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GASIFICATION FOR COMBINED PRODUCTION OFELECTRIC POWER AND CHEMICALSELECTRIC POWER AND CHEMICALS

R. Domenichini - Technical Director Foster Wheeler Italiana - Power Division

Gasification Technology Conference, October 2008 – Washington (USA)

Gasification for Combined Production of Electric Power and Chemicals

A G E N D A

• INTRODUCTION INTRODUCTION

• BASES OF DESIGN AND PLANT ALTERNATIVES

• PROCESS DESCRIPTION

• PERFORMANCE DATA

• INVESTMENT COSTS

• COST OF ELECTRICITY (C.O.E.) AND COST OF CHEMICALS (C.O.C)

• SENSITIVITY ANALYSIS

• SUMMARY FINDINGS

© Foster Wheeler. All rights reserved


INTRODUCTION

The target of this study is to investigate the technical-economical feasibility of capture-ready IGCCplants, designed for the combined production of electric power and chemicals, from coal and petcokeplants, designed for the combined production of electric power and chemicals, from coal and petcoke

Two main case studies are developed:

Co-production of methanol and electric power from coal gasification (IGCC-MeOH)

Co-production of urea and electric power from petcoke gasification (IGCC-Urea)p p p g ( )

Overall performances and investment costs are evaluated and shown through:

• A sensitivity analysis on Cost of Electricity and Cost of Chemicals

• Performance and cost penalties due to the CO2 capture retrofit



IGCC Electrical Energy and Methanol Co-productiongy p

Air Separation Unit

Air

Electric Power

Nitrogen

GasificationIsland

Syngas treatment (CO shift)

Gas Turbine

HRSGCoal Syngas

Electric Power

Steam / BFW

Oxygen

Acid GasRemoval

Sulphur Recovery Unit

Steam TurbineSlag / Filter Cake

SulphurClean Syngas

CO2 drying and i

UtilitiesMethanol Plant

Methanol

CCS case

compression

CO2



IGCC Electrical Energy and Urea Co-production

Air Separation Unit

Gas TurbineAir Electric PowerNitrogen

Unit

GasificationIsland

Syngas treatment (CO shift)

HRSG

Steam TurbineCoal Syngas

Steam / BFWOxygen

Island ( )

Acid GasRemoval

Sulphur Recovery Unit

Slag / Filter Cake

Sulphur Clean Syngas Offgas toPostfiring

CO2 drying and Utilities

y

H2

Urea

Ammonia Plant

Urea

PSACCS case

compressionUtilities

CO2

Plant

CO2



BASES OF DESIGN AND PROCESS ALTERNATIVES

Case Feedstock CO2 capture GT Methanol / Urea production, t/d p

IGCC-MeOH Bitumious Coal No 250 MWe F-class 5,000

IGCC-MeOH Bitumious Coal Yes 250 MWe F-class 5,000

IGCC-Urea Petcoke No 120 MWe E-class 3 400 IGCC-Urea Petcoke No 120 MWe E-class 3,400

IGCC-Urea Petcoke Yes 120 MWe E-class 3,400

i i i E l i i d d di i• Location is a generic European coastal site at iso-standard conditions

• Gaseous emissions (mg/Nm3 @ 15% O2 vol. dry):- NOx : < = 50

GASIFIERS CAPACITY IS FIXED TO PRODUCE REQUIRED SYNGASFOR THE TARGETED CHEMICAL PRODUCTION

- SOx : < = 10


FOR THE TARGETED CHEMICAL PRODUCTIONAND TO SATISFY THE APPETITE OF THE SELECTED GAS TURBINE


PERFORMANCE DATA

MeOH / Urea G Net Power Overall carbon

CASE Fuel MeOH / Urea production

Gross Power Output

Net Power Output

CO2 emission removal efficiency *

t/h t/d MWe MWe t/h %

IGCC-MeOH 474.5 5,000 563.3 253.7 782.8 26.8

IGCC-MeOH with CCS 474.5 5,000 563.3 212.4 183.5 82.8

IGCC-Urea 174.8 3,400 303.5 132.6 414.6 20.0

IGCC-Urea with CCS 174.8 3,400 303.5 110.8 70.6 86.4

* Including carbon present in the chemicals produced (methanol or urea).

Petcoke case meets the target of a modern refinery (delayed coker capacity 100,000 BPSD and internal electrical cons.)


g y ( y p y , )


INVESTMENT COSTS

The overall investment cost includes:

Di t t i l ( i t d b lk t i l )• Direct materials (equipment and bulk materials)• Construction (mechanical erection, instrument and electrical installation, civil

works and site preparation)

• Other costs (temporary facilities, solvents, catalysts, etc.)

