PUERTOLLANO IGCC POWER PLANT....2007/10/04 · 8 Puertollano IGCC Power Plant - ELCOGAS IGCC, NGCC...
Transcript of PUERTOLLANO IGCC POWER PLANT....2007/10/04 · 8 Puertollano IGCC Power Plant - ELCOGAS IGCC, NGCC...
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Puertollano IGCC Power Plant - ELCOGASPUERTOLLANO IGCC POWER PLANT. OPERATIONAL EXPERIENCE AND
CURRENT DEVELOPMENTS.
International Freiberg Conference on IGCC & XtL Technologies
8-12 May, 2007 —
Freiberg, GermanyPedro Casero, Elcogas, S.A.
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Puertollano IGCC Power Plant - ELCOGAS
European company established in April 1992 to undertake the planning, construction, management and operation of a 335 MWISO IGCC plant located in Puertollano (Spain)
THE ELCOGAS COMPANY
EDF INTERNATIONAL
31,4%
ENEL4,3%
Autocartera0,2%
SIEMENS2,5%
Krupp Koppers GMBH0,04%
Hidrocantábrico4,3%
Electricidade de Portugal
4,3%ENDESA
GENERACIÓN 40,9%
Babcock Wilcox
Española0,1%
Iberdrola Generación
12,0%
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Puertollano IGCC Power Plant - ELCOGAS
G
GAS TURBINE
200 MWISO
Flue gas to stack
SteamHeat Recovery
Steam Generator
G
STEAM TURBINE
135MWISO
Cooling tower
Hot combustion gasCondenser
Coal Petroleum CokeLimestone
Coalpreparation Gasifier
Slag
Sulfur (99.8%)
SulfurRecovery
Quench Gas
O2
Air
Clean syngas
Raw GasCoal - N2
HP Boiler
MP Boiler Waterwash
Fly ash
Claus gas
HP Steam
MP Steam
Air Separation Unit
N2
O2
Compressed air
Waste N2
Process description
Filtration Sulfur Removal
Tail Gas
Waterto treatment
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Puertollano IGCC Power Plant - ELCOGAS
Fuel
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
Power output and emissions
GASTURBINE
(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
Main design data
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Puertollano IGCC Power Plant - ELCOGAS
Raw and clean gas data (2006 update)
Actual average Design Actual average Design
CO (%) 59.26 61.25 CO (%) 59.30 60.51
H2 (%) 21.44 22.33 H2 (%) 21.95 22.08
CO2 (%) 2.84 3.70 CO2 (%) 2.41 3.87
N2 (%) 13.32 10.50 N2 (%) 14.76 12.5
Ar (%) 0.90 1.02 Ar (%) 1.18 1.03
H2 S (%) 0.81 1.01 H2 S (ppmv) 3 6
COS (%) 0.19 0.17 COS (ppmv) 9 6
HCN (ppmv) 23 38 HCN (ppmv) - 3
Raw Gas Clean Gas
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Puertollano IGCC Power Plant - ELCOGAS
Emissions in NGCC and IGCC modes Natural gas (mg/Nm3 at 6% O2 dry)
2,9
291,7
29,24,2
223,8
0,50,0
50,0
100,0
150,0
200,0
250,0
300,0
350,0
SO2 NOx Partículas
EEC 88/609ELCOGAS Permit limitsELCOGAS 2006 average
Coal gas (mg/Nm3 at 6% O2 dry)
500
50
135,9
0,450
400
650
200
25
200
70,2
0
100
200
300
400
500
600
700
SO2 NOx Partículas
EU Directive 88/609/EECEU Directive 2001/80/EECELCOGAS Permit limitsELCOGAS 2006 averageNGCC mode
IGCC mode
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Puertollano IGCC Power Plant - ELCOGAS
19961997
19981999
20002001
20022003
20042005
20062007
2008
Oct ‘96 - Commercial operation of CC with NG (1st CC in Spain)Mar ‘98 - 1st Switch-over to syngas in the GT. 1st production as IGCC
Dec ‘06: 14,673 GWh (9,184 GWh with coal gas)
Severe fault in main generation transformer of GT50.000 EOH Gas Turbine major overhaul
Power plant main milestonesPower plant main milestones
75.000 EOH Gas Turbine major overhaul
March ’07: New record on syngas: 958 hours
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Puertollano IGCC Power Plant - ELCOGAS
IGCC, NGCC and Total yearly production
9335
911
1.3911.595
1.371 1.2931.129 1.150
744
836
622
321
343
301 452
421 312
0
500
1.000
1.500
2.000
2.500
1998 1999 2000 2001 2002 2003 2004 2005 2006
year
NGCC GWhIGCC GWh
752
1,171
1,5331,712
1,938
1,672 1,7441,550
1,462
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Puertollano IGCC Power Plant - ELCOGAS
Variable Cost of Electricity (2006)
Fuel mode Fuel Heat rate
(kJHHV /kWh)Fuel cost(€/GJHHV )
Partial cost
(€/MWh)
Total cost (€/MWh)
GNCC Natural gas 7,649 7.84 59.97 59.97
IGCC
Coal 2,934 2.19 6.4318.01
Petcoke 5,994 1.44 8.63
NG aux 376 7.84 2.95
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Puertollano IGCC Power Plant - ELCOGAS
Variable Cost of Electricity vs Fuel cost evolution
29,37
35,34
59,97
30,71
18,0115,85
14,5513,45
0
1
2
3
4
5
6
7
8
9
10
2003 2004 2005 2006
€/GJ HHV
0
10
20
30
40
50
60
MWh/ €
Variable cost of electricity produced with NG
Variable cost of electricity produced with coal-Cost of Natural
Cost of coal
Cost of pet coke
COST OF FUEL
VARIABLE COST OF
ELECTRICITY
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Puertollano IGCC Power Plant - ELCOGAS
Availability 2006
80,8
68,0
65,0
52,0
13,716,9
17,8
17,4
5,515,017,230,6
0%
20%
40%
60%
80%
100%
IGCC GASIFIER POWER BLOCK ASU
Availability Planned Outages Unplanned Outages
Puertollano IGCC Power Plant - ELCOGAS
ASU
6%
GASIFICATION
46%
COMBINED CYCLE
29%
BOP
19%
FLY ASH 14%
WATER STEAM30%
COAL PREPARATION
2%
QUENCH GAS CIRCULATION
6%START UP BURNER7%
FUEL FEEDING7%
GAS TREATMENT11%
SULFUR RECOVERY
11%SLAGS
12%
GAS SATURATOR
6%WATER STEAM CYCLE19%
GAS TURBINE75%
WASTE NITROGEN PRODUCTION
62%
PURE NITROGEN PRODUCTION
22%
OXYGEN PRODUCTION
16%
DCS16%
SERVICE SYSTEMS
6%
ELECTRIC SYSTEMS
78%
IGCC unavailability 2004-2006
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Puertollano IGCC Power Plant - ELCOGAS
Project title: Advanced technologies of CO2 conversion, capture and storage (PSE-CO2)
Programme: Spanish National Energy Programme (Ministry of Education and Research)
Coordinator: CIEMAT
Status: Started on 2005.
