gasification technology conference “ · power plant area (6) boiler area (7) steam turbine area...

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“2007 GASIFICATION TECHNOLOGY CONFERENCE” October 14-17, 2007 – San Francisco (USA)

“ GASIFICATION TECHNOLOGY “ GASIFICATION TECHNOLOGY CONFERENCE “CONFERENCE “

San Francisco (USA) San Francisco (USA) –– OctoberOctober, 2007, 2007

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IGCC PLANT IGCC PLANT -- Falconara M.maFalconara M.ma“PERFORMANCE UPDATE AND FUTURE ENHANCEMENTS”“PERFORMANCE UPDATE AND FUTURE ENHANCEMENTS”

PAOLO CICCARELLIPAOLO CICCARELLI STEFANO BERTOLINISTEFANO BERTOLINI MAURO BEDETTIMAURO BEDETTIDirector of OperationsDirector of Operations Process Superintendent Process Superintendent Environmental Superintendent Environmental Superintendent

& T& Tech. Develop. Specialist ech. Develop. Specialist

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IGCC PLANT LAYOUTIGCC PLANT LAYOUT

OUTFALL SEA WATER

INTAKE

1

2

GASIFICATIONAREA

GASIFICATIONAREA (1) GASIFICATION AREA

(2) ABSORPTION AREA

3

4

5

AUXILIARYSYSTEMS

TO GASIFICATION

AUXILIARYSYSTEMS

TO GASIFICATION

(3) SULPHUR RECOVERY AREA

(4) GREY WATER TREATMENT AREA

(5) AIR SEPARATION UNIT AREA

6

8

7

9

10

11

COMBINED CYCLEPOWER PLANT AREACOMBINED CYCLE

POWER PLANT AREA

(6) BOILER AREA

(7) STEAM TURBINE AREA

(8) GAS TURBINE AREA

(9) ANNEX BUILDING AREA

(10) SEA WATER PUMPHOUSE AREA

(11) SEA WATER INTAKE AREA

132 KV SUBSTATION

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MILESTONES OF THE PROJECTMILESTONES OF THE PROJECT

Jan, 1997 Jan, 1997 CONSTRUCTION STARTCONSTRUCTION START--UPUP( Project Financing ~600.000.000€600.000.000€ )

Apr, 2001Apr, 2001 ACCEPTANCE TEST (PAC)ACCEPTANCE TEST (PAC)

2001 2001 –– 20032003 INTERRUPTED OPERATIONINTERRUPTED OPERATION( Availability Factor < 70%< 70% )

2002 2002 -- 20042004 RELIABILITY IMPROVEMENT PROJECT RELIABILITY IMPROVEMENT PROJECT ( Upgrading Investment = 50.000.000 €50.000.000 € )

20042004--20072007 RELIABLE OPERATIONRELIABLE OPERATION( Availability Factor > 90%> 90% )

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MAIN UPGRADINGSMAIN UPGRADINGS““RELIABILITY IMPROVEMENT PROJECT” CONCERNED THE RELIABILITY IMPROVEMENT PROJECT” CONCERNED THE

FOLLOWING ASPECTS:FOLLOWING ASPECTS:

AUTOMATIC CONTROL AND EMERGENCY LOGICS OPTIMIZATION;

(Gasifiers load control, ASU Supervision, GT emergency change-over, Master Controller)

UPGRADING OF EQUIPMENT AND PIPING METALLURGY;(Carbon Extraction: Superduplex / Oxygen System: Monel / Grey Water: Hastelloy)

SUBSTITUTION/UPGRADING OF SOME EQUIPMENT(UNDERSIZED, NON SUITABLE MATERIALS, UNRELIABLE)

(Air Intake Filters, Main Air Compressor, Water Flash Separator)

IMPROVEMENT OF PLANT INSTRUMENTATION AND REDUNDANCY

OVERALL TECHNOLOGICAL IMPROVEMENTS(New DeNOx System, Gas Turbine XL Technology, Gasifiers ….)