• EPC services CASE Total Investment Cost

106 € • Land purchase

• Technology fees

106 €

IGCC-MeOH 2,051

IGCC M OH ith CCS 36 (d lt ) • Contingencies

IGCC-MeOH with CCS + 36 (delta)

IGCC-Urea 1,558


IGCC-Urea with CCS + 26 (delta)


PRODUCTION COSTS

Main Economic Data:

• Methanol selling price: 380 €/t (Sensitivity to 250÷450 €/t)

• Urea selling price: 260 €/t g p(Sensitivity to 230÷300 €/t)


Graphs from “nitrogen + syngas” - September / October 2008


PRODUCTION COSTS

Main Economic Data:

C t f t k 35 €/t (S iti it t 20 50 €/t)• Cost of petcoke: 35 €/t (Sensitivity to 20÷50 €/t)

• Cost of coal: 85 €/t (Sensitivity to 60÷110 €/t)( y )

• 7,621 syngas equivalent operating hours (87% equivalent availability)

• 10% discount rate on the investment cost over 25 years

• Maintenance cost: approx 3.0% of the total capital costs



COST OF ELECTRICITYCOST OF ELECTRICITY

CASE MeOH / Urea prod. t/d

Cost of Coal / Petcoke €/t

Cost of MeOH / Urea €/t

C.O.E. cent€/kWh

IGCC-MeOH 5,000 85 380 3.6

IGCC-MeOH with CCS 5,000 85 380 4.7

IGCC-Urea 3,400 35 260 2.8

IGCC-Urea with CCS 3,400 35 260 3.9



IGCC-MeOH

SENSITIVITY TO COAL COST(MeOH price = 380 €/t)

0.1

0.12

0.06

0.08

O.E

. (€/

kWh)

0.02

0.04C.

060 65 70 75 80 85 90 95 100 105 110

Coal Cost (€/t)


no CCS CCS


IGCC-Urea

SENSITIVITY TO PETCOKE COST(Urea price = 260 €/t)

0 05

0.06

0.07

0.03

0.04

0.05

O.E

. (€/

kWh)

0.01

0.02

C.O

020 25 30 35 40 45 50

Petcoke Cost (€/t)


no CCS CCS


IGCC-MeOH

SENSITIVITY TO MeOH SELLING PRICE(Coal cost = 85 €/t)

0.16

0.18

0.2

0.1

0.12

0.14

O.E

. (€/

kWh)

0 02

0.04

0.06

0.08

C.O

0

0.02

250 270 290 310 330 350 370 390 410 430

MeOH Price (€/t)


no CCS CCS


IGCC-Urea

SENSITIVITY TO UREA SELLING PRICE(Petcoke cost = 35 €/t)

0 06

0.07

0.08

0.04

0.05

0.06

O.E

. (€/

kWh)

0.01

0.02

0.03C.O

0230 240 250 260 270 280 290

Urea Price (€/t)


no CCS CCS


IGCC-MeOH

SENSITIVITY TO CARBON TAX – no-CCS vs. CCS(Coal cost = 85 €/t; MeOH price = 380 €/t)

0.14

0.16

0.18

0.08

0.1

0.12

.E. (

€/kW

h) 18 Euro/t (CCS with 10€/t)

0.02

0.04

0.06C.O

.

5 Euro/t (CC only)

0

0.02

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0

Carbon Tax (€/t CO2 )


CCS no CCS CCS incl. transport & storage


IGCC-Urea

SENSITIVITY TO CARBON TAX – no-CCS vs. CCS(Petcoke cost = 35 €/t; Urea price = 260 €/t)

0.14

0.16

0.18

0.08

0.1

0.12

O.E

. (€/

kWh)

16 Euro/t (CCS with 10€/t)

0.02

0.04

0.06C.O

4 Euro/t (CC only)0

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0

Carbon Tax (€/t CO2 )

( y)


CCS no CCS CCS incl. transport & storage


SUMMARY FINDINGS

• Capture-ready IGCC with electric power and chemicals co-production showsattractive COE especially for a low value feedstock like petcokeattractive COE, especially for a low value feedstock like petcoke

• IGCC-MeOH case is significantly affected by coal cost and MeOH price.98 €/t (b 85€/t) f C l> 98 €/t (base 85€/t) of Coal

< 350 €/t (base 380 €/t) of MeOHnon-competitive COE values

for European electrical market

• IGCC-Urea case is less affected by the petcoke cost and Urea price.

> 60 €/t (base 35 €/t) of Petcoke< 230 €/t (base 260 €/t) of Urea

non-competitive COE valuesfor European electrical market



SUMMARY FINDINGS

CO t t fit i hi bl ith l f d t• CO2 capture retrofit is achievable with low performance and costpenalties.

• CCS alternatives are economically viable even at a very low level ofcarbon tax (> 18 €/t for IGCC-MeOH and > 16 €/t for IGCC-Urea, assuming10 €/t for CO2 transport and storage)

• Improvements in the main areas like GT, gasifiers and ASU are expectedin the next years, thus making IGCC’s more and more attractive


THANK YOUTHANK YOU

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Gasification Technology Conference, October 2008 – Washington (USA)

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