1 IGCC: Towards zero emissions power plants Francisco García Peña – Engineering R&D Director,...

1

IGCC: Towards zero emissions power plants

Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain

Conference on Clean Coal and Carbon Capture and Storage Technologies

2nd and 3rd December, 2013 at Trichy (India)

2

Index

1. The ELCOGAS company

2. Puertollano IGCC power plant

3. Future of IGCC technology

4. ELCOGAS R&D investment plan

5. Conclusions

3

Index





5. Conclusions

4

ELCOGAS is an Spanish company established in April 1992 to

undertake the planning, construction, management and operation of a 335 MWeISO IGCC

plant located in Puertollano (Spain)

Enel, SpA4,32%

Siemens Project Ventures GmbH

2,53%

Hidrocantábrico Explotación de Centrales SAU

4,32%

Electricité de France

International, S.A.31,48%

Endesa Generación, S.A.

40,99%

Krupp Koppers GmbH0,04%

Iberdrola Generación, S.A.

12,00%

Hidroeléctrica del Cantábrico, S.A.

4,32%

ENCASUR (open cast coal mine)

REPSOL refinery

Puertollano IGCC Plant

The ELCOGAS company

Shareholders

Puertollano

5

Index





5. Conclusions

6

Description of the Puertollano IGCC process

G

Flue gas to stack

SteamHeat Recovery Steam

Generator STEAM TURBINE135MWISO

Cooling towerHot combustion gas

Condenser

GAS TURBINE200 MWISO

GGasifier

Slag

Sulfur (recovery of 99.8%)

Quench Gas

O2

Air

Clean

SyngasRaw Gas

Coal - N2

HP Boiler

MP Boiler

Coal PetCoke

Limestone

Fly ash

Claus Gas

HP Steam

MP Steam

Air Separation Unit

N2 O2

Compressed air

Waste N2

TailGas

Waterto treatment

Coalpreparation

FiltrationWater wash

Sulfur removal

Sulfur recovery

G

Flue gas to stack

SteamHeat Recovery Steam

Generator STEAM TURBINE135MWISO

Cooling towerHot combustion gas

Condenser

GAS TURBINE200 MWISO

GGasifier

Slag

Sulfur (recovery of 99.8%)

Quench Gas

O2

Air

Clean

SyngasRaw Gas

Coal - N2

HP Boiler

MP Boiler

Coal PetCoke

Limestone

Fly ash

Claus Gas

HP Steam

MP Steam

Air Separation Unit

N2 O2

Compressed air

Waste N2

TailGas

Waterto treatment

Coalpreparation

FiltrationWater wash

Sulfur removal

Sulfur recovery

Combined cycle

Gasification

ASU

General view of the Puertollano IGCC plant

Fuel preparation

Gasifier

Clean-up of gas

Combined cycleLaboratory and

water treatment

CO2 capture

Air separation unit

7

8

Description of the Puertollano IGCC process

Fuel design values

Syngas composition

Fuel design is a mixture 50/50 of coal/coke which now is 45/55. Moreover some tests with biomass were undertaken (meat bone meal, grape seed meal, olive oil waste).

Real average Design Real average Design

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

H2 (%) 21.44 22.33 (%) 21.95 22.08

CO2 (%) 2.84 3.70 2.41 3.87

N2 (%) 13.32 10.50 14.76 12.5

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

H2S (%) 0.81 1.01 H2S (ppmv) 3 6

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

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

RAW GAS CLEAN GAS

H2

N2 (%)

CO2 (%)

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

With those fuels at 50:50, the whole plant demonstrated a gross efficiency of 47.2%

and a net efficiency of 42%, under acceptance tests in 2000 year

9

1st 5 years: Learning curve2003: Major overhaul Gas Turbine findings2004 & 2005: Gas turbine main generation transformer isolation fault2006: Gas turbine major overhaul & candle fly ash filters crisis2007 & 2008: ASU WN2 compressor coupling fault and repair MAN TURBO

2010: No operation due to non-profitable electricity price (30-40 days).2011: 100,000 EOH Major Overhaul 2012: 1,498 hours in stand-by due to regulatory restrictions. (3,969 in 2013)

