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15/24/2010© 2010 General Electric Company.
Bottomless Refinery & GasificationImprove Refinery Economics & Reduce Emissions through Gasification
Mike Thuillez Region Commercial Director
Copyright 2010 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
25/24/2010© 2010 General Electric Company.
Leadership•
Gasification leader since 1948 with
65 facilities currently operating worldwide
•
130 gasification vessels in operation
•
~40 industrial gasification plants separating carbon today
Experience•
First oil gasification plant in 1961
•
First coal gasification plant in 1978
•
First pet coke gasification plant in 1984
•
30 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 Edwardsport commercial plant …COD 2012
GE’s leadership & experience
35/24/2010© 2010 General Electric Company.
Gasification for refinery upgrades
•
Hydroskimming refinery is long on fuel oil …
decreasing margins
•
Demand for transportation fuels is increasing …
residue conversion
•
Regulations require lower sulfur …
short H2
•
Gasification utilizes refinery bottoms to produce H2
, Steam, Electric Power
Bottomless refinery …
higher margins & lower emissions
45/24/2010© 2010 General Electric Company.
Integrate residue conversion & gasification
Atm. or Vacuum Residue
Simple Refinery
• Visbreaker (Tar)
• Solvent Deasphalting (Asphalt)
• Delayed Coking (Coke)
Residue Conversion Secondary Processing
• Hydrocracker
• FCCU
• Hydrotreating (Sulfur)
(By-products)
Gasification & power island
- H2
- Steam
- Power
Polygeneration
(Integration)
- Heat Integration
- Common Sulfur Removal
- Common AGR
- Save on H2
compression
- Reduced emissions
55/24/2010© 2010 General Electric Company.
SyngasRefinery
Bottoms
Heavy oil based IGCC –
H2
& Power
GasificationIsland
Air
Separation
Unit
Shift and Cooling
O2
Solid waste
Acid Gas Removal
PowerIsland
Electric
Power
Pressure
Swing
Adsorption
Pure H2
To Refinery
Sulfur Recovery
Sulphur
H2
S
Clean Syngas
H2
CO2Shifted
Syngas
•
Combined cycle for higher efficiency …
Gas Turbine, Heat Recovery Steam Generator, Steam Turbine
•
Particulate clean-up through a simple scrubber which requires no filters
•
Carbon extraction & filtration for metals reclamation from soot water
65/24/2010© 2010 General Electric Company.
GE’s quench gasifier for heavy oil
•
High throughput entrained flow quench gasifier
•
Simple pressure vessel configuration for local manufacturing
•
Single feed injector with a symmetric flame pattern reducing refractory wear
•
Refractory is low cost & reliable thermal barrier
•
Hot syngas immediately quenched by direct water contact
•
Syngas is warm & saturated with water…
ideal for sour CO shift → hydrogen production
•
Commercial application up to 86 barg
•
Proven and reliable gasifier sizes up to 25.5 m3
(900 ft3)
Key Characteristics
75/24/2010© 2010 General Electric Company.
Case studyBasis•
70:30 mix of Arab Light/Heavy…
Visbreaker Tar, Solvent Deasphalting, and Delayed Coking
•
Refinery size of 6 MM TPA and 10 MM TPA
•
Configuration enhanced for high H2
availability
Results•
Most attractive case:3200 MTPD Feed
E-Class Combined Cycle
76,000 NCMH H2
•
Reduced Emissions:NOX < 50 mg/NCM
SOX < 10 mg/NCM
• COE ~4-5 Cents/kWh
85/24/2010© 2010 General Electric Company.
GE Gasification
Gas Cooling
Oxygen
Visbreaker Tar
150 t/h
Sulphur
Sulphur Removal & Recovery
Steam to Refinery
LP =85 t/hPower to Grid
551 MW
Sarlux Refinery polygeneration
GE Combined
Cycle
Hydrogen Production
H2 to Refinery
40,000 Nm3/h
WastewaterPretreatment
Filter Cake
to metals reclaimer
Steam to Refinery MP = 100 t/h
Licensee/Owner: Sarlux S.r.l
Operator:
SARAS S.p.A.
Location:
Sarroch (Cagliari), Sardinia, Italy
Startup: 2001
Feedstock: Visbreaker tar
Design Capacity: 50 t/h (per gasifier)
Gasifier Size:
3 x 900 ft³
Power Block: 550MW –
3x109E CC Units
>90% availability (no spare)
95/24/2010© 2010 General Electric Company.
GE Gasification
& Carbon Extraction
Gas Cooling &
COS Hydrolysis
Oxygen
Asphalt
140 t/h
147 t/hr(Future)
Sulphur
Sulphur Removal & Recovery
Steam to Refinery
LP = 6 t/hPower to Export
550 MW
ISAB Energy Refinery IGCC
Combined Cycle
WastewaterPretreatment
Filter Cake
to metals recovery
Steam to Refinery MP= 16 t/h
>90% availability (no spare)
Licensee/Owner: ISAB Energy S.r.l.Operator: ISAB Energy Services S.r.l.Location: Priolo, Gargallo, Sicily, ItalyStartup: 2000Feedstock: Asphalt Design Capacity: 70 t/h (per gasifier)Operation Pressure: 70 barGasifier Size: 2 x 600 ft³ QuenchEPC Contractor: Foster Wheeler Italiana
105/24/2010© 2010 General Electric Company.
ISAB Refinery emissions results
S0x NOx Particulates*Data provided by ISAB Energy Services on behalf of ERG
Refinery before gasification
DM 12/07/90 Authority limitsRefinery after GE gasification technology
0
1000
20001700
400
74
500
20052 80 50 10
Emis
sion
s (m
g/N
m3)
115/24/2010© 2010 General Electric Company.
Coffeyville ResourcesLicensee/Owner: Coffeyville ResourcesOperator: Coffeyville ResourcesLocation: Coffeyville, Kansas, USAStartup: 2000Feedstock: Petroleum Coke Design Capacity: 1300 STPD (per gasifier)Operation Pressure: 620 psig (43 bar)Gasifier Size: 2 x 900 ft³ QuenchEPC Contractor: Black & Veatch
GE Gasification & Syngas Scrubbing
CO Shift
& Cooling
Oxygen
Petcoke
1300 t/d
Fertilizer
Acid Gas Removal
Pressure Swing
Absorption
Ash / Slag
Handling
>90% availability (no spare)
CO2
Capture
Sulphur Recovery
CO2
Purification
UAN Plant
Ammonia Synthesis
NH3 Product
1100 STPD
Sulphur
125/24/2010© 2010 General Electric Company.
Feedstock
No. of Gasification
Plants
No. of Operating Gasifiers
Commercial Operation Since
Naphtha 3 3 1997Crude Oil 1 2 1961
Heavy Fuel Oil 7 14 1966Visbreaker Tar 3 6 2000
Steam Cracked Tar 1 2 2001Heavy Residue 1 2 1995
Vacuum Residue 9 17 1980Asphaltenes 2 5 2000
Petcoke 5 11 1984
Total 32 Plants 62 Gasifiers
GE Gasification refinery experience
135/24/2010© 2010 General Electric Company.
Summary
•
Convert low value contaminated refinery bottoms to H2
, Steam, & Power
•
Reduce Fuel Oil surplus …
Cutter-Stock
•
Lower net refinery emissions
•
Improve refining gross margins
•
COE estimated at ~4-5 Cents/kWh
Bottomless Refinery …Gasification … Utility Island for Refinery