ITM Oxygen: The New Oxygen Supply for the New IGCC Market

Transcription

1 ITM Oxygen: The New Oxygen Supply for the New IGCC Market Phillip A. Armstrong Douglas L. Bennett E.P. (Ted) Foster VanEric E. Stein Air Products and Chemicals, Inc. Presented at Gasification Technologies 2005 San Francisco, California 9-12 October Air Products and Chemicals, Inc. This paper was written with support of the U.S. Department of Energy under Contract No. DE-FC26-98FT The Government reserves for itself and others acting on its behalf a royalty-free, nonexclusive, irrevocable, worldwide license for Governmental purposes to publish, distribute, translate, duplicate, exhibit and perform this copyrighted paper.

2 2 Ion Transport Membranes Will Significantly Impact Our Environment and Other National Interests Including Energy Security ITM Oxygen Power Generation Through Coal Gasification (IGCC) Hydrogen from Coal Oxygen Enrichment of Coal Combustion ITM Syngas/H2 Hydrogen from Natural Gas Production of Environmentally Superior Transportation Fuels ITM SEOS Military Oxygen Supply Controlled Environments Commercial Introduction Now FutureGen is One of Many Examples

3 Three Disruptive Technologies With Broad Applications Our Driver Fundamentals ITM SEOS Pt. of use O2/High Purity % Cost Reduction Oxygen Product, pressurized ITM Oxygen 30+% Capital Reduction 35+% Power Reduction O 2 Product ITM Syngas 30+% Capital Reduction Product of Reaction Ambient Pressure Air High Pressure Air Low Pressure Air Planar Membrane Design Status 3 liter/min 1 KSCFD Syngas 0.5 T/D Current Level of Prototypes 5 liter/min 24 KSCFD Throughput 3 5 T/D

4 Air Products ITM Program Ion Transport Membranes (ITM) Extremely selective and very fast transport for oxygen Non-porous ceramic membranes Multi-component metallic oxides Operate at high temperature, typically greater than 700 C Material formulation is complex and dependent upon application Crystalline structure incorporates oxygen ion vacancies Started R&D in 1988 Biggest and longest single R&D program Currently ~60 US Patents and equivalents in other countries Materials and catalysts Membrane and module structures Process cycles Applications and integrations 4

5 Cryogenic Oxygen Supply is a Central Element in Gasification Processes (from Mature, reliable technology Energy intensive Requires 100 s of equilibrium stages Represents ~15% of an IGCC s capital cost 5

6 A Typical Air Separation Plant Major Components Main Air Compressor Front-end Cleanup Main Heat Exchanger Distillation Columns Reboilers Product Compression Low Pressure Column N2 O2 Waste Main Air Compressor Front - End Cleanup Main Reboiler High Pressure Column Main Heat Exchanger 6

7 Ceramic Membranes: Revolutionary Technology for Tonnage Oxygen Supply Compressed Air Oxygen Product Single-stage air separation leads to compact designs Low pressure drop on the high-pressure side High-temperature process has better synergy with power generation systems 0.5 TPD module (commercial-scale) 7

8 ITM Oxygen integrates well with power generation cycles STEAM OXYGEN AIR HRSG OXYGEN BLOWER FUEL ELECTRIC POWER HEAT EXCHANGE AIR OXYGEN ION TRANSPORT MEMBRANE ITM Oxygen requires 35% less capital and 35-60% less energy 8

9 ITM Oxygen is Simpler and Requires Less Power Cryogenic Air Separation Main Air Compressor Front-End Cleanup Low Pressure Column Waste O2 N2 Main Reboiler High Pressure Column OXYGEN Oxygen Blower AIR Heat Exchange ITM Oxygen With Power Integration FUEL Air Oxygen HRSG STEAM ELECTRIC POWER Main Heat Exchanger 9 ITM O2 Has Much Simpler Flow Sheet and >35% Less Capital ITM O2 Has 35-60% Less Compression Energy Associated with Oxygen Separation

10 ITM Oxygen shows significant benefits for IGCC Integration with ITM Oxygen reduces specific capital cost by 7% and increases efficiency by 2%, with >35% capital and power savings in oxygen production Cryo O2 ITM O2 Δ ( %) IGCC Net Efficiency (% HHV) Oxygen Plant Power (kwh/ton O 2 ) Oxygen Plant Cost ($/stpd O 2 ) 20,100 13, IGCC Specific Capital Cost ($/kw) ITM Oxygen plant capacity 3,200 stpd, 438 MW net power 10 Stein et al., 2002.

