Lurgi’s M PG and BGL G asifiers at SVZ Schwarze Pum pe

Status and Experiences in IGCC Application

C. Erdm ann, W . Liebner, Lurgi O el · G as · Chem ie G m bHW . Seifert, SVZ G m bH

presented at

1999 Gasification Technologies Conference

October 17-20, 1999San Francisco, California

ContentsMPG-IGCC Experience

Presentation

• Waste Utilization Centre at SVZ

• Gasification Technologies at SVZFixed Bed Grate (FBG)

British Gas Lurgi (BGL)Multi Purpose Gasification (MPG)

• The Combined Cycle Power PlantCC Concept

CC Contracting and ExecutionCC Operation

• “Waste to Value” by IGCC with co-production

Plastics

Fluff

Contam inatedW ood

M unicipalW astes

Sewage Sludge

ShredderLight Fraction

Others

Receiving+Storage

Preparation+Pelletizing120000 tpy

M PG

ConditioningRectisol

Purification

ConditioningStorage

Tars

Oils

LiquidResidues

Slurries

Com bined Cycle

Power Plant

M ethanolSynthesis+Distillation

75 M W e

120000 tpyGrade AA

Sales overthe fence

Fuel Gas

Binder(Coal, M olasses)

Fe+M etals

Ash

Sour G asto SRU

W aterTreatm ent

W ater

Slag

O 2Steam

O 2Steam

O 2Steam

ShiftSteam

District Heat

BGL -Gasifier (1)

SVZ-GrateGasifiers (7)

Slag

Oil / Tar

∼∼

SVZ Schwarze Pumpe

SVZ-IGCC ConceptM PG-IG CC Experience

M PG Reactor ConfigurationsM PG-IG CC Experience

MPG - Quench Configuration

SVZ-IGCC Fuel GasesM PG-IG CC Experience

MPG - Boiler Configuration

SVZ-IGCC Fuel GasesM PG-IG CC Experience

GT- BaseParameter Clean Gas Purge Gas NG Case

Flow m3/h 0 … 49,400 0 … 21,480 0 … 3,000 33,700

Pressure bar 20.5 … 23.5 20.5 … 53 27 … 32

H2 Vol.-% 56.3 … 63.9 39.5 … 52.5 0 53.6

CO Vol.-% 18.7 … 27.1 11.4 … 12.0 0 16.5

CH4 Vol.-% 4.0 … 16.9 22.4 … 35.0 95.0 20.2

CmHn Vol.-% 2.9 … 3.3 5.2 … 6.0 3.0 1.6

CO2 Vol.-% 2.9 … 3.3 5.2 … 6.0 0 4.5

N2 Vol.-% 1.7 … 3.0 4.6 … 5.0 2.0 3.6

LHV kJ/Nm3 12,000 … 15,412 16,543 … 20,610 35,922 16,116

Fuel Gases to CC-Block

SVZ-IGCC Fuel GasesM PG-IG CC Experience

• Utilization of syngas/cleangas and of all offgasesabove 19 bar system pressure

• Utilization of all untreated fuelgases (offgases)

• Cover internal demand of 15 … 22 MWel

• Sale of 40 … 50 MWel

• Continuous power production > 8000 h/a

• Provision of process steam on three levels (35, 16, 5 bar)

• Provision of feed water (two qualities)

IGCC-Concept: Requirements

SVZ-IGCC ConceptM PG-IG CC Experience

- A combined cycle block with two additionaloffgas boilers fits the demand profile

- The HRSG and the two offgas boilers raiselive steam at 125 bar, 525 °C

- The HRSG is equipped with auxiliary burners

- The IGCC feed gas mixer works as pressure control ofthe synthesis gas grid and of the gasification units

- Back-up on the fuel side by NG and light heating oil

- Back-up on the power side by local utility

IGCC-Concept: Solutions

SVZ-IGCC ConceptM PG-IG CC Experience

!!!! CC-Block GT : Frame 6, 133 MWth, 44 MWel

NOx reduction by steam injection

ST : Extraction / Condensing, 31 MWel

Process steam at 35, 16, 5 bar

HRSG : Single tract / two pressure, 181 t/h hp-steam

additional firing max. 115 MWth

!!!! Offgas Boiler #1 : 55 t/h hp-steam

Sep. combustion chamber for NH3-water

!!!! Offgas Boiler #2 : 60 t/h hp-steam

!!!! FGD : Limestone; gypsum sold to panel manufacturer

75 MW Combined Cycle with Auxiliary Boilers

SVZ-IGCC 75 M W Com bined CycleM PG-IG CC Experience

Contracts

SVZ-IGCC Project ExecutionM PG-IG CC Experience

Planning / General Contractor

Main Contractor

Control System Supplier /

Contractor (SVZ)

