PUERTOLLANO IGCC: Pilot plant for CO 2 capture and H 2 production. Francisco García-Peña Engineering R&D Director ELCOGAS

Transcription

1 PUERTOLLANO IGCC: Pilot plant for CO 2 capture and H 2 production Francisco García-Peña Engineering R&D Director ELCOGAS

2 INDEX INTRODUCTION R&D INVESTMENT PLAN. Lines CO 2 capture and H 2 co-production pilot plant 2

3 INTRODUCTION. The Elcogas company Spanish company established in April 1992 to undertake the planning, construction, management and operation of a 335 MWe ISO IGCC plant located in Puertollano (Spain) Hidrocantábrico Explotación de Centrales SAU 4,32 Hidroeléctrica del Cantábrico, S.A. 4,32 Iberdrola Generación, S.A. 12,00 Siemens Project Ventures GmbH 2,53 Enel, SpA 4,32 Krupp Koppers GmbH 0,04 Endesa Generación, S.A. 40,99 Electricité de France International, S.A. 31,48 Repsol YPF Refinery Puertollano IGCC Power Plant ENCASUR (open cast coal mine) 3

4 Puertollano IGCC power plant description Process description Flue gas to stack HP Steam Heat Recovery Steam Generator Steam G STEAM TURBINE 135MW ISO Coal PetCoke Limestone Coal preparation HP Boiler MP Boiler Gasifier MP Steam Raw Filtration Gas Water wash Hot combustion gas Sulfur Removal Clean Syngas Condenser G Cooling tower Coal - N 2 N 2 O 2 Quench Gas Water to treatment Air O 2 Tail Gas Sulfur Claus Gas Recovery GAS TURBINE 200 MW ISO Slag Fly ash Sulfur (99.8) Air Separation Unit Waste N 2 Compressed air 4

5 Puertollano IGCC power plant description Main Design Data The design fuel is a mixture 50/50 of coal/petcoke COAL PET COKE FUEL MIX (50:50) Moisture (w) Ash (w) C (w) H (w) N (w) O (w) S (w) LHV (MJ/kg) POWER OUTPUT EFFICIENCY (LHV) Power output and emissions GAS TURBINE (MW) STEAM TURBINE (MW) GROSS TOTAL (MW) NET TOTAL (MW) GROSS NET EMISSIONS g/kwh mg/nm 3 (6Oxygen) SO NO x Particulate Raw Gas Raw and clean gas data Clean Gas Actual average Design Actual average Design CO () CO () H 2 () H 2 () CO 2 () CO 2 () N 2 () N 2 () Ar () Ar () H 2 S () H 2 S (ppm) 3 6 COS () COS (ppm) 9 6 HCN (ppm) HCN (ppm) - 3 5

6 Operational data IGCC, NGCC and Total yearly production GWh IGCC GWh NGCC GWh 1,938 1, ,744 1,803 1,672 1,698 1, , ,462 1, , , year 1 st 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 WN 2 compressor coupling fault and repair MAN TURBO 2010: No operation due to non-profitable electricity price (30-40 days). 6

7 Operational data Natural gas (mg/nm 3 at 6 O 2 dry) EEC 88/609 ELCOGAS Enviro nmental Permit ELCOGAS 2010 average 29,2 12,5 7,9 4,2 4,2 0,8 Coal gas (IGCC) 291,7 250,0 SO2 Particles NOx ,3 Natural gas (NGCC) Coal gas (mg/nm 3 at 6 O2 dry) , EU Directive 88/609/EEC EU Directive 2001/80/EEC ELCOGA S Enviro nmental P ermit ELCOGA S 2010 average 116,3 50 SO2 NOx Particles 5 1,06 ELCOGAS power plant emissions in NGCC & IGCC modes (2010) 7

8 Operational data Costs Fuel mode Fuel Consume (GJ P CS ) Production (GWh) Heat rate (GJ P CS /GWh) Fuel cost ( /GJ P CS ) Partial cost ( /MWh) Total cost ( /MWh) GT Natural gas , ,12 147,43 147,43 NGCC Natural gas , ,12 81,40 81,40 NGCC + A SU Natural gas , ,12 91,48 91,48 NGCC+ASU+ Gasifier (by flare) Natural gas ,12 85,03 Coal , ,39 8,37 111,46 Petocke ,34 18,06 NG auxiliar consumption Note: Net energy variable costs (average 2010) ,12 1,77 IGCC Coal , ,39 8,09 27,32 Petocke ,34 17,46 8