IGCC, NGCC and Total yearly production

9

335

911

1.3

91

1.5

95

1.3

71

1.2

93

1.1

29

1.1

50

1.1

30

1.1

62

1.5

27

1.4

35

1.3

58

1.1

66

74

3

83

6

62

2

32

1

34

3

30

1

45

2

42

1

31

2

25

9

32

7

27

7

26

3

26

5

25

1

0

500

1.000

1.500

2.000

2.500

1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

year

GW

h

NGCC GWh

IGCC GWh

752

1,171

1,533

1,712

1,938

1,6721,744

1,5501,462

1,3891,489

1,8031,698

1,623

1,417

Operational data: Annual energy production

10ELCOGAS power plant emissions in NGCC & IGCC modes

Natural gas (NGCC)

Coal gas (IGCC)

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

250

4

292

294

294

250

13NINI

125

0,46,7

155,3

0

50

100

150

200

250

300

350

SO2 NOx Particles

EEC 88/609EU Directive 2001/80/EECELCOGAS Environmental PermitEU Directive 2010/75/EU DEIELCOGAS 2012 average

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

20

650

400

50

200

500

200

5

300

200

111

200,40

100

200

300

400

500

600

700

SO2 NOx Particles

EU Directive 88/609/EECEU Directive 2001/80/EECELCOGAS Environmental PermitEU Directive 2010/75/EECELCOGAS 2012 average

Operational data: Emissions 2012

11

Note: Net energy variable costs (average 2012)

Fuel mode FuelConsume (GJPCS)

Production (GWh)

Heat rate (GJPCS/ GWh)

Fuel cost (€/ GJPCS)

Partial cost (€/ MWh)

Total cost (€/ MWh)

GT Natural gas 59.987 2,891 20.748 10,46 216,98 216,98

NGCC Natural gas 249.495 22,154 11.262 10,46 117,77 117,77NGCC + ASU Natural gas 1.854.675 155,148 11.954 10,46 125,01 125,01

Natural gas 351.147 10.522 10,46 110,03

Coal 67.459 2.021 3,49 7,05

Petocke 195.947 5.871 1,98 11,61

NG auxiliar consumption

257.700 260 10,46 2,71

Coal 2.536.891 2.555 3,49 8,91

Petocke 7.368.734 7.422 1,98 14,67

NGCC+ASU+Gasifier

(by flare)33,373 128,69

IGCC 992,811 26,30

Operational data: Variable costs 2012

12

Index





5. Conclusions

• Multi-fuel (coal, biomass, wastes) • Multi-product (H2, electricity, liquid fuels, chemicals)• CO2 capture and storage

Potential demonstrating of new process with synthesis

gas partial flow.

Future of IGCC technology

GASIFICATIONGAS

CLEAN UP

COMBINED

CYCLE

XtLAlternative Fuel &

Chemicals

COAL + BIOMASS + WASTES

CO2

H2 CO + H2O CO2 + H2

H2/CO2 SEPARATION

GASIFICATIONCO2 CAPTURE &

H2PURIFICATION

PROCESS

SECONDARY

PRODUCTION H2:

WATER-GAS REACTIONPREPARATION

CO2

H2

Step 1: Syngas production from Gasification

Fly ash

Char

Cl-

CN-

SH2

COS

CO2

N2 …

Step 3: “Shifting” or water-gas reaction

Step 4: H2 and CO2 separation H2 CO2&

CO + H2O CO2 + H2

Carbon compound + O2 + H2O CO + H2 + Impurities400-1600ºC10-40 bar

Step 2:Conditioning fly ash removal, particles and sulphur comp.

H2 production from fossil fuels involves CO2 generation To talk about “clean” H2 it is required to consider CCS

H2 Production by coal gasificationFuture of IGCC technology

15

Index





5. Conclusions

In 2007 a R&D investment plan was elaborated and results are yearly reported to

Spanish authorities for evaluation. Its 6 master research lines are:

ELCOGAS R&D investment plan

PUERTOLLANO IGCC ACTIVITIES: Based on the opportunity that an IGCC plant represents

Can be relevant in:

• climate change mitigation

• energy supply reliability

CO2 emission reduction in utilization of fossil fuels

H2 production by

gasification of fossil fuels

Diversification of raw fuels

and products

Other environment improvements

IGCC process

optimization

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.

