puertollano igcc power plant....2007/10/04 · 8 puertollano igcc power plant - elcogas igcc, ngcc...

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Puertollano IGCC Power Plant - ELCOGASPUERTOLLANO IGCC POWER PLANT. OPERATIONAL EXPERIENCE AND

CURRENT DEVELOPMENTS.

International Freiberg Conference on IGCC & XtL Technologies

8-12 May, 2007 —

Freiberg, GermanyPedro Casero, Elcogas, S.A.

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Puertollano IGCC Power Plant - ELCOGAS

European company established in April 1992 to undertake the planning, construction, management and operation of a 335 MWISO IGCC plant located in Puertollano (Spain)

THE ELCOGAS COMPANY

EDF INTERNATIONAL

31,4%

ENEL4,3%

Autocartera0,2%

SIEMENS2,5%

Krupp Koppers GMBH0,04%

Hidrocantábrico4,3%

Electricidade de Portugal

4,3%ENDESA

GENERACIÓN 40,9%

Babcock Wilcox

Española0,1%

Iberdrola Generación

12,0%

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G

GAS TURBINE

200 MWISO

Flue gas to stack

SteamHeat Recovery

Steam Generator

G

STEAM TURBINE

135MWISO

Cooling tower

Hot combustion gasCondenser

Coal Petroleum CokeLimestone

Coalpreparation Gasifier

Slag

Sulfur (99.8%)

SulfurRecovery

Quench Gas

O2

Air

Clean syngas

Raw GasCoal - N2

HP Boiler

MP Boiler Waterwash

Fly ash

Claus gas

HP Steam

MP Steam

Air Separation Unit

N2

O2

Compressed air

Waste N2

Process description

Filtration Sulfur Removal

Tail Gas

Waterto treatment

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Fuel

COAL PET COKE FUEL MIX(50:50)

Moisture (%w) 11.8 7.00 9.40Ash (%w) 41.10 0.26 20.68C (%w) 36.27 82.21 59.21H (%w) 2.48 3.11 2.80N (%w) 0.81 1.90 1.36O (%w) 6.62 0.02 3.32S (%w) 0.93 5.50 3.21LHV (MJ/kg) 13.10 31.99 22.55

Power output and emissions

GASTURBINE

(MW)

STEAMTURBINE

(MW)

GROSSTOTAL(MW)

NETTOTAL(MW)

POWEROUTPUT

182.3 135.4 317.7 282.7

GROSS NETEFFICIENCY(LHV) 47.12% 42.2%

EMISSIONS g/kWh mg/Nm3 (6% Oxygen)SO2 0.07 25NOx 0.40 150

Particulate 0.02 7.5

Main design data

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Raw and clean gas data (2006 update)

Actual average Design Actual average Design

CO (%) 59.26 61.25 CO (%) 59.30 60.51

H2 (%) 21.44 22.33 H2 (%) 21.95 22.08

CO2 (%) 2.84 3.70 CO2 (%) 2.41 3.87

N2 (%) 13.32 10.50 N2 (%) 14.76 12.5

Ar (%) 0.90 1.02 Ar (%) 1.18 1.03

H2 S (%) 0.81 1.01 H2 S (ppmv) 3 6

COS (%) 0.19 0.17 COS (ppmv) 9 6

HCN (ppmv) 23 38 HCN (ppmv) - 3

Raw Gas Clean Gas

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Emissions in NGCC and IGCC modes Natural gas (mg/Nm3 at 6% O2 dry)

2,9

291,7

29,24,2

223,8

0,50,0

50,0

100,0

150,0

200,0

250,0

300,0

350,0

SO2 NOx Partículas

EEC 88/609ELCOGAS Permit limitsELCOGAS 2006 average

Coal gas (mg/Nm3 at 6% O2 dry)

500

50

135,9

0,450

400

650

200

25

200

70,2

0

100

200

300

400

500

600

700

SO2 NOx Partículas

EU Directive 88/609/EECEU Directive 2001/80/EECELCOGAS Permit limitsELCOGAS 2006 averageNGCC mode

IGCC mode

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19961997

19981999

20002001

20022003

20042005

20062007

2008

Oct ‘96 - Commercial operation of CC with NG (1st CC in Spain)Mar ‘98 - 1st Switch-over to syngas in the GT. 1st production as IGCC

Dec ‘06: 14,673 GWh (9,184 GWh with coal gas)

Severe fault in main generation transformer of GT50.000 EOH Gas Turbine major overhaul

Power plant main milestonesPower plant main milestones

75.000 EOH Gas Turbine major overhaul

March ’07: New record on syngas: 958 hours

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IGCC, NGCC and Total yearly production

9335

911

1.3911.595

1.371 1.2931.129 1.150

744

836

622

321

343

301 452

421 312

0

500

1.000

1.500

2.000

2.500

1998 1999 2000 2001 2002 2003 2004 2005 2006

year

NGCC GWhIGCC GWh

752

1,171

1,5331,712

1,938

1,672 1,7441,550

1,462

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Variable Cost of Electricity (2006)

Fuel mode Fuel Heat rate

(kJHHV /kWh)Fuel cost(€/GJHHV )

Partial cost

(€/MWh)

Total cost (€/MWh)

GNCC Natural gas 7,649 7.84 59.97 59.97

IGCC

Coal 2,934 2.19 6.4318.01

Petcoke 5,994 1.44 8.63

NG aux 376 7.84 2.95

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Variable Cost of Electricity vs Fuel cost evolution