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GAS TURBINE PICTURESGAS TURBINE PICTURES

NEW GT AIR INTAKE FILTERNEW GT AIR INTAKE FILTER

NEW GT BLADESNEW GT BLADES“XL VERSION”“XL VERSION”

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MAIN AIR COMPRESSOR PICTURESMAIN AIR COMPRESSOR PICTURES

NEW AIR COMPRESSOR NEW AIR COMPRESSOR MOTORMOTOR

(24MW)

NEW AIR COMPRESSOR ROTORNEW AIR COMPRESSOR ROTOR(5 STAGES)

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RUNNING HOURS and AVAILABILITYRUNNING HOURS and AVAILABILITYIGCC - Operating Hours [%]

0%

20%

40%

60%

80%

100%

2001 2002 2003 2004 2005 2006 2007YEARS

OPE

RATI

NG H

OUR

S [h

]

IGCC - Gross Power Output [MWh]

0

250

500

750

1000

1250

1500

1750

2000

2250

2500

2001 2002 2003 2004 2005 2006 2007YEARS

GPO

[GW

h]

GPO [GWh]2001 13872002 14752003 14622004 22522005 21682006 21412007 2200

*Expected

OH [h]2001 64.2%2002 68.8%2003 62.4%2004 95.3%2005 90.4%2006 89.7%2007 91.0%

*Q3 - 2007

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ANNUAL OPERATING PLANT RESULTSANNUAL OPERATING PLANT RESULTS

91.0%89.7%90.4%95.0%TOTAL AVAILABILITY

90.1%88.3%87.6%90.4%AVAILABILITY at SYNGAS

2 (A + B)1 (C)2 (B - A)1 (A)NUMBER of INSPECTIONS

6434338187UNSCHEDULED S/D [h]

523870504252SCHEDULED S/D [h]

64118.7243403DIESEL OPERATION [h]

5901773776747943SYNGAS OPERATION [h]

Q3-2007200620052004

CONTINUOUS REDUCTION OF DIESEL OIL OPERATIONCONTINUOUS REDUCTION OF DIESEL OIL OPERATION

DECREASE IN UNSCHEDULED SHUTDECREASE IN UNSCHEDULED SHUT--DOWN HOURSDOWN HOURS

PRESERVING EXCELLENT PLANT AVAILABILITYPRESERVING EXCELLENT PLANT AVAILABILITY

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FUTURE ENHANCEMENTS

CO2 CAPTURE CO2 CAPTURE STUDIESSTUDIES

REDUCTION OF NOx EMISSIONREDUCTION OF NOx EMISSION

HYDROGEN PRODUCTION HYDROGEN PRODUCTION FROM SYNGASFROM SYNGAS

BIOFUEL COBIOFUEL CO--GASIFICATIONGASIFICATION

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SCOPE OF THE PROJECTSCOPE OF THE PROJECTSupply Biofuels to Gasification mixed with heavy residues

GOALSGOALSRespond to increasing requests to improve environmental protection. Increase the environmental friendly value of the IGCC Technology.

Access to “Green Certificate System”

TARGETTARGETTo produce 20-30 MW of “green energy” by feeding ~5 ton/h of biofuel

into Gasifiers (7-10% of the overall power production)

BIOFUEL COGASIFICATION

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STEPS OF THE PROJECTCOMPLETE FAMILIARIZATION WITH AUTHORITY REGULATIONS

IDENTIFICATION OF THE MOST SUITABLE BIO-FUELS(compatible both with technology and legislation )

ECONOMICAL EVALUATION

FEASIBILITY TESTS

GENERAL BIO FUEL SUPPLY CONTRACTS

DETAILED ENGINEERING OF PLANT MODIFICATIONS

FINALIZATION OF LEGISLATIVE PERMISSIONS(approval of plant modifications and authorization of incentive rates)

PLANT MODIFICATION

CO-GASIFICATION START UP

IN PROGRESSIN PROGRESS

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STRENGTHS &WEAKNESSESCOGASIFICATION STRENGTHSCOGASIFICATION STRENGTHS

ENVIRONMENTALLY COMPATIBLE TECHNOLOGY

MILD REDUCTION OF CO2 EMISSION

EASY TO BE IMPLEMENTED (just minor plant modifications needed)

ECONOMICAL VALUE OF GREEN CERTIFICATES

INCREASE PLANT PROFITABILITY

COGASIFICATION WEAKNESSESCOGASIFICATION WEAKNESSESHIGH COSTS OF CONVENTIONAL BIOFUELS (in continuous increase);

LACK OF A CLEAR AUTHORITY REGULATION

UNCLEAR LIST OF ACCEPTED BIOFUELS (Glycerin ?)

RAW BIO-PRODUCTS NOT EASILY AVAILABLE (for about 50000 t/y)

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INTEGRATION WITH EXISTING PLANT

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“ GASIFICATION TECHNOLOGY “ GASIFICATION TECHNOLOGY CONFERENCE “CONFERENCE “

San Francisco San Francisco –– OctoberOctober 14th14th--17th, 200717th, 2007

www.apienergia.com

gasification technology conference “ · power plant area (6) boiler area (7) steam turbine area...

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