GT HRSG ST

Supplier Supplier Supplier

HT-Equipment

Supplier

Civils

Contractor

SVZ

responsibility

separate

contracts

Schedule

SVZ-IGCC Project ExecutionM PG-IG CC Experience

Start General Planning Oct. 94

Start Detail Planning Apr. 95

Construction Aug. 95 - Sep. 96

Commissioning & S/U Aug. 96 - Aug. 97

Conclusion

Complex system - Many interfaces - Rewarding result

T.I.C. of CC-Block ~ 590 $/kW

SVZ-IGCC Block Flow DiagrammMPG-IGCC Experience

BESIK60 t/h

REAK55 t/h

HRSG67 - 180 t/h

GT

HP GasMixing

(< 19 bar)

ST ~

M

LP Offgas

Cleangas

NG

LP Offgas

NG+Clean Gas

NH3 Exp. gas

HEL

HEL

Purgegas

Cleangas

NG

HP Steam 125 bar/520 °C

CW

Condensate

IP-Steam35 bar/360 °C

MP-Steam15 bar/230 °C

LP-Steam 5 bar

Wobbe-Index GasturbineMPG-IGCC Experience

Temperature [°C]

Wobbe-IndexkJ/Nm3K1/2

0 10 20 30 40 50 60 70 80 90 100

1400

1500

1600

1700

1800

1900

1300

GT- BaseParameter Clean Gas Purge Gas NG Case

Flow m3/h 0 … 49,400 0 … 21,480 0 … 3,000 33,700

Pressure bar 20.5 … 23.5 20.5 … 53 27 … 32

H2 Vol.-% 56.3 … 63.9 39.5 … 52.5 0 53.6

CO Vol.-% 18.7 … 27.1 11.4 … 12.0 0 16.5

CH4 Vol.-% 4.0 … 16.9 22.4 … 35.0 95.0 20.2

CmHn Vol.-% 2.9 … 3.3 5.2 … 6.0 3.0 1.6

CO2 Vol.-% 2.9 … 3.3 5.2 … 6.0 0 4.5

N2 Vol.-% 1.7 … 3.0 4.6 … 5.0 2.0 3.6

LHV kJ/Nm3 12,000 … 15,412 16,543 … 20,610 35,922 16,116

Fuel Gases to CC-Block

SVZ-IGCC Fuel GasesM PG-IG CC Experience

0 10 20 30 40 50 60 70 80

1005

1110

1215

1320

1425

1530

20

22

24

26

28

30

RG2

RG2

BF6

RG1

BF4

RG3

BF2

BF1PG

BF3

Remarks:1. Wobbe-Index (GE) in BTU/SCF/SQR T(°Rankine)2. Wobbe-Index in kJ/Nm3/SQR t(°Kelvin)

3. Legend:- BF1 bis BF6: Mixed gas, cases 1 to 6- RG1 bis RG3: Clean gas, cases 1 to 3- PG: Purgegas

Gastemperature [°C]

Wobbe-Index (GE)

Wobbe-Index

Wobbe-Index operating casesMPG-IGCC Experience

-5

0

5

10

15

20

25

30

35

40

45

50A

ug

98

Sep

98

Oct

98

No

v 9

8

Dez

98

Jan

99

Fe

b 9

9

Ma

r 9

9

Ap

r 9

9

Ma

y 9

9

Ju

ne

99

Ju

l 99

Au

g 9

9

Sales VEAG Sales AGA Internal Cons. Import

Gross Power Production 1998/99MPG-IGCC Experience

Electric Power19 MJ

Transportation80 MJ

Coal 6.85 GJ

Oxygen6.5 MJRaw Water20 MJ

Methanol5.4 GJ

Export ElectricPower1.35 GJ

Steam/Heating0.26 GJ

= 44.7%ˆ

Fluegas0.81 GJ

Heat Losses8.74 GJ

Cleaned Waste Water28 MJ

1 t Waste9 GJ

SVZ-IGCC Energy FlowMPG-IGCC Experience

Current state, basis 1 t waste

SummaryMPG-IGCC Experience

Three Gasification Processes(FBG, BGL, MPG)

as basis of an

IGCC - Co-production Plantoperated for two years at

High Conversion Efficiencydelivering:

“Value from Waste” a Gasification Success !