Clean Coal Technologies 2009Clean Coal Technologies 2009Third International Freiberg Conference on IGCC and Third International Freiberg Conference on IGCC and XtLXtL

TechnologiesTechnologies

Dresden, GermanyMay 18-21, 2009

17 YEARS OF EXPERIENCE GAINED FROM THREE 17 YEARS OF EXPERIENCE GAINED FROM THREE GASIFICATION PLANTS OPERATING IN ITALYGASIFICATION PLANTS OPERATING IN ITALY

Vincenzo Fabio Ciccotosto (Speaker) Saipem S.p.A. - Italy

Coauthors:Pierpaolo Mezzanotte Eni R&M S.p.A. – Italy

Giuseppe Pitari, Filippo Galletta ISAB Energy Services S.p.A. – Italy

Vincenzo Rottino ENI Power S.p.a. - Italy

Dr. Daslav Brkic Saipem S.p.a. - Italy

INDEXINDEX

Introduction Projects overviewPlant AvailabilityOutage DistributionConclusion

Topics:• “Learning curve” in design, construction and

operation• High Availability of IGCC plants >90%• Experience & Lesson learned

IntroductionIntroduction

IntroductionIntroduction Contract SummaryContract Summary

Client ISAB Sarlux Eni-EniPower

Contract type LSTK LSTK LSScope of work EPC EPC EPCContractor(s) SP(50)/FWI(50) SP(58)/GE(42) SP

Licensor(s) GE(Texaco) GE(Texaco) Shell Dow/Lurgi UOP/Lurgi Dow/UOP

Detailed eng. SP/FWI SP SPConstruction SP/FWI SP SP

POWER BLOCK Ansaldo Industria GE AnsaldoEnergia

Projects OverviewProjects Overview SummarySummary

SARLUX (SARLUX (~550 ~550 MWeMWe)) ISAB Energy (ISAB Energy (~560 ~560 MWeMWe)) ENI (~250 ENI (~250 MWeMWe))

- Feedstock: VVR(Tar) - Feedstock: Asphalt - Feedstock: VVR(Tar)- GE(Texaco) “quench” - GE(Texaco) “quench” - Shell “radiant cooler”- “Low” pressure (38 barg) - “High” pressure (67 barg) - “High” pressure (62 barg)- “Physical” SRU (Selexol-UOP) - “Hybrid” SRU (MDEA-Dow) - “Hybrid” SRU (MDEA-Dow)- Sulphur tail gas recycled - Sulphur tail gas to incinerat. - Ni-Carbonyls removal- Hydrogen (Membr.+PSA -UOP) - Expander - Hydrogen (Membr.+PSA) - 3 x STAG109E (GE/NP) - 2 x V94.2 (Siemens/Ansaldo) - 1 xV94.2K(Siemens/Ansaldo)- 3 gasif.trains + 2 LTGC etc. - 2 gasif.+ 1 LTGC etc. - 2 gasif.+ 1 LTGC etc.

- Comm.op.: Jan.2001 - Comm.op.: April 2000 Comm. op.: July 2006

Projects OverviewProjects Overview SARLUX IGCC SARLUX IGCC –– ISAB IGCC ISAB IGCC

ISAB ENERGY IGCC PLANTSARLUX IGCC PLANT

Projects OverviewProjects Overview SARLUX IGCC SARLUX IGCC –– ISAB IGCC ISAB IGCC

Projects OverviewProjects Overview ENI IGCCENI IGCC

Projects OverviewProjects Overview ENI IGCCENI IGCC

Ansaldo-SiemensV94-3A.2(400 MW)

Ansaldo-SiemensV94-3A.2(400 MW)

Ansaldo-SiemensV94-2K

(250 MW)

EniPower

Eni Refining & Marketing

Eni Gas & Power

Gasification plant50 t/h Tar

H2

Syngas

Natural gas (12.5 km new pipeline)

Refinery

CCUSYNGAS

TAR

FUELG

AS

CW

HYD

RO

GEN

TAIL G

AS

AC

ID G

ASES

BD

MPS

DW BD

(FIRE WATER, IW, WATER TREAT., IA, SIGNAL EXCH., etc.)

CCUPPU

Projects Overview ENI IGCCProjects Overview ENI IGCC

Projects Overview Projects Overview Feed Feed

ENI ISAB SARLUX Element composition (dry basis)

VVR TAR ASPHALT VVR TAR

Carbon %wt 85.73 84.33 85.07 Hydrogen %wt 9.05 7.77 9.15 Sulphur %wt 3.54 6.0 5.00 Feed flowrate

t/h 50.0 140.0 147.0

HHV MJ/kg 41.28 38.73 42.47 * LHV MJ/kg 39.30 n.a. 38.52 * Calculated value based on element analysis, Dulong formula (ref. Perry and Chilton 1973, par. 9–4).

Projects Overview Projects Overview ProductsProducts

Plant Output ENI ISAB Energy

SARLUX

Syngas (no hydrogen production)

t/d t/d

2 280 (2 560)

17 988 12 910

Gross Power MWe 250 560 550 Hydrogen recovery

Nm3/h 38 000 none 60 000

Steam Export

t/h 73 (HP) n.a. 150 (MP+LP)

AvailabilityAvailability

Plant AvailabilityPlant Availability Syngas productionSyngas production

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

I II III IV V VI VII VIII

Year of commercial operation

ISAB Energystart-up 2000

SARLUXstart-up 2001

ENI R&Mstart-up 2006

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

I II III IV V VI VII VIII

Year of commercial operation

ISAB Energystart-up 2000

SARLUXstart-up 2001

ENI Powerstart-up 2006

Plant AvailabilityPlant Availability Power productionPower production

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

I II III IV V VI VII VIII

Year of commercial operation

ISABEnergy

SARLUX

ENIPower

Power Capacity FactorPower Capacity Factor

Instrumentation, 33%

Mechanical, 13%Operational, 10%Common part, 4%

External , 33%

Planned, 8%

Cause of shutdown distributionCause of shutdown distribution ENI R&M Gasification PlantENI R&M Gasification Plant

period: 2006 -2008

Duration of shutdown distributionDuration of shutdown distribution ENI R&M Gasification PlantENI R&M Gasification Plant

Instrumentation, 4%Operational, 1%Common part, 5%

External , 16%

Planned, 36%

Mechanical, 38%

period: 2006 -2008

Instrumentation13% Mechanical

8%

Operational41%

Common part10%

Planned3%

External 25%

Cause of shutdown distributionCause of shutdown distribution ISAB Energy Gasification PlantISAB Energy Gasification Plant

period: 2003 -2008

Instrumentation14%

Mechanical4%

Operational16%

Common part19%

External 24%

Planned23%

Duration of shutdown distributionDuration of shutdown distribution ISAB Energy Gasification PlantISAB Energy Gasification Plant

period: 2003 -2008

ConclusionConclusion

• Lack of gasification plant availability has been a significant hindrance for the power industry in the past years. The data presented in this work confirm once again that the technology has reached high levels of performance and great strides have been made in the design of reliable systems.

• The substantial experience thus gained in heavy oil residue gasification can be extended to identify bottlenecks also in coal gasification, and can be used to guide the design and implementation efforts of technology licensors, equipment suppliers, engineering and construction contractors, as well as project Owners and developers.

S a i p e m SpA

Vincenzo CiccotostoSenior Process Engineer

Phone: 39-02-52053592Fax: 39-02-52053504e-mail: vincenzo.ciccotosto@saipem.eni.it

THANK YOUTHANK YOU