9 R&D INVESTMENT PLAN. Lines BASIS of the PUERTOLLANO IGCC R&D PLAN Based on the opportunity that an IGCC plant represents Contribution can be relevant in: -- climate change mitigation -- energy supply reliability MAIN LINES OF THE R&D PLAN CO 2 emission reduction using fossil fuels H 2 production by gasification of fossil fuels DIVERSIFICATION of raw fuels and products Other ENVIRONMENTAL improvements IGCC processes OPTIMISATION DISSEMINATION of results 9

10 R&D INVESTMENT PLAN. Lines Diversification of raw fuels and products. Biomass co-gasification Biomass selection criteria: Size < 25 mm Humidity < 12 Price < 150 /t Availability in large quantities Battery of co-gasification tests undertaken with olive oil waste (orujillo) Critical parameter for the biomass selection was the behavior on the ELCOGAS grinding system. Olive oil waste storage area Test Month/Year orujillo dosage ratio in weight orujillo tonnes (t) Test duratio n (h) 100 gasifer load () ,84 800, , March ,86 64,4 June ,90 46 Sept , clean gas flow () CO clean gas () Nm3/h TOTAL 3.661, ,7 30 H 2 clean gas () Load during 8 olive oil waste co-gasification test /06/2009 7:12 14/06/ :00 14/06/ :48 14/06/ :36 15/06/2009 2:24 15/06/2009 7:12 15/06/ :00 15/06/ :48 15/06/ :36 16/06/2009 2:24 16/06/2009 7:12 16/06/ :00 16/06/ :48 16/06/ :36 17/06/2009 2:24 17/06/2009 7:12 Orujillo 17/06/ :00 17/06/ :48 17/06/ :36 18/06/2009 2:24 18/06/2009 7:12 18/06/ :00 18/06/ :48 18/06/ :36 19/06/2009 2:24 19/06/2009 7:12 19/06/ :00 19/06/ :48 19/06/ :36 20/06/2009 2:24 20/06/2009 7:12 20/06/ :00 20/06/ :

11 R&D INVESTMENT PLAN. Lines CO 2 capture and H 2 production (pre-combustion) GASIFICATION PREPARATION SECONDARY PRODUCTION H 2 : WATER-GAS REACTION CO 2 CAPTURE & H 2 PURIFICATION PROCESS CO 2 H 2 Step 1: Syngas production from Gasification Carbon compound + O 2 + H 2 O ºC bar CO + H 2 + Impurities Step 2:Conditioning fly ash removal, particles and sulphur comp. Step 3: Shifting or water-gas reaction CO + H 2 O CO 2 + H 2 Fly ash Char Cl - Step 4: H 2 and CO 2 separation H 2 CO 2 & CN - SH 2 COS CO 2 capture using pre-combustion technology involves H 2 generation CO 2 N 2 11

12 PSE-CO 2 project : CO 2 Capture Pilot Plant TARGETS To demonstrate the feasibility of capture of CO 2 and production of H 2 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 ) COORDINATION Project of pilot plant in an existing IGCC of Puertollano (pre-combustion technology) is part of a Spanish national initiative, Advanced technologies of CO 2 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

13 PSE-CO 2 project : CO 2 Capture Pilot Plant Puertollano IGCC power plant and pilot plant location PRENFLO Gasifier Coal preparation ASU Pilot plant general view New CO 2 capture pilot plant Sulphur Recovery Combined Cycle IGCC power plant general view 13

14 PSE-CO 2 project : CO 2 Capture Pilot Plant Pilot plant diagram process COAL + COKE Recycle compressor GASIFICATION Raw gas FILTRATION SYSTEM Nm 3 /h PURIFICATION & DESULPHURATION Clean gas COMBINED CYCLE PILOT PLANT CLEAN GAS 2 of total flow (3,600 Nm 3 /h) 22,6 bar 130ºC 60,5 CO 22,1 H 2 MP STEAM Pilot plant size: 1:50 ~ 14 MW t H 2 rich gas 37,5 CO 2 50,0 H 2 3,0 CO SHIFT Reactor CO 2 & H 2 (Sweet /Acid) separation (Chemical, amdea) CO + H 2 O CO 2 + H t/d 40 CO 2 H 2 S? Raw H 2 (80 of purity) HYDROGEN PURIFICATION (PSA) Tail gas 1,3 bar Pure H 2 (2 t/d) 99,99 H 15 bar 14

