NPRC Negishi IGCC Startup and Operation

Transcription

1 NPRC Negishi IGCC Startup and Operation Gasification Technologies 2003 San Francisco, California October 12-15, 2003 JGC Corporation Takuya Ono 1

2 Contents 1. Outline of Negishi IGCC Block Flow Process Outline Project Outline Schedule Plant Control System 2. Plant Performance of Negishi IGCC Power Generation Environmental Performance Availability 3. Key to Success in IGCC Project 4. JGC s Syngas Business 2

3 Block Flow ASU GT ST 342MW Sale HP O2 HHP Steam Steam Integ. HRSG Deaerator 89MW VR 83t/h Gasifier 70bar/1400 Gas Scrubber Steam System LTGC Syngas COS/HCN NH3 Scrubber AGR VR+ Soot Black Wt. Flash SWS SRU/AGE/TGT CEU NH3 CTW Pre-WWT Ash Filter NH3 Stripper WWT Sulfur 100t/d Chemical Ash Emergency Power Cond. Flare Start Steam/Pure Water/Start Fuel/Naphtha/NH3 fm. Outline of Negishi IGCC 3

4 Process Outline Gasifier CCU ASU S-Block -ChevronTexaco Direct Quench Type x One Train -Scrubber/LTGC/CEU x One Train -Asphalt 2,000MTPD (Low Sulfur Oil used for startup and shutdown while syngas flare to be required) -MHI 701F GT x One Train -MHI ST x One Train + MHI Vertical HRSG x One Train -Gross Power 431MW -Net Power 342MW -Kerosene as Alternate Fuel -Air Liquide France/Japan -Oxygen 2,300MTPD (with the production of GT N2, Claus O2, Instrument air, and plant air/n2) x One Train -Shell Adip Acid Gas Removal x One Train -Lurgi OxyClaus x One Train -LS Scot TGT x One Train -COS/HCN Hydrolysis Pre-Acid Gas Removal (Catalyst developed by JGC) -Total Sulfur Recovery Rate 99.8% Outline of Negishi IGCC 4

5 Project Outline First IGCC in Japan, the success recorded landmark. Owner Location Nippon Petroleum Refining Co., LTD. (NPRC) Negishi, Yokohama Japan (Located in the midst of Yokohama suburb) Owner Side Contractor NIPPO Corporation (Old name: Nippon Oil Engineering & Construction Co. LTD) EPC Contractor Power Demand Condition Others JGC Corporation EPC and Commissioning for all units in the IGCC. LSTK Contract 100% net power generation during daytime on weekdays. 75% net power generation on weekends and holidays and night time on weekdays. Tough environmental requirements in emission and noise. Outline of Negishi IGCC 5

6 Schedule Negishi IGCC attained the goal on schedule. Event From To Contract January, 1998 ChevronTexaco PDP February, 1998 August, 1998 EPC Design and Assess September, 1998 February, 2000 Government Application September, 2000 Construction Starts October, 2000 Mechanical Completion July, 2002 CCU Starts October, 2002 (w/kerosene) ASU Starts November, 2002 Gasifier Start February, % Operation with Syngas April, 2003 Commercial Operation June, 2003 (on Schedule) Outline of Negishi IGCC 6

7 Plant Control System The plant location, in the midst of Yokohama suburb, does not allow frequent and extended periods of syngas flaring that might cause public nuisance. The state of the art IGCC plant control system is applied to enable the following; (1) No syngas flare is required during daily load change at the ramp rate of 1 to 3%/minute. It means that all units in the IGCC follow the ramp speed by changing their loads. (2) Syngas flare only required in minimum periods during gasifier startup and shutdown operations. All one-train design requires power generation with kerosene firing at CCU while the gasifier feed injector is to be replaced. The kerosene-firing period shall be minimized. The state of the art IGCC plant control system is applied to enable the following; (3) Smooth and quick CCU fuel changes, syngas to kerosene and vice versa, done in five to one minute. (4) Smooth and quick gasifier feed change, asphalt to low sulfur oil and vice versa. (5) Smooth and quick depressurization and pressurization of gasification systems. (6) ASU, Sulfur Block and other units smoothly shift from normal operation to stand-by operation and vice versa. Outline of Negishi IGCC 7

8 Plant Performance Power Generation Accurate designs ensured plant at minimum cost. (At ambient temperature of 15 degree C) Performance Design Gross Power Generation 433MW(*1) 431MW Power Consumption 85MW 89MW Net Power Generation 348MW 342MW *1: Allowed only for short period of time during test run. Environmental Performance Meet the tough environmental requirements. SOx emission from CCU NOx emission form CCU Particulate matters emission from CCU COD Mn in water discharge Suspended Solid in water discharge Total N in water discharge Well below the design, 2 vol.ppm (16% O2 dry base) Well below the design, 2.6 vol.ppm (16% O2 dry base) Well below the design, 1.4mg/Nm3 (16% O2 dry base) Well below the design, 10 mg/l Well below the design, 10 mg/l Well below the design, 4 mg/l Plant Performance of Negishi IGCC 8

9 Availability (Time Base) Negishi IGCC Availability (as of August 15, 2003) is; From Gasifier First Lit From Commercial Operation Start Total Time 4,584 hrs 1,128 hrs Power Availability 80.7 % 99.3 % Syngas Availability 72.3 % 96.1 % Notes: Forced Outage Rate = Unplanned / (On Stream + Unplanned) Availability = On Stream + Product Not Required x (1-(Forced Outage Rate)/100) 9 Plant Performance of Negishi IGCC

10 Key to Success in IGCC Project (1) Good Licenser/Maker Technologies and Designs (2) Good EPC Skill Integration of technologies of different cultures/incorporation of operation know-how to designs/ Plant optimization (reliability, environment, cost and efficiency) /Development of control/safety systems (3) Good Operation Skill through Training (OTS, at Site) (4) All Involved Companies Working Side by Side as One Team TGPS Licenser Owner (NPRC)/Group Co. CCU Supplier ASU Supplier Design Package Technologies Operation Know-How EPC Contractor (JGC) Operation and Maintenance S-Block Licensers Experienced Gasification Operator EPC/Commissioning Plant Optimization Control/Safety Systems High Performance IGCC Other Involved 10

11 Natural Gas N aphtha O ff G as Coal Residue Tar Cokes Pitch O rim ulsion G arbage W aste P lastic Bio-m ass Partial O xidation + De-Sulfur De-Sulfur + Steam /C O 2 Reform er De-Sulfur + Auto-Therm al Reform er D e-s ulfur + C atlytic P artial O xidation NGCC CFB GTW BSF JGC s Syngas Business Negishi IGCC, Bintulu SMDS and Further to Come Sulfur Recovery/Utilization C arbon Recovery M etal R ecovery Shift Membrene PSA CO2 R em oval C O 2 Injection (Future G EN) W aste W ater U tilization Power (IGCC) GTL DME Olefin M ethanol Chemical Steam C o-g eneration Poly-G eneration 11