Target:
Development of CO2 capture technologies, allowing a sustainable use of coal for power productionDevelopment of conversion technologies that facilitate CO2 captureDevelopment of deep geological storage capacities for captured CO2
Structure Composed by 5 sub-projects
Spanish Research Initiative in CO2
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Puertollano IGCC Power Plant - ELCOGAS
PSE-CO2 S/1: Pre-combustion CO2 separation technologyCoordinator: ELCOGAS
Partners: University of Castilla la Mancha, Empresarios Agrupados, Técnicas Reunidas, INCAR-CSIC, CIEMAT
Target:To validate at industrial, bench and laboratory scale the technologies of pre-combustion CO2 capture associated to an IGCC Power Plant
Rationale:-To test the concept of CO2 capture in a industrial IGCC plant-To help in the design of the next generation IGCC plant-To maintain the concept of innovation that Elcogas plays in Europe
Approach:
Assessment of commercial technologies for CO2 separation (Pilot Plant Installation 1:50 scale)Assessment of appropriate technologies but still not commercially available for CO2 separation (bench & laboratory scale)
Budget: ∼19 M€
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Puertollano IGCC Power Plant - ELCOGAS
CO2 capture and H2 production Pilot Plant
REACTOR 2
GAS PREPARATION AMINES UNIT
H2 rich gasPSA unit
480ºC
350ºC
390ºC
SHIFT conversion
REACTOR 1
310ºC
H2: 53,7 %CO: 11,4 %CO2: 0,12 %Q: 1.511 Nm3/h
Clean syn-gasH2: 21,9 %CO: 60,4 %CO2: 2,7 %COS: 12 ppmH2S: 0,2 ppmQ: 3.600 Nm3/hP: 20 barT: 135 ºC
H2: 50,0 %CO: 3,1 %CO2: 37,5 %COS: 0 ppmH2S: 8 ppmQ: 5.610 Nm3/hP: 16,4 bar
H2: 50,0 %CO: 3,1 %CO2: 37,5 %COS: -- ppmH2S: 8 ppmQ: 5606 Nm3/h
CO2 topost-treatment
H2: 0,2 %CO: 0,01 %CO2: 99,8 %H2S: 21 ppmQ: 2.108 Nm3/h
H2: 79,9 %CO: 4,9 %CO2: 0,05 %H2S: 0 ppmQ: 3.498 Nm3/h
pure H2
tail gas
H2: 99,9 %CO: 4 ppmQ: 1.987 Nm3/h
Electrical consumption:1.389 kWMP steam consumption: 4,5 t/hBP steam consumption: 19 t/hRefrigeration water: 320 t/h
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Puertollano IGCC Power Plant - ELCOGAS
P&ID Shift Converter Unit
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Puertollano IGCC Power Plant - ELCOGAS
Pilot Plant implementation
Gasification unit
Air Separation Unit
Power Block
Pilot Plant for CO2 capture and H2 production
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Puertollano IGCC Power Plant - ELCOGAS
Pilot Plant implementation
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Puertollano IGCC Power Plant - ELCOGAS
Project title: Research Project on Biodiesel Support in Spain (PIIBE)
Programme: Strategic National Consortia (Ministry of Industry)
Coordinator: REPSOL-YPF
Target:Move Spain into vanguard of R&D in renewable biodiesel sectori) To reduce production cost down to those of gas-oil from petroleumii) To expand availability of local raw materials
ELCOGAS ACTIVITY:
Leader of “Biodiesel production through gasification”: to assess the viability of biodiesel production through biomass gasification ⇒
execution of real co-gasification tests up to 10% with biomass (estimated biomass consumption of 3000 t during 2 years).Started in 2006. Budget: 900 k€
Spanish Research Initiative in Biodiesel
Orujillo(olive oil waste) Almond shells
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Puertollano IGCC Power Plant - ELCOGAS
PUERTOLLANO IGCC POWER PLANT. OPERATIONAL EXPERIENCE AND
CURRENT DEVELOPMENTS.
Thank you
for
your
attention
Pedro Casero, Elcogas, S.A.www.elcogas.es