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Francisco García Peña
ELCOGAS, S.A. www.elcogas.es
R & D plan R & D plan resultsresults andand experienceexperience in in thethe Puertollano IGCCPuertollano IGCC
The
4th International Freiberg
Conference
on IGCC & XtL
Technologies
3-5 May 2010-
Dresden, Germany
2
1.
OPERATIONAL STATUS
2.
R&D
PLAN. REPORT
INDEX
33
1. PUERTOLLANO IGCC POWER PLANT DESCRIPTION
GAS TURBINE
200 MWISO
Flue gas to stack
SteamHeat Recovery
Steam Generator STEAM
TURBINE
135MWISO
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
Waste N2
Process description
Filtration Sulfur Removal
Tail Gas
Waterto treatment
G
G
Cooling tower
Compressed air
4
1st
5
years: Learning
curve
2003: Major
overhaul
Gas Turbine
findings
2004 & 2005: Gas turbine
main
generation transformer
isolation
fault
2006: Gas turbine
major
overhaul
& candle
fly
ash
filters
crisis
2007 & 2008: ASU WN2
compressor
coupling
fault
and
repair
MAN TURBO
1. PUERTOLLANO IGCC POWER PLANT: Operating data
IGCC, NGCC and Total yearly production
9
1.1621.527
744
836
622
321343
301 452421 312 259 327
277
335
911
1.3911.595
1.371 1.293 1.129 1.150 1.130
0
500
1.000
1.500
2.000
2.500
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009
year
GW
hNGCC GWhIGCC GWh
752
1,171
1,5331,712
1,938
1,672 1,7441,550 1,462 1,389 1,489
1,803
5
Emissions in NGCC and IGCC modes1. PUERTOLLANO IGCC POWER PLANT: Operating data
Emissions in NGCC mode
Emissions in IGCC mode
Natural gas (mg/Nm3 at 6% O2 dry)
4,229,2
291,7250,0
4,212,5
178,2
8,4 0,10
50100150200250300350
SO2 Particles NOx
EEC 88/609ELCOGAS Environmental PermitELCOGAS 2009 average
Coal gas (mg/Nm3 at 6% O2 dry)
50
400
650
500
200
5
200
0,1234,6
137,6
0100200300400500600700
SO2 NOx Particles
EU Directive 88/609/EECEU Directive 2001/80/EEC
ELCOGAS Environmental PermitELCOGAS 2009 average
6
AVAILABILITY 2009
64,777,7
86,0 89,4
9,9 10,16,2 3,1
25,4 12,2 7,8 7,5
0%
20%
40%
60%
80%
100%
IGCC Gasifier Power Block ASU
Availability Planned Outages Unplanned Outages
1. PUERTOLLANO IGCC POWER PLANT: Operating data
7
Gasification
WATER STEAM SYSTEMS & BOILERS
28%
GAS WET TREATMENT17%
SLAGS8%
DRY DEDUSTING & FLY ASH SYSTEMS
32%
QUENCH GAS RECIRCULATION
1%
SULPHUR RECOVERY &TAIL GAS RECYCLE
0%
MIXING & GRINDING PLANT
3%
START-UP BURNER & FLAME MONITORS
2%
DUST FUEL CONVEYING & FEEDING
9%
Combined cycle
WATER-STEAM CYCLE ; 7%
GAS SATURATOR; 22%
GAS TURBINE; 71%
BOP
AUXILIARY SYSTEM; 37%
DCS; 63%
ELECTRICAL SYSTEM; 0%
IGCC UNAVAILABILITY 2009
ASU
WASTE NAITROGEN PRODUCTION; 47%
GAS OXYGEN PRODUCTION; 48%
PURE NITROGEN PRODUCTION; 5%
Islands Unavailability
Gasification65%
Combined Cycle12%
BOP5%
ASU18%
1. PUERTOLLANO IGCC POWER PLANT: Operating data
8
1.
OPERATIONAL STATUS
2.
