the reliability of igcc power generation units · 2006-05-21 · • support the electric power...
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![Page 1: The Reliability of IGCC Power Generation Units · 2006-05-21 · • Support the Electric Power & Industrial Process markets… • Recognized leader through ORAP… the Most Comprehensive](https://reader034.vdocument.in/reader034/viewer/2022042017/5e75a4c4fb5da14e412c061d/html5/thumbnails/1.jpg)
1SYNGAS CONSULTANTS LTD
The Reliability of IGCC Power
Generation Units
ACHEMA 2006
Frankfurt, 18th May 2006
Chris Higman, Syngas Consultants Ltd.
Sal DellaVilla, Bob Steele, Strategic Power Systems, Inc
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2SYNGAS CONSULTANTS LTD
Overview
• SPS’s ORAP database
• Project goals and methodology
• Project schedule
• Some preliminary findings
• Conclusions
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3SYNGAS CONSULTANTS LTD
SYNGAS CONSULTANTS LTD.
• Specialists in syngas production from gasification
and steam reforming
• Activities
– Process integration
– Project consultancy
– Feasibility studies
– Training seminars
– Plant audits
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4SYNGAS CONSULTANTS LTD
Who is SPS? What is ORAP?• An Information Technology & Reliability Engineering Company — Since 1987
• Support the Electric Power & Industrial Process markets…
• Recognized leader through ORAP… the Most Comprehensive Global Database in Our Industry … Unbiased & Accurate� Monitors Gas & Steam Turbine Plants . . . ISO 9001 Certified� Database in place since 1976� Over 2,000 Units Worldwide, Over 20,000 unit years of operating information available . . .
� Strong Influence on Industry Standards . . . ISO 3977 Standard
• Provide “Knowledge Based” Engineering Services & Software Products focused on:� Data analysis and evaluation… Availability & Reliability� Knowledge transfer… Benchmarking & “Best Practices”� Remote Monitoring… Real-Time Data for Maintenance & Life Planning
Reliable Data for Effective Decision Support through ORAPReliable Data for Effective Decision Support through ORAP
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5SYNGAS CONSULTANTS LTD
Where is IGCC now?
�Superior environmental performance
�Higher efficiency
�Installed cost
? Reliability
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6SYNGAS CONSULTANTS LTD
Effect of Reliability
+/- 5% Outage rate
+/- 5% Heat rate
+/- 5% CAPEX
41 42 43 44
Cost of Electricity US$/MWh
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7SYNGAS CONSULTANTS LTD
Current Reliability Performance
98.1%
0.0%
0.8%
1.1%
1.9%
75%
5%
7%
13%
20%
Plant A
Plant B
� On stream
� Not required/despatched
� Planned outage
� Unplanned outage
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8SYNGAS CONSULTANTS LTD
Reliability - BP, Gelsenkirchen
90
92.5
95
97.5
100
85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 01 02
Year
Reliab
ilit
y (
%)
Source: Laege, 2002
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9SYNGAS CONSULTANTS LTD
Project Goals
• Establish reliable, evidence-based expectation for IGCC availability
– Using public domain reliability data
– Using actual plant data
– Using common definitions
• Update prediction models with “best-of-class” plant data
• Identify strengths and weaknesses
– Inside/outside core gasifier unit
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10SYNGAS CONSULTANTS LTD
Public domain literature
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11SYNGAS CONSULTANTS LTD
Potential Participating Plants
• 14 IGCCs
– 8 solid feedstock
– 6 liquid feedstock
• 11 chemical and refinery plants
– 3 solid feedstock
– 8 liquid feedstock
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12SYNGAS CONSULTANTS LTD
Include some chemical plants
• Increases sample for improved validation
• Provides representative data on
– Oxygen supply
– Gasification
– Gas treatment
• Ammonia plants will supply data on CO2 capture
(and compression where integrated urea plant)
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13SYNGAS CONSULTANTS LTD
Project Schedule
�Data base structure and codes July 2005
�Evaluate public domain data End Aug 2005
�Preliminary findings Oct 2005
• Plant interviews ongoing
• Preliminary report June 2006
• Detail evaluation &
prediction model End 2006
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14SYNGAS CONSULTANTS LTD
Some preliminary findings
• Air Separation Units
• Gasification Units
• Acid Gas Removal/ Sulfur Recovery Units
