Shell Coal Gasification Process for Power and CO 2 capture Gasification Conference Freiberg, June 2005 Rik van der Ploeg Rob van den Berg Ico van den Born Shell Coal Gasification Process for Power and CO 2 capture Introduction, Progress Features, Benefits European Case Study 400 MW_e net - German Brown Coal - Results With/Without Capture Conclusions 2005 2 1
Shell Gasification Optional Products Coal Lignite Petroleum Coke CO CO 2 2 CC_Cogen Power Generation Electricity Steam Biomass Oil/Resid Gas Shell (Coal) Gasification Process Syngas Chemical feedstock Conditioning/ distribution Hydrogen other chemicals Town gas Orimulsion Liquefaction Transportation Fuel 3 Shell Gasification Projects New SGP projects: - Agip Sannazzaro Refinery - Opti, Canada - Rafineria Gdanska, Poland - Fujian, China New SCGP projects: -12 projects in China - 1 project USA (WMPI) 4 2
Shell CoalGasification Projects in China Owner Place Feed t/d H2+CO 10 6 Nm 3 /d Products Startup 1 2 3 4 5 Sinopec/Shell Shuanghuan Liuzhou Sinopec Sinopec Yueyang Yingcheng Liuzhou Zhijiang Anqing 2000 900 1200 2000 2000 1.4 1.7 2005 2005 6 7 8 9 10 11 Yuntianhua Yunzhanhua Dahua Shenhua Yongcheng Zhongyuan Anning Huashan Dalian Majiata Yongcheng Puyang 2700 2700 1100 2 x 2200 2100 2100 1.7 2 x 3.7 3.2 3.2 H2 2007 2007 2007 12 Kaixiang Yima, Henan 1100 1.7 2008 5 SCGP Process Flow Diagram COAL/PETCOKE FLY ASH RECIRC. MILLING/DRYING N2 GASIFIER 1600 C QUENCH GAS 900 C Or MP Steam only HP STEAM MP STEAM MP-HP BFW COAL FEEDING DRY SOLIDS REMOVAL WET SCRUBBING GAS TREATING CLEAN SYNGAS LP STEAM SLAG FLY ASH SYSTEM WATER TREATMENT STM CONDENSATE O2 FLY ASH TO MILLING AND DRYING SALTS SULPHUR 6 3
SCGP Reactor & Cooler Assembly Features/Benefits Reactor Membrane wall life-time expected > 25 yrs Burner life-times > 20,000 hrs Reactor-Syngas Cooler train feasible up to 5000 tpd Reactor-Syngas Cooler ~40% cheaper - Steam system simplified (MP only, piping, materials) - Wider procurement options equipment, standardization N 2 or CO 2 as carrier gas Availability 90% (scheduled maintenance project specific) - Water-cooled skirt - Slag crusher - Improved ASU interface (ASU itself separate issue) 7 Shell Treating in Synthesis Gas Service ADIP/Sulfinol (wordwide > 700 licenses) 13 Oil gasification (2 in combination with SGP) 16 Synthesis gas from steam reforming 2 Coal gasification SCOT, SulFerox, HCN/COS hydrolysis, Shell-Paques 8 4
Gas Treating Building Blocks Amine + Acid Gas Processing SulFerox 9 Shell SulFerox Process H 2 S removal by liquid redox treated gas V-11 V-12 depleted air to vent H 2 S + 2 Fe 3+ 2 H + + S + 2 Fe 2+ fuel gas or flare sulfur filter sour gas C-11 V-13 E-11 C-21 K-21 P-21A/B V-21 P-31A/B P-32 Applications -Low-S AGR (up to 15 t/d S) -Absolute selectivity for H 2 S -Applied in several waste gasification units 10 5
SCGP IGCC Brown Coal Study Main Premises Project location Germany (ISO conditions) Project life 25 years, 85% full load IGCC Project cost basis 2005, US Gulf Coast budget type EPC contractor soft costs typical, no Owners Cost s/risks Single string 400 MW_e net power, V94.3 based Low-S, high moisture (>50%) Brown Coal, steam dried CO 2 @80 bara dried, 85% capture included (Cases 2,3) Electricity price (year 0) 50 $/MWh (higher than now) Fuel price (year 0) 1 $/GJ (assumed) 11 SCGP IGCC Brown Coal Case Study Case 1 CO2 + NOX Multi BFW export HPS + Reheat LPS export Condensate to DA HPS + MPS HRSG GT(G) STG Elec. Partial Air Draw-off Fuel Gas & N2 & H2O Condensate to HRSG/DA ASU Partial N2 Return Fuel Conditioner BFW LPS HPN2 HPO2 Coal/ Petcoke Coal Milling & Drying & Feeding Feed MF Gasification Reactor & Syngas Cool Dry & Wet Solids Removal COS/HCN Hydrolysis & AGR Claus/SCOT S Heat BFW Slag Removal Sour Slurry Stripper & WWT Process Water Acid Gas to SRU CO2 Process Water Slag Flyash Effluent Water IGCC Reference Case 12 6
SCGP IGCC Brown Coal Case Study Cases 2, 3 H2O + NOX (+ CO2) HPS + Reheat Multi BFW export Condensate to DA MPS Elec. HPS (option) HRSG GT(G) STG Partial Air Draw-off H2 & N2 & H2O Condensate to HRSG/DA Partial N2 Return ASU Condensate Recovery Fuel Conditioner & Preheat BFW HPN2 HPO2 MPS H2-rich Syngas LPS Brown Coal Coal Milling & Drying & Feeding Feed MF Gasification & Dry/Wet Solids Removal CO shift COS/HCN Hydrolysis SulFerox H2S Removal DIPA CO2 Removal CO2 CO2 to pipeline Compressor & Dryer LPS Flyash BFW S Slag Removal & Primary Water Treat Acid Gas to Incin Process Slag Effluent Water Water Brown Coal IGCC with CO 2 Capture 13 SCGP IGCC Brown Coal Study Econ Results (1) Capex [$/kw_e] 2000 1800 1600 1400 1200 1000 800 600 400 200 0 Relative investment increase 24-31% due to capture Ref - CO2 - CO2 - SGC130 SGC130 SGC50 Case 1 Case 2 Case 3 CC Power Plant Gasification ASU AGR-SRU-Shift-CO2 IGCC general 14 7
SCGP IGCC Brown Coal Study Econ Results (2) 70 Relative Cost Of Electricity increase ~20% due to capture COE_zeroprofit [$/MWh 60 50 40 30 20 10 0 Ref - SGC130 CO2 - SGC130 CO2 - SGC50 Case 1 Case 2 Case 3 15 Conclusions SCGP based IGCC for Carbon Capture Non-Captured IGCC400 Reference (HP steam system SCGP) LHV efficiency 44-45% including steam drying IGCC costs can be as low 1350 $/kw_e Captured IGCC400 Plants Options (HP and/or MP steam system) LHV efficiency 35.7-37.7% including steam drying IGCC costs can be as low as 1680-1760 $/kw_e Relative investment increase 24-31% Relative Cost Of Electricity increase ~20% (excluding pipe, wells) And more improvements / synergy options in the pipeline 16 8