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Gasification Technology Conference 2009Gasification Technology Conference 2009
Colorado Springs, USAOctober 04-07, 2009
Prospects for Gasification in a Carbon Constrained Prospects for Gasification in a Carbon Constrained ppWorld:World: A European PerspectiveA European Perspective
Fausto Ferrari (Speaker) Saipem S.p.A. - Italy
Coauthor:Coauthor:
Ivano Miracca Saipem S.p.A. – Italy
IndexIndex
IntroductionIntroduction Gasification Projects OverviewPl t A il bilitPlant AvailabilityCCS PerspectiveSaipem CCS ExperienceConclusionConclusion
Saipem Global PresenceSaipem Global PresenceHuman Resources by Nationality:
Italy18%
India10%
Nigeria8%
Others <2%17%
Algeria Philippines
• 37,990 people @ December 31, 2008•115 Nationalities
Malaysia2%
2%
Nepal2%
UK2%
Saudi Arabia2%
Angola3%Russia
3%
Perù4%
France7%Venezuela
5%
8%
Kazakhstan7%
Paris Milan
Operating and E i i H b
Fano
ChennaiEngineering HubsEngineering CentresYards & Main Logistic BasesOther Main Areas and Other Main Areas and Representative Offices
Saipem FinancialsSaipem Financials
(M€)
Revenues Backlog
1910519105 1901519015
New Contract Acquisitions
100941009493189318
92019201
70497049
1543615436913591351386013860
1184511845
75227522
53245324
313100
51255125
93189318
472472435435
51585158
24062406
14631463701701
3759375934173417
17271727
38043804
7522752260706070
1197119716441644 760760635635 50685068
23402340
38633863
00
34633463420420
24062406
21972197286286269269
2008200820072007 1H20091H2009
4682468242154215 43494349
2008200820072007 1H20091H2009
4381438134963496
16441644 23402340
331331533533
186418642008200820072007 1H20091H2009
OnshoreOffshore
Saipem Group Business UnitsDrilling Offshore
Onshore
IntroductionIntroduction
Topics:Topics:• “Learning curve” in design, construction and
operation of IGCCp• High Availability of IGCC plants >90%• Experience & Lesson learnedExperience & Lesson learned• CCS application to gasification• Economics of CCS• Economics of CCS• CCS activities in Saipem
Gasification PlantGasification PlantContract SummaryContract Summary
Cli tClient ISAB Sarlux Eni-EniPower
Contract type LSTK LSTK LSScope of work EPC EPC EPCScope of work EPC EPC EPCContractor(s) SP(50)/FWI(50) SP(58)/GE(42) SP
Licensor(s) GE(Texaco) GE(Texaco) ShellDow/Lurgi UOP/Lurgi Dow/UOP
Detailed eng SP/FWI SP SPDetailed eng. SP/FWI SP SPConstruction SP/FWI SP SP
POWER BLOCK Ansaldo Industria GE AnsaldoEnergia
Projects OverviewProjects OverviewSSSummarySummary
SARLUX (SARLUX (~550 MWe)~550 MWe) ISAB Energy (ISAB Energy (~560 MWe)~560 MWe) ENI (~250 MWe)ENI (~250 MWe)
- Feedstock: VVR(Tar) - Feedstock: Asphalt - Feedstock: VVR(Tar)- GE(Texaco) “quench” - GE(Texaco) “quench” - Shell “radiant cooler”- “Low” pressure (38 barg) - “High” pressure (67 barg) - “High” pressure (62 barg)- “Physical” SRU (Selexol-UOP) - “Hybrid” SRU (MDEA-Dow) - “Hybrid” SRU (MDEA-Dow)- Sulphur tail gas recycled - Sulphur tail gas to incinerat. - Ni-Carbonyls removal- Hydrogen (Membr.+PSA -UOP) - Expander - Hydrogen (Membr.+PSA) - 3 x STAG109E (GE/NP) - 2 x V94.2 (Siemens/Ansaldo) - 1 xV94.2K(Siemens/Ansaldo)- 3 gasif.trains + 2 LTGC etc. - 2 gasif. + 1 LTGC etc. - 2 gasif. + 1 LTGC etc.
