Post on 31-Mar-2015
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CFB Firing of PetcokeCFB Firing of Petcoke for Repower Applications for Repower Applications
By Scott L. DarlingBy Scott L. DarlingCommercial DirectorCommercial Director
Foster Wheeler North America CorporationFoster Wheeler North America Corporation
0
2,100
Bill
ion
KW
hrs
Renewable(excl. Hydro)Natural Gas
Nuclear
Coal
Fuel Use In Electricity Generation
Increasing Natural Gas Demand Driven Increasing Natural Gas Demand Driven By Utilities For Electricity GenerationBy Utilities For Electricity Generation
50,000
100,000
150,000
200,000
250,000
300,000
350,000
Source: EIA
“The number of producing gas wells has tripled since 1971, while production has declined, clear indication that existing basins are becoming tired…”
Natural gas deregulated
Number of Producing Natural Gas Wells in Number of Producing Natural Gas Wells in U.S.U.S.
0
5
10
15
20
25
1970 1975 1980 1985 1990 1995 2000
T F
t3
1994199420022002
Source: EIA
“Domestic production peaked back in 1971…”
U.S. Dry Natural Gas ProductionU.S. Dry Natural Gas Production
0246
8101214
J an-
94
J an-
95
J an-
96
J an-
97
J an-
98
J an-
99
Dec-99
Dec-00
Dec-01
Dec-02
$/mm Btu
Sources: EIA, Wall Street Journal
Floor below $2
Floor above $4
Natural Gas Price Is RisingNatural Gas Price Is Rising
High Fuel Price
Gas is a premium fuel
Increased demand, limited supply has increased gas prices
Typical gas price; $4-6/mm Btu
Volatile Fuel Price
Weather and other effects can produce significant gas price spikes
Low Boiler Efficiency
High H2 content means high H2O vaporization losses
Gas-Fired Boilers: High Operating CostsGas-Fired Boilers: High Operating Costs
Low Fuel Price Coke is a refinery byproduct
Coke price close to delivery cost
Typical coke price < $1.00/mm Btu
Relatively Stable Fuel Price Similar to coal
Broad Fuel Flexibility Can co-fire opportunity fuels such as biomass, etc.
High Boiler Efficiency
Low H2 content means low H2O vaporization losses
Coke-Fired CFB Boilers: Low-Cost Fuel Coke-Fired CFB Boilers: Low-Cost Fuel Provides Low Operating CostsProvides Low Operating Costs
CFB Repowering Requires Low Investment CFB Repowering Requires Low Investment CostCost
• Replace gas-fired boilers with CFB boilers, by adding the following equipment;• New CFB boiler w/ baghouse
• Solid fuel storage, handling
• Limestone and ash storage, handling
• Foundations, electrical, controls
• Re-use existing turbine-generator, balance of plant equipment
CFB Repowering Requires Low Investment CFB Repowering Requires Low Investment CostCost
$/kw
800
1000
1200
1400
1600
1800
2000
2200
20 40 60 80 100
MW, net
$/k
w Greenfield
Repower
Coke-Fired CFB Repowering: Operating Cost Coke-Fired CFB Repowering: Operating Cost Savings Provide Rapid Payback of Investment Savings Provide Rapid Payback of Investment
CostsCosts
Payback Calculations Based on:
Gas Price Range: $4 – 7/mm Btu
Coke Price: $0.75/mm Btu
Boiler (Plant) Size: 35 – 100 MWe (net)
Capital Cost: $960 - $1250/low
Payback: Simple Payback
Coke Fired CFB RepoweringCoke Fired CFB RepoweringProvides Rapid Payback of Investment Provides Rapid Payback of Investment