15 Pilot plant diagram process:3d view 2 CO 2 Capture Unit 1 1 Shifting unit PSA Unit 1 Electrical and control building Shifting Unit (several suppliers): 1. Desulphurization reactor 2. Shifting reactors 3. Heat exchangers: kettles and shell&tube PSA Unit (Linde): 1. Adsobers 6.5 m 2. Tail gas drum 12.5 m 3. Valve skid CO 2 Capture Unit (Linde Caloric): 1. Syngas absober 12 m 2. CO 2 stripper 16.5 m Electrical/control building: 1. Control room 2. Electrical room 15 15

16 PSE-CO 2 project : CO 2 Capture Pilot Plant Milestones Construction permit: December 2008 Commissioning: May-October st CO 2 t captured: 13 September 2010 End of sweet capture tests: February 2011 End of programmed tests (within PSE-CO 2 ): June 2011 Main suppliers Engineering CO 2 Unit PSA Unit Civil work Control Reactors Heat exchangers Catalysts Piping and fitting Valves Electrical components On-line analysis system Mechanical erection Electrical I&C erection Empresarios Agrupados Linde-Caloric Linde Construcciones Ocaña-Cañas Zeus Control Técnicas Reunidas Técnicas Reunidas y Boreal-Vila Johnson Matthey Sidsa y Cuñado SAMSON, Tyco Valves and Controls y SAIDI GE Power ABB Process Automation Division HGL y MASA MEISA 16

17 Pilot plant diagram process (I) Shifting unit Flow kg/h P bar T ºC CO H 2 CO 2 H 2 O H 2 S COS Coal gas Shifted gas to separation unit IP saturated steam to feed Sweet 3, Sour 3, ,70 0,11 Sweet 8, Sour 8, Sweet 5, Sour 4, General view of Shifting Unit IP saturated steam to feed IP steam Coal gas N 2 (start-up) Desulphuration reactor Pre-heater SHIFTED GAS TO SEPARATION UNIT Shifting rectors 17

18 Pilot plant diagram process (II) From shifting unit CO2 product LP steam CO 2 separator Cooling stage Y Process Cond. Cond. Separator Absorber Shifted gas CO 2 Stripper LP steam to reboiler Y 40 Syngas separator H2 to PSA Rich H2 gas 60 Separation unit General view of Separation Unit Shifted gas to absorber Process condensated CO 2 product H 2 to PSA Rich H 2 gas LP Steam to reboiler Flow kg/h P bar T ºC CO Sweet 5, Sour 5, Sweet 3, Sour 3, Sweet 4, Sour 4, Sweet Sour Sweet 1, Sour 1, Sweet 4, Sour 4, H 2 CO 2 H 2 O H 2 S COS 18

19 Pilot plant diagram process (III) PSA unit Flow Nm 3 /h P bar T ºC CO H 2 CO 2 H 2 S COS H 2 from separation unit H 2 product Tail gas Sweet 1, Sour 1, Sweet Sour Sweet Sour H2 product Tail gas drum Adsorbers General view of PSA unit H2 from separation unit Rich H 2 gas (40 flow) Tail gas 19

20 Comparative : sweet vs sour (design data) Sweet Sour C.G.E s+a 88,5 88,2 Global (shifting+amines) Thermal efficiency s+a 60,2 62,5 CO 2 recovery 91,7 93,6 20

21 Block diagram. Control flexibility Flare PC CO2 Syngas FC PC Shifting CO2 Flare N2 PC FC PC H2 FC Flare PSA Tail gas PC Flare Pure H2 PC Flare 21

22 Some Test results CO2 composition() 44 97, ,5 96, ,6 96,4 42,5 96, ,8 95,6 41,5 95,4 95, ,1 1,2 1,3 1,4 1,5 1,6 vapor/gas rate Total CO conversion () CO2 composition Total CO conversion () Shifting: Coversion rate has to be reconsidered! CO Fuga 2 leak CO2 Fuga H 2 leak H2 CO 2 -H 2 separation: Desortion temperature can be optimised CO Fuga 2 leak CO Desortion T desorción T (ºC) 1,0 0,8 0,6 0,4 0,2 0,0 H Fuga H2 2 leak 22

