Lurgi’s MPG and BGL Gasifiers at SVZ Schwarze Pumpe …Lurgi’s MPG and BGL Gasifiers at SVZ...
Transcript of Lurgi’s MPG and BGL Gasifiers at SVZ Schwarze Pumpe …Lurgi’s MPG and BGL Gasifiers at SVZ...
Lurgi’s M PG and BGL G asifiers at SVZ Schwarze Pum pe
Status and Experiences in IGCC Application
C. Erdm ann, W . Liebner, Lurgi O el · G as · Chem ie G m bHW . Seifert, SVZ G m bH
presented at
1999 Gasification Technologies Conference
October 17-20, 1999San Francisco, California
ContentsMPG-IGCC Experience
Presentation
• Waste Utilization Centre at SVZ
• Gasification Technologies at SVZFixed Bed Grate (FBG)
British Gas Lurgi (BGL)Multi Purpose Gasification (MPG)
• The Combined Cycle Power PlantCC Concept
CC Contracting and ExecutionCC Operation
• “Waste to Value” by IGCC with co-production
Plastics
Fluff
Contam inatedW ood
M unicipalW astes
Sewage Sludge
ShredderLight Fraction
Others
Receiving+Storage
Preparation+Pelletizing120000 tpy
M PG
ConditioningRectisol
Purification
ConditioningStorage
Tars
Oils
LiquidResidues
Slurries
Com bined Cycle
Power Plant
M ethanolSynthesis+Distillation
75 M W e
120000 tpyGrade AA
Sales overthe fence
Fuel Gas
Binder(Coal, M olasses)
Fe+M etals
Ash
Sour G asto SRU
W aterTreatm ent
W ater
Slag
O 2Steam
O 2Steam
O 2Steam
ShiftSteam
District Heat
BGL -Gasifier (1)
SVZ-GrateGasifiers (7)
Slag
Oil / Tar
∼∼
SVZ Schwarze Pumpe
SVZ-IGCC ConceptM PG-IG CC Experience
M PG Reactor ConfigurationsM PG-IG CC Experience
MPG - Quench Configuration
SVZ-IGCC Fuel GasesM PG-IG CC Experience
MPG - Boiler Configuration
SVZ-IGCC Fuel GasesM PG-IG CC Experience
GT- BaseParameter Clean Gas Purge Gas NG Case
Flow m3/h 0 … 49,400 0 … 21,480 0 … 3,000 33,700
Pressure bar 20.5 … 23.5 20.5 … 53 27 … 32
H2 Vol.-% 56.3 … 63.9 39.5 … 52.5 0 53.6
CO Vol.-% 18.7 … 27.1 11.4 … 12.0 0 16.5
CH4 Vol.-% 4.0 … 16.9 22.4 … 35.0 95.0 20.2
CmHn Vol.-% 2.9 … 3.3 5.2 … 6.0 3.0 1.6
CO2 Vol.-% 2.9 … 3.3 5.2 … 6.0 0 4.5
N2 Vol.-% 1.7 … 3.0 4.6 … 5.0 2.0 3.6
LHV kJ/Nm3 12,000 … 15,412 16,543 … 20,610 35,922 16,116
Fuel Gases to CC-Block
SVZ-IGCC Fuel GasesM PG-IG CC Experience
• Utilization of syngas/cleangas and of all offgasesabove 19 bar system pressure
• Utilization of all untreated fuelgases (offgases)
• Cover internal demand of 15 … 22 MWel
• Sale of 40 … 50 MWel
• Continuous power production > 8000 h/a
• Provision of process steam on three levels (35, 16, 5 bar)
• Provision of feed water (two qualities)
IGCC-Concept: Requirements
SVZ-IGCC ConceptM PG-IG CC Experience
- A combined cycle block with two additionaloffgas boilers fits the demand profile
- The HRSG and the two offgas boilers raiselive steam at 125 bar, 525 °C
- The HRSG is equipped with auxiliary burners
- The IGCC feed gas mixer works as pressure control ofthe synthesis gas grid and of the gasification units
- Back-up on the fuel side by NG and light heating oil
- Back-up on the power side by local utility
IGCC-Concept: Solutions
SVZ-IGCC ConceptM PG-IG CC Experience
!!!! CC-Block GT : Frame 6, 133 MWth, 44 MWel
NOx reduction by steam injection
