eastman gasification overview gtc regulators · pdf filechemicals, synfuels, fertilizers,...
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Eastman Gasification Overview
GTC Regulators Workshop
April 12, 2005
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hFounded in 1920 as part of Eastman Kodak - wood to methanol plant hSpun off from Kodak - January 1, 1994hOver $6 B in annual saleshHeadquarters - Kingsport, TNhManufacturing sites around the world
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Oxygen
Coal or Petcoke
Water
What is Gasification?
Products (syngas):
CO (Carbon Monoxide)
H2 (Hydrogen)
[CO/H2 ratio can be adjusted]
By-products:
H2S (Hydrogen Sulfide)
CO2 (Carbon Dioxide)
Slag (Minerals from coal)
• Controlled Chemical Reaction• Up to 1,000 psig or more• Nominal 2,600 Deg F
GasClean-Up
BeforeProduct
Use!
Carbon + Oxygen + Water Carbon Monoxide + Hydrogen
C + O2 + H2O CO + H2
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"Dirty Syngas"CO,H2,CO2,H2S
Clean Solvent
Dirty Solvent
"Clean Syngas"CO, H2
Three Main Technologies:
• MDEA (methyldiethanolamine) – Chemical absorption, 98% to 99+% S removal, large CO2 slip (unless use a second stage for CO2 recovery), moderate operating temperature, lowest AGR capital cost
• Selexol tm (primarily dimethyl ethers of polyethylene glycol, DEPE) – Physical absorption, 99+% S removal, variable CO2 slip (based on design), higher AGR cost than MDEA but overall AGR/SRU system costs are similar
• Rectisol tm (methanol) - Physical absorption, 99.5% to 99.9+% S removal, complete CO2 removal possible, highest AGR cost, coldest operating temperatures
[Used by Eastman]
AGR Technologies Can Provide Near 100% Sulfur Removal If Required
(AGR = Acid Gas Removal)
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So what can you do with CO and H2 ?
Syngas
Building Blocks for Chemical
Industry
Clean ElectricityTransportation Fuels
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Integrated Gasification Combined-Cycle (IGCC)
Contaminants Removed
Pre-Combustion !!!
Air SeparationUnit (ASU)
GasificationBlock
Coal(or otherCarbonSource)
Water
Air
Oxygen
VolatileMercury
PureSulfur
CO2 Capture (ready for sequestration) Electricity
CrudeSyngas
CleanSyngas
90+%Removal
98-99+%Removal
SlagCombined-
CyclePower Block
Gas Clean-UpBlock
Eastman Coal Gas Facility
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Sulfur
CO2
Low Temp Gas Cooling
Shift Rx(option)
VolatileMercuryRemoval
ParticulateScrubber
Slag/Frit
GE"Quench"Gasifier
Coal
H2O
+
Air Separation Unit (ASU)
O2
Slurry
Acid Gas Removal
What is IGCC?
CO/H2
Fines/Char
Flexibility for CO2 Sequestration
(Concentrated Stream)
Sulfur RecoveryClaus/Scot
PRE-COMBUSTIONTreatment of Pollutants
•High pressure•Low Volume•Concentrated stream(easier to treat)
Air
Sulfur RecoveryClaus/Scot
Combustion Turbine
Compressed Air to ASU
HRSG
Steam Turbine
Electricity
Electricity
>90%Removal
98-99+% SRemoval
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Electricity
Natural Gas
and/or Oil
Gasification-Based Polygeneration:Replace NG and/or Oil With Coal/Petcoke
Syngas from Coal/Petcoke Gasification(adjacent or via pipeline)
X
Chemicals,Synfuels,
Fertilizers,and/or Hydrogen
+
Combined-CyclePower Plant
ChemicalFacilities
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Coal/Petcoke
Dimethyl EtherMethanol
Fischer-Tropsch Liquids
Fuel/Town GasPower & Steam
Acetic AcidEthylene
&Propylene
Methyl Acetate
VAM
Acetic Anhydride
Ketene
Diketene & Derivatives
PVAPolyolefins
FT Diesel
Polygeneration Potential of Gasification
Ammonia& UreaH2
Oxo Chemicals
Synthesis Gas
Car Fuel
Waxes
GasificationNaphtha
Acetate Esters
Iron Reduction
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Benefits of Polygeneration• Higher overall value creation• Higher overall thermal efficiency and
feedstock utilization• Synergistic usage of low grade steam
and waste streams• Enhanced ability to load follow
(intermediate vs. baseload operation)• Higher employment for the community• Enhanced reliability, with potential to
store syngas as a liquid fuel
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Why Gasification?• It is the cleanest coal/petcoke technology …
– Inherently lower SOX , NOX , and PM (approaching NG)– Lowest collateral solid wastes and wastewater (30-50% less)– Potential for lowest cost removal of mercury and CO2
• It is proven technology …– 21+ years of successful commercial operation at Eastman– Multiple commercial IGCC’s (e.g., TECO Polk, Wabash)
• It is becoming increasingly competitive …– Capital cost at parity with other clean coal and dropping– Lowest dispatch cost of all fossil fuel technologies