23 Test results UNIT START 23

24 PSE-CO 2 project : CO 2 Capture Pilot Plant SHIFTING UNIT CONVERSION / TEMPERATURE (SWEET) 20,0 20/01/11 17:24-28:35 CO () 15,0 10,0 The inlet second reactor temperature is higher than expected FIRST REACTOR Conversion very close to theoric, although higher reactor outlet temperature. STEAM GENERATOR Real values (SWEET3 test) 5,0 0,0 JM - Fresh catalyst SECOND REACTOR JM simulation (01/10/10) Temperature(ºC) Johnson Matthey Selection High temperature Fresh Potential (Johnson Matthey) Potential (High temperature) The high conversion obtained in the first step (near 95) will make considering a shifting process only with one step. 24

25 PSE-CO 2 project : CO 2 Capture Pilot Plant Expected vs. obtained compositions of main streams (SWEET) Shifted gas CO 2 H 2 rich gas Pure H 2 Design Lab Analysis Design Lab Analysis Design Lab Analysis E Design Lab Analysis H CO ppm N/A CO ppm N/A N ppm 4-17 ppm Ar ppm 3-14 ppm i) All compositions are in vol. (dry basis) ii) Analysis carried out by ELCOGAS Laboratory CO 2 capture & H 2 co-production pilot plant. Tests Comparison of sweet & sour catalysts: sweet tests up to Feb 2011, sour tests up to June 2011 Optimization of steam/gas ratio at shifting unit Optimization of energy balance Real costs of CO 2 capture and H 2 production. 25

26 PSE-CO 2 project : CO 2 Capture Pilot Plant The main learning in project phase: The finance delay: MICINN (Spanish Science & Research Minister) and JCCM (Regional Government). Delay in main equipment supply: more than months. Detailed engineering: conditioned by suppliers. PP construction step: delay due to safety permits since it is installed in an operating plant. Delay of commissioning: low availability of experimented personnel. The main learning in commissioning & operation phases: Investment costs: 13 million Unexpected reactivity: 95 CO conversion in first step of shifting unit Estimated: 85 consider a shifting process with only one step. CO 2 and H 2 design specifications: easily achieved CO 2 capture rate: 91.7 CO Auxiliary consumption: lower than estimated in design 2 > 99 H 2 pure > Integration of O&M in the existing IGCC: very easy 26

27 PSE-CO 2 project : CO 2 Capture Pilot Plant CO 2 Capture Costs Comparison 1) Scaled up 100 Puertollano IGCC synthetic gas from the 14MWt pilot plant. 2) Existing plant capture cost = f (investment costs and operational costs). CO 2 capture cost, /t CO 2 CAPEX OPEX Captured CO tonnes 2 3) First ELCOGAS estimations show values of / t CO 2 4) Comparing to other studies 30 for ELCOGAS retrofit Fuente: DOE/NETL CCS RD&D ROADMAP December

28 PSE-CO 2 project : CO 2 Capture Pilot Plant CO 2 cost, /t CO IGCC plant efficiency w ith CO 2 capture, h h h h h h h h h h Variables Data CO 2 Capture Costs (SWEET). As IGCC retrofit Expected life Bank interest Bank fee Scale factor Operating hours (IGCC mode) Average load factor Electricity price Net efficiency of power plant with CO 2 capture ,500 h /MWh 33 Treated gas

29 PSE-CO 2 project : CO 2 Capture Pilot Plant Minimum pure H 2 price depending on the electricity price 6 /Kg Better to sell H Minimum H2 price per fix cost of production (external personal and spares) depending on anual production hours Kg/y 1080 h Kg/y 720h Kg/y 1440 h Kg/y 5040 h Kg/y 2160 h Better to sell electricity /MWh

30 Pilot Plant beyond PSE project Pilot plant for CO 2 capture and production of H 2 and electricity with IGCC technology Other activities: To be done after PSE as R&D platform: Water shift reaction catalyst optimization. Tests of different catalyst New processes to separate CO 2 -H 2 CO 2 different treatment processes Improvement of integration efficiency between CO 2 separation processes and IGCC plant ELCOGAS offers both the Puertollano IGCC and the Pilot Plant for CO 2 capture and H 2 production as technical platforms to develop of process, equipments, components, or even pre-engineering of new plants with CCS and Zero emissions 30

31 Thank you for your attention Francisco García-Peña Engineering R&D Director ELCOGAS