refinery residue based igcc power plants and market … · use of high efficient siemens v94.2 gas...

10/17/2001 page 1

Standard Oil - IGCC Krupp Uhde

Gasification Technologies 2001

Refinery Residue Based IGCC PowerPlants and Market Potential

Joachim Wolff (Speaker), Karsten RadtkeKrupp Uhde GmbH

Jürgen Karg, Werner GünsterSiemens AG Power Generation

10/17/2001 page 2


Content

1. Incentives

2. Design Conditions

3. Plant Concept

4. IGCC Overall Performance

5. Economic Evaluation

6. Project Execution

7. OutlookG

G

G

Scrubber/Soot

RemovalDesulphuri-

zationGasification

SootFiltration

SulphurRecovery

AirSeparation

Unit

Syngas Cooler Raw Gas

HP Steam, sat

HP Steam for Gasification

Flue Gas

Steam Turboset

FuelGas

Saturator

Waste Nitrogen

Soot Water Sour GasOxygen

HP Steam

Oxygen

Gas Turboset

Feedwater Make-upAirAirSulphurWaste Water

SootFilterCakeVisbreaker Residue

Gas Island Power Island

Boiler Feedwater

Condenser

Clean Gas

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Integrated Gasification Combined Cycle -Advantages

“Clean“ Technology High Efficiency is not the Driver for Low-value Fuels Fuel Flexibility Repowering of Existing Plants Modularity + Phased Construction

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Typical IGCC Project CostsGTC2000-McConnel, Drnevich; Simbeck

Gas Turbine/CC - 30% Gasification/Gas Cleaning - 25%

Owners Cost - 10-20% ASU - 15%

Off Sites - 10-25% Project Development - 5-15%

± 20%

± 10%

± 25% ± 5%

± 5%

± 2%

10/17/2001 page 5


Incentives

Optimised Overall IGCC-Plant Concept Definition of an Overall Control Philosophy Minimisation of Plant Emissions Reducing Cost by Location Synergies/Greenfield Site Co-ordinate Interface and Integration Engineering Reducing Cost for Project Development Reducing Time for Project Implementation Evaluation of Realistic EPC Cost (+/- 10%)

10/17/2001 page 6


Market Potential for Residue-Based IGCCLiquid residues from existing refineries (302 Mio t/a) arecorresponding to a general IGCC potential of 170 GW

Existing Refineries: Accessible Sharefor IGCC Applications 90 GW

Existing Refineries: Non AccessibleShare for IGCC Applications 80 GW

IGCC Potential from Refinery NewCapacity Additions until 2010:30 GW

Total Potential for Residue-Based IGCC up to 2010:120 GW

NAFTA 28 GW

C/S Americas 9 GW

Western Europe 12 GW Eastern Europe 5 GW

Asia/Pacific 50 GW

Africa/Middle East 16 GW Restrictions on the refinery sites used for evaluationof effective IGCC potential for existing refineries:

• minimum oil throughput/plant output by site• maximum share of IGCC in national plant capacities• national power plant market• country-specific status of liberalization

Restrictions on the refinery sites used for evaluationof effective IGCC potential for existing refineries:

• minimum oil throughput/plant output by site• maximum share of IGCC in national plant capacities• national power plant market• country-specific status of liberalization

10/17/2001 page 7


Market Potential for Residue-Based IGCC up to 2010subdivided into Net Frequency and Power Output Ranges

(Total possible capacity 120 GW)

50 Hz Market: 61 GW 60 Hz Market: 59 GW

05000

100001500020000250003000035000

- 300MW

300 - 600MW

600 - 900MW

900 -1200MW

1200-1500MW

05000

100001500020000250003000035000

- 300MW

300 - 600MW

600 - 900MW

900 -1200MW

1200-1500MW

05000

100001500020000250003000035000

- 300MW

300 - 600MW

600 - 900MW

900 -1200MW

1200-1500MW

05000

100001500020000250003000035000

- 300MW

300 - 600MW

600 - 900MW

900 -1200MW

1200-1500MW

The Highest Potential for Residue-Based IGCC is in thePower Output Range of 300 to 600 MW.

The Highest Potential for Residue-Based IGCC is in thePower Output Range of 300 to 600 MW.

Refinery new capacity additions are assumed to be mainly in the range of 7 Mio t/a crude oil capacity,resulting in a Residue-Based IGCC power output of about 500 MW

MW MW

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Standard IGCC - Scope of Work

Definition of Basis of Design

Concept Calculation andOptimisation

Preparation of Cost Estimate

Development of a Sound ProjectImplementation Program

Definition of further Activities

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Lessons Learned

IGCC Applications requires• Co-ordinated “Interface and Integration Engineering”

• Yes: Close Co-operation of all participating parties

• No: “Black Box Philosophy” with limited directcommunication

Plant operation is heavily influenced by theoverall control philosophy/system and itsoptimisation for the different plant section

Well trained operators as well as optimisedautomation degree improves plant availability

