TRONDHEIM CCS CONFERENCE June 15, 2011 6th Trondheim Conference on CO 2 Capture, Transport and Storage Pedro Casero Cabezón (pcasero@elcogas.es) ELCOGAS S.A (www.elcogas.es) 1
SCOPE IGCC & ELCOGAS, S.A CARBON CAPTURE PILOT PROJECT MAIN LEARNINGS TEST RESULTS COSTS 2
SCOPE IGCC & ELCOGAS, S.A 3
IGCC & ELCOGAS, S.A 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% COAL C (%p) 36.27 Ash (%p) 41.10 S (%p) 0.93 LHV (MJ/kg) 13.10 PET COKE C (%p) 82.21 Ash (%p) 0.26 S (%p) 5.50 LHV (MJ/kg) 31.99 Repsol YPF Refinery POWER OUTPUT EFICIENCIA (PCI) GROSS TOTAL (MW) NET TOTAL (MW) 317.7 282.7 GROSS (%) NET (%) 47.12 42.2 Puertollano IGCC Power Plant ENCASUR (open cast coal mine) 4
IGCC & ELCOGAS, S.A 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 5
SCOPE CARBON CAPTURE PILOT PROJECT 6
CARBON CAPTURE PILOT PROJECT Consejería de Educación, Ciencia y Cultura Company Location Feed gas Size ELCOGAS, S.A. IGCC Puertollano Power Plant Coal gas 20-24 bar 14 MWt (2% slip-stream of the IGCC plant) Capture Technology Precombustion. Capture > 90%. It is not expected CO 2 storage. Budget Construction and commissioning: 13,5 M Funding programme Started 2005 Operation Octubre 2010 PSE, cofinanced by MICINN and JCCM 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.
CARBON CAPTURE PILOT PROJECT Pilot plant diagram process COAL + COKE Recycle compressor GASIFICATION Raw gas FILTRATION SYSTEM 183.000 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 Pilot plant size: 1:50 ~ 14 MW t H 2 rich gas 37,5 % CO 2 50,0 % H 2 3,0 % CO MP STEAM SHIFT Reactor CO 2 & H 2 (Sweet /Acid) separation (Chemical, amdea) CO + H 2 O CO 2 + H 2 100 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 2 @ 15 bar 8
CARBON CAPTURE PILOT PROJECT IP Steam Generator Adsorber PSA1 Adsorber PSA2 Adsorber PSA3 Adsorber PSA4 Product H2 IP Steam Coal Gas Shifting Reactor 1 Shifting Reactor 2 Nitrogen Start-Up Desulfuration Reactor Aircooler Process Gas Preheater Steam LP Generator Tail Gas H2 Rich Gas Water Refrigerator Syngas Separator Cond. Separator Process Cond. Absorber Syngas CO2 Product CO2 cooler CO2 Separator To Pump Stripper CO2 From CO2 Separator Pump Reboiler amdea MDEA cooler MDEA/MDEA exchanger 9
CARBON CAPTURE PILOT PROJECT Milestones Construction permit: December 2008 Commissioning: May-October 2010 1 st CO 2 t captured: 13 September 2010 100 hours run with sweet gas and co-production of hydrogen: Nov 2010 End of sweet capture tests: February 2011 End of programmed tests (within PSE-CO 2 ): June 2011 700 t of CO 2 captured and 6 t of H 2 pure produced up to Feb 2011 10
CARBON CAPTURE PILOT PROJECT 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 Main suppliers Engineering CO 2 Unit PSA Unit Control Reactors Catalysts On-line analysis system Construction Empresarios Agrupados Linde-Caloric Linde Zeus Control Técnicas Reunidas Johnson Matthey ABB Process Automation Division Local companies 11
CARBON CAPTURE PILOT PROJECT Shifting unit + CO 2 wash unit 12
CARBON CAPTURE PILOT PROJECT Official Presentation 29/04/2011 13
INDEX MAIN LEARNINGS 14
MAIN LEARNINGS 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 12-14 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. 16.000 14.000 12.000 TOTAL QUOTE OF THE PP PROJECT UPDATED EVERY YEAR (k of the quoted year) 547 535 521 241 531 235 521 542 1.088 EQUIPMENTS SERVICES PERSONNEL OTHERS 509 833 508 508 877 877 10.000 514 693 4.010 4.875 5.156 8.000 6.000 13.000 13.000 13.000 2.383 Total quote of the PP project updated every year 4.000 7.004 8.441 8.300 8.173 2.000 0 2005 2006 2007 2008 2009 2010 2011 15
INDEX TEST RESULTS 16
