Pre-Commercial Demonstration of High Efficiency, Low Cost Syngas Cleanup Technology for Chemical, Fuel, and Power Applications 2012 Gasification Technologies Conference October 30, 2012 David Denton (speaker) Raghubir Gupta Ben Gardner Brian Turk RTI International is a trade name of Research Triangle Institute. www.rti.org
Gasification is a Very Flexible Technology Power & Steam Carbon Source Iron Reduction Synthetic Natural Gas Gasification Fuel/Town Gas Naphtha & Waxes Syngas To Liquids Synthesis Gas H 2 Ammonia & Urea Alcohols Diesel/Jet/Gasoline Fuels Methanol Dimethyl Ether Ethylene & Acetic Acid Methyl Acetate Propylene VAM Ketene Acetate Esters Oxo Chemicals PVA Diketene & Derivatives Acetic Anhydride Chart Source: Eastman Chemical Company Polyolefins
But Gasification is Expensive: How to Reduce Its Cost? Efficiency Improvements Reduce All Elements of Cost ISBL Equivalent Capital Costs 2:1 Syngas ASU Syngas Cleanup is a Significant Cost Driver Coal/Pet Coke Gasification Graphics Source: Eastman Chemical Company CO 2 Compression SRU/TGTU AGR Cooling Train Shift Reactor
Regenerable ZnO sorbents Sulfur Transport reactor Direct Sulfur Recovery Process Regenerable NH 3 /HCN adsorbents RTI Warm Syngas Cleanup Technology Platform Hg adsorbents (disposable) As adsorbents (disposable) Se adsorbents (disposable) HCl adsorbents (disposable) Regenerable CO 2 sorbents Improves efficiency and lowers costs! Developed over 10+ years from concept to pre-commercial scale R&D 100 Award (2004) for regenerable desulfurization sorbent Operating temperatures > 450ºF to improve overall energy efficiency Pressure independent Effective for all forms of sulfur Fully compatible with conventional and warm CO 2 capture Flexible modular approach meets: Electric power generation specifications Industrial/chemical production specifications or ultra-clean power
High-Temperature Desulfurization Process Transport System ZnO + H 2 S ZnS + H 2 O ZnO + COS ZnS + CO 2 (600-1000 F) (300-600 psig) ZnS + 3/2O 2 ZnO+SO 2 (1200-1400 F) (300-600 psig) CLEAN SYNGAS SO 2 / N 2 TO SULFUR RECOVERY ADSORBER REGENERATOR REGENERATED SORBENT REGENERATED SORBENT TO ADSORBER MIXING ZONE RAW SYNGAS N 2 /O 2 (Air) RTI High-Temperature Desulfurization Process (HTDP) [Similar to Commercial FCC Reactor Designs] HTDP Pilot Plant at Eastman Chemical Co.
High Temperature Desulfurization Process (HTDP) > 99.9% removal of H 2 S and COS (< 5 ppmv effluent S) at temperatures > 600 F and pressures up to 600 psig > 3,000 hours of operation and parametric testing Lower attrition than commercial FCC systems Commercial-scale sorbent production at Süd Chemie Direct Sulfur Recovery Process (DSRP) > 99.8% SO 2 conversion to elemental sulfur Pilot-Scale Field Testing Accomplishments Trace Contaminant Removal Process (TCRP) > 95% NH 3 /HCN removal with regenerable sorbent > 90% Hg and As removal with fixed-bed sorbent Picture Source: Eastman Chemical Company
Pre-Commercial 50 MW e Syngas Cleanup Demonstration Project Objective: Demonstrate RTI s Warm Syngas Clean-up technology with integrated carbon capture at pre-commercial scale at an operating gasification plant Project Team RTI Tampa Electric Shaw Group, AMEC CH2M Hill BASF Süd-Chemie DOE/NETL Eastman Chemical Role Project management; technology developer Host site and operations oversight Engineering (Shaw - FEED, AMEC - EPC) Owner s engineer Technology (amdea ) for syngas CO 2 capture Produce sulfur sorbent & other catalysts Funding agency; project consultation Technical and operations support Tampa Electric Company s Polk Power Station Project Detail: Combined syngas cleanup /water gas shift/carbon capture demonstration $170M (DOE funding) to design, construct, and operate 50 MW e equivalent scale; capture > 90% of CO 2
Integration of Syngas Cleaning and Carbon Capture Systems at Tampa Site HTDP Water Gas Shift Reactor Syngas Cooling amdea CO 2 Recovery Air Project Scope To recycle, vent, or sequestration Air Separation Oxygen Coal/Petcoke GE Gasifier (400 psig) Slag Syngas Cooling Char Syngas Diluent (N 2 ) Scrubbers COS Hydrolysis Process Condensate Syngas Cooling Regenerator Gas MDEA Clean Fuel Gas Reheat/ Humidify Sulfuric Acid Plant Acid Gas Sulfuric Acid Extraction Air 8% H 2 O Raw Syngas ~ ~ 128 Mwe (122 Mwe) Process Clean 20% slipstream test (~50 MW Water Fuel Gas e ) enables direct commercial scale-up from this demonstration scale
CO 2 Capture: BASF amdea Process Feed Gas / Liquid CO 2, H 2 S amdea Source: BASF Higher absorption capacity Higher absorption kinetics Lower energy requirement for regeneration No degradation Chemically and thermally stable Non-corrosive nature Non-toxic and readily biodegradable amdea has the lowest specific energy consumption of any standard amines for acid gas removal. amdea s higher absorption kinetics and capacity reduce equipment size resulting in lower capex and opex. Exploiting amdea for CCS in IGCC requires upstream selective sulfur removal technology for syngas.
