siemens igcc and gasification technology – today’s...
TRANSCRIPT
Copyright ® Siemens Power Generation, Inc. 2007All rights reserved
Siemens IGCC and GasificationTechnology –Today’s Solution and DevelopmentsFrank Hannemann, Manfred Schingnitz, Gerhard ZimmermannSiemens Power Generation
3
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
• Competitive terms & economics
• Compliance with tightening environ-mental standards
• Continuation of coal use
• Multi-pollutant emissions legislation
• CO2 mitigation efforts
• Coal price stability and availability
• High natural gas price
• Security of supply
Market drivers and challenges for clean coal
• Material enhancements
• Experience from IGCC demon-stration plants
• Gas turbine development
• Single source IGCC product
• Carbon capture and storage technologies (CCS)
Innovation
Clean Coal
Customer Requirements
Energy Sources -
Fuels
Government Influence
4
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Siemens PG FG (Fuel Gasification):Origins and focus of new PG entity
Sustec Holding AG
FUTURE ENERGYGmbH Sustec AG Sustec
Industries AG
Sustec GSP China Corp. Ltd.
SustecSchwarze Pumpe
GmbH
Scope of acquisition Not included
100% 100% 100%
50% (50% Shenhua Ningxia Coal Group)
Siemens acquired Sustec
Holding with subsidiaries
FUTURE ENERGY GmbH
(Freiberg, Saxony),
entrained-flow gasifier
technology company
(~ 60 employees)
Sustec GSP China Corp. Ltd.,
50% of the Joint Venture
(Beijing)
(~ 20 employees)
5
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Gasifier –Current SFG Design with Full Water Quench
Attributes☺ Flexible feedstock ☺ World class gasification test facility☺ Cooling screen for high availability☺ Dry feed for high efficiency☺ Quench technology for simplicity &
improved reliability☺ High water content in rawgas
partial CO shiftbenefit for chemical synthesesand IGCC with CO2 capture
Coal/Feedstock
Oxygen Steam
QuenchWater
Raw Gas
LP Steam
VenturiWash
Partial Condenser
to gas cleaning
Reaction 1300 to 1800°C
Quench
170 to 230°C
Black Water Treatment
Water
Sludge
LP Steam
Slag
Current designCooling of the raw gas to about 200°C by direct water quench and subsequent mechanical cleaning (water wash) for downstream gas treatment and synthesis
6
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Gasifier –NCPP: Largest Coal to Chemical Plant in China
Recent Success: 5 x 500 MWth (Ningxia Coal Based Polypropylen Project ) Contract signed Q1/2007; Start commissioning Q1/2009
NCPP Project:Province Ningxia
Distance to federal capital appr. 40 km
Customer:SNCG - Shenhua Ningxia Coal Industry
Group Co., Ltd.IPMT - Integrated Project Management Team
consisting of SNCG and AMEC
SFGT Scope:Engineering Contract (PDP)Engineering Supply Contract (Training, TFA ..)Equipment Supply Contract (Reactor, Burner ..)
7
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Gasifier –Determination of Parameters / First Project Phase
Anthracite
Petcoke
Lean coal
Forge coal
Fatcoal
Medium
-volatile coal
High-
volatile coal
Hard
brown coal
Soft
brown coal
95
90
85
80
75
70
65
60
55
Carboncontent Cdaf
[wt.-%]
0 10 20 30 40 50 60 70
Volatile matter content Vdaf [wt.-%]
5251 41
272621
282324 22
25
29
14 01
0215
1312
04
11
03
Coal known
Ultimate / Proximate AnalysisDetermination of Ash Fusion Temperature
Coal and Ash properties
known
Determination of Moisture Leveland Particel Size Distribution
Fluidisation Tests
Slag Viscosity and Deeper Coal Analysis
(e.g. Petrological)
Gasification Tests for high Ash Containing Coals or critical
Fusion Temperature
Basic Engineering Package and Project Execution
yes
yes
no
no
Costumer Inquiry
8
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Objective:• Measurements of slag melting behaviour up to 1800°C under
reducing atmosphere and with 2 different viscometers
Rotational viscometer
Falling body viscometer
Target:• Optimization of gasification temperature
• Systematic analysis of different slag compositions produced under both oxidised and reduced conditions
Correlation in melting behaviour
Set up of database
Gasifier -High Temperature Viscometer
0
5
10
15
20
25
30
35
40
1150 1200 1250 1300 1350 1400 1450 1500
Temperature [°C]
Visc
osity
[Pa
s]
T25 =1206°C
- Example of a short coal ash slag● Measurement with rotational viscometer
of Australien lignite
Viscosity Temperature Diagram
9
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Gasifier -High Pressure Test Rig for Coal Feeding
VV5000 M
ATMOSPHERE
FEED
ING LI
NE
INERT GAScontinuous40 bar
INERT GASdiscontinuous40 bar
DRUM DISCHARGE
WEIGHINGVESSEL
PULVERIZED
PNEUMATICCONVEYOR
ROTARYFEEDER
LOCKHOPPER
ATMOSPHERE
ROTARYFEEDER
FEEDERVESSEL
PULVERIZED
INERT GAS6 bar
DRUM STATION
COAL BIN
COAL BIN
LOCKHOPPER
ObjectiveTest of coal dust flow measurement and monitoring devices Comparison of different velocity measurements(capacity, frictional electricity .. .)