- Comm. op.: Jan.2001 - Comm. op.: April 2000 Comm. op.: July 2006
Projects OverviewProjects OverviewENI IGCCENI IGCCENI IGCCENI IGCC
EniPowerEni Gas & Power
Ansaldo-SiemensV94-3A.2
EniPowerEni Gas & PowerNatural gas (12.5 km new pipeline)
(400 MW)
Ansaldo-SiemensV94 3A 2V94-3A.2(400 MW)
A ld Si
Eni Refining & Marketing
G ifi i lH2 Ansaldo-SiemensV94-2K
(250 MW)
Gasification plant50 t/h Tar
H2
Syngas
Projects Overview ENI IGCCProjects Overview ENI IGCCCCU
SYNGASCCUPPU
T FU
HYD
TA
AC
I
R fi
TAR
UELG
AS
CW
DR
OG
EN
AIL G
AS
ID G
ASES
BD
MPS
DW BD
Refinery(FIRE WATER, IW, WATER TREAT., IA, SIGNAL EXCH., etc.)
Plant AvailabilityPlant AvailabilitySyngas ProductionSyngas ProductionSyngas ProductionSyngas Production
90%
100%
70%
80%
90%
ISAB Energystart-up 2000
50%
60% SARLUXstart-up 2001
ENI R&M
30%
40%
ENI R&Mstart-up 2006
10%
20%
0%I II III IV V VI VII VIII
Year of commercial operation
Shutdown Duration DistributionShutdown Duration Distribution
Planned
ISAB Energy gasification ENI R&M gasification
InstrumentationExternal
Planned23%
External , 16%
Planned, 36%
14%External
24%
C t 5%Mechanical
4%
Operational
Instrumentation, 4%Operational, 1%Common part, 5%
Operational16%
Common part19%
Mechanical, 38%
period: 2006 -2008period: 2003 -2008
GasificationGasification
• Saipem gasification plants have reached 94% of availability
• First year of operation availability enhanced to 74%
• First year performance to be increasedFirst year performance to be increased implementing feedback and lesson learnt to get 90% of availability during the first year Such results can be extended to coal• Such results can be extended to coal gasification
Gasification + CCSGasification + CCS
Next step: gasification + CCSNext step: gasification CCS• Many countries (EU, USA, Australia, Canada, New Zealand, Japan)
has introduced CO2 emission limit and/or capture & sequestration economic bonuseconomic bonus
• CCS application will develop following stringent trend of emission reduction regime
• Gasification is the “natural” technology for CCS concept application• Gasification is the natural technology for CCS concept application since pure (and dried) CO2 can be easily separated
• All major components of CCS technically proven and referenced (shift & AGR unit CO compression and liquefation transportation &(shift & AGR unit, CO2 compression and liquefation, transportation & storage)
• Storage and pipeline are the key factor for CCS economics
Hydrogen From GasificationHydrogen From Gasification
SULPHUR
H2 from gasification + CCS Process Block DiagramNITROGEN
AIRSEPARATION
UNIT
SULPHURRECOVERYAIR
OXYGEN
SULPHUR
GASIFICATION & SHIFTACID GASREMOVAL
ACID GAS
HYDROGEN
CARBON DIOXIDE
FILTRATION & CO2 PSA
SLAG & ASH
FEEDSTOCKSLAG / ASH
CARBON DIOXIDE
COMPRESSION& LIQUEFATION
FEEDSTOCK HANDLING TREATMENT
HYDROGEN
FILTER CAKE
TRANSPORTATION
INJECTION &= unit added for CCS application INJECTION & STORAGE
= unit added for CCS application
Power From GasificationPower From GasificationPower from gasification + CCS
Process Block Diagram
AIRSEPARATION
UNIT
SULPHURRECOVERYAIR
SULPHURNITROGEN
GASIFICATION & SHIFT ACID GASREMOVAL
ACID GASOXYGEN
POWER FILTRATION & CO2 SATURATION
SLAG & ASH
FEEDSTOCKSLAG / ASH
CARBON DIOXIDE
COMPRESSION& LIQUEFATION
FEEDSTOCK HANDLING TREATMENT
FILTER CAKE
TRANSPORTATION
INJECTION &= unit added for CCS application INJECTION & STORAGE
unit added for CCS application
= unit modified for CCS application
CCS Economical ImpactCCS Economical Impact
€/kg CO2
(low)
€/kg CO2
(high)
Notes
Gasification to
Hydrogen
9.3 14.5
Gasification to 24 29 2
CO2 delta cost: LOW case=
Availability of storage ready to
be fed and the shortGasification to
power
24 29.2 be fed and the short
transportation distance
Cost includes Capex and OpexNatural gas to
power
38.9 45.1 Cost includes Capex and Opex
1 Mt/year CO2 case study
based on in-house data
Location: Italy
Gasification + CCSGasification + CCS
European policyEuropean policy• European enviromental policy based on Emission
Trading Scheme (ETS)• ETS applied to european industrial and energy
installations (nationals quotes decided by centralized authority)authority)