• It is gaining acceptance …– Gaining support of environmental groups (e.g., NRDC, CATF)– Numerous state and federal initiatives and incentives
• It provides great promise for the future …– Flexible feedstocks, process options, and products– Opens new markets for coal (synfuels, chemicals, fertilizers)– It provides the only feasible bridge from coal to hydrogen
(directly converts coal/petcoke to hydrogen)
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Eastman Performance with Rectisol AGR
Eastman Operational Data, Jan-Mar '04Total Sulfur in Clean Syngas, ppm
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
1/1/2004 1/8/2004 1/15/2004 1/22/2004 1/29/2004 2/5/2004 2/12/2004 2/19/2004 2/26/2004
ppm
Sul
fur
Sulfur levels in exhaust gas after combustion would be ~1/8 these levels for an IGCC.
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Vapor-PhaseMercury Removal
High pressure, concentrated stream low volume, low cost,
high removal efficiency
Demonstrated for 21 years at Eastman !The cost of volatile mercury removal by IGCC is estimated to be < $0.25/MWh, almost an order of magnitude lower than for PC technologies using activated carbon, according to a 2002 DOE report
by Parsons (DOE Report, "The Cost of Mercury Removal in an IGCC Plant", September, 2002).
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DOE Report "Major Environmental Aspects of Gasification-Based Power Generation Technologies", December 2002
IGCC: Low-Risk Option for Carbon Capture
IGCC Minimizes Capital Cost Penalty of CO2 Capture
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IGCC's True Environmental Capability is More than Marginal Improvement
• Inherently lower in air emissions and collateral solid wastes and wastewater; consumes substantially less water than coal combustion options.
• For < $100/KW estimated added cost, IGCC's can reduce sulfur in syngas by 99.5% or more (vs. 98 to 99+% standard).
• For < $0.25/MWh, IGCC's can remove essentially all volatile mercury from syngas (>90-95+% removal).
• IGCC's can capture CO2 at a fraction of the comparative cost for PC or NGCC (~1/5 the parasitic power loss).
• These enhanced capabilities are all commercially proven. Eastman has practiced high sulfur removal plus volatile mercury removal and CO2 capture (but without sequestration) for more than 21 years.
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Eastman’s Experience with Gasification• We were a pioneer in coal gasification …
– First commercial U.S. coal gasification facility in 1983– Designated as ACS National Historic Chemical Landmark
• Industry leading operating performance …– > 98% on-stream time since 1984– < 1-2% forced outage rate– Highest production rate per unit of capacity– Single-train reliability of ~88-90% (~94% excl. refractory change)
• Excellent safety record …– Plantwide OSHA recordable rate of ~1.0– No lost time in gasification area in over 12 yrs
• Exceptional environmental performance …– Remove >99.9% of sulfur– Patented sulfur-free start-up process– Volatile mercury removal for over 21 years
• Continual process improvement …– Reduced maintenance costs 20-30% in past 6 years– Patented feed injector designs for longer run life
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Air
Oxy
gen
N2/ArA
SU
Compressor
Water
Coal
SlurryPump
Grinding Rod Mill
Lock Hopper
Particulate Scrubber
Solids Filtration
Water recycle
Flash drum
GEGasifier
(1 + Spare)
Shift Reactor
Hg Removal
Sulfur Recovery
Sulfur
CO2
Gas Clean-up (Rectisol) A
cid
Gas
es
COH2
CO/H2Separation (Cryogenic)
Syngas Conversion
Chemicals
Gasification at Eastman Basic Flow Diagram
Acetic AnhydrideAcetic AcidMethyl AcetateMethanol
Clean SyngasSteamAir Products
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Syn Gas (CO + H2)
Carbon Monoxide (CO)
Chemicals from Coal – The Chemistry
Methyl Acetate Plant
Methyl Acetate
CH3OH+ CH3COOH CH3CO2CH3 (methyl acetate)Acetic
Anhydride
CO + CH3CO2CH3 (CH3CO)2O (acetic anhydride)Acetic Acid
Carbonylation Plant
CH3OH + CO CH3COOH (acetic acid)
MethanolPlant
Methanol
CO + H2 CH3OH (methanol)
Primary Reactions:
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Eastman Gasification Plant
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Eastman Gasification Plant Layout
Gasifier BuildingSlurry Prep
Soot Recovery
Rectisol AGR Sulfur Recovery
Flare
Total area, all operations, parking, Control room, shops, coal storage and unloading, etc = 32 Acres
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Acetic AnhydrideAcetic AcidMethanol
Methyl AcetateCoal
Eastman Chemicals from Coal – The Big Picture
Several major products are single-sourced from Eastman's coal gasification process!!