HTDP Scale-Up Factors EMN Pilot Plant Demonstration Commercial Size (MWe) 0.3 50* 600** Gas Flow (KSCFH) 17 2,000 24,000 Footprint (ft 2 ) 260 1,100 3,000 Absorber Mixing Zone Riser Regenerator Mixing Zone Riser 15 H x 2.5 ID 40 H x 1.5 ID 10 H x 1.5 ID 20 H x 1 ID 16 H x 54 ID 50 H x 28 ID 21 H x 14 ID 44 H x 8 ID 16 H x 15 ID 50 H x 8 ID 21 H x 4 ID 44 H x 2.5 ID * About half the size of commercial industrial gasification systems which are typically ~100 MWe. ** Approximately the size of current state-of-the-art IGCC reference plants (~600 MWe)
3-D Model Demonstration Project Objectives Demonstrate RTI s technology to reduce capital costs, improve efficiency, and lower the carbon footprint of advanced gasification Mitigate design and scale-up risks for the first commercial plant Obtain 5,000 to 8,000 hours of operations Establish RAM targets Determine performance metrics Verify capital and operating costs Validate start-up and shut-down procedures Capture >90% of carbon dioxide in syngas Extend development of trace contaminant removal, warm CO 2 capture, and direct sulfur recovery technologies
Project Status Engineering and EPC Shaw completed FEED in Sept., 2011 FEED-level cost estimate bids received from three EPC firms RTI selected AMEC Kamtech, Inc. as EPC contractor in October, 2011 Started detailed engineering early 2012 DOE/NETL approved proceeding to procurement, construction, and startup/ commissioning in September, 2012 Procurement and site construction was started in October, 2012 Mechanical completion targeted for January, 2014 Demonstration tests to be completed by July, 2015
Demonstration Project Schedule FEED 2011 2012 2013 2014 2015 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Complete Permit Air Permit UIC Permit EA Complete Complete Exploratory Complete; Descoped Detailed Eng Started Procurement Started Construction MC - 1/2014 Commissioning Schedule Assumes BP2 Authorization by Sept, 7, 2012 SC - 3/2014 SU/Operations and current vendor deliveries hold Decommissioning (Decommissioning shown as hatched may not be needed)
Benefits of RTI Technology for Power Generation RTI Warm Syngas Clean-Up technology benefits versus conventional syngas clean-up technologies (study performed by Nexant for 600-MW IGCC case): Increases overall efficiency by ~10% (3.6 points HHV) Dispatches ~10% more power Reduces CAPEX/KW by ~15% Reduces LCOE by ~10% Reduces makeup water consumption by ~25% Reduces wastewater by ~60% Reduces high-pressure N 2 requirements by ~40% Independent analysis performed by DOE/Noblis showed similar benefits. Detailed engineering estimates to date for the 50-MW demonstration project indicate that the projected benefits from these studies were conservative!
RTI s warm syngas cleanup technology coupled with carbon capture (using an advanced activated amine process) is also expected to: Benefits of RTI Technology for Industrial Applications Be 15-30% cheaper than conventional syngas cleanup technologies with carbon capture Produce syngas cleaning to levels suitable for use in chemical/industrial applications Provide higher overall efficiencies for conversion of feedstocks to finished products
Comparison of Technologies for Syngas S Removal and CO 2 Capture Characteristics Rectisol Selexol RTI + amdea Capture Mechanism Physical absorption Physical absorption Solid sorbent + chemical absorption Pressure Dependent? Yes Yes No Operating Temperature -40 F to -80 F 0 F to 40 F Sulfur Removal < 0.1 ppmv H 2 S + COS < 20 ppmv H 2 S (COS hydrolysis required) S removal: > 600 F CO 2 capture: ~100 F < 0.1 ppmv H 2 S + COS CO 2 Capture ~100% > 90% > 97% Relative Efficiency w/co 2 Capture < X% HHV X% HHV X+3% HHV Relative Capital Cost 1.0-1.15X 1.0X ~ 0.8X
Conclusions Gasification is a very flexible and useful technology, but existing technologies to clean syngas are expensive and reduce overall process efficiency, particularly when capturing carbon. RTI s warm syngas cleanup technology platform offers opportunities to both improve efficiency and significantly reduce costs of gasification for power generation and industrial/chemical applications. RTI s technologies have been proven with real coal-derived syngas at the pilot scale and a pre-commercial demonstration facility is now being constructed to mitigate technical and scale-up risks and enable commercial deployment of the technologies by 2015.
Acknowledgements DOE/NETL Jenny Tennant David Lyons Tampa Electric Company Eastman Chemical Company Shaw Energy & Chemicals (now acquired by Technip) AMEC Kamtech, Inc. CH2M Hill BASF Süd-Chemie (now acquired by Clariant)
QUESTIONS? David L. Denton Sr. Director, Business Development RTI International ddenton@rti.org (919) 485-2609