• Allowances are allocated to industrial operators (CAP)• New stringent policy for 2013-2020 to be set on g p y
december 2009 (deviation foreseen)• Operators within ETS limit can trade the allowance• CAP will decrease starting 2012 increasing the price of
carbon trade
CCS PerspectiveCCS Perspective
Emissions vs EU Cap Trend
31003300
Emissions
2500270029003100
O2
EU CAP
1900210023002500
Mt C
15001700
2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
CCS PerspectiveCCS Perspective
CCS economical impact vs EUA EUAp
30 035,040,0
EUA
CCS (H2
10 015,020,025,030,0
€/kg
CO
2 plant) - lowcaseCCS (H2plant) high
0,05,0
10,0
008
008
008
009
009
009
011
013
015
017
020
€ plant) - highcaseCCS (powerplant) - low
02/01
/20002
/05/200
02/09
/20002
/01/200
02/05
/20002
/09/200
23/09
/20122
/10/201
21/11
/20120
/12/201
19/01
/202
date
caseCCS (powerplant) - highcasedate case
CCS PerspectiveCCS Perspective
• CCS applied to gasification is sustainable due to pp geuropean (and other countries) carbon emission policy
• CO2 emissions price forecast stable in future atCO2 emissions price forecast stable in future at high level due to limitation in GHG emission
• Capex difference between NGCC and IGCC d d ith CCS i l t tireduced with CCS implementation
• High impact of transportation and storage on CCS economicsCCS eco o cs
• Availability of onshore, exhausted wells close to the plant will drop the capex of CCS
CCS: Saipem ExperienceCCS: Saipem Experience
• Saipem built experience on the whole chain of p pCCS supporting ENI in the preparation of the CO2 injection in Cortemaggiore: scheduled start in 2010.
• Saipem services included:o Modeling / simulation of the diffusion of injected CO2 in the reservoir
using an in-house software (TMGAS).g ( )o Modeling / simulation of CO2 interaction with the caprock and the
wellbore cement using software validated on experimental results.o Coordination of caprock integrity studies to evaluate the risk of leakage.o Design /installment of a sub-surface tool for continuous monitoring ofo Design /installment of a sub surface tool for continuous monitoring of
CO2o Design of the surface facilities for storage/injection of CO2
CCS: Saipem ExperienceCCS: Saipem Experience
evolution of the CO2 plume in the reservoir in 2 years
• Start of CO2 injection on 2010:
o Three years of CO2 injectiono Two years of monitoring
ConclusionConclusion
• Lack of gasification plant availability was a significantLack of gasification plant availability was a significant hindrance for the gasification application in the power industry.
• Saipem has reached over 90% of availability on 3 IGCC plants in Italy for a total of 1.4 GWe installed
• Same results can be achieved in coal gasification: 90% of availability starting from first year of operation is a reachable targetTh t t f ifi ti i t d b th CCS• The next step of gasification is represented by the CCS implementation to permit the respect of new GHG emission policy of many countries
• The application of CCS would increase the cost of gasificationThe application of CCS would increase the cost of gasification products (power and hydrogen) to be recovered trading the CO2 allowance developed due to new environmental policy
ConclusionConclusion
• In European Community the forecast is to have CO2 emission price covering the investment for CCS unit starting 2013T t ti d t t t it• Transportation and storage represent an opportunity to reduce the capex and increase the economics of such technologyS i h l t d id i ti• Saipem has a complete and wide experience acting as a complete EPC contractor from gasification to CO2 storage passing through capture and transportationtransportation.
THANKS TO:THANKS TO:Claudio Allevi SarluxClaudio Allevi, Sarlux
Roberto Lavecchia, ENI Power;, ;
Raffaella Lucarno and Claudio Zanelli, ENI R&M;
G.Guarino and Daniele Castiglia, ISAB Energy;
THANK YOUTHANK YOU
S����� S���A�
Fausto FerrariGasification Technology Manager
Phone: +39-02-52049841Phone: +39-02-52049841Fax: +39-02-52049834e-mail: fausto.ferrari@saipem.eni.it
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