Test of alternative coal flow measurement technologies
Investigation of CO2 and other feeding gases for pressurisation, fluidisation and coal feeding
Optimisation of lock hopper cycle and de-pressurisationwith different throttling devices (silencer plates or ceramic valves)
Long term test of different dust flow valves
Investigation of fluidisation behaviour under elevated pressure condition
10
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Own gasification technology allows to optimize the complete system and offer competitive IGCC solutions
Transportation fuelsMethanolAmmoniaHydrogen
Air Separation Unit
Oxygen
Raw syngas
CO2 disposal or Enhanced Oil Recovery
(EOR)
Gasifier
Gas Island
Co-Production of Chemicals
Synthesis
Power Island
CCPP(Combined Cycle
Power Plant)
Siemens PG scope of delivery
Gasifier-Island
Raw GasShift
Coal Preparation
Coal
SulfurRemoval
Air
Slag and Filter cake
Sulfur
CO2Removal
Electricity
N2
H2 rich Syngas
Plant Design -Siemens Gasification Combined Cycle (SGCC)
11
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Gasifier –Partial Quench with Heat Recovery as Future Option
Future design for IGCCCombination of
Water quench of raw gas and slag down to 700 to 900°C(below ash melting point)Efficient use of the high temperature heat in the steam generator for HP steam generation (optional: IP steam)
Mid-term R&D project together with partnersSFG optimized for IGCC applications.
Optimization of the reactor similar to current designReliability
Optimization and design of the partial quench system by investigation of mass and heat transfer (supported by CFD)Development of a waste heat recovery steam generatorConstructional aspectsExperimental testing on pilot plant
12
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
500 MW~120.000 Nm3/h
(H2+CO)
1000 MW~246.000 Nm3/h
(H2+CO)
Objective :Optimized IGCC concept consisting of one gasifier and single shaft power train configuration
Advanced F Class SGCC Design with CO2 Capture
Plant Design -Optimized Concept between Gas Turbine and Gasifier
13
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Plant Design -Gas Conditioning as a Parameter for Optimization
Dilution with nitrogenHumidification
Mitigation of combustion conditions (reactivity, NOxformation)Enhancement of overall plant performance (increase mass flow, use of low temperature heat)
Linde Engineering
Integration of Air Separation Unitair- and nitrogen-side
Evaluation of integration concepts needs to look at the complete IGCC plant performance.
14
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Plant Design –Integration of Air Separation Unit
Linde Engineering
Nitrogen-side partial or non-integrated systems☺ Advanced premix combustion systems do
not need high dilution (and H2O moreeffective)
☺ Lower N2 compressor mass flow
Air-side partial or non-integrated systems☺ Operational behavior☺ ASU as separate plant unit for
independent gas supply ("over thefence") in case of non-integration
100 %
0 % 0 % 100 %
N2
Inte
grat
ion
Air-side Integration
100 %
0 % 0 % 100 %
N2
Inte
grat
ion
Air-side Integration
IGCC net power output IGCC net efficiency
GT power output limit
Compressormass flowreduced
Guide vanesfully open
Net power
Air-side integration
Thermodynamic study of effect of ASU on power output and efficiency –Typical trends
15
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Plant Design –Integration of Air Separation Unit
Linde Engineering
Nitrogen-side partial or non-integrated systems☺ Advanced premix combustion systems do
not need high dilution (and H2O moreeffective)
☺ Lower N2 compressor mass flow
Air-side partial or non-integrated systems☺ Operational behavior☺ ASU as separate plant unit for
independent gas supply ("over thefence")
100 %
0 % 0 % 100 %
N2
Inte
grat
ion
Air-side Integration
100 %
0 % 0 % 100 %
N2
Inte
grat
ion
Air-side Integration
air inlet pressurewaste N2 productpressurepower demand
ASU concepts differregarding
IGCC net power output IGCC net efficiency
16.5 bar air inlet5 bar N2
3 columns
6 bar air inlet1 bar N2
2 columns
11 bar air inlet3 bar N2
2 columns
16
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Plant Design –Integration of Air Separation Unit
Linde Engineering
Nitrogen-side partial or non-integrated systems☺ Advanced premix combustion systems do
not need high dilution (and H2O moreeffective)
☺ Lower N2 compressor mass flow
Air-side partial or non-integrated systems☺ Operational behavior☺ ASU as separate plant unit for
independent gas supply ("over thefence")
Integration defined by burner & turbine, plant layout, operational & economical aspects.For optimal performance optimum ASU configuration is needed.
100 %
0 % 0 % 100 %
N2
Inte
grat
ion
Air-side Integration
100 %
0 % 0 % 100 %
N2
Inte
grat
ion
Air-side Integration
Restriction bysyngas burner(combustability,geometry of gaspassages, etc.)
IGCC net power output IGCC net efficiencyH
eatin
gVa
lue
17
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Conclusion / Summary
Coal based ZEIGCC application are ready for demonstration and
subsequent commercialisation
Siemens offers both IGCC key components and provides integrated
and cost effective IGCC solutions
Siemens Gasification Combined Cycle (SGCC) Technology is
optimised for concepts with CO2 capture
Siemens gasification technology is well accepted and several
gasification projects are under consideration
High R&D investment into Freiberg facility ensures further
technology development
18
Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007
All rights reserved
Disclaimer
This document contains forward-looking statements and information – that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on the SEC’s website, www.sec.gov. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated.
Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.