Shell Coal Gasification Process for Power and Hydrogen ... · GTC Oct 2004 Washington 2 Shell Coal...

Shell Coal Gasification Process for Powerand Hydrogen/Chemicals

GTC October 2004 Washington

P.L. Zuideveld

2GTC Oct 2004 Washington

Shell Coal Gasification Process for Powerand Hydrogen/Chemicals

• Introduction, Progress• Features, Benefits• US Case Study

- Basis Of Design- Results

• Conclusions

2GTC2004 Washington


Shell Gasification Optional Products

Shell(Coal)

GasificationProcess

Syngas

CC_CogenPower

Generation

CoalLignitePetroleum CokeBiomass

Oil/ResidGasOrimulsion

Electricity

Chemicalfeedstock

Conditioning/distribution

Liquefaction

Steam

AmmoniaMethanolHydrogenother chemicals

Town gas

TransportationFuel


From Deer Park (US) to Buggenum (NL)

1993 – Present2000 tpd coal253 MW_e Demo Plant

1987-1995250-400 tpd


Shell Gasification Projects

New SGP projects:- Agip Sannazzaro Refinery- Opti, Canada- Rafineria Gdanska, PolandNew SCGP projects:-12 projects in China- 1 project USA (WMPI)


SCGP Licences China

89

12

4

1

3

6

Yueyang Sinopec and Shell Coal Gasification Co Ltd2,000 t/d plant to supply a fertiliser plant.* 2001Hubei Shuanghuan Chemical Group Co Ltd900 t/d plant to supply a fertiliser plant. 2001Liuzhou Chemical Industry Co Ltd1,200 t/d plant to supply fertiliser plant. 2001Sinopec Hubei Chemical Fertiliser Co2,000 t/d plant to supply a fertiliser plant. 2003Sinopec Anqing Chemical Fertiliser Co2,000 t/d plant to supply a fertiliser plant. 2003Yunnan Tianan Chemical Co Ltd2,700 t/d plant to supply a fertiliser plant. 2003Yunnan Zhanhua Co Ltd2,700 t/d plant to supply a fertiliser plant. 2003Dahua Group Ltd1,100 t/d plant to supply methanol plant. 2004Yongcheng Coal and Power Group2,150 t/d plant to supply a methanol plant. 2004Shenhua Coal Liquefaction Corporation2x2,250 t/d plant to supply H2 for coal liq. 2004Zhongyuan Dahua Group2,150 t/d plant to supply methanol plant. 2004Kaixiang Group1,000 t/d plant to supply methanol plant. 2004

1

2

3

4

5

6

7

8

9

10

25

7

10

* Shell-Sinopec 50/50 joint venture

11

11

12


SCGP Process Flow Diagram

REMOVALSOLIDS WET

SCRUBBINGCOAL FEEDING

MILLING/DRYING

MILLING AND DRYINGFLY ASH TO

HP STEAM

MP STEAM

SLAG

COAL/PETCOKE FLY ASHRECIRC.FLY ASHRECIRC.

QUENCH GAS

GASIFIER

SALTS SULPHUR

CLEANSYNGAS

WATERTREATMENT

WATERTREATMENT

1600 °C

900 °C

GAS TREATING

FLY ASH SYSTEM

O2

N2MP-HP BFW

DRY

LP STEAM

STM CONDENSATE


SlagBath

Gasifier

Duct

Quench

Evaporator 1

Evaporator 2

SCGP ReactorSyngas Cooler

Assembly


SCGP Key Benefits since Buggenum (NUON)

• Reactor Membrane wall expected life-times > 25 yrs• Burner life-times > 20,000 hrs• Reactor-Syngas Cooler ~40% cheaper (international supply)• Steam system simplified (headers, pipe spec, materials optimized)• Water-cooled skirt Reactor• Slag crusher• Wider procurement options equipment • Reactor-Syngas Cooler train up to 5000 tpd• Unplanned outages < 4% (scheduled maintenance project specific)

Prov

enN

ew P

ojec

ts


SCGP IGCC Case Study – Holland Michigan

HOLLAND

Powder River Basin

Pittsburgh #8


SCGP IGCC USA Case Study – Block FlowAir Separation Unit

SyngasManufacturingProcessPlant

HPO2 Air

HPN2 MPN2

1-2 string combinations Net Elec.400 MW550 MW800 MW

Pitts#8PRBPRB/C HPS

MPS

BFW

Cond

CombinedCyclePowerPlant

W501FW501G

Syngas


SCGP IGCC USA Study – Economic Premises (NPV)

