Freiberg, 16-17 June 2005

Improving the Puertollano IGCC dedusting system: pilot plant erection

and testing

B. Navarrete, M. Lupión, F.J. Gutiérrez, V.J. Cortés, P. Coca, F. García Peña

escuela superior de escuela superior de

INGENIEROS DE SEVILLA INGENIEROS DE SEVILLA

Presentation by: Mónica Lupión

Escuela Superior de Ingenieros de Sevilla

CONTENTS

PUERTOLLANO IGCC PLANT• Main design data

• Dedusting system

TEST FACILITY

• Main characteristics

• Basic Diagram

• Components details

EXPERIMENTAL FILTRATION TEST PLANNING• Fundamental Variables

• Experimental Parameters and Range

• Test matrix

• Experimental planning

CONCLUSIONS

ELCOGAS shareholders and ELCOGAS shareholders and percentage of capitalpercentage of capital

THE ELCOGAS COMPANYTHE ELCOGAS COMPANY

European company established in European company established in April 1992 to undertake the April 1992 to undertake the

planning, construction, management planning, construction, management and operation of a 335 MWand operation of a 335 MWISOISO IGCC IGCC plant located in Puertollano (Spain)plant located in Puertollano (Spain)

0,04% 0,1%2,5%

4,3%4,3%4,3%

12,0%

31,4%

40,9%

0,2%ENDESA GENERACION S.A.

EDF INTERNATIONAL S.A.

IBERDROLA GENERACION S.A.

HIDROCANTABRICO S.A

EDP PARTICIPAÇOES-SGPS,SA

ENEL SPA

SIEMENS PROJECT VENTURES GMBH

KRUPP KOPPERS GMBH

BABCOCK WILCOX ESPAÑOLA S.A

AUTOCARTERA

PUERTOLLANO IGCC PLANT

ELCOGAS IGCC POWER PLANTELCOGAS IGCC POWER PLANT

PUERTOLLANO IGCC PLANT

N2

candle

P = 24 bar, T= 250 ºC3 t/h of fly ash

500,000 Nm3/h of raw gas

ELCOGAS DEDUSTING SYSTEMELCOGAS DEDUSTING SYSTEM

PUERTOLLANO IGCC PLANT

Fly ash on the external surface (membrane)

Body support

Body support

Ceramic grains free of fly ash

Body support

Fly ash filling holes between ceramic grains

Cross section of a ceramic filter (SEM, x125)

candle

PUERTOLLANO IGCC PLANT

Consequences of ceramic filter contamination Consequences of ceramic filter contamination

• Reducing of filter useful life

• Rising of O&M costs

• Reducing of plant availability

• Rising of ceramic filter DP

PUERTOLLANO IGCC PLANT

TEST FACILITY: Location

escuela superior de

INGENIEROS DE SEVILLA

11-20 bar(a)5 bar(a)Cleaning pulse

250-850 Nm3/h50-100 Nm3/hGas flow

5.5-8.5 bar(a)1 bar(a)Pressure

235-600 ºCTemperature

Ash collected from ELCOGAS IGGC plant / Biomass gasificationParticulate matter

NITROGEN/AIRCleaning gas

AIR / SYNGASOperation gas

TEST FACILITY: Main characteristics of the pilot design

AIR

TEST FACILITY: Basic diagram of the pilot

AIR

HEATER

ASHINJECTION

HEATER

NITROGENSUPPLY

NITROGENDEPOSIT

OPACIMETER

CLEANGAS

SOLIDS

FILTRATIONVESSEL

SAMPLINGSYSTEM

GASIFIER

COMPRESSOR

BLOWER

SAMPLINGSYSTEM

SOLIDSSTORAGE

TEST FACILITY: General view

TEST FACILITY: Compression system

TEST FACILITY: Heaters

Nitrogen heater Air heaters

TEST FACILITY: Dosing System

TEST FACILITY: Vessel Filter

TEST FACILITY: Nitrogen injection

TEST FACILITY: Particulate sampling system

Long-term and short-term tests to investigate the variations of FUNDAMENTAL VARIABLES under various operating conditions