Thus, reliability is critical!!!
It’s likely you have used a product based on coal gasification from Eastman’s facility!
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Reliable Gasification Operation
Yes, it can be done!
“The Devil is in the details.”
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Eastman Operating StatisticsThree-Year Cycle (09/01 – 09/04)
including planned shutdown
On-Stream98.0 %
Unplanned1.2%
Planned0.8%
Not Needed0.0%
Industry-Leading Performance !!!
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Eastman Operating StatisticsOne-Year Cycle (Sept 2002 - Sept 2003)
On-Stream98.9 %
Unplanned1.1%
Planned0.0%
Not Needed0.0%
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Sustained Low Forced Outage RateEastman Gasification Plant
Historical Forced Outage Rate
0
1
2
3
4
5
6
7
8
9
10
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
% F
orce
d O
utag
e R
ate
Forced Outage Rate has Averaged < 2% since 1984 !!!
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Keys to High Reliability:•Feedstock Characteristics and Operational Experience Incorporated into Design:
•Every coal seam is different; petcoke is different than coal •Fluxant or no Fluxant?•Redundancy where needed based on reliability experience
•Effective Functional Checkout•Involving field operators where possible
•Training •Real-time DCS simulators (Eastman Simulator)•Effective training programs for both apprentices and experienced operators
•Standardized Operating Procedures and Checklists•Maintenance Program
•Efficient gasifier "turnaround" process is critical•Preventative and Predictive Maintenance Programs
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Maintenance…
Reliability-Based Maintenance
• Preventative/predictive mode
• Advanced monitoring tools utilized
• Data on individual equipment analyzed
• Equipment criticality rankings vs. reliability performance set the maintenance schedule
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Safety
• Plantwide OSHA recordable injury rate ~ 1.0[Equates to one injury in over 15 years for a family of four!]
[OSHA injuries = injuries that require more than minor 1st aid]
• Last gasification area work day out case was over 12 years ago (sprained ankle stepping off a curb)
• Plant site received Tennessee OSHA “Volunteer Star”safety certification in 2001
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Eastman Environmental Performance
• Cleanest U.S. coal gasification facility. • Sulfur removal is > 99.9% (with Rectisol);
<0.1 ppm sulfur in our syngas.• Eastman has a patented sulfur-free
start-up process (no SO2 from flare).• Eastman has practiced essentially
complete vapor-phase mercury removal from syngas since our initial plant start-up.
• Excellent environmental record and reputation.
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Eastman will help gasifier owners get more out of their plants, including faster
start-ups and improved long-term availability and reliability
• World-class operational performance
• Intelligent design choices to limit capital costs
• Patented technology improvements
• Exceptional safety and environmental records
• Best partner for polygeneration options
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Service Offerings:h Operations, maintenance, and management
contractsh Technical servicesh Critical spare parts fabricationh Specific technology licensingh Cooperative services agreement with
ChevronTexaco/GEh Project development
Eastman Gasification Services CompanyA subsidiary of Eastman Chemical Company
Building on Past Success
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Together we can realize thefull potential of gasification!
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QUESTIONS?www.gasificationservices.eastman.com