• Project location factor HOLLAND Michigan USA (ISO conditions)• Project life 25 years, 7008 h/a (80% full load IGCC)• O&M 50 $/kW_e net/a + 0.002 $/kWh• Depreciation 15 years, 90% of investment• Debt/equity ratio = 80/20; discount rate 5.5%, tax 38.2% (Harvard)• Inflation/escalation rate 4% (coal no inflation)• EPC contractor soft costs typical ratio’s, no Owners Costs• Electricity price (year 0) 40 $/MWh • Fuel price (year 0) 0.6-1-1.24 $/MMBtu (Cokes-PRB, PRB, P#8)


SCGP IGCC USA Study – Economics Steam Pressure

Specific Investment for 800 MW_e IGCC

10001020104010601080110011201140116011801200

Powder River Basin

Inve

stm

ent [

$/kW

_e]

SGC_125 barSGC_50 bar

Simpler Steam Systemreduces $/kW_e 5-6%

(1)

IGCC_eff46.5 %HHV

IGCC_eff45 %HHV


Specific IGCC Investment Powder River Basin

0100200300400500600700800900

10001100120013001400

418 572 572 837

2959 4097 4097 5918

Net Power [MW_e] & Coal Capacity [tpd]

$/kW

_e CCPPGasificationASUAGR-SRUSyngas MF H2OSyngas MF gen

SCGP IGCC USA Study – Economy Of Scale

1–2 IGCC

2-2 => 1-2 IGCC reduces $/kW_e12%

Power

Coal

2-2 IGCC1–1 IGCC

(2)

2-2 IGCC


SCGP IGCC USA Study – Economics Coals/Pet Coke

Specific Investment for 800 MW_e IGCC

1120

1130

1140

1150

1160

1170

1180

1190

Pitts#8 PRB PRB-Petcoke

Spec

ific

Inve

stm

ent [

$/kW

_e]

Payout for 800 MW_e IGCC

0.00.51.01.52.02.53.03.54.04.5

Pitts#8 PRB PRB-Petcoke

Payo

ut [y

rs]

SCGP insensitive to coal types for $/kW_e;max. 4% bituminous vs sub-bituminous types

SCGP IGCC economics improve as a result!


Comparison SCGP vs US Literature [Pittsburgh#8]

Ref. Harvard Report/EPRI Summary Cases ‘03:- 2* Syngas Manufaturing Blocks (2R)- 2* 7FA Power Block 550 MW_e- Owners Costs/Contingency ~4% included

Shell New Comparison [US Paper 2004]:- 1* or 2* Syngas MF Blocks (1R or 2R)- 2* W501F Power Block 550 MW_e- Shell study ‘04 without OC/Contingency- BOP robust (Cooling Towers, FO back-up)

12741243

1170

1030

900

1000

1100

1200

1300

Shell Study '04

IGCC Investment [$/kW_e]

Harvard Report

Shell-2R_125b

Shell-2R_50b

Shell-1R_50b

41

45.544 43.8

35

37

39

41

43

45

47

Shell Study '04

IGCC Efficiency [%HHV]

Harvard Report

Shell_nR_125b

Shell_nR_50b

Shell_drycoal

(1)

(2)


Conclusions SCGP based IGCC

• IGCC costs can be lowered to 1000-1100 $/kW_e in 2 steps:- By simplifying steam system (SGC pressure 50-77 bar)- By scaling up SCGP with SMPP units > 4000 tpd

• HHV efficiencies 44-45% including 1.5% drop for 125->50 bar SGC• SCGP $/kW_e insensitive to Sub-bit coals (~3-4% HHV)• Petcoke coal mixes can be economic• SCGP systems do not need spare reactor due to reliable design

Shell Coal Gasification Process for Power and Hydrogen ... · GTC Oct 2004 Washington 2 Shell Coal...

Documents

Transcript of Shell Coal Gasification Process for Power and Hydrogen ... · GTC Oct 2004 Washington 2 Shell Coal...