advances in igcc projects & technology for the next ... · • 33 ge licensed gasification...

23
Advances in IGCC projects & Technology for the next generation of IGCC & Carbon Capture CC(+S) plants Marcus Scholz 2010 GE Energy

Upload: truongthu

Post on 21-Jul-2018

214 views

Category:

Documents


0 download

TRANSCRIPT

Advances in IGCC projects & Technology for the next generation of IGCC & Carbon Capture CC(+S) plants

Marcus Scholz2010

GE Energy

���������� ������

Agenda

• IGCC Project experience & current activity• Lessons learnt & technology

improvements• GE’s Carbon Island™ technology• Carbon Capture levels• Gas Turbine hydrogen fuel flexibility

���������� ������

Leadership • Gasification leadership since 1948 with

>70 facilities operating worldwide • >130 gasification vessels in operation

Experience• First coal gasification plant in 1978• First pet coke gasification plant in 1984• 27 gas turbines operating on syngas …> 1 million

operating hours• IGCC leader… > 3 GW with GE technologies

- Cool Water technology demo plant 1984-1989- TECO commercial demonstration plant 1996-

present- DUKE Energy commercial plant …COD 2012

GE’s leadership & experience

���������� ������

Diverse Solutions – based on Gasification

Substitute Natural Gas• SNG

…> 60 years !

Chemicals• Ammonia• Methanol• Oxo-chemicals

Power Generation• Electricity• Steam• Hydrogen + CO2

Refinery Polygeneration• Hydrogen• Steam• Power

Transportation Fuels• Jet• Diesel

Feedstocks:• Coal • Pet coke• Asphalt• Heavy Oil• Vacuum Residue

���������� ������

Syngas to Hydrogen (CO2 separation)

Gasification

Partial oxidization

“Shift”- Process

Water-Steam / Syngas Reactor

Copper or Zinc Basis

CO2 Capture + Compression

AGR & CO2 CompressionSelexol Refrigeration: >90% Removal

Power GTDiffusion burner

Diluent (N2, Steam)

Syngas shift & extract carbon photos courtesy of Air Products, Baytown, TX facility.

CO + H2O > CO2 + H2H2 & CO H2 & CO2

H2

CO2

GE Carbon Island* option

* Carbon Island is a trademark of the General Electric Company.

���������� ������

IGCC Plants evolution

Pilot(1984-89)

Coolwater• 120 MW IGCC

• 7E Gas Turbine

• development project

Tampa Electric • 250 MW IGCC

• 7FA Gas Turbine

• 5 Year Construction

Duke Energy• 630 MW IGCC

• 7FB Gas Turbine

• 3 Year Construction

Commercial(1996 – today)

LargeCommercial(2012 - tomorrow)

���������� ������

Licensee/Owner: Sarlux S.r.lOperator: SARAS S.p.A.Location: Sardinia, ItalyStartup: 2001Feedstock: Visbreaker tarDesign Capacity: 1,200 mTPDOperating Pressure: 38 barGasifier Size: 3 x 900 ft³Power Block: 3 x GE 9E GT’s,

3 x GE Steam turbinesEPC Contractor : Snamprogetti S.p.A.

Gasification & Carbon Extraction

Gas Cooling &

COS Hydrolysis

Oxygen

VisbreakerTeer

ElementalSulfur

Sulfur Claus &

Recovery

Steam export refinery

Power to Grid

IGCC – Polygeneration SARLUX 550MW

GE Combined

Cycle

Hydrogen Production

H2 to Refinery

3,600 t/day

551 MW

40,000 Nm3/h

MP = 100 t/h; LP =85 t/h

Black WaterTreatment

Filtration cake

Metal recovery

Steam to export

90+% availability (no spare)

���������� ������

Duke Energy Edwardsport IGCC • Nominal 630MW, 207FB CCGT

• COD in 2012

• Construction on-track

• 2x RSC + gasifier shipped in 2009

• 7F Syngas turbines ship in 2010

• Wide coal & pet coke fuel envelopeDuke Energy Edwardsport site construction, Sept. 2009

���������� ������

Gasifier & Radiant syngas cooler sections�������������������� ����������������������� ���

����������� ����������������� ������

����������������������������

������������������������

��������������

��������������������������

Gasifier productionItaly, 2009

Transport in 2 sectionseach.