TEST RESULTS 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 Design Lab Analysis H 2 50.05 51.88 0.19 0.314-1.31 79.75 82.3 83.14 99.99 99.959-99.995 CO 2.92 1.85 0 0.053-0.07 4.65 2.86-3.78 4 ppm N/A CO 2 37.56 37.36 99.78 98.2-99.622 0.5 0.02-0.82 1 ppm N/A i) All compositions are in % vol. (dry basis) ii) Analysis carried out by ELCOGAS Laboratory N 2 8.76 8.30 0.01 0.05-0.28 13.97 12.2-13.6 15 ppm 4-17 ppm Ar 0.71 0.60 0.02 0.01-0.09 1.13 0.89-0.97 80 ppm 3-14 ppm i) All compositions are in % vol. (dry basis) ii) Analysis carried out by ELCOGAS Laboratory 17
TEST RESULTS Sweet 3 20-22 Jan 2011 Characterization of the water gas shift reaction unit with sweet gas 20,0 15,0 The inlet second reactor temperature is higher than expected 20/01/11 17:24-28:35 FIRST REACTOR Conversion very close to theoric, although higher reactor outlet temperature. CO (%) 10,0 STEAM GENERATOR 5,0 JM FRESH SECOND REACTOR JM Simulation (01/01/10) Real Values (SWEET3 test) 0,0 300 350 400 450 500 550 600 Temperature (ºC) Johnson Matthey Selection Fresh Potential (Johnson Matthey) High Temperature Potential (High Temperature) The high conversion obtained in the first step (near 95%) will make considering a shifting process with only one step. 18
TEST RESULTS Sweet 2 17-20 Jan 2011 Characterization of the CO 2 & H 2 separation unit (amine washing) with sweet gas Steam consumption vs CO 2 recovery Inlet gas F LOW (2502 Kg/h)) Desortion T HIGH (104 ºc) Steam consumption (MWh/TonCO 2 ) Pump circ F LOW (25 m 3 /h) Desortion T LOW (81,7ºC) Desortion P LOW (0,6 bar.g) Desortion P HIGH (1,2 bar.g) Pump circ F HIGH (57 m 3 /h) Inlet gas F INTERMEDIATE (4400 Kg/h) % CO 2 recovery 19 14
TEST RESULTS Sweet 1 15-19 Nov 2011 Characterization of the H 2 purification unit with sweet gas Test Parameter Variation Assessment Effect on cycle time Effect on H 2 purity Effect on H 2 recovery rate 1 2 3 4 Pure H 2 pressure Tail gas pressure Inlet temperature Increase O.F 5 Inlet flow Increase Not good Increase Decrease Good = = = Increase Decrease Good = Decrease = Increase Decrease Not good = = Decrease Increase Increase Good = = Increase Increase Decrease Decrease Good Decrease Increase Decrease Not good Increase = Decrease The PSA is quite stable and not affected by variation of the different parameters 20 14
TEST RESULTS Comparison versus design Parameter Design Real 1 C.G.E 88,6 % 88,0 % 2 η thermal 75,3 % 73,1 % Shifting 3 Ratio steam/gas 1,37 1,42 4 Mol ratio steam/co 2,88 2,85 5 C.G.E 99,9 % 96,9 % 6 Aminas η thermal 71,2 % 69,9 % 7 Ratio steam/co 2 0,88 MWh/tn CO 2 0,79 MWh/tn CO 2 8 C.G.E 88,5 % 85,3 % 9 Global η thermal 60,2 % 57,2 % (shifting+aminas) 10 CO 2 recovered 91,7 % 90,6 % 21 14
INDEX COSTS 22
COSTS 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 25-30 / t CO 2 4) Comparing to other studies 30 for ELCOGAS retrofit Fuente: DOE/NETL CCS RD&D ROADMAP December 2010 23
COSTS Variables Data Expected life 25 Bank interest 3.0 % CO 2 Capture Costs (SWEET) CO 2 cost, /t CO 2 Bank fee 0.5 % Scale factor 0.75 Operating hours (IGCC mode) 6,500 h Average load factor 0.92 Electricity price 40 /MWh Net efficiency of power plant with CO 2 capture 33 % Treated gas 100 % 90 80 70 60 50 40 30 3.000 h 3.500 h 4.000 h 4.500 h 5.000 h 5.500 h 6.000 h 20 6.500 h 10 27 28 29 30 31 32 33 34 35 36 37 IGCC plant efficiency w ith CO 2 capture, % 7.000 h 7.500 h 24
COSTS Minimum pure H 2 price depending on the electricity price 6 /Kg Better to sell H 2 5 Minimum H2 price per fix cost of production (external personal and spares) depending on anual production hours. 4 3 90.000 Kg/y 1080 h 60.000 Kg/y 720h 2 120.000 Kg/y 1440 h 1 420.000 Kg/y 5040 h 180.000 Kg/y 2160 h Better to sell electricity 0 0 50 /MWh 100 150 25
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 26
TRONDHEIM CCS CONFERENCE June 15, 2011 6th Trondheim Conference on CO 2 Capture, Transport and Storage Pedro Casero Cabezón (pcasero@elcogas.es) ELCOGAS S.A (www.elcogas.es) 27