R&D
PLAN. REPORT
INDEX
9
PUERTOLLANO IGCC ACTIONS FOR THE PUERTOLLANO IGCC ACTIONS FOR THE FUTUREFUTURE
OUR PLANS ARE BASED ON THE OPPORTUNITY THAT REPRESENTS TO HAVE AN OPERATIVE IGCC PLANT NOW AND FOR THE FUTURE
CONTRIBUTION CAN BE RELEVANT IN SUSTAINABILITY ENERGY CONCERNS:
CLIMATE CHANGE MITIGATIONCLIMATE CHANGE MITIGATION
&&
ENERGY SUPPLY RELIABILITYENERGY SUPPLY RELIABILITY
2. ELCOGAS R&D INVESTMENT PLAN
10
Since 2007 ELCOGAS has defined a R&D Investment Plan to develop IGCC technology in order to decrease the environmental impact of power production as main target
ELCOGAS presents a yearly results report of that R&D Plan to Spanish government for evaluation
CO2 EMISSION REDUCTION IN UTILIZATION OF FOSSIL FUELS
H2 PRODUCTION BY GASIFICATION OF FOSSIL FUELS
DIVERSIFICATION OF RAW FUELS AND PRODUCTS
OTHER ENVIRONMENTAL IMPROVEMENTS
IGCC PROCESSES OPTIMIZATION
DISSEMINATION OF RESULTS
MAIN LINES OF R&D PLAN ARE:
2. ELCOGAS R&D INVESTMENT PLAN
11
Dissemination of results• Forum participations. CO2 , H2 , and sustainability associations and Technological Platforms. European and Spanish. Coordinating working groups in Technological Spanish Platforms.• Participation in conferences, seminars, congresses. • Consulting services. Germany, China, Chile • Attending and promoting technical visits. Generally international visits.
2. ELCOGAS R&D INVESTMENT PLAN
www.elcogas.es
12
Optimization of IGCC processes. Oriented to improve availability and costs. • Gasifier materials. Life extension. • Syngas corrosion processes. Optimization and tests of materials.• Elimination of water leakages of membrane at reaction chamber. • Ceramic filters. Many tests with alternatives have been done. Final
assessment is to install a new filter system provided by Pall.• Gas Turbine reliability improvement and life extension.• Improvement of integration with ASU. (Start up compressor).• O&M specific availability incidents analysis.
2. ELCOGAS R&D INVESTMENT PLAN
Gasifier materials/syngas corrosion processes
Ceramic filters
13
Other environmental improvements• Liquid wastes reduction. Change of waste
water treatment plant• Improvement of syngas cleaning systems.
Currently participating in project AGAPUTE (RFCS, 2004-08, to study improvements in syngas cleaning). Hg task.
• Improvements in Sulphur Recovery plant. In progress several modifications to improve availability and to reduce S emissions.
• Operation and additives parameters optimization. Included in AGAPUTE to study dosing of limestone, oxygen, steam, vs. concentration of contaminants in slags, fly ash and washing water
• Emissions reduction during start up and other transitory situations.
2. ELCOGAS R&D INVESTMENT PLAN
Overview of the test rig for mercury and carbonyls analysis
Cross correlation between limestone content in the fuel and Se bulk fly ash content
14
Diversification of raw fuels and products Project PIIBE (ESP-CENIT). To impulse biofuels technologies in Spain.
ELCOGAS coordinates the subproject about biodiesel from gasification by real co-gasification 10% of biomass and syngas characterization (F-T process in laboratory)
Agreement with a private European Company to install a pilot plant in IGCC of Puertollano to develop process to obtain gasoline from syngas
Project PEIXE VERDE. (ESP-PSE). Technical-economic study about uses of syngas as fuel for fishing ships in different scales of production
Co-gasification of car manufacture wastes (shredder fibres) was agreed with supplier.
Available to do tests of gasification of different fuels at large scale to help in design of new IGCC plants
Clean H2 by gasification of fuels H2 production in IGCC. Project HYDROSEP (RFCS, to study IGCC adaptation to H2 production) Study and tests of new processes of H2 purification. Project SPHERA (ESP-CENIT)Available to collaborate with new H2 & Fuel Cells Experimental National Centre of Puertollano
2. ELCOGAS R&D INVESTMENT PLAN
Biomass yard
15
CO2 EMISSION REDUCTION• IGCC Efficiency Optimization
Analysis of viability to improve efficiency based on Critical Assessment of Puertollano IGCC design
Auxiliary consumption optimization. New revisionDevelopment of tools to improve efficiency. Supervision on line
of main (120) equipment efficiency. Installed and in tests Integration optimization. Improvement of controls to adjust heat
& mass balances in real operationAnd
• CO2 capture for CCS with IGCC
2. ELCOGAS R&D INVESTMENT PLAN
16
To demonstrate the feasibility of capture of CO2 and production of H2 in an IGCC that uses solid fossil fuels and wastes as main feedstock.
To obtain economic data enough to scale it to the full Puertollano IGCC capacity in synthetic gas production.
