power generation and chemicals/fuels. RTI s WDP has potential to integrate with most CO 2 capture technologies (e.g., amines, activated amines, Selexol, Rectisol, sorbents) to enable them to meet syngas purities for chemicals/fuels applications and for ultra-clean power generation with competitive economics. The WDP pre-commercial (50-MW e ) testing program was a success and the unique transport system design and sorbent combination performed as expected, replicating previous lab and pilot scale performance and providing critical data to support full-scale commercial deployment. RTI WDP was integrated with an amdea carbon capture system and total sulfur levels dropped to sub-ppmv levels (up to % removal), performance levels needed for most chemicals/fuels applications as validated by microreactor testing with commercial FT and methanol catalysts. RTI WDP technology performance has been consistently proven at lab, bench, pilot plant (>3,000 syngas operation hours), and pre-commercial scales (>3,500 syngas operation hours). RTI is now in discussions with potential partners to offer the technology (via license) and sorbent (via sale) commercially later this year.
18 Acknowledgements RTI Co-Authors/Contributors U.S. Department of Energy / National Energy Technology Laboratory for Funding Support Development and Project Partners: Tampa Electric Company Eastman Chemical Company Technip Amec Foster Wheeler CH2M Hill BASF Clariant 18
19 QUESTIONS? Contact: David Denton Sr. Director, Business Development Energy Technology Division RTI International (W), (M) RTI Warm Syngas Demonstration Project 19
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