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G

Gas Cooling

Gas Cleaning

Gas Saturation

G

SGP Gasifier Visbreaker Residue

Minimal Sulphur and Dust Emissions

Use of Low Level Heat for Clean Gas Saturation

Design for Secondary Fuel

Use of High Efficient Siemens V94.2 Gas Turbine (Syngas Proven)

Use of Siemens Reheat Steam Turbine (KN Series)

Use of Sensible Raw Gas Heat to Produce High Pressure Steam

50 % Integration of Air Separation Unit (ASU)

100 % Waste Nitrogen from ASU to Gas Turbine (GT)

Low NOx Combustion Resulting in Low (< 25 ppm) NOx Emission

Low HRSG Exhaust TemperatureT = 126 °C

Triple Pressure Heat Recovery Steam Generator (HRSG)

HRSG(SCR Optional)

Liquide Fuel

ASUSulphur

Recovery

Fuel Oil

10/17/2001 page 11


SyngasCooler Quench

SyngasCooler Quench Scrubber

SulphurRecovery

Unit

SaturatorSystem

SaturatorSystem

GasTurbo

Set

Desulphuri-zation

ASU

ASU

Sulphur

Waste Water

Air

Air

Power

Power

Exhaust Gas

Exhaust Gas

Power

Feedwater Make-Up

SteamTurbo

Set

Oxygen

Oxygen

Air

Extracted Air

Extracted Air

HP Steam

Boiler Feedwater

Gasification Steam

SGPReactor

SGPReactor

HRSG

HRSG

VisbreakerResidue Raw Gas

DustfreeRaw Gas

GasTurbo

Set

G

Quench Water

Expander

Soot Water

SootFiltration

Scrubber

Filtrate

Soot Filter Cake

Clean Gas

Waste Nitrogen

Waste Nitrogen

Sour Gas

Gasifier Pressure 66 bar

50-100% Load Range Capability of the Plant

Municipal Supply of Make-up Water

Syngas Cooling

Back-up Fuel: Fuel Oil

Base Load Operation

10/17/2001 page 12


Typical Data for Used Liquid FeedstocksFeedstock Type Standard Vacuum Liquid Liquid

Feed Residue Coke WasteFeedstock PropertiesSpecific Gravity , 15°CC/H Ratio, wtSulphur , % wtAsh, %wtFeedstock [kg]Oxygen Feed 99.5 %, [kg]SGP Product Gas (150°C, 62 bar)Composition , % vol. (Dry)Hydrogen & Carbon MonoxideH2/CO Ratio ( mole /mole )Steam Export [kg] 2)

1.11

9.35.00.18376385

92.90.89712

1.109.76.80.08350333

92.90.88650

1.2511.98.00.16350316

92.80.78615

0.959.23.10.01360390

94.00.89740

Basis: Production of 1,000 m 3 (N) 1) of CO+H 21) m3(N) = m 3 at 0°C and 1.013 bar

2) steam production corrected by gasification steam consumption

No Feedstock Limitation for SGP

10/17/2001 page 13


Site ConditionsSite elevation m above sea level 0 (*)Elevation of the plant (expected) m above sea level 8Atmospheric pressure bar 1.013 (*)Relative humidity (average) % 60 (*)Relative humidity (maximum) % 95Ambient air temperature °C -5Ambient air temperature °C 30Ambient air temperature °C 60Ambient air temperature (average) °C 15 (*)Wet bulb temperature °C 12Average rainfall mm/month 130Average rainfall mm/year 1,000Wind velocity (maximum) km/hr 150Earthquake factor - negligible(*) ISO Conditions used for Performance Calculation

10/17/2001 page 14


Performance Data

Feedstock to Gasifiers kg/h 106,960Fuel Heat Input (LHV) MW 1,131.9Fuel Heat Input GTs (LHV) MW 939.5Output Gas Turbines MW 2 x 166.6Output Steam Turbine MW 219.5Output Expander MW 6.9Total Gross Output MW 559.6Power Consumption Power Island MW 15.9Power Consumption ASU MW 55.6Power ConsumptionGasification/Gas Cleaning

MW 3.2

Net Power Output MW 484.9Net Efficiency Power Island (LHV) % 57.1Net Efficiency IGCC (LHV) % 42.8

Waste Water m³/h 27.6Sulphur t/h 5.3Filtercake t/h 5.1

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Modular Design allowsany Adaptation to SiteSpecifics

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Scope of Supply

Complete IGCC, including

Fuel Storage for Back-up Fuel Liquid Sulphur Handling Waste Water Pre-Treatment Filter Cake Loading Cell Cooling Towers

10/17/2001 page 17


Exclusions Owners Cost

Process Licence Fee andRoyalties

Land Sales Tax Transmission Lines Permitting Owner’s Project Management

Site Specifics Site Levelling and Demolition Piling, Rock Blasting or similar Measures Groundwater lowering

Provision of Fuel, Utilities and Labour forCommissioning

10/17/2001 page 18


Economic Evaluation> Western European Greenfield Site> Comparison of 500 MW Standard Oil - IGCC (“E Class” GT,

V94.2) with 700-MW Steam Power Plant and 780-MWCombined Cycle Power Plant (“F Class” GT, V94.3A) forNatural Gas

> Variation Investment Costs, Fuel Price, Plant Load Factor,Depreciation Period, Electricity Rate, etc.

