New Gas Turbine Integration Options for ITM Oxygen in ...¾ITM Oxygen plant capacity: 4,550 sTPD...
Transcript of New Gas Turbine Integration Options for ITM Oxygen in ...¾ITM Oxygen plant capacity: 4,550 sTPD...
New Gas Turbine Integration Optionsfor ITM Oxygen in
Gasification Applications
VanEric SteinPhil Armstrong
Ted FosterAir Products and Chemicals, Inc.
Gasification Technologies 2007San Francisco, CA17 October 2007
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Mature, reliabletechnologyEnergy intensiveRequires 100’s ofequilibrium stagesRepresents ~15% of IGCC capital costConsumes ~15% of IGCC gross power output
Cryogenic Distillation is state-of-the-art for tonnage oxygen
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• Mixed-conducting ceramic membranes (non-porous)
• Typically operate at 800-900 °C
• 100% selective for O2
• O2 flux ∝
Ion Transport Membranes (ITMs) produce high-purity oxygenat high flux
''2
'2ln1
⎟⎟⎟
⎠
⎞
⎜⎜⎜
⎝
⎛
OPOP
L
O2- electrons
compressed air
oxygen
P’
P’’O2
O2
O2- ½O2 + 2e-
½O2 + 2e- O2-
L
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We are building ½-ton/day commercial-scale ITM modules …
Single-stage air separation yields compactdesigns
Low ΔP on the air side
All-ceramic construction
High-tempprocess has better synergy w/ gasification systems
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… and testing them in pilot plant
Heater
Control Room
Heat Exchangers
VacuumPumps
Make-up Streams
ITM Vessel
6 IndependentProduct Trains
Flow Duct Installed
2 Modules Installed
ITM Vessel Internals
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Initial pilot plant testing highly successful
Several trials with ½-ton/day modules during the last yearDemonstrated >99% oxygen purity from commercial-scale module and sealOxygen flux consistently met or exceeded expectations and has remained steady over multi-week testsJust completed retrofit of advanced control system to improve reliability during startup/shutdown cycles
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ITM Oxygen integrates well with gas turbine power cycles
SYNGAS
OXYGENSUPPLY toGASIFIER
OXYGENCOOLING
IONTRANSPORTMEMBRANE
OXYGENCOMP’R
OXYGEN
VITIATED AIR
NON-PERMEATE
AIRHRSG
STEAM
ELECTRICPOWER
SYNGASe.g., SiemensSGT6-6000G
~300 MW
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Full integration with advanced gas turbine poses challenges …
SYNGAS
OXYGENSUPPLY toGASIFIER
OXYGENCOOLING
IONTRANSPORTMEMBRANE
OXYGENCOMP’R
OXYGEN
VITIATED AIR
800 – 900 °C
AIRHRSG
STEAM
ELECTRICPOWER
SYNGAS
ITM-SPECIFICGAS TURBINE
e.g., SiemensSGT6-6000G
~300 MW
RECUPERATOR ?
ΔP
ΔPΔP
ΔP
Air extractionlimitations
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Multi-dimensional evaluation determined optimum configuration
With Boost Compressor
No Boost Compressor
NoRecuperator
With Recuperator
Vitiated Air
ReturnTemp
NoRecuperator
With Recuperator
717 oC717 oC
600 oC600 oC
445 oC445 oC
BC-wR-445
BC-wR-600
BC-wR-717
NB-NR-717
NB-NR-600
BC-NR-717
BC-NR-600BC-NR-650
NB-wR-717
NB-wR-600
NB-wR-456
Ref: “Integrated ITM Oxygen – Gas TurbineSystem for IGCC,” presented at FreibergConference on IGCC, May 2007.