FUNDAMENTAL VARIABLES

EXPERIMENTAL FILTRATION TEST PLANNING

PRESSURE DROP

CLEANING PULSE INTERVAL

BASELINE PRESSURE DROP

DURABILITY/ DETERIORATION

FOULING FACTOR

EXPERIMENTAL PARAMETERS AND RANGE

FILTRATION ELEMENTS

Bag Filters: PTFE Membrane

P84 (Polyimide)

Candles: DIA SCHUMALIT

OPERATING MODE

Continuous

Swing

PULSE CLEANING

Pressure

Duration

EXPERIMENTAL FILTRATION TEST PLANNING

EXPERIMENTAL PARAMETERS AND RANGE

FILTRATION VELOCITY (Gas flow rate)

Bag Filters: 4.5-9 ft/min

Candles: 3-6 ft/min

SOLIDS LOADING1 – 22 kg/h

MAXIMUM TEMPERATURE

600 ºC

PRESSURE

1 – 8.5 bar(a)

MAXIMUM PRESSURE DROP

60-500 mmwc

EXPERIMENTAL FILTRATION TEST PLANNING

TEST MATRIX

EXPERIMENTAL FILTRATION TEST PLANNING

PARAMETERS OPTIONS/LEVELS

FILTRATION ELEMENTS Bag Filter 1 (PTFE) Bag Filter 2 (P84) Candle (Dia-Schumalit)

OPERATING MODE Continuous Swing

PRESSURE PULSE CLEANING High level Low level

DURATION PULSE CLEANING Long pulse duration Short pulse duration

FILTRATION VELOCITY High Medium Low

PARTICLE LOADING High Medium Low

PRESSURE 1 bar(a) 5.5 bar(a) 8.5 bar(a)

MAXIMUM PRESSURE DROP High Medium Low

EXPERIMENTAL PLANNING

1. START-UP TESTS

2. SHORT TERM FUNCTIONAL TESTS (6-8 h)

3. LONG TERM FUNCTIONAL TESTS (100 h)

EXPERIMENTAL FILTRATION TEST PLANNING

1. START-UP TESTS

2. SHORT TERM FUNCTIONAL TESTS (6-8 h)

3. LONG TERM FUNCTIONAL TESTS (100 h)

EXPERIMENTAL PLANNING

EXPERIMENTAL FILTRATION TEST PLANNING

EXPERIMENTAL PLANNING

1. START-UP TESTS

2. SHORT TERM FUNCTIONAL TESTS (6-8 h)

3. LONG TERM FUNCTIONAL TESTS (100 h)• Base Case Selection

• Test Matrix Selection and Evaluation

• Repeatability and Sensibility Tests

• Parametric Tests

• Trends Confirmation Tests

EXPERIMENTAL FILTRATION TEST PLANNING

EXPERIMENTAL PLANNING

1. START-UP TESTS

2. SHORT TERM FUNCTIONAL TESTS (6-8 h)

3. LONG TERM FUNCTIONAL TESTS (100 h)

EXPERIMENTAL FILTRATION TEST PLANNING

CONCLUSIONS

Activities addressed to solve ELCOGAS dedustingsystem problems which are responsible for the current plant operational constraints

Availability of a very versatile hot gas filtration pilot plant under a wide range of operating conditions

Unique test platform for new hot gas filtration technologies

Excellent capabilities for further investigations under specific agreements or new R&D contracts

To the former EUROPEAN COAL AND STEEL

COMMUNITY (now RESEARCH FUND FOR COAL

AND STEEL, RFCS) for its financial support

ACKNOWLEDGEMENT

Freiberg, 16-17 June 2005

Improving the Puertollano IGCC dedusting system: pilot plant erection

and testing

B. Navarrete, M. Lupión, F.J. Gutiérrez, V.J. Cortés, P. Coca, F. García Peña

escuela superior de escuela superior de

INGENIEROS DE SEVILLA INGENIEROS DE SEVILLA

Presentation by: Mónica Lupión

Escuela Superior de Ingenieros de Sevilla