ELCOGAS R&D investment plan Dissemination of results

Oriented to improve availability & costs

Gasifier materials/Syngas corrosion processes

Ceramic filters

Elimination of membrane water leakages at reaction

chamber

Test materials

ELCOGAS R&D investment plan Optimization of IGCC process

Overview of the test rig for mercury and carbonyls analysis

ELCOGAS R&D investment plan Other environmental improvements

• Liquid wastes reduction (Zero Liquid Discharges). Installation of a new liquid waste treatment plant (evaporation – crystallization).

•Improvements in the dry dedusting system.

•Improvements in Sulphur Recovery plant.

In progress several modifications to improve availability and to reduce S emissions.

•Optimization of additives parameters.

Internal research for improve the quality of subproducts

•Emissions reduction during start up and other transitory situations.

Overview of the new ZLD plant

•Project FECUNDUS (RFCS-CT-2010-00009, 2010-2013) Selection of biomass and undertake real co-gasification test (2 and 4 % in weight of biomass) for asset its influence in CO2 capture process.

•Project PIIBE (ESP-CENIT).

To impulse biofuels technologies in Spain. ELCOGAS has coordinated the subproject about biodiesel from gasification by real co-gasification 10% of biomass and syngas characterization (F-T process in laboratory).

•Meat and Bone Meal (MBM) co-gasification test (2001)

•Possibility to install a pilot plant in IGCC of Puertollano to develop process to obtain gasoline / diesel from syngas

•Availability to undertake tests of gasification of different fuels at large scale to help in design of new IGCC plants Biomass yard

ELCOGAS R&D investment plan Diversification of raw fuels and products

Pre-selected biomasses

LOAD DURING 8% ORUJILLO CO-GASIFICATION TEST

0

10

20

30

40

50

60

70

80

90

100

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6/20

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6:48

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1:36

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6/20

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6/20

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2:00

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6:48

%

0

20.000

40.000

60.000

80.000

100.000

120.000

140.000

160.000

180.000

200.000

Nm

3/hCO clean gas (%)

H2 clean gas (%)

% Orujillo

clean gas flow (%)

gasifer load (%)

Battery of Biomass co-gasification tests

Test Month/Year

Biomass type

Biomass dosage

ratio (%wt)Biomass

(t)

Test Duration

(h)

2001

Meat Bone &

Meal 1%-4,5% 93.3 15

2007- 2009

Oil olive waste

(Orujillo)

1 -2 % 1,572.8 800.3

2008 4% 652.1 154

Mar. 2009 6% 395.8 64.4

Jun. 2009 8% 383.9 46

Sept. 2009 10% 656.6 62

Nov - Dec 2011 Oil olive waste

(Orujillo)

2% 218.1 106

Oct - Nov 2012 4% 409.3 153.5

Oct. 2012 Grape Seed Meal

2% 179.3 127

Nov - Dec 2012 4% 425.7 119.5

TOTAL 4,986.9 1,647.7

Critical parameter for biomass selection was the behavior on the ELCOGAS grinding system

Load during 8% olive oil waste co-gasification test

Biomass selection criteria:

Size < 25 mmHumidity < 12 %Price < 150 €/tAvailability in large quantities

ELCOGAS R&D investment plan Diversification of raw fuels and products

Clean H2 production by gasification of fuels

Collaboration in several projects (HYDROSEP (UE-RFCS) and SPHERA (ESP-CENIT)

H2 production optimization using the CO2-H2 Pilot Plant

Possibility to collaborate with The National Center for Hydrogen “CNH2” (SPAIN)

CO2 Emission reduction

IGCC Efficiency Optimization• Analysis of viability to improve efficiency based on Critical Assessment of

Puertollano IGCC design.

• Auxiliary consumption optimization. New revision

• Development 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 operation

And

CO2 capture for CCS with IGCC

ELCOGAS R&D investment plan H2 production and CO2 emission reduction

23

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.