���������� ������

Gasification Area

Coal unloading Area

RSC assembly area

Duke Edwardsport IGCC … July 2009

Gasification IslandConstruction

COALHarbour

GasifierSection assembly

���������� ������

Take aways: IGCC is about integration

����

� ��� � �����

���

��� ���

���� �����

��������

Value proposition:– 48 month cycle (FEED to COD)

Eliminate 1 yr. from custom IGCC sched.– Wide bituminous fuel envelope (ash+S) – Carbon capture ready– Fully integrated Mark VIe control

system with 12 mo. factory accept. test– Virtual plant simulator…Failure modes

mitigated, Operators trained before startup

���������� ������

Today:• Detailed design complete• Components at site• On-site assembly in process

Radiant syngas cooler

2006:• Lessons learned• Detailed analysis• Improved design meth.• Availability &

performance improvmt.• 30% better perform.;

30% lower cost; higher reliability versus TECO configuration

1996:First application:TECO

���������� ������

Today:• Stage testing in process• Simulators in operation• Operators in training• Design validation

Next Steps:• Site transition• ICS delivery

Integrated controls and simulation

��

��������� �����

�������� ��� ���� ��������������������� ��� ������

����� �� ��� ���� �������������������� �������

������������� �������� ������

� ������� � ��� ����! ���" ������� #��$��

������� �� � ����� ���� �� �!�"����� ��

#�� � ����� �� �!�����$ �% ����� �

& ��'�(��� ��� ���� ��� � �)*%

#�� � ����� �� ���� ����$ �% ����� �

�#��

��%

�#��

��&

�#��

��'

�������� ��� ���� ��������������������� ��� ������

��� ���� ������������������

�(�� ����� � �������������� �

�(�� �������������������������� ��� ����

(��� ��� ��+��� �)*%

������� ������,��� ��� ��� ������� � ������

�� ���������$ � �������- �� ��� ��� �

#�� � ���� ������� ����� ���� �� ������������ ��� ���� �� � ��

)������*��� �� �

2006:NPI Project

2008:Detailed Validation Plan• Physics based - emulated• Stage testing• Field validation• Operator training simulator

���������� ������

Metal Wall

Syngas Tube

Water Tube

OperatorTraining

SimulatorEngineering Simulator

Control Hardware Emulator

Simulation Model

Control Software

Instructor Station

Generate Physics Based Transient Equipment Models

Engineering Class Simulation for Controls Operability & Operator Training

Simulation reduces time to maturity

Operability Optimization• Enhance Start-up Times and Trip Avoidance• Operational Flexibility… Emissions, Heat

Rate• Plant-wide Availability/ Reliability Studies • Improved Transient Performance• Customer Training

� �� ���+�! �� ������,���,��+ ����-

���������� ������

Improving initial availability

Reference plant Goal: initial availability of 85%

47.8

64.8

88.7 92.7 90.688.7

1996 1997 1998 1999 2000 2001

TECO Polk Unit 1 IGCC AvailabilityGasifier on Stream Factor

Combined Cycle Availability Factor

���������� ������

IGCC flexibility for carbon value

0

20

40

60

80

Entitlement5% Capture

Eintitlement20% Capture

NG EquivalentRetrofit

60% Capture

NG EquivalentGreenfield

65% Capture

Greenfield90% Capture

CO

2A

void

ed C

ost $

/ton

1

Lowest capital cost

Lowest operating penalty

Highest avoided cost

CCS Readymeets proposed

EU regulation

Flexible – NGCC CO2 Performance

1 Capture with compression to 150 bar, excludes T&S

EOR or High CO2

Value

Source: GE Energy internal data

COEcc ($/MWh) – COEbase($/MWh)

CO2base(ton/MWh) – CO2cc (ton/MWh)Avoided Cost ($/ton) =

���������� ������

GE’s Carbon IslandTM

• Greenfield • Retrofit

– Minimal cost/availability impact– Integrated with existing Acid Gas

Removal (AGR)– Installed during turbine

maintenance • Multiple carbon capture capability

options• Commercial technologies

– 33 GE-licensed units operating worldwide using shift reaction

. High purity CO2

. Small footprint – 2 acres

. Reliable CO2 separation process

. Install as greenfield or as an economical retrofit for 65% CO2 capture

���������� ������

IGCC CO2 Capture Readiness

CO2SHg

Water Gas Shift(50%-65% capture)

