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6th Trondheim Conference on CO2 Capture, Transport and Storage
TRONDHEIM CCS CONFERENCEJune 15, 2011
Pedro Casero Cabezón ([email protected]) ELCOGAS S.A (www.elcogas.es)
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SCOPE
IGCC & ELCOGAS, S.A CARBON CAPTURE PILOT PROJECT MAIN LEARNINGS TEST RESULTS COSTS
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SCOPE
IGCC & ELCOGAS, S.A
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IGCC & ELCOGAS, S.A
Spanish company established in April 1992 to undertake the
planning, construction, management and operation of
a 335 MWeISO IGCC plant located in Puertollano (Spain)
Puertollano IGCC Power Plant
Repsol YPF Refinery
ENCASUR (open cast coal mine)
Enel, SpA4,32%
Siemens Project Ventures GmbH
2,53%Hidrocantábrico Explotación de Centrales SAU
4,32%
Electricité de France
International, S.A.31,48%
Endesa Generación, S.A.
40,99%
Krupp Koppers GmbH0,04%
Iberdrola Generación, S.A.
12,00%
Hidroeléctrica del Cantábrico, S.A.
4,32%
COAL
C (%p) 36.27
Ash (%p) 41.10
S (%p) 0.93
LHV (MJ/kg) 13.10
PET COKE
C (%p) 82.21
Ash (%p) 0.26
S (%p) 5.50
LHV (MJ/kg) 31.99
GROSS TOTAL (MW)
NET TOTAL (MW)
POWER OUTPUT
317.7 282.7 GROSS
(%) NET (%) EFICIENCIA
(PCI) 47.12 42.2
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Process description
Air Separation Unit
N2 O2
Compressed air
Waste N2
Cooling tower
Hot combustion gasCondenser
G
Flue gas to stack
SteamHeat Recovery
Steam Generator
STEAM TURBINE
135MWISO
GAS TURBINE
200 MWISO
GGasifier
SlagSulfur (99.8%)
Sulfur
Recovery
Quench Gas
O2
Air
Clean
SyngasRaw
Gas
Coal - N2
HP Boiler
MP Boiler Waterwash
Coal PetCoke
Limestone
Coal
preparation
Fly ash
Claus Gas
HP Steam
MP Steam
FiltrationSulfur
Removal
Tail Gas
Waterto treatment
IGCC & ELCOGAS, S.A
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SCOPE
CARBON CAPTURE PILOT PROJECT
CARBON CAPTURE PILOT PROJECT
Consejería de Educación, Ciencia y Cultura
Company ELCOGAS, S.A.Location IGCC Puertollano Power PlantFeed gas Coal gas 20-24 barSize 14 MWt (2% slip-stream of the IGCC plant)Capture Technology Precombustion. Capture > 90%. It is not expected CO2
storage.Budget Construction and commissioning: 13,5 M€Funding programme PSE, cofinanced by MICINN and JCCMStarted 2005Operation Octubre 2010Targets To demonstrate the feasibility of capture of CO2 and
production of H2 in an IGCC that uses solid fossil fuels andwastes as main feedstock.
To obtain economic data enough to scale it to the full PuertollanoIGCC capacity in synthetic gas production.
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Pilot plant diagram process
CLEAN GAS2% of total flow (3,600 Nm3/h)
22,6 bar130ºC
60,5 %CO22,1% H2
Tail gas1,3 bar
MP STEAM
SHIFT Reactor CO2 & H2separation
(Chemical, aMDEA)CO + H2O → CO2 + H2
PIL
OT P
LA
NT
40%
CO2¿H2S?100 t/d
Raw H2 (80% of purity)
H2 rich gas
37,5 % CO250,0 % H23,0 % CO
HYDROGENPURIFICATION
(PSA)
COMBINED CYCLE
COAL + COKE
GASIFICATION
Raw gas FILTRATION
SYSTEM
Clean gas PURIFICATION
& DESULPHURATION
183.000 Nm3/h
Recycle compressor
Pilot plant size: 1:50 ~ 14 MWt
Pure H2 (2 t/d)99,99% H2 @ 15 bar
/Acid)(Sweet
CARBON CAPTURE PILOT PROJECT
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CARBON CAPTURE PILOT PROJECT
CO2Product
AdsorberPSA4
IP Steam
Coal Gas
NitrogenStart-Up
DesulfurationReactor
Process GasPreheater
ShiftingReactor
1
ShiftingReactor
2
IP Steam Generator
AbsorberSyngas
WaterRefrigerator
Aircooler
Steam LPGenerator
ProcessCond.Cond.