Overall Accuracy of Cost Estimate is +/-10%.91% Availability for Power/87% Availability for SyngasVisbreaker Residue, 5% Sulphur, HHV 40,139 kJ/kg dry/17,257 Btu/lb dry

10/17/2001 page 19


��

��

Activity MonthDescription -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39

Key DatesContract Award/Notice to proceedTaking Over of Site from Client

Water- and Power Supply available6 kV/aux. Power availableFirst Ignition of GT (Back-up Fuel)First BFW to GasificationFirst Steam to GasificationFirst Air from GT to ASUFirst Oxygen to GasificationFirst Nitrogen from ASU to GTFirst Ignition of GT (Syngas)Mechanical CompletionPlant Acceptance

GeneralPreliminary ActivitiesSoil InvestigationSite Preparation

Detailed EngineeringPower IslandGas Island

Procurement & ManufacturingGas TurbinesSteam TurbinesGasifierASUOthers

Civil & ConstructionProcess UnitsCombined CycleDCSElectrical

CommissioningStart-up

10/17/2001 page 20


4

3

2

1

0

Levelized Electricity Generation Costs [USct/kWh]

0 1 2 3 4 5

5

Fuel Costs [US$/GJ]

IGCCCCPP

Residues Coal Natural Gas

SPP

10 - 30 $/t 23 - 47 $/t

IGCC = Standard Oil-IGCC

SPP = Steam Power Plant

CCPP = Comb. Cycle Power Plant

10/17/2001 page 21


Siem

ens

- Kru

pp U

hde

Proj

ect D

irect

orat

e

K r u p p U h d e

S i e m e n s

Power Island

Gas Island

VisbreakerResidue O2

AirO2

PretreatedWaste Water

Filter Cake Sulphur

Desulphuri-zation

SootScrubbing

SyngasEffluentCooler

Shell OilGasification

FirefightingSystem

SulphurRecovery

FiltrationUnit

WasteWater

Stripper

AirSeparation

Unit

Instrument.Air System

CoolingWater

System

Balanceof Plant

Demin.Water

System

Instrument.&ControlSystem

FlareSystem

SteamTurbine HRSG Gas

Turbine Saturator

Flue Gas Power

SteamCondensate

System

Power

Air

Steam

Filtrate SootWater Sour Gas

Steam

10/17/2001 page 22


Customer

Siemens-Krupp Uhde Project DirectorateSingle Point Responsibility

Shell

Gasification

BDP

License

Siemens

Power Island

Krupp Uhde

GasGenerationIsland

ASU Vendor

Air SeparationUnit

LSTK Contract

wrap-around liability

10/17/2001 page 23


Determination of EPC Cost Basic Engineering for Accuracy +/- 10%

Start-up and Shut-down of the IGCC Minimisation of Time Minimisation of Flaring

Plant Automation Concept Implementation of Standard Modules for

Gasification

Air Separation Plant Minimisation of Cooling Water Consumption

and Internal Power Consumption

Gas Turbine Application 60 Hz

Outlook (Next Steps)Minimisation and Optimisationof Low Level Heat Integration

Cost Reduction versus Efficiency

Plant LayoutOverall ConceptCooling Tower ConceptHRSG with Natural Circulation

10/17/2001 page 24


End of the Presentation

10/17/2001 page 25


Emissions

Draft ECDirective

StandardIGCC

StandardIGCC

FutureEPA9)

Dust 5 mg/Nm³ 1), 4), 5) < 5 mg/Nm³ 1), 5) 0.004 8) 0.009 – 0.010 8)

NOx 120 mg/Nm³ 1), 2), 3) < 50 mg/Nm³ 1), 2) 0.080 8) 0.036 – 0.060 8)

SOx 35 mg/Nm³ 1), 5), 6), 7) < 18 mg/Nm³ 1), 5) 0.047 8) 0.040 – 0.100 8)

1) Nm³ refers to standard temperature (273.15 K) and pressure (101.325 kPa) conditions.2) Related to dry exhaust gas at 15 vol. % O23) For gas turbines with > 50 MW thermal input at ISO conditions and gaseous fuels other than natural gas4) For gaseous fuels “as a rule”5) Related to dry exhaust gas at 3 vol. % O2 at Gas turbine Stack6) For new plants and gaseous fuels in general7) For new and existing plants and low calorific gases from gasification of refinery residues the emission limit would be 800

mg/Nm³8) Total emissions in lb per MMBTU heat input (LHV) (3,862 MMBTU/hr)9) Proposal GTC

refinery residue based igcc power plants and market … · use of high efficient siemens v94.2 gas...

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