TARGETS

Project of pilot plant in an existing IGCC of Puertollano (pre-combustion technology) 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 oxyfuel combustion to be applied in the construction of a pilot plant (20-30 MW) 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

PARTICIPANTS & BUDGET

ELCOGAS – UCLM – Ciemat – INCAR CSIC 14.5 M€ (initially 18.5 M€)

COORDINATED

PSE-CO2 project

ELCOGAS R&D investment plan – Line CO2

Puertollano IGCC power plant and pilot plant location

PRENFLO Gasifier

Coal preparation

Sulphur Recovery

Combined Cycle

New CO2 capture pilot

plant

ASU

ELCOGAS R&D investment plan – Line CO2

25

COMBINEDCYCLE

COAL + COKE

GASIFICATION

Raw gas FILTRATION

SYSTEM

Syngas

PURIFICATION &

DESULPHURATION

Tail gas1.3 bar

IP STEAM

SHIFTING REACTORS

CO2

CO2 & H2

separation(Chemical, aMDEA)

100 t/d

CO + H2O → CO2 + H2

Raw H2 (80% of purity)

40%

H2 rich gas

37.5 % CO2

50.0 % H2 3.0 % CO

HYDROGENPURIFICATION

(PSA)

Recycle compressor

Pure H2 (2 t/d)

99.99% H2 @ 15 bar

SWEET /SOUR

+H2S (1.44%)

2% 2%

SWEET SOUR

Flow

(Nm3/h)3,610 4,006

P (bar)

19.8 23.6

T (ºC) 126 138

% CO2 60.45 53.72

% H2 21.95 19.57

% H2O 0.29 10.40

% H2S 0 0.70

% COS 0 0.11

CO2 capture & H2 production

Pilot plant

Installation unique in the worldInstallation unique in the world: 14 MWt pre-

combustion technology integrated in an existing IGCC.

3 step process: shifting unit, CO2/H2 separation

by chemical absorption, and H2 purification by

PSA. All technology used is commercialtechnology used is commercial.

100 t/d of CO100 t/d of CO22 are captured and 2 t/d of pure 2 t/d of pure

HH22 are produced

In service since October 2010. Operation is Operation is intermittent,intermittent, linked to official Research projects, collaborations and internal research campaigns.

1,017 hours of operation accumulated.

Cost of construction (equipment & services): 13.5 Million €

No storage is foreseen

Consejería de Educación, Ciencia y Cultura

CO2 stripper

CO2 absorber

PSA adsorbers

WGS reactors

Control room

26


Pilot plant

1) The carbon capture pilot Project has been a success: first of its kind in the

world, >90% capture rate achieved and CO2 capture cost can be <30 €/t

2) Commercial technology at any scale is available: the singularity comes

from “integration in a existing IGCC plant”

3) Tests carried out show room for improvement in operating conditions and

optimization of energy balance.

4) Carbon capture cost estimations come from figures of a real project.

5) From now on, the pilot is being used for internal research

6) But it is also open for international research projects and for other kinds of

collaboration

CO2 capture & H2 production Conclusions

28

With SWEET catalyst

With SOUR catalyst

CO2 capture in IGCC plants

Fuel preparation Gasification

Filtrationand wet scrubbing

Desulphurization and sulphur

recovery

Unit of CO2 capture

Combined cycle

S CO2

Fuelpreparation Gasification

Filtrationand wet

scrubbing

Unit of CO2

captureCombined

cycle

CO2 + H2S

Based on our CO2 capture pilot plant, we have scaled the cost of a CO2 capture unit at scale 1:1 about 350 M€. Approximately, it represents the cost of the desulphurization and sulphur recovery units in an IGCC w/o CO2 capture.

By installing an IGCC with CO2 acid capture to store or use CO2 together with ~1.5% H2S, the investment costs are similar to those w/o CO2 capture. And the only penalty is the

decreasing efficiency: From 42 33% currently

and from 50 44% near future

(1.5%)


Results and learning

29

Index





5. Conclusions

Conclusions

IPCC Unless greenhouse gas emissions are cut by 50-80% by 2050 (especially CO2), the impact of global warming can be disastrous.

World energy demand Expect to be doubled by 2050.

We must act fast using a portfolio of solutions

(energy efficiency improvement, renewables

& CCS) to reduce CO2

emissions in the required massive scale

IGCC technology can contribute to this aim because:

Existing IGCC plants are an opportunity to develop cleaner electricity with fossil fuels, so next IGCC generation must learn from them

IGCC is a promising technology with the minimum variable costs and the best environmental performance and it can be adapted to multifuel and polygeneration

Main burden for IGCC technology deployment is high investment requires a long term regulatory frame

30

31

IGCC: Towards zero emissions power plants

Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain

Conference on Clean Coal and Carbon Capture and Storage Technologies

2nd and 3rd December, 2013 at Trichy (India)

THANK YOU FOR YOUR ATTENTION

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