Separator
MDEA cooler
MDEA/MDEAexchanger
Stripper CO2
CO2 cooler
CO2 Separator
TailGas
ProductH2Adsorber
PSA1Adsorber
PSA2Adsorber
PSA3
H2 RichGas
Reboiler aMDEA
SyngasSeparator
Pump
ToPump
From CO2Separator
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Construction permit: December 2008
Commissioning: May-October 2010
1st CO2 t captured: 13 September 2010
100 hours run with sweet gas and co-production of hydrogen: Nov 2010
End of sweet capture tests: February 2011
End of programmed tests (within PSE-CO2): June 2011
700 t of CO2 captured and 6 t of H2 pure produced up to Feb 2011
Milestones
CARBON CAPTURE PILOT PROJECT
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Puertollano IGCC power plant and pilot plant location
PRENFLO Gasifier
Coal preparation
Sulphur Recovery
Combined Cycle
New CO2capture pilot
plant
ASU
Pilot plant general view IGCC power plant general view
EngineeringCO2 UnitPSA Unit
ControlReactorsCatalysts
On-line analysis systemConstruction
Empresarios AgrupadosLinde-CaloricLindeZeus ControlTécnicas ReunidasJohnson MattheyABB Process Automation DivisionLocal companies
Main suppliers
CARBON CAPTURE PILOT PROJECT
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Shifting unit + CO2 wash unit
CARBON CAPTURE PILOT PROJECT
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Official Presentation 29/04/2011
CARBON CAPTURE PILOT PROJECT
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INDEX
MAIN LEARNINGS
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The main learning in project phase:
● The finance delay: MICINN (Spanish Science & Research Minister) and JCCM (RegionalGovernment).
• Delay in main equipment supply: more than 12-14 months.
• Detailed engineering: conditioned by suppliers.
• PP construction step: delay due to safety permits since it is installed in an operating plant.
• Delay of commissioning: low availability of experimented personnel.
MAIN LEARNINGS
TOTAL QUOTE OF THE PP PROJECT UPDATED EVERY YEAR (k€ of the quoted year)
13.000 13.000 13.000
7.0048.441 8.300 8.173
1.088
2.383
4.010 4.875 5.156
521 531
542
693
833877 877547 535
521
514
509508 508
241 235
0
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
2005 2006 2007 2008 2009 2010 2011
EQUIPMENTS SERVICES PERSONNEL OTHERS
Total quote of the PP project updated every year
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INDEX
TEST RESULTS
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Expected vs. obtained compositions of main streams (SWEET)
i) All compositions are in % vol. (dry basis)ii) Analysis carried out by ELCOGAS Laboratory
Shifted gas CO2 H2 rich gas Pure H2
Design Lab Analysis Design Lab
Analysis Design Lab Analysis Design Lab Analysis
H2 50.05 51.88 0.19 0.314 - 1.31 79.75 82.3 – 83.14 99.99 99.959- 99.995
CO 2.92 1.85 0 0.053 - 0.07 4.65 2.86 - 3.78 4 ppm N/A
CO2 37.56 37.36 99.78 98.2 - 99.622 0.5 0.02 - 0.82 1 ppm N/A
N2 8.76 8.30 0.01 0.05 - 0.28 13.97 12.2 - 13.6 15 ppm 4 - 17 ppm
Ar 0.71 0.60 0.02 0.01 - 0.09 1.13 0.89 - 0.97 80 ppm 3 - 14 ppm
i) All compositions are in % vol. (dry basis)ii) Analysis carried out by ELCOGAS Laboratory
TEST RESULTS
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0,0
5,0
10,0
15,0
20,0
300 350 400 450 500 550 600Temperature (ºC)
CO
(%
)
Johnson Matthey Fresh High TemperatureSelection Potential (Johnson Matthey) Potential (High Temperature)
JM FRESH
20/01/11 17:24-28:35
Real Values (SWEET3 test)
JM Simulation (01/01/10)
FIRST REACTOR
SECOND REACTOR
STEAM GENERATOR
Conversion very close to theoric, although higher reactor outlet temperature.
The inlet second reactor temperature is higher than expected
The high conversion obtained in the first step (near 95%) will make considering a shifting process with only one step.
