Pilot plant for CO capture and H2 production · Main Design Data Actual average ... Puertollano...
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PUERTOLLANO IGCC: Pilot plant for CO 2 capture and H 2 production Francisco García-Peña Engineering – R&D Director ELCOGAS
Transcript of Pilot plant for CO capture and H2 production · Main Design Data Actual average ... Puertollano...
PUERTOLLANO IGCC: Pilot plant for CO2 capture and H2 production
Francisco García-PeñaEngineering – R&D Director
ELCOGAS
2
INDEX
INTRODUCTION
R&D INVESTMENT PLAN. Lines
CO2 capture and H2 co-production pilot plant
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INTRODUCTION. The Elcogas company
Spanish company established in April 1992 to undertake the
planning, construction, management and operation of
a 335 MWeISO IGCC plant located in Puertollano (Spain)
Puertollano IGCC Power Plant
Repsol YPF Refinery
ENCASUR (open cast coal mine)
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%
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Process description
Air Separation Unit
N2 O2
Compressed air
Waste N2
Cooling tower
Hot combustion gasCondenser
G
Flue gas to stack
SteamHeat Recovery
Steam Generator
STEAM TURBINE
135MWISO
GAS TURBINE
200 MWISO
GGasifier
SlagSulfur (99.8%)
Sulfur Recovery
Quench Gas
O2
Air
Clean Syngas
Raw Gas
Coal - N2
HP Boiler
MP Boiler Waterwash
Coal PetCoke
Limestone
Coal
preparation
Fly ash
Claus Gas
HP Steam
MP Steam
FiltrationSulfur
Removal
Tail Gas
Waterto treatment
Puertollano IGCC power plant description
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Power output and emissionsGAS
TURBINE(MW)
STEAMTURBINE
(MW)
GROSSTOTAL(MW)
NETTOTAL(MW)
POWEROUTPUT
182.3 135.4 317.7 282.7
GROSS NETEFFICIENCY(LHV) 47.12% 42.2%
EMISSIONS g/kWh mg/Nm3 (6% Oxygen)SO2 0.07 25NOx 0.40 150
Particulate 0.02 7.5
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
Main Design Data
Actual average Design Actual average DesignCO (%) 59.26 61.25 CO (%) 59.30 60.51H2 (%) 21.44 22.33 H2 (%) 21.95 22.08CO2 (%) 2.84 3.70 CO2 (%) 2.41 3.87N2 (%) 13.32 10.50 N2 (%) 14.76 12.5Ar (%) 0.90 1.02 Ar (%) 1.18 1.03
H2S (%) 0.81 1.01 H2S (ppm) 3 6COS (%) 0.19 0.17 COS (ppm) 9 6
HCN (ppm) 23 38 HCN (ppm) - 3
Raw Gas Clean GasRaw and clean gas data
The design fuel is a mixture 50/50 ofcoal/petcoke
Puertollano IGCC power plant description
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Operational data
IGCC, NGCC and Total yearly production
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1.1621.527 1.435
744
836
622
321343
301 452421 312 259 327
277263
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 2010
year
GW
hIGCC GWh NGCC GWh
752
1,171
1,5331,712
1,938
1,6721,744
1,550 1,4621,389
1,489
1,8031,698
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
2010: No operation due to non-profitable electricity price (30-40 days).
