Bottomless Refinery & Gasification - · PDF fileGasification leader since 1948 with ... High...

15/24/2010© 2010 General Electric Company.

Bottomless Refinery & GasificationImprove Refinery Economics & Reduce Emissions through Gasification

Mike Thuillez Region Commercial Director

Copyright 2010 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.


Leadership•

Gasification leader since 1948 with

65 facilities currently operating worldwide

•

130 gasification vessels in operation

•

~40 industrial gasification plants separating carbon today

Experience•

First oil gasification plant in 1961

•

First coal gasification plant in 1978

•

First pet coke gasification plant in 1984

•

30 gas turbines operating on syngas …

> 1+ million operating hours

•

IGCC leader…

>3 GW with GE technologies

— Cool Water technology demo plant 1984-1989

— TECO commercial demonstration plant 1996-present

— Duke Energy Edwardsport commercial plant …COD 2012

GE’s leadership & experience


Gasification for refinery upgrades

•

Hydroskimming refinery is long on fuel oil …

decreasing margins

•

Demand for transportation fuels is increasing …

residue conversion

•

Regulations require lower sulfur …

short H2

•

Gasification utilizes refinery bottoms to produce H2

, Steam, Electric Power

Bottomless refinery …

higher margins & lower emissions


Integrate residue conversion & gasification

Atm. or Vacuum Residue

Simple Refinery

• Visbreaker (Tar)

• Solvent Deasphalting (Asphalt)

• Delayed Coking (Coke)

Residue Conversion Secondary Processing

• Hydrocracker

• FCCU

• Hydrotreating (Sulfur)

(By-products)

Gasification & power island

- H2

- Steam

- Power

Polygeneration

(Integration)

- Heat Integration

- Common Sulfur Removal

- Common AGR

- Save on H2

compression

- Reduced emissions


SyngasRefinery

Bottoms

Heavy oil based IGCC –

H2

& Power

GasificationIsland

Air

Separation

Unit

Shift and Cooling

O2

Solid waste

Acid Gas Removal

PowerIsland

Electric

Power

Pressure

Swing

Adsorption

Pure H2

To Refinery

Sulfur Recovery

Sulphur

H2

S

Clean Syngas

H2

CO2Shifted

Syngas

•

Combined cycle for higher efficiency …

Gas Turbine, Heat Recovery Steam Generator, Steam Turbine

•

Particulate clean-up through a simple scrubber which requires no filters

•

Carbon extraction & filtration for metals reclamation from soot water


GE’s quench gasifier for heavy oil

•

High throughput entrained flow quench gasifier

•

Simple pressure vessel configuration for local manufacturing

•

Single feed injector with a symmetric flame pattern reducing refractory wear

•

Refractory is low cost & reliable thermal barrier

•

Hot syngas immediately quenched by direct water contact

•

Syngas is warm & saturated with water…

ideal for sour CO shift → hydrogen production

•

Commercial application up to 86 barg

•

Proven and reliable gasifier sizes up to 25.5 m3

(900 ft3)

Key Characteristics


Case studyBasis•

70:30 mix of Arab Light/Heavy…

Visbreaker Tar, Solvent Deasphalting, and Delayed Coking

•

Refinery size of 6 MM TPA and 10 MM TPA

•

Configuration enhanced for high H2

availability

Results•

Most attractive case:3200 MTPD Feed

E-Class Combined Cycle

76,000 NCMH H2

•

Reduced Emissions:NOX < 50 mg/NCM

SOX < 10 mg/NCM

• COE ~4-5 Cents/kWh


GE Gasification

Gas Cooling

Oxygen

Visbreaker Tar

150 t/h

Sulphur

Sulphur Removal & Recovery

Steam to Refinery

LP =85 t/hPower to Grid

551 MW

Sarlux Refinery polygeneration

GE Combined

Cycle

Hydrogen Production

H2 to Refinery

40,000 Nm3/h

WastewaterPretreatment

Filter Cake

to metals reclaimer

Steam to Refinery MP = 100 t/h

Licensee/Owner: Sarlux S.r.l

Operator:

SARAS S.p.A.

Location:

Sarroch (Cagliari), Sardinia, Italy

Startup: 2001

Feedstock: Visbreaker tar

Design Capacity: 50 t/h (per gasifier)

Gasifier Size:

3 x 900 ft³

Power Block: 550MW –

3x109E CC Units

>90% availability (no spare)


GE Gasification

& Carbon Extraction

Gas Cooling &

COS Hydrolysis

Oxygen

Asphalt

140 t/h

147 t/hr(Future)

Sulphur

Sulphur Removal & Recovery

Steam to Refinery

LP = 6 t/hPower to Export

550 MW

ISAB Energy Refinery IGCC

Combined Cycle

WastewaterPretreatment

Filter Cake

to metals recovery

Steam to Refinery MP= 16 t/h


Licensee/Owner: ISAB Energy S.r.l.Operator: ISAB Energy Services S.r.l.Location: Priolo, Gargallo, Sicily, ItalyStartup: 2000Feedstock: Asphalt Design Capacity: 70 t/h (per gasifier)Operation Pressure: 70 barGasifier Size: 2 x 600 ft³ QuenchEPC Contractor: Foster Wheeler Italiana


ISAB Refinery emissions results

S0x NOx Particulates*Data provided by ISAB Energy Services on behalf of ERG

Refinery before gasification

DM 12/07/90 Authority limitsRefinery after GE gasification technology

0

1000

20001700

400

74

500

20052 80 50 10

Emis

sion

s (m

g/N

m3)


Coffeyville ResourcesLicensee/Owner: Coffeyville ResourcesOperator: Coffeyville ResourcesLocation: Coffeyville, Kansas, USAStartup: 2000Feedstock: Petroleum Coke Design Capacity: 1300 STPD (per gasifier)Operation Pressure: 620 psig (43 bar)Gasifier Size: 2 x 900 ft³ QuenchEPC Contractor: Black & Veatch

GE Gasification & Syngas Scrubbing

CO Shift

& Cooling

Oxygen

Petcoke

1300 t/d

Fertilizer

Acid Gas Removal

Pressure Swing

Absorption

Ash / Slag

Handling


CO2

Capture

Sulphur Recovery

CO2

Purification

UAN Plant

Ammonia Synthesis

NH3 Product

1100 STPD

Sulphur


Feedstock

No. of Gasification

Plants

No. of Operating Gasifiers

Commercial Operation Since

Naphtha 3 3 1997Crude Oil 1 2 1961

Heavy Fuel Oil 7 14 1966Visbreaker Tar 3 6 2000

Steam Cracked Tar 1 2 2001Heavy Residue 1 2 1995

Vacuum Residue 9 17 1980Asphaltenes 2 5 2000

Petcoke 5 11 1984

Total 32 Plants 62 Gasifiers

GE Gasification refinery experience


Summary

•

Convert low value contaminated refinery bottoms to H2

, Steam, & Power

•

Reduce Fuel Oil surplus …

Cutter-Stock

•

Lower net refinery emissions

•

Improve refining gross margins

•

COE estimated at ~4-5 Cents/kWh

Bottomless Refinery …Gasification … Utility Island for Refinery

Bottomless Refinery & Gasification - · PDF fileGasification leader since 1948 with ... High...

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