20-22 Jan 2011 Characterization of the water gas shift reaction unit with sweet gas
TEST RESULTS
Sweet 3
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TEST RESULTS
17-20 Jan 2011Sweet 2 Characterization of the CO2 & H2 separation unit (amine washing) with sweet gas
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Pump circ F LOW
(25 m3/h) Desortion T LOW
(81,7ºC)
Desortion T HIGH
(104 ºc)
Pump circ F HIGH
(57 m3/h)
Inlet gas F LOW
(2502 Kg/h))
Inlet gas F INTERMEDIATE
(4400 Kg/h)
% CO2 recovery
Ste
am c
onsu
mpt
ion
(MW
h/To
nCO
2)
Steam consumption vs CO2 recovery
Desortion P LOW
(0,6 bar.g)
Desortion P HIGH
(1,2 bar.g)
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TEST RESULTS
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Test Parameter Variation Assessment Effect on cycle time Effect on H2purity
Effect on H2 recovery rate
1 Pure H2pressure
Increase Not good Increase= =
Decrease Good =
2 Tail gas pressure
IncreaseGood = Decrease =
Decrease
3 Inlet temperature
IncreaseNot good = = Decrease
Decrease
4 Increase O.F
IncreaseGood = = Increase
Increase
5 Inlet flow
IncreaseGood
Decrease DecreaseIncrease
DecreaseIncrease =Decrease Not good Decrease
15-19 Nov 2011 Characterization of the H2 purification unit with sweet gasSweet 1
The PSA is quite stable and not affected by variation of the different parameters
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TEST RESULTS
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Parameter Design Real
1
Shifting
C.G.E 88,6 % 88,0 %2 η thermal 75,3 % 73,1 %3 Ratio steam/gas 1,37 1,424 Mol ratio steam/CO 2,88 2,855
AminasC.G.E 99,9 % 96,9 %
6 η thermal 71,2 % 69,9 %7 Ratio steam/CO2 0,88 MWh/tn CO2 0,79 MWh/tn CO2
8Global
(shifting+aminas)
C.G.E 88,5 % 85,3 %9 η thermal 60,2 % 57,2 %10 CO2 recovered 91,7 % 90,6 %
Comparison versus design
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INDEX
COSTS
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CO2 Capture Costs Comparison
1) Scaled up 100% Puertollano IGCC synthetic gas from the 14MWt pilot plant.2) Existing plant capture cost = f (investment costs and operational costs).
3) First ELCOGAS estimations show values of 25-30 €/ t CO2
4) Comparing to other studies
tonnesCO CapturedOPEXCAPEXCO€/t cost, capture CO2
22+
=
Fuente: DOE/NETL CCS RD&D ROADMAP December 2010
30 forELCOGAS
retrofit
COSTS
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10
20
30
40
50
60
70
80
90
27 28 29 30 31 32 33 34 35 36 37
IGCC plant efficiency with CO2 capture, %
CO
2 co
st, €
/t C
O2
3.000 h
3.500 h
4.000 h
4.500 h
5.000 h
5.500 h
6.000 h
6.500 h
7.000 h
7.500 h
Variables Data
Expected life 25
Bank interest 3.0 %
Bank fee 0.5 %
Scale factor 0.75
Operating hours (IGCC mode) 6,500 h
Average load factor 0.92
Electricity price 40 €/MWh
Net efficiency of power plant with CO2 capture 33 %
Treated gas 100 %
CO
2 C
ap
ture
Co
sts
(SW
EET)
COSTS
25
0
1
2
3
4
5
6
0 50 100 150€/MWh
€/K
g
60.000 Kg/y 720h
120.000 Kg/y 1440 h
180.000 Kg/y 2160 h
420.000 Kg/y 5040 h
90.000 Kg/y 1080 h
Better to sell H2
Better to sell electricity
Minimum H2 price per fix cost of production (external personal and spares) depending on anual production hours.
Minimum pure H2 price depending on the electricity price
COSTS
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Pilot plant for CO2 capture and production of H2 and electricity with IGCC technology
Other activities: To be done after PSE as R&D platform:
Water shift reaction catalyst optimization. Tests of different catalyst
New processes to separate CO2-H2
CO2 different treatment processes
Improvement of integration efficiency between CO2separation processes and IGCC plant
ELCOGAS offers both the Puertollano IGCC and the Pilot Plant for CO2 capture and H2 production as
technical platforms to develop of process, equipments, components, or even pre-engineering of new plants
with CCS and Zero emissions
Pilot Plant beyond PSE project
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6th Trondheim Conference on CO2 Capture, Transport and Storage
TRONDHEIM CCS CONFERENCEJune 15, 2011
Pedro Casero Cabezón ([email protected]) ELCOGAS S.A (www.elcogas.es)