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Boost compressor / recuperatoryields best overall IGCC
0.92
0.93
0.94
0.95
0.96
0.97
0.98
0.99
1
1.01
1.02
36.5% 37.0% 37.5% 38.0% 38.5% 39.0% 39.5% 40.0% 40.5%
HHV Efficiency
Rel
ativ
e Pl
ant C
ost p
er k
ilow
att BC-NR-600
BC-NR-650BC-NR-717BC-wR-445BC-wR-600BC-wR-717NB-NR-600NB-NR-717NB-wR-456NB-wR-600NB-wR-717
No BoostCompressor
WithBC
With Recuperator
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Boost compressor / recuperatorminimizes GT design impact
AIRHRSG
STEAM
ELECTRICPOWER
SYNGAS
ITM-SPECIFICGAS TURBINE
SiemensSGT6-6000G
~300 MW
SYNGAS
OXYGENSUPPLY toGASIFIER
OXYGENCOOLING
IONTRANSPORTMEMBRANE
OXYGENCOMP’R
OXYGEN
VITIATED AIR
RECUPERATOR
BOOST COMP’R
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SGT6-6000G gas turbine modifications for ITM Oxygen
Compressor Section:Compressed air extraction (55%)
Combustion Section:Vitiated air injectionSyngas combustion with vitiated air
Casings & Structural:Hot gas piping & manifolding
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Partial integration with standard GT also achievable …
OXYGENSUPPLY toGASIFIER
OXYGENCOOLER
HRSGAIR
STEAM
OXYGENCOMP’R
SYNGAS
ELECTRICPOWER
OXYGEN
VITIATEDAIR
SYNGAS
AIR
AIRCOMP’R
STANDARD OEMGAS TURBINE
DILUENT (N2)
TO HRSGITM
SYSTEM
Ref: “Novel Integrated Oxygen Supply Technologyfor Gasification,” published at Power-Gen, November 2006.
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… while preserving significant benefits for IGCC
Integration with modified ITM Oxygen cycle can reduce IGCC specific capital cost by 9% and increase efficiency by 1.2%, with 25% capital savings in oxygen production
ITM Oxygen plant capacity: 4,550 sTPD oxygen + 13,200 sTPD diluent
- 91,3681,500IGCC Specific Capital Cost ($/kW)
- 2518,70025,000Oxygen Plant Cost ($/sTPD O2)
+ 1.238.938.4IGCC Net Efficiency (% HHV)
+ 15627543IGCC Net Output (MW)Δ ( %)ITM O2Cryo O22-on-1 GE 7FA+e design basis
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DEDICATEDGT FOR
O2 PROD’N
Minimal integration using dedicated ITM GT offers flexible flowsheet
HRSGAIR
STEAM
ELECTRICPOWER
FUEL
BASELOADGAS TURBINE
AIR
FUEL
OXYGEN
VITIATED AIR
AUX. ELECTRICPOWER
FUEL (optional)OXYGENCOOLER
OXYGENCOMP’R OXYGEN
SUPPLY toAPPLICATIONITM
“Stand-alone” ITM Oxygen plant with minimal power co-production:10 MWe per 1000 TPD Oxygen60 MWe per 4500 TPD Oxygen(e.g., with Siemens GT35P, GT140P)
Oxygen-consuming application, e.g., IGCC, oxycoal combustion, etc…
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GT35P/GT140P developed for full air extraction and off-board combustion
6 GT35P PFBC installations world-wide (’89-’98)1 GT140P PFBC installation (’99)
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ITM dev’t plan meets FutureGenschedule and market timing
5
150
2000
Phase 2
Phase 3
FutureGen
500
5000+
Cap
acity
(TPD
)
2000 2005 2010 2015 2020
(large energy applications)
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The future remains bright for ITM Oxygen
Commercial-scale ITM Oxygen modules are being built and tested successfullyConceptual full integration with SGT6-6000G maximizes ITM benefits while minimizing GT design / development impact
– Partial integration with standard OEM gas turbine preserves significant benefits
– Minimal integration using dedicated ITMGT offers good early entry prospects
Air Products and the DOE are accelerating development of ITM Oxygen to reach large-tonnage scale for FutureGen plant
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A significant portion of this report was prepared by Air Products and Chemicals, Inc. pursuant to a Cooperative Agreement partially funded by the United States Department of Energy, and neither Air Products and Chemicals, Inc. nor any of its contractors or subcontractors nor the United States Department of Energy, nor any person acting on behalf of either:
1. Makes any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately owned rights; or
2. Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this report. Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Department of Energy. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Department of Energy.
This paper was written with support of the U.S. Department of Energy under Contract No. DE-FC26-98FT40343. The Government reserves for itself and others acting on its behalf a royalty-free, nonexclusive, irrevocable, worldwide license for Governmental purposes to publish, distribute, translate, duplicate, exhibit and perform this copyrighted paper.
Acknowledgment: DOE/NETL
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