17 YEARS OF EXPERIENCE GAINED FROM THREE GASIFICATION … · 2018. 4. 17. · Clean Coal...
Transcript of 17 YEARS OF EXPERIENCE GAINED FROM THREE GASIFICATION … · 2018. 4. 17. · Clean Coal...
Clean Coal Technologies 2009Clean Coal Technologies 2009Third International Freiberg Conference on IGCC and Third International Freiberg Conference on IGCC and XtLXtL
TechnologiesTechnologies
Dresden, GermanyMay 18-21, 2009
17 YEARS OF EXPERIENCE GAINED FROM THREE 17 YEARS OF EXPERIENCE GAINED FROM THREE GASIFICATION PLANTS OPERATING IN ITALYGASIFICATION PLANTS OPERATING IN ITALY
Vincenzo Fabio Ciccotosto (Speaker) Saipem S.p.A. - Italy
Coauthors:Pierpaolo Mezzanotte Eni R&M S.p.A. – Italy
Giuseppe Pitari, Filippo Galletta ISAB Energy Services S.p.A. – Italy
Vincenzo Rottino ENI Power S.p.a. - Italy
Dr. Daslav Brkic Saipem S.p.a. - Italy
INDEXINDEX
Introduction Projects overviewPlant AvailabilityOutage DistributionConclusion
Topics:• “Learning curve” in design, construction and
operation• High Availability of IGCC plants >90%• Experience & Lesson learned
IntroductionIntroduction
IntroductionIntroduction Contract SummaryContract Summary
Client ISAB Sarlux Eni-EniPower
Contract type LSTK LSTK LSScope of work EPC EPC EPCContractor(s) SP(50)/FWI(50) SP(58)/GE(42) SP
Licensor(s) GE(Texaco) GE(Texaco) Shell Dow/Lurgi UOP/Lurgi Dow/UOP
Detailed eng. SP/FWI SP SPConstruction SP/FWI SP SP
POWER BLOCK Ansaldo Industria GE AnsaldoEnergia
Projects OverviewProjects Overview SummarySummary
SARLUX (SARLUX (~550 ~550 MWeMWe)) ISAB Energy (ISAB Energy (~560 ~560 MWeMWe)) ENI (~250 ENI (~250 MWeMWe))
- Feedstock: VVR(Tar) - Feedstock: Asphalt - Feedstock: VVR(Tar)- GE(Texaco) “quench” - GE(Texaco) “quench” - Shell “radiant cooler”- “Low” pressure (38 barg) - “High” pressure (67 barg) - “High” pressure (62 barg)- “Physical” SRU (Selexol-UOP) - “Hybrid” SRU (MDEA-Dow) - “Hybrid” SRU (MDEA-Dow)- Sulphur tail gas recycled - Sulphur tail gas to incinerat. - Ni-Carbonyls removal- Hydrogen (Membr.+PSA -UOP) - Expander - Hydrogen (Membr.+PSA) - 3 x STAG109E (GE/NP) - 2 x V94.2 (Siemens/Ansaldo) - 1 xV94.2K(Siemens/Ansaldo)- 3 gasif.trains + 2 LTGC etc. - 2 gasif.+ 1 LTGC etc. - 2 gasif.+ 1 LTGC etc.
- Comm.op.: Jan.2001 - Comm.op.: April 2000 Comm. op.: July 2006
Projects OverviewProjects Overview SARLUX IGCC SARLUX IGCC –– ISAB IGCC ISAB IGCC
ISAB ENERGY IGCC PLANTSARLUX IGCC PLANT
Projects OverviewProjects Overview SARLUX IGCC SARLUX IGCC –– ISAB IGCC ISAB IGCC
Projects OverviewProjects Overview ENI IGCCENI IGCC
Projects OverviewProjects Overview ENI IGCCENI IGCC
Ansaldo-SiemensV94-3A.2(400 MW)
Ansaldo-SiemensV94-3A.2(400 MW)
Ansaldo-SiemensV94-2K
(250 MW)
EniPower
Eni Refining & Marketing
Eni Gas & Power
Gasification plant50 t/h Tar
H2
Syngas
Natural gas (12.5 km new pipeline)
Refinery
CCUSYNGAS
TAR
FUELG
AS
CW
HYD
RO
GEN
TAIL G
AS
AC
ID G
ASES
BD
MPS
DW BD
(FIRE WATER, IW, WATER TREAT., IA, SIGNAL EXCH., etc.)