ST : Extraction / Condensing, 31 MWel
Process steam at 35, 16, 5 bar
HRSG : Single tract / two pressure, 181 t/h hp-steam
additional firing max. 115 MWth
!!!! Offgas Boiler #1 : 55 t/h hp-steam
Sep. combustion chamber for NH3-water
!!!! Offgas Boiler #2 : 60 t/h hp-steam
!!!! FGD : Limestone; gypsum sold to panel manufacturer
75 MW Combined Cycle with Auxiliary Boilers
SVZ-IGCC 75 M W Com bined CycleM PG-IG CC Experience
Contracts
SVZ-IGCC Project ExecutionM PG-IG CC Experience
Planning / General Contractor
Main Contractor
Control System Supplier /
Contractor (SVZ)
GT HRSG ST
Supplier Supplier Supplier
HT-Equipment
Supplier
Civils
Contractor
SVZ
responsibility
separate
contracts
Schedule
SVZ-IGCC Project ExecutionM PG-IG CC Experience
Start General Planning Oct. 94
Start Detail Planning Apr. 95
Construction Aug. 95 - Sep. 96
Commissioning & S/U Aug. 96 - Aug. 97
Conclusion
Complex system - Many interfaces - Rewarding result
T.I.C. of CC-Block ~ 590 $/kW
SVZ-IGCC Block Flow DiagrammMPG-IGCC Experience
BESIK60 t/h
REAK55 t/h
HRSG67 - 180 t/h
GT
HP GasMixing
(< 19 bar)
ST ~
M
LP Offgas
Cleangas
NG
LP Offgas
NG+Clean Gas
NH3 Exp. gas
HEL
HEL
Purgegas
Cleangas
NG
HP Steam 125 bar/520 °C
CW
Condensate
IP-Steam35 bar/360 °C
MP-Steam15 bar/230 °C
LP-Steam 5 bar
Wobbe-Index GasturbineMPG-IGCC Experience
Temperature [°C]
Wobbe-IndexkJ/Nm3K1/2
0 10 20 30 40 50 60 70 80 90 100
1400
1500
1600
1700
1800
1900
1300
GT- BaseParameter Clean Gas Purge Gas NG Case
Flow m3/h 0 … 49,400 0 … 21,480 0 … 3,000 33,700
Pressure bar 20.5 … 23.5 20.5 … 53 27 … 32
H2 Vol.-% 56.3 … 63.9 39.5 … 52.5 0 53.6
CO Vol.-% 18.7 … 27.1 11.4 … 12.0 0 16.5
CH4 Vol.-% 4.0 … 16.9 22.4 … 35.0 95.0 20.2
CmHn Vol.-% 2.9 … 3.3 5.2 … 6.0 3.0 1.6
CO2 Vol.-% 2.9 … 3.3 5.2 … 6.0 0 4.5
N2 Vol.-% 1.7 … 3.0 4.6 … 5.0 2.0 3.6
LHV kJ/Nm3 12,000 … 15,412 16,543 … 20,610 35,922 16,116
Fuel Gases to CC-Block
SVZ-IGCC Fuel GasesM PG-IG CC Experience
0 10 20 30 40 50 60 70 80
1005
1110
1215
1320
1425
1530
20
22
24
26
28
30
RG2
RG2
BF6
RG1
BF4
RG3
BF2
BF1PG
BF3
Remarks:1. Wobbe-Index (GE) in BTU/SCF/SQR T(°Rankine)2. Wobbe-Index in kJ/Nm3/SQR t(°Kelvin)
3. Legend:- BF1 bis BF6: Mixed gas, cases 1 to 6- RG1 bis RG3: Clean gas, cases 1 to 3- PG: Purgegas
Gastemperature [°C]
Wobbe-Index (GE)
Wobbe-Index
Wobbe-Index operating casesMPG-IGCC Experience
-5
0
5
10
15
20
25
30
35
40
45
50A
ug
98
Sep
98
Oct
98
No
v 9
8
Dez
98
Jan
99
Fe
b 9
9
Ma
r 9
9
Ap
r 9
9
Ma
y 9
9
Ju
ne
99
Ju
l 99
Au
g 9
9
Sales VEAG Sales AGA Internal Cons. Import
Gross Power Production 1998/99MPG-IGCC Experience
Electric Power19 MJ
Transportation80 MJ
Coal 6.85 GJ
Oxygen6.5 MJRaw Water20 MJ
Methanol5.4 GJ
Export ElectricPower1.35 GJ
Steam/Heating0.26 GJ
= 44.7%ˆ
Fluegas0.81 GJ
Heat Losses8.74 GJ
Cleaned Waste Water28 MJ
1 t Waste9 GJ
SVZ-IGCC Energy FlowMPG-IGCC Experience
Current state, basis 1 t waste
SummaryMPG-IGCC Experience
Three Gasification Processes(FBG, BGL, MPG)
as basis of an
IGCC - Co-production Plantoperated for two years at
High Conversion Efficiencydelivering:
“Value from Waste” a Gasification Success !