PowerPower

Oxygen,Feedstock

Process Gas OnlyHigh P, Low Vol

High Driving Force

Slag

Proven Process

AGR / SRUAGR / SRUOptional ShiftOptional ShiftGasificationGasification

Diffusion CombustorDiluent NOx

Control

H2

Proven Turbines

Proven Gasification

• 27 GE Gas Turbines operating at 50%-95% H2

• 70 GE Licensed Gasification Plants operating worldwide

• 33 GE Licensed Gasification Plants operating worldwide removing CO2 and producing H2

���������� ������

Experience

Scale-up Pilot(10-30MWt)

Small Commercial(50-100MWt)

LargeCommercial

(>350MWt)

Com

mer

cial

Sta

tus

Med

2Lo

w3

Full1

1Commercially offered… guaranteed cost & performance2 Requires shared risk & cost for scale-up to pre-or-full commercial3 Technical feasibility only… unknown cost, performance &

integration barriers

Pre-combustion (IGCC)Commercial plants

(up to 450MWt >90% CC)

Post-Combustion (Amine)

Slipstream NG & coal(Max ~60MWt NGCC)

Post-Combustion (Powerspan)

Slipstream pilot (1MW)

Post-Combustion (Chilled Ammonia)Slipstream Pilot (5MW)

Oxy-combustion30MW pilot

Chemical LoopingMe/MeO ox/red

Bench scale

Carbon capture technology maturity

Feasibility(1-5MWt)

Bench

���������� ������

Combustion SystemCombustion System

Cold End

Drive

Axial Exhaust

Small Modifications to existing Gas Turbine Platform

Hot Gas PathHot Gas Path

Hydrogen Combustion in Gas Turbines

Hydrogen has been used in Gas Turbines for over 30 years,

primarily in Refinery applications..

���������� ������

B/E-class High Hydrogen ExperienceProject / Site

GT Model

No. Units

Fuel Gas Features

Geismer, US MS6001B 1 PG up to 80% H2 Refinery, US MS6001B 1 RFG 12 - 50% H2 Korea MS6001B 1 PG up to 95% H2 Tenerife, Spain MS6001B 1 RFG ~70% H2 Cartagena, Spain MS6001B 1 RFG 66% H2 San Roque, Spain MS6001B 2 RFG 70% H2 Antwerpen, Belgium MS6001B 1 RFG 78% H2 Puertollano, Spain MS6001B 2 RFG up to 60% H2 La Coruna, Spain MS6001B 1 RFG up to 52% H2 Rotterdam, NL MS6001B 1 RFG 59% H2 Schwarze Pumpe, GER MS6001B 1 IGCC 62% H2

Vresova, CZ MS9001E 2 IGCC 46.8% H2 Fawley, UK MS9001E 1 RFG ~50% H2 Georgia Gulf, US MS7001EA 3 Blend Methane + 50% H2 Milazzo, ITA MS5001P 1 RFG 30 - 50% H2 Ref., India MS5001P 1 RFG 50% H2 Paulsboro, US MS5001P 2 RFG 20 - 60% H2 Ref., Int'l MS5001P 1 RFG Propane + 60% H2 Reutgerswerke, US MS3002J 1 PG 60% H2 NUP MS3002J 1 TG ~60% H2 Donges, US GE10 1 RFG 76% H2 Refinery, Jordan PGT10 1 RFG 82% H2 RFG = Refinery Gas, TG = Tail Gas, PG = Process Gas, IGCC = Syngas

Fleet Leaderavg. 90% H2more than 10 yrs

���������� ������

F-class Hydrogen ExperiencePSI

WabashTampa

PolkExxon

SingaporeValaro

DelawareTurbine 7FA 7FA 2x6FA 2x6FAH2 (% vol) 24.8 37.2 44.5 32.0

CO 39.5 46.6 35.4 49.5CH 4 1.5 0.1 0.5 0.1CO2 9.3 13.3 17.9 15.8N2+Ar 2.3 2.5 1.4 2.2H2O 22.7 0.3 0.1 0.4

LHV BTU/ft 3 209 253 241 248kJ/m3 8,224 9,962 9,477 9,768

Tfuel F/C 570/ 300 700/ 371 350/ 177 570/ 299H2/CO Ratio 0.63 0.80 1.26 0.65Diluent Steam N2 Steam H2O/ N2

Equiv BTU/ft 3 150 118 116 150kJ/m3 5,910 4,649 4,600 5,910

���������� ������

Summary• 60 years of experience in gasification

operation and innovation

• 25 years of IGCC experience

• Significant investments in design methods; tools; and validation facilities

• 16 months from first fire of Duke Energy IGCC facility

• Investing in next generation industrial and power gasification technology