29,37

35,34

59,97

30,71

18,0115,85

14,5513,45

0

1

2

3

4

5

6

7

8

9

10

2003 2004 2005 2006

€/GJ HHV

0

10

20

30

40

50

60

MWh/ €

Variable cost of electricity produced with NG

Variable cost of electricity produced with coal-Cost of Natural

Cost of coal

Cost of pet coke

COST OF FUEL

VARIABLE COST OF

ELECTRICITY

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Availability 2006

80,8

68,0

65,0

52,0

13,716,9

17,8

17,4

5,515,017,230,6

0%

20%

40%

60%

80%

100%

IGCC GASIFIER POWER BLOCK ASU

Availability Planned Outages Unplanned Outages


ASU

6%

GASIFICATION

46%

COMBINED CYCLE

29%

BOP

19%

FLY ASH 14%

WATER STEAM30%

COAL PREPARATION

2%

QUENCH GAS CIRCULATION

6%START UP BURNER7%

FUEL FEEDING7%

GAS TREATMENT11%

SULFUR RECOVERY

11%SLAGS

12%

GAS SATURATOR

6%WATER STEAM CYCLE19%

GAS TURBINE75%

WASTE NITROGEN PRODUCTION

62%

PURE NITROGEN PRODUCTION

22%

OXYGEN PRODUCTION

16%

DCS16%

SERVICE SYSTEMS

6%

ELECTRIC SYSTEMS

78%

IGCC unavailability 2004-2006

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Project title: Advanced technologies of CO2 conversion, capture and storage (PSE-CO2)

Programme: Spanish National Energy Programme (Ministry of Education and Research)

Coordinator: CIEMAT

Status: Started on 2005.

Target:

Development of CO2 capture technologies, allowing a sustainable use of coal for power productionDevelopment of conversion technologies that facilitate CO2 captureDevelopment of deep geological storage capacities for captured CO2

Structure Composed by 5 sub-projects

Spanish Research Initiative in CO2

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PSE-CO2 S/1: Pre-combustion CO2 separation technologyCoordinator: ELCOGAS

Partners: University of Castilla la Mancha, Empresarios Agrupados, Técnicas Reunidas, INCAR-CSIC, CIEMAT

Target:To validate at industrial, bench and laboratory scale the technologies of pre-combustion CO2 capture associated to an IGCC Power Plant

Rationale:-To test the concept of CO2 capture in a industrial IGCC plant-To help in the design of the next generation IGCC plant-To maintain the concept of innovation that Elcogas plays in Europe

Approach:

Assessment of commercial technologies for CO2 separation (Pilot Plant Installation 1:50 scale)Assessment of appropriate technologies but still not commercially available for CO2 separation (bench & laboratory scale)

Budget: ∼19 M€

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CO2 capture and H2 production Pilot Plant

REACTOR 2

GAS PREPARATION AMINES UNIT

H2 rich gasPSA unit

480ºC

350ºC

390ºC

SHIFT conversion

REACTOR 1

310ºC

H2: 53,7 %CO: 11,4 %CO2: 0,12 %Q: 1.511 Nm3/h

Clean syn-gasH2: 21,9 %CO: 60,4 %CO2: 2,7 %COS: 12 ppmH2S: 0,2 ppmQ: 3.600 Nm3/hP: 20 barT: 135 ºC

H2: 50,0 %CO: 3,1 %CO2: 37,5 %COS: 0 ppmH2S: 8 ppmQ: 5.610 Nm3/hP: 16,4 bar

H2: 50,0 %CO: 3,1 %CO2: 37,5 %COS: -- ppmH2S: 8 ppmQ: 5606 Nm3/h

CO2 topost-treatment

H2: 0,2 %CO: 0,01 %CO2: 99,8 %H2S: 21 ppmQ: 2.108 Nm3/h

H2: 79,9 %CO: 4,9 %CO2: 0,05 %H2S: 0 ppmQ: 3.498 Nm3/h

pure H2

tail gas

H2: 99,9 %CO: 4 ppmQ: 1.987 Nm3/h

Electrical consumption:1.389 kWMP steam consumption: 4,5 t/hBP steam consumption: 19 t/hRefrigeration water: 320 t/h

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P&ID Shift Converter Unit

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Pilot Plant implementation

Gasification unit

Air Separation Unit

Power Block

Pilot Plant for CO2 capture and H2 production

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Pilot Plant implementation

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Project title: Research Project on Biodiesel Support in Spain (PIIBE)

Programme: Strategic National Consortia (Ministry of Industry)

Coordinator: REPSOL-YPF

Target:Move Spain into vanguard of R&D in renewable biodiesel sectori) To reduce production cost down to those of gas-oil from petroleumii) To expand availability of local raw materials

ELCOGAS ACTIVITY:

Leader of “Biodiesel production through gasification”: to assess the viability of biodiesel production through biomass gasification ⇒

execution of real co-gasification tests up to 10% with biomass (estimated biomass consumption of 3000 t during 2 years).Started in 2006. Budget: 900 k€

Spanish Research Initiative in Biodiesel

Orujillo(olive oil waste) Almond shells

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PUERTOLLANO IGCC POWER PLANT. OPERATIONAL EXPERIENCE AND

CURRENT DEVELOPMENTS.

Thank you

for

your

attention

Pedro Casero, Elcogas, S.A.www.elcogas.es

puertollano igcc power plant....2007/10/04 · 8 puertollano igcc power plant - elcogas igcc, ngcc...

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