Project of pilot plant in existing IGCC of Puertollano is part of a Spanish national initiative, “Advanced technologies of CO2 conversion, capture and storage” and it is coordinated with other related projects:
Project # 2 is to explore CO2 capture with oxyfuel technology in a 20MW pilot plant. To be built in El Bierzo, NW of Spain. CIUDEN
Project # 3 is to study and regulate geological storage in Spain. IGME
Project #4 is to study public awareness of CCS technologies. CIEMAT
ELCOGAS – UCLM – Ciemat – INCAR CSIC 14 M€ (initially 18.5 M€)
TARGETS
PARTICIPANTS & BUDGET
COORDINATED
2. ELCOGAS R&D INVESTMENT PLAN.CO2
line –
“Singular and strategic project PSE‐CO2
”
17
COMBINEDCYCLE
COAL + PETCOKE
GASIFICATIONRawgas FILTRATION
SYSTEM
CleangasPURIFICATION
& DESULPHURISATION
Clean Gas2% of total flow (3600 Nm3/h)
22.6 bar130 ºC
60.5 % CO22.1% H2
Tail Gas1,3 bar
MP steam
SHIFT REACTOR(Sour /Sweet)
CO2¿SH2
?
CO2 AND SULPHURREMOVAL
(Chemical, aMDEA)
183,000 Nm3/h
100 t/d
CO + H2
O →
CO2
+ H2
H2
99,99%
2 t/d
PIL
OT
PL
AN
T
Raw H2 (80%)
40%
H2
rich gas:37,5 % CO250,0 % H23,0 % CO
H2
PURIFICATION (PSA UNIT)
Recycle gas compressor
Pilot plant size: 1:50 ~ 14 MWth
2. ELCOGAS R&D INVESTMENT PLAN.CO2 line –
“Singular and strategic project PSE‐CO2”
18
Executed (March 2010)100 % engineering work100 % equipment supply95 % construction
Detailed engineeringCO2 unitPSA unit
Civil workControl system supply
Reactors supplyHeat exchangers
Catalyst supplyPiping and fitting supply
Control valvesSafety valves
Manual valvesElectrical components
Analyzers system
Empresarios AgrupadosLinde-CaloricLindeConstrucciones Ocaña-CañasZeus ControlTecnicalTecnical y Boreal-VilaJohnson MattheySidsa, Cuñado, MASASAMSONTyco Valves & ControlsSAIDIGE PowerABB División de automatización de procesos
Start-up: April 2010End of the tests to obtain data for different operating conditions and purity grades March 2011
MAIN SUPPLIERS
2. ELCOGAS R&D INVESTMENT PLAN.CO2 line –
“Singular and strategic project PSE‐CO2”
19
2. ELCOGAS R&D INVESTMENT PLAN.CO2
line –
“Singular and strategic project PSE‐CO2
”
Pilot plant location
Pilot plant 3D view
PRENFLO
gasifier
Coal preparation
Sulfur recovery plant
Combined cycle
Pilot plant for CO2 capture
and production of
H2
20
2. ELCOGAS R&D INVESTMENT PLAN. CO2 line –
“Singular and strategic project PSE‐CO2”
Civil work (August 2009)
PSA unit buffers and absorbers (Linde)
21
2. ELCOGAS R&D INVESTMENT PLAN. CO2 line –
“Singular and strategic project PSE‐CO2”
Aerial view (November 2009)
22
2. ELCOGAS R&D INVESTMENT PLAN. CO2 line –
“Singular and strategic project PSE‐CO2”
Aerial view (February 2009)
Operation display of the pilot plant
23
2. ELCOGAS R&D INVESTMENT PLAN. CO2 line –
“Singular and strategic project PSE‐CO2”
TOTAL QUOTE OF THE PP PROJECT UPDATED EVERY YEAR(K€ of the quoted year)
13.000 13.000 13.000
7.0048.441 8.535
1.088
2.383
4.010 4.329
521 531542
693
833 830547 535
521
514
509 509235241
0
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
2005 2006 2007 2008 2009 2010 2011
EQUIPMENTS SERVICES PERSONNEL OTHERS
24
Pilot plant for CO2 capture and production of H2 and electricity with IGCC technology
Other activities: To be done after PSE as R&D platform: Water shift reaction catalyst optimization. Tests of different catalyst
New processes to separate CO2-H2
CO2 different treatment processes
Improvement of integration efficiency between CO2 separation processes and IGCC plant
Other proposals from Industry or Research community to use the IGCC plant and its pilot plant to develop of process, equipments, components, or even pre-engineering of new plants with CCS and Zero emissions
4. ELCOGAS R&D INVESTMENT PLAN.
CO2
line
25
Francisco García Peña
ELCOGAS S A www elcogas es
R & D plan R & D plan resultsresults andand experienceexperience in in thethe Puertollano IGCCPuertollano IGCC
THANK YOU FOR YOUR ATTENTIONTHANK YOU FOR YOUR ATTENTION