11 ITM Oxygen Program Goal: Reduce Cost of Oxygen by One-Third DOE/Air Products R&D started 1999 (9 year, $89 million) Phase 1: Technical Feasibility (0.1 TPD O2) Phase 2: Prototype (1-5 TPD O2) Phase 3: Pre-commercial Development (25+ TPD) Considering 150 TPD Development Team GE Energy SOFCo EFS (McDermott) 11

12 The Heart of ITM Oxygen Technology Planar Membrane Wafer Stack Thin membrane Porous membrane support compressed-air C psig Dense, slotted backbone Spacer between wafers Product Withdrawal Tube Pure Oxygen 12

13 Commercial Vessel Concept Stack planar wafers into modules, Add modules to increase production 13

14 Ceramic Processing Development is a Major Component of This Program Producing Commercial-size Wafers Since

15 Commercial-scale ITM Oxygen Modules have been Fabricated Step 1: Submodule Construction Step 2: Module Construction 12-wafer submodule 0.5 TPD O 2 Our goal: 1 TPD modules 15

16 Developed ceramic processing steps and forward pathways using full-scale equipment Ceramic Processing Infrastructure Continuous Tapecaster High Speed Laser Cutter Lamination and Cutting Operations Kiln 16

17 We Have Made Significant Progress A Summary Of Major Milestones Developed a stable, high-flux material Devised a planar wafer architecture Demonstrated the commercial flux target under anticipated operating conditions Demonstrated stable operation Scaled-up and produced commercial-size wafers in large quantities Built first commercial-scale ITM Oxygen modules Re-confirmed the economic benefits of the technology Confirm machinery integration pathway Test first commercial-scale ITM Oxygen modules 17

18 Gas Turbine Integration with ITM Oxygen OXYGEN AIR HRSG STEAM OXYGEN BLOWER ΔP FUEL ΔP ELECTRIC POWER Recuperator required? 18 HEAT EXCHANGE ΔP AIR OXYGEN ION TRANSPORT MEMBRANE ITM Oxygen Needs: Significant air extraction (>50%) Re-insertion of non-permeate stream into turbine (pressure loss) Independent flow and temperature control of extracted air stream and non-permeate Good efficiency and capital cost advantage retained ΔP ΔP

19 Collaboration with Siemens SGT6-6000G (W501G ) 266 MW Compressor Section Turbine Section Exhaust Cylinder & Diffuser Rotor & Operations Combustion Section Casings & Inlet Section Structural 19 Integration strategy: achieve air extraction/hot gas re-insertion without altering the existing compressor and turbine sections of the SGT6-6000G engine

20 Siemens SGT6-6000G /ITM Oxygen Integration: Issues and Solutions Issue Syngas vs. Natural Gas Hot non-permeate return to combustor NOx control Solution Redesign of burner New connections to burner Physical piping arrangement considered Materials selection Recuperation advantageous Steam injection 50% Air Extraction Achieved 55% air extraction without substantial changes to compression section. 20

21 Siemens SGT6-6000G /ITM Oxygen Integration: Issues and Solutions, cont d Pressure Drop Issue Solution Effects of pressure drop can be mitigated by various process changes. Hot gas manifolding Maximize gas distribution uniformity. System Operation Control system adds complexity, but does not pose any insurmountable challenges 21

22 SGT6-6000G/ITM Oxygen Layout Turbine Inlet Air Filter Air-to-air Cooler CO2 Fire Protection Syngas to ITM Preheater ITM Vessel Moist Syngas to GT Start Pkg Generator Turbine Exhaust Stack Vitiated Air to GT Compressed Air to ITM Auxiliaries ITM Vessel 22

23 Siemens SGT6-6000G /ITM Oxygen Integration: Work in Progress Identify Major Obstacles and Solution Paths Develop Conceptual Designs Estimate Nth Unit Costs Estimate Development Requirements/Costs 23

24 Phase 2 Concludes with Operation of a Subscale Engineering Prototype (SEP) Broad Project Goals: Test Commercial Scale Modules (up to 1 TPD oxygen each) Test concepts for vessel internal design Test process control strategy 24

25 SEP Test Facility Process Cycle Recycle Compressor Make-up gases (e.g., air) Commercial Scale Modules Economizer Oxygen to flow measurement Heater ITM Oxygen Vessel Vacuum pumps Forced air cooler Recycle Loop minimizes compressed feed gas requirement Performance of individual modules monitored independently Fully instrumented for remote operation/monitoring 25

26 ITM Oxygen Prototype for 1-5 TPD Oxygen 0.5 TPD O 2 Currently in Start-up Commercial-scale Module 26

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29 29 SEP Flow Duct Houses ITM Oxygen Modules with 3-6 TPD Capacity

30 ITM Oxygen ITM O2, Development Possible Plan DOE Being Proposal Developed With The DOE 10 Consistent with current DOE FutureGen timing of 2012 Capacity (T/D) Phase 2 Phase 3 FutureGen Year Onstream 30

31 Acknowledgment: DOE/NETL This paper was written with support of the U.S. Department of Energy under Contract No. DE-FC26-98FT The Government reserves for itself and others acting on its behalf a royalty-free, nonexclusive, irrevocable, worldwide license for Governmental purposes to publish, distribute, translate, duplicate, exhibit and perform this copyrighted paper. Disclaimer A significant portion of this report was prepared by Air Products and Chemicals, Inc. pursuant to a Cooperative Agreement partially funded by the United States Department of Energy, and neither Air Products and Chemicals, Inc. nor any of its contractors or subcontractors nor the United States Department of Energy, nor any person acting on behalf of either: 1. Makes any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately owned rights; or 2. Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this report. Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Department of Energy. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Department of Energy. 31

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