10/17/2001 page 1 Standard Oil - IGCC Krupp Uhde Gasification Technologies 2001 Refinery Residue Based IGCC Power Plants and Market Potential Joachim Wolff (Speaker), Karsten Radtke Krupp Uhde GmbH Jürgen Karg, Werner Günster Siemens AG Power Generation
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Refinery Residue Based IGCC Power Plants and Market … · Use of High Efficient Siemens V94.2 Gas Turbine (Syngas Proven) Use of Siemens Reheat Steam Turbine (KN Series) Use of Sensible
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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
“Clean“ Technology High Efficiency is not the Driver for Low-value Fuels Fuel Flexibility Repowering of Existing Plants Modularity + Phased Construction
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
Standard Oil - IGCC Krupp Uhde
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
Standard Oil - IGCC Krupp Uhde
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: 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
Standard Oil - IGCC Krupp Uhde
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
10/17/2001 page 8
Standard Oil - IGCC Krupp Uhde
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
10/17/2001 page 9
Standard Oil - IGCC Krupp Uhde
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
10/17/2001 page 10
Standard Oil - IGCC Krupp Uhde
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
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
Standard Oil - IGCC Krupp Uhde
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
Standard Oil - IGCC Krupp Uhde
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
10/17/2001 page 15
Standard Oil - IGCC Krupp Uhde
Modular Design allowsany Adaptation to SiteSpecifics
10/17/2001 page 16
Standard Oil - IGCC Krupp Uhde
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
Standard Oil - IGCC Krupp Uhde
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
Standard Oil - IGCC Krupp Uhde
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
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
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