7ELCOGAS power plant emissions in NGCC & IGCC modes (2010)
Natural gas (NGCC)
Coal gas (IGCC)
Natural gas (mg/Nm 3 at 6% O2 dry)
4,229,2
291,7250,0
4,212,5
169,3
7,9 0,80
50100150200250300350
SO2 Particles NOx
EEC 88/609ELCOGAS Environmental PermitELCOGAS 2010 average
Coal gas (mg/Nm3 at 6% O2 dry)
50
400
650
500
200
5
200
1,0639,3
116,3
0100200300
400500600700
SO2 NOx Particles
EU Directive 88/609/EECEU Directive 2001/80/EEC
ELCOGAS Environmental PermitELCOGAS 2010 average
Operational data
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Note: Net energy variable costs (average 2010)
Fuel mode FuelConsume (GJPCS)
Production (GWh)
Heat rate (GJPCS/GWh)
Fuel cost (€/GJPCS)
Partial cost (€/MWh)
Total cost (€/MWh)
GT Natural gas 68.777 3,79 18.150 8,12 147,43 147,43
NGCC Natural gas 84.005 8,38 10.021 8,12 81,40 81,40
NGCC + ASU Natural gas 1.725.092 153,19 11.261 8,12 91,48 91,48
Natural gas 616.828 10.467 8,12 85,03
Coal 145.769 2.474 3,39 8,37
Petocke 455.056 7.722 2,34 18,06
NG auxiliar consumption 265.814 218 8,12 1,77
Coal 2.914.823 2.390 3,39 8,09
Petocke 9.104.375 7.465 2,34 17,46
IGCC 1.219,61 27,32
NGCC+ASU+Gasifier (by flare)
58,93 111,46
Costs
Operational data
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CO2 emission reduction using fossil fuels
H2 production by gasification of fossil fuels
DIVERSIFICATION of raw fuels and products
Other ENVIRONMENTAL improvements
IGCC processes OPTIMISATION
DISSEMINATION of results
BASIS of the PUERTOLLANO IGCC R&D PLAN
Based on the opportunity that an IGCC plant represents
Contribution can be relevant in:
-- climate change mitigation
-- energy supply reliability
MAIN LINES OF THE R&D PLAN
R&D INVESTMENT PLAN. Lines
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Battery of co-gasification tests undertaken with olive oil waste (orujillo)
Test Month/Year
orujillo dosage ratio in weight%
orujillo tonnes (t)
Test duratio
n (h)2007- 2009 1 -2 % 1.572,84 800,3
2008 4 % 652,14 154March 2009 6 % 395,86 64,4June 2009 8 % 383,90 46Sept. 2009 10 % 656,68 62
TOTAL 3.661,42 1.126,7
Diversification of raw fuels and products. Biomass co-gasification
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%
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20.000
40.000
60.000
80.000
100.000
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140.000
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180.000
200.000
Nm
3/hCO clean gas (%)
H2 clean gas (%)
% Orujillo
clean gas flow (%)
gasifer load (%)
Load during %8 olive oil waste
co-gasification test
Biomass selection criteria:
Size < 25 mmHumidity < 12 %Price < 150 €/tAvailability in large quantities Critical parameter for
the biomass selection was the behavior on the ELCOGAS grinding system.
Olive oil waste storage area
R&D INVESTMENT PLAN. Lines
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Step 1: Syngas production from Gasification
Fly ash Char Cl-
CN-
SH2
COS CO2
N2 …
Carbon compound + O2 + H2O CO + H2 + Impurities400-1600ºC10-40 bar
GASIFICATIONCO2 CAPTURE &
H2PURIFICATION PROCESS
SECONDARY PRODUCTION H2:
WATER-GAS REACTION
PREPARATIONCO2
H2
Step 3: “Shifting” or water-gas reaction
Step 4: H2 and CO2 separation H2 CO2&
CO + H2O CO2 + H2
Step 2:Conditioning fly ash removal, particles and sulphur comp.
CO2 capture using pre-combustion technology involves H2 generation
CO2 capture and H2 production (pre-combustion)R&D INVESTMENT PLAN. Lines
To demonstrate the feasibility of capture of CO2 and production of H2 in an IGCC that usessolid fossil fuels and wastes as main feedstock.
To obtain economic data enough to scale it to the full Puertollano IGCC capacity insynthetic 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, captureand storage” and it is coordinated with other related projects:
Project # 2 is to explore oxyfuel combustion to be applied in the construction of a pilotplant (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 & BUDGETELCOGAS – UCLM – Ciemat – INCAR CSIC 14.5 M€ (initially 18.5 M€)
COORDINATION
PSE-CO2 project : CO2 Capture Pilot Plant
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Puertollano IGCC power plant and pilot plant location
PRENFLO Gasifier
Coal preparation
Sulphur Recovery
Combined Cycle
New CO2capture pilot
plant
ASU
Pilot plant general view
IGCC power plant general view
PSE-CO2 project : CO2 Capture Pilot Plant
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Pilot plant diagram process
CLEAN GAS2% of total flow (3,600 Nm3/h)
22,6 bar130ºC
60,5 %CO22,1% H2
Tail gas1,3 bar
MP STEAMSHIFT Reactor CO2 & H2
separation(Chemical, aMDEA)
CO + H2O → CO2 + H2PIL
OT
PLA
NT
40%
CO2¿H2S?100 t/d
Raw H2 (80% of purity)
H2 rich gas 37,5 % CO250,0 % H23,0 % CO
HYDROGENPURIFICATION
(PSA)
COMBINED CYCLE
COAL + COKE
GASIFICATIONRaw gas FILTRATION
SYSTEM
Clean gas PURIFICATION
& DESULPHURATION
183.000 Nm3/h
Recycle compressor
Pilot plant size: 1:50 ~ 14 MWt
Pure H2 (2 t/d)99,99% H2 @ 15 bar
/Acid)(Sweet
PSE-CO2 project : CO2 Capture Pilot Plant
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Shifting unit
1
2
Shifting Unit (several suppliers):1. Desulphurization reactor2. Shifting reactors3. Heat exchangers: kettles
and shell&tube
CO2 Capture Unit
CO2 Capture Unit (Linde Caloric):1. Syngas absober – 12 m2. CO2 stripper – 16.5 m
1
2
PSA Unit
2
PSA Unit (Linde):1. Adsobers – 6.5 m2. Tail gas drum – 12.5 m3. Valve skid
Electrical and control building
3
3
2
1
Electrical/control building:1. Control room2. Electrical room
1
Pilot plant diagram process:3D view
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Empresarios AgrupadosLinde-CaloricLindeConstrucciones Ocaña-CañasZeus ControlTécnicas ReunidasTécnicas Reunidas y Boreal-VilaJohnson MattheySidsa y CuñadoSAMSON, Tyco Valves and Controls y SAIDIGE PowerABB Process Automation DivisionHGL y MASAMEISA
Construction permit: December 2008Commissioning: May-October 20101st CO2 t captured: 13 September 2010End of sweet capture tests: February 2011End of programmed tests (within PSE-CO2): June 2011
Main suppliers
Mile
ston
es
EngineeringCO2 UnitPSA Unit
Civil workControl
ReactorsHeat exchangers
CatalystsPiping and fitting
ValvesElectrical components
On-line analysis systemMechanical erection
Electrical I&C erection
PSE-CO2 project : CO2 Capture Pilot Plant
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Shifting unit
Coal gas
IP saturated steam to feed
N2 (start-up)
IP steam
Desulphuration reactor
Shifting rectors
General view of Shifting Unit
Flow kg/h
Pbar
TºC
CO%
H2%
CO2%
H2O%
H2S%
COS%
Coal gasSweet 3,677 19.8 126 60.45 21.95 2.66 0.29 0.0 0.0
Sour 3,999 23.6 138 53.72 19.57 2.70 10.40 0,70 0,11
Shifted gas to separation unit
Sweet 8,732 17.3 274 1.68 28.37 21.34 43.26 0.0 0.0
Sour 8,705 21.1 277 1.40 28.39 21.53 42.73 0.74 0.0
IP saturated steam to feed
Sweet 5,055 34.0 243 0.0 0.0 0.0 100 0.0 0.0
Sour 4,706 34.0 243 0.0 0.0 0.0 100 0.0 0.0
Pilot plant diagram process (I)
Pre-heater
SHIFTED GAS TO SEPARATION UNIT
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Separation unit
Flow kg/h Pbar
TºC
CO%
H2%
CO2%
H2O%
H2S%
COS%
Shifted gas to absorber
Sweet 5,318 15.9 45 2.9 49.7 37.3 0.7 0.0 0.0
Sour 5,318 19.7 45 2.46 49.7 37.69 0.62 0.51 0.0
Process condensated
Sweet 3,414 15.9 45 0.0 0.0 0.0 100 0.0 0.0
Sour 3,387 19.7 45 0.0 0.0 0.0 100 0.0 0.0
CO2 productSweet 4,185 1.5 40 0 0.18 95.32 4.47 0.0 0.0
Sour 4,295.5 1.55 40 0.01 0.21 94.02 4.47 1.27 0.0
H2 to PSASweet 481.7 15.2 40 4.63 79.37 0.5 0.48 0.0 0.0
Sour 457.3 19.1 40 4.02 80.44 0.5 0.39 0.0001 0.0
Rich H2 gasSweet 1,190.1 15.6 40 4.63 79.37 0.5 0.48 0.0 0.0
Sour 1,135.2 19.4 40 4.02 80.44 0.5 0.39 0.0001 0.0
LP Steam to reboiler
Sweet 4,763 4.1 144 0.0 0.0 0.0 100 0.0 0.0
Sour 4,797 4.1 144 0.0 0.0 0.0 100 0.0 0.0
General view of Separation Unit
Pilot plant diagram process (II)
YCO2 product
Rich H2 gas
LP steam
Y 40 %
60 %
LP steam to reboiler
H2 to PSA
From shifting unit
Cooling stage
Absorber
CO2Stripper
CO2 separator
Syngas separator
Cond. Separator
Process Cond.
Shiftedgas
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PSA unit
General view of PSA unit
Flow Nm3/h
Pbar
TºC
CO%
H2%
CO2%
H2S%
COS%
H2 from separation unit
Sweet 1,431 15.2 40 4.63 79.37 0.5 0.0 0.0
Sour 1,412 19.1 40 4.02 80.44 0.5 0.0001 0.0
H2 productSweet 795 14.7 43 0.0004 99.99 0.0001 0.0 0.0
Sour 795.1 18.6 43 0.0004 99.99 0.0001 0.0 0.0
Tail gasSweet 636 1.3 35.9 10.42 53.58 1.13 0.0 0.0
Sour 616.9 1.3 35.7 9.2 55.23 1.14 0.0002 0.0
Rich H2 gas (40 % flow)
Tail gas
H2 product
Adsorbers
H2 fromseparation unit
Tail gas drum
Pilot plant diagram process (III)
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Comparative : sweet vs sour (design data)
Sweet Sour
Global(shifting+amines)
C.G.E s+a 88,5 % 88,2 %
Thermal efficiency s+a 60,2 % 62,5 %
CO2 recovery 91,7 % 93,6 %
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Block diagram. Control flexibility
CO2Syngas FC PC
FC
Shifting CO2
PSA
H2
FlareTail gas
Flare
Pure H2
FlarePC
PC
Flare
PC
Flare
PC
N2
FCPC
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Some Test results
41
41,5
42
42,5
43
43,5
44
1,1 1,2 1,3 1,4 1,5 1,6
vapor/gas rate
CO
2 co
mpo
sitio
n(%
)
9595,295,495,695,89696,296,496,696,89797,2
Tot
al C
O c
onve
rsio
n (%
)
CO2 composition
Total COconversion (%)
0123456789
10
75 80 85 90 95 100 105 110
T desorción (ºC)
% F
uga
CO
2
0,0
0,2
0,4
0,6
0,8
1,0
% F
uga
H2
Fuga CO2 Fuga H2CO2 leak H2 leak
% C
O2
leak
% H
2le
ak
Desortion T (ºC)
Shifting:
Coversion rate has to be reconsidered!
CO2-H2 separation:
Desortion temperature can be optimised
23
Test results
UNIT START
24
SHIFTING UNIT CONVERSION / TEMPERATURE (SWEET)
0,0
5,0
10,0
15,0
20,0
300 350 400 450 500 550 600
Temperature(ºC)
CO (%
)
Johnson Matthey Selection High temperature Fresh Potential (Johnson Matthey) Potential (High temperature)
20/01/11 17:24-28:35
JM simulation (01/10/10)
Real values(SWEET3 test)
JM - Fresh catalyst
FIRST REACTOR
SECOND REACTOR
STEAM GENERATOR
Conversion very close to theoric, although higher reactor outlet temperature.
The high conversion obtained in the first step (near 95%) will make considering a shifting process only with one step.
PSE-CO2 project : CO2 Capture Pilot Plant
The inlet second reactor temperature is higher than expected
25
Expected vs. obtained compositions of main streams (SWEET)
i) All compositions are in % vol. (dry basis)ii) Analysis carried out by ELCOGAS Laboratory
Comparison of sweet & sour catalysts: sweet tests up to Feb 2011, sour tests up to June 2011
Optimization of steam/gas ratio at shifting unit
Optimization of energy balance
Real costs of CO2 capture and H2 production.
CO2 capture & H2 co-production pilot plant. Tests
Shifted gas CO2 H2 rich gas Pure H2
Design Lab Analysis Design Lab Analysis Design Lab
AnalysisE
Design Lab Analysis
H2 50.05 51.88 0.19 0.314 - 1.31 79.75 82.3 – 83.14 99.99 99.959- 99.995
CO 2.92 1.85 0 0.053 - 0.07 4.65 2.86 - 3.78 4 ppm N/A
CO2
37.56 37.36 99.78 98.2 - 99.622 0.5 0.02 - 0.82 1 ppm N/A
N2 8.76 8.30 0.01 0.05 - 0.28 13.97 12.2 - 13.6 15 ppm 4 - 17 ppm
Ar 0.71 0.60 0.02 0.01 - 0.09 1.13 0.89 - 0.97 80 ppm 3 - 14 ppm
PSE-CO2 project : CO2 Capture Pilot Plant
26
The main learning in project phase:● The finance delay: MICINN (Spanish Science & Research Minister) and JCCM(Regional Government). Delay in main equipment supply: more than 12-14 months. Detailed engineering: conditioned by suppliers. PP construction step: delay due to safety permits since it is installed in an operatingplant. Delay of commissioning: low availability of experimented personnel.
The main learning in commissioning & operation phases:● Investment costs: € 13 million● Unexpected reactivity: 95% CO conversion in first step of shifting unit
Estimated: 85% consider a shifting process with only one step.● CO2 and H2 design specifications: easily achieved● CO2 capture rate: 91.7%● Auxiliary consumption: lower than estimated in design● Integration of O&M in the existing IGCC: very easy
CO2 > 99 %H2 pure > 99.995 %
PSE-CO2 project : CO2 Capture Pilot Plant
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CO2 Capture Costs Comparison
1) Scaled up 100% Puertollano IGCC synthetic gas from the 14MWt pilot plant.2) Existing plant capture cost = f (investment costs and operational costs).
3) First ELCOGAS estimations show values of 25-30 €/ t CO2
4) Comparing to other studies
tonnesCO CapturedOPEXCAPEXCO€/t cost, capture CO2
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Fuente: DOE/NETL CCS RD&D ROADMAP December 2010
30 forELCOGAS
retrofit
PSE-CO2 project : CO2 Capture Pilot Plant
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1015202530354045505560
27 28 29 30 31 32 33 34 35 36 37
IGCC plant efficiency w ith CO2 capture, %
CO
2 co
st, €
/t C
O2
3.000 h
3.500 h
4.000 h
4.500 h
5.000 h
5.500 h
6.000 h
6.500 h
7.000 h
7.500 h
CO2 Capture Costs (SWEET). As IGCC retrofit
PSE-CO2 project : CO2 Capture Pilot Plant
100 %Treated gas
33 %Net efficiency of power plant with CO2 capture
40 €/MWhElectricity price
0.92 Average load factor
6,500 hOperating hours (IGCC mode)
0.75Scale factor
0.5 %Bank fee
3.0 %Bank interest
25 Expected life
Data Variables
100 %Treated gas
33 %Net efficiency of power plant with CO2 capture
40 €/MWhElectricity price
0.92 Average load factor
6,500 hOperating hours (IGCC mode)
0.75Scale factor
0.5 %Bank fee
3.0 %Bank interest
25 Expected life
Data Variables
29
Minimum H2 prices depending on electricity price
0
1
2
3
4
5
6
0 50 100 150€/MWh
€/Kg
60.000 Kg/y 720h
120.000 Kg/y 1440 h
180.000 Kg/y 2160 h
420.000 Kg/y 5040 h
90.000 Kg/y 1080 h
Better to sell H2
Better to sell electricity
Minimum H2 price per fix cost of production (external personal and spares) depending on anual production hours.
Minimum pure H2 price depending on the electricity price
PSE-CO2 project : CO2 Capture Pilot Plant
30
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 CO2separation processes and IGCC plant
ELCOGAS offers both the Puertollano IGCC and the Pilot Plant for CO2 capture and H2 production as
technical platforms to develop of process, equipments, components, or even pre-engineering of new plants
with CCS and Zero emissions
Pilot Plant beyond PSE project
Francisco García-PeñaEngineering – R&D Director
ELCOGAS [email protected]
Thank you for your attention