CCUPPU
Projects Overview ENI IGCCProjects Overview ENI IGCC
Projects Overview Projects Overview Feed Feed
ENI ISAB SARLUX Element composition (dry basis)
VVR TAR ASPHALT VVR TAR
Carbon %wt 85.73 84.33 85.07 Hydrogen %wt 9.05 7.77 9.15 Sulphur %wt 3.54 6.0 5.00 Feed flowrate
t/h 50.0 140.0 147.0
HHV MJ/kg 41.28 38.73 42.47 * LHV MJ/kg 39.30 n.a. 38.52 * Calculated value based on element analysis, Dulong formula (ref. Perry and Chilton 1973, par. 9–4).
Projects Overview Projects Overview ProductsProducts
Plant Output ENI ISAB Energy
SARLUX
Syngas (no hydrogen production)
t/d t/d
2 280 (2 560)
17 988 12 910
Gross Power MWe 250 560 550 Hydrogen recovery
Nm3/h 38 000 none 60 000
Steam Export
t/h 73 (HP) n.a. 150 (MP+LP)
AvailabilityAvailability
Plant AvailabilityPlant Availability Syngas productionSyngas production
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
I II III IV V VI VII VIII
Year of commercial operation
ISAB Energystart-up 2000
SARLUXstart-up 2001
ENI R&Mstart-up 2006
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
I II III IV V VI VII VIII
Year of commercial operation
ISAB Energystart-up 2000
SARLUXstart-up 2001
ENI Powerstart-up 2006
Plant AvailabilityPlant Availability Power productionPower production
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
70.00%
80.00%
90.00%
100.00%
I II III IV V VI VII VIII
Year of commercial operation
ISABEnergy
SARLUX
ENIPower
Power Capacity FactorPower Capacity Factor
Instrumentation, 33%
Mechanical, 13%Operational, 10%Common part, 4%
External , 33%
Planned, 8%
Cause of shutdown distributionCause of shutdown distribution ENI R&M Gasification PlantENI R&M Gasification Plant
period: 2006 -2008
Duration of shutdown distributionDuration of shutdown distribution ENI R&M Gasification PlantENI R&M Gasification Plant
Instrumentation, 4%Operational, 1%Common part, 5%
External , 16%
Planned, 36%
Mechanical, 38%
period: 2006 -2008
Instrumentation13% Mechanical
8%
Operational41%
Common part10%
Planned3%
External 25%
Cause of shutdown distributionCause of shutdown distribution ISAB Energy Gasification PlantISAB Energy Gasification Plant
period: 2003 -2008
Instrumentation14%
Mechanical4%
Operational16%
Common part19%
External 24%
Planned23%
Duration of shutdown distributionDuration of shutdown distribution ISAB Energy Gasification PlantISAB Energy Gasification Plant
period: 2003 -2008
ConclusionConclusion
• Lack of gasification plant availability has been a significant hindrance for the power industry in the past years. The data presented in this work confirm once again that the technology has reached high levels of performance and great strides have been made in the design of reliable systems.
• The substantial experience thus gained in heavy oil residue gasification can be extended to identify bottlenecks also in coal gasification, and can be used to guide the design and implementation efforts of technology licensors, equipment suppliers, engineering and construction contractors, as well as project Owners and developers.
S a i p e m SpA
Vincenzo CiccotostoSenior Process Engineer
Phone: 39-02-52053592Fax: 39-02-52053504e-mail: [email protected]
THANK YOUTHANK YOU