CostCost
1.50
2.00
2.50
3.00
3.50
4.00
4.50
5.00
5.50
$4.00 $5.00 $6.00 $7.00
Gas Price - per MMBtu
Pa
yb
ac
k -
ye
ars
35 MW
50 MW
75 MW
100 MW
Petcoke Fired CFB:Petcoke Fired CFB:Lower Power Cost Than NGCCLower Power Cost Than NGCC
20 Year Levelized COE
0
1
2
3
4
5
6
7
Cen
ts/k
Wh
CFB RepowerPetcoke
NGCC
Capital
Fixed O&M
Variable O&M
Fuel
($.75/mmBtu)
($4.00/mmBtu)
3.82
6.19
Leading the WorldLeading the Worldin CFB Technologyin CFB Technology
* Equivalent to over 27,500 MWe Excludes CFB’s Designed in China
0
50
100
150
200
250
300
350
400
450
500
77 79 81 83 85 87 89 91 93 95 97 99 01 03
Number ofCFB Boilers
Year of Sale
Source: McCoy Power Reports
CFB Technology Is Mature:CFB Technology Is Mature:Over 480 CFB Boilers Worldwide*Over 480 CFB Boilers Worldwide*
Based on MWeSource: McCoy Power Reports
Foster Wheeler:Foster Wheeler:Market Leader In CFB Technology 1977 - Market Leader In CFB Technology 1977 -
20032003
Foster Wheeler47%
B&W 2%
Babcock Borsig 2%
Kvaerner7%
Lurgi/Lentjes12%
Alstom30%
• Over 200 Units in Design/Operation
• 300 MWe Units in Operation
• 460 MWe Unit in Design
• Units in Service Over 24 Years
• Experience with a Range of Fuels
• High Availability Demonstrated
• Sizes to 600 MWe Offered
Foster Wheeler:Foster Wheeler:Leading The World In CFB TechnologyLeading The World In CFB Technology
Oil Refinery Bottoms Natural Gas Peat Agricultural Waste
– Woodwaste– Rice Husks– Bagasse Pith
Tires Sludge Refuse Derived Fuel
Coal
– Anthracite
– Bituminous
– Sub-Bituminous
– Lignite
Waste Coal
– Bituminous Gob
– Anthracite Culm
Petroleum Coke
– Delayed
– Fluid
Oil Shale
CFB Technology Offers Fuel FlexibilityCFB Technology Offers Fuel Flexibility
Feature
Low FurnaceTemps.
Hot CirculatingSolids
Long SolidResidence Time
Benefit
Low NOx
Low SO2
Fuel Flexibility
Handles PoorFuels
Simple FeedSystems
Good FuelBurnout
Good SorbentUtilization
1500-1700oF
15-16 ft/sec
Air
Limestone1/20” x 0
Air
Flue Gas1500-1700oF
Fuel1/2” x 0
CFB Process Design Offers Significant CFB Process Design Offers Significant AdvantagesAdvantages
BackpassFurnaceCyclone
Foster Wheeler CFB:Foster Wheeler CFB:Improved Performance With Less Improved Performance With Less
EquipmentEquipment
Plant Size Fuel RemarksNISCO 2 x 120 MWe Pet Coke Replaced Gas-Fired(Louisiana) Boilers
Turow 3 x 235 MWe Brown Coal Replaced Coal-Fired (Poland) PC Boilers
Centerior-Bay Shore 1 x 180 MWePet CokeReplaced Coal-Fired (Ohio) PC Boilers
JEA-Northside 2 x 300 MWe Pet Coke Replaced Oil/Gas Fired(Florida) Boilers
SIPC 1 x 120 MWe Waste Coal Replaced Coal-Fired(Illinois) Cyclone Boilers
Foster Wheeler Has SignificantFoster Wheeler Has SignificantExperience With CFB RepoweringExperience With CFB Repowering
Location
Westlake, Louisiana (USA)
Unique Features
• IPP Project With EPC Contractor
• Repowering of 25+ Year Old Gas Fired Plant
• 2 x 120 MWe CFB Boilers
• World’s Largest Petcoke-fired CFB’s
• IPP Project Based on Petcoke From Nearby Refineries (Citgo, Conoco)
• Low Cost Fuel and Commercial Uses for CFB Ash
NISCO: First Petcoke RepowerNISCO: First Petcoke Repower