• Combined Cycle Units
• Overall Picture
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15SYNGAS CONSULTANTS LTD
NERC GADS Data 2000-2004
Not availableNot availableNot availableCombined Cycle
GTs
93.13.84.3Single Cycle GTs
93.03.75.1Aero-derivatives
87.671.983.2Coal-fired boilers
86.527.541.1Oil-fired boilers
87.523.140.0Gas-fired boilers
Availability
Factor (%)
Capacity Factor
(%)
Service Factor
(%)
Source: DellaVilla, 2004
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16SYNGAS CONSULTANTS LTD
ASU: Public Domain Data
Unplanned outages
0
2.5
5
7.5
10
12.5
15
1999 2000 2001 2002 2003
% U
np
lan
ned
ou
tag
es
Puertollano
Buggenum
Polk
Wabash
Negishi
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17SYNGAS CONSULTANTS LTD
GasificationAverage of four plants
0
3
5
8
10
13
15
2001 2002 2003
% U
np
lan
ne
d o
uta
ge
Black water
Scrubber
Dry Filtration
Syngas Piping
Syngas Coolers
Slag Disposal
Gasifier
Feed systems
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18SYNGAS CONSULTANTS LTD
Acid Gas RemovalAverage of Four Plants
0.00
2.50
5.00
7.50
10.00
12.50
15.00
1999 2000 2001 2002 2003
% U
np
lan
ned
ou
tag
es
Sulfur Recovery Unit
Acid Gas Removal
COS Hydrolysis
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19SYNGAS CONSULTANTS LTD
ORAP – Forced and Scheduled Outage
2.3%
3.7%
1.2%
4.3%
2.2%
6.8%
0%
2%
4%
6%
8%
10%
Aeroderivatives Mature Class F Class
Simple Cycle Plant Forced Outage Factor and Scheduled Outage
Factor
2000 - 2005
ORAP Data
Forced Outage Factor (%) Scheduled Outage Factor (%)
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20SYNGAS CONSULTANTS LTD
ORAP Data 2000-2005
98.191.755.2Non-Utility
97.690.160.6F-Class
Utility
99.095.062.0Non-Utility
98.894.118.2E-Class
Utility
97.994.355.3Non-Utility
96.592.134.7Aeroderivative
Utility
Reliability
(%)
Availability
(%)
Service Factor
(%)
Source: DellaVilla, 2004
Simple Cycle Plant Statistics
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21SYNGAS CONSULTANTS LTD
Power Block: Public Domain Data
Note: Wabash data estimated from “Syngas not required”
Data for some plants/years incomplete
0.00
2.50
5.00
7.50
10.00
12.50
15.00
1999 2000 2001 2002 2003 2004 2005
% P
lan
ne
d +
Un
pla
nn
ed
ou
tag
es
Puertollano
Buggenum
Polk
Wabash
Negishi
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22SYNGAS CONSULTANTS LTD
Overall Outage Data – Coal IGCCsAverage of four plants
0
5
10
15
20
25
30
35
2001 2002 2003
% U
np
lan
ne
d o
uta
ge
CCU
AGR-SRU
Gasifier
ASU
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23SYNGAS CONSULTANTS LTD
Italian Resid IGCC Configurations
65 t/h steam
40,000 Nm³H2/h
180 t/h steam
Co-products
241 MW551 MW512 MWPower output
Alstom
1 x 13E2
GE
3 x STAG 109E
Siemens
2 x V94.2K
Gas turbine
SelexolSelexolMDEAAGR
GE (2 gasifiers)
1440 t/d
~60 bar
GE (3 gasifiers)
3559 t/d
38 bar
GE (2 gasifiers)
3168 t/d
67 bar
Gasifier
Feed rate
Pressure
NoneNone
(Air Liquide)
None
(Air Liquide)
ASU Integration
api Energia
(Falconara)
Sarlux
(Sardinia)
ISAB
(Sicily)
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24SYNGAS CONSULTANTS LTD
Performance of Italian Resid. IGCCs
Sources: Collodi,2003; Arienti, 2005; Allevi, 2006, Jaeger, 2006
40%
50%
60%
70%
80%
90%
100%
Year 1 Year 2 Year 3 Year 4 Year 5
Year of operation
Av
ail
ab
ilit
y
ISAB
Sarlux
Falconara
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25SYNGAS CONSULTANTS LTD
Sarlux IGCC 2002 Operation
Source: Collodi, GTC 2003
� On stream
� Not required/despatched
� Planned outage
� Unplanned outage
90.76%
0.25%
7.37%
0.45%
1.16%
1.61%
ASU
PPU+CCU
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26SYNGAS CONSULTANTS LTD
Improvement Targets for Coal IGCCs
0%
5%
10%
15%
20%
25%
30%
Achieved 2001-2003 2006 Target 2010 Target
CCU
Gas treating
Gasification
ASU
Planned Outage
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27SYNGAS CONSULTANTS LTD
Summary
• “Maybe folks are now beginning to realize that there is
more to reliability than just a spare gasifier.”
• The introduction of advanced technology anywhere in the
system has its attendant risks.
• Attention to detail in “standard” auxiliary units can
contribute substantially to IGCC reliability.
• ORAP RAM tracking can help identify the areas for
improvement
• Implementation of “lessons learned” at all levels is key to
success.
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28SYNGAS CONSULTANTS LTD
Thank you
Any questions?
SYNGAS CONSULTANTS LTD
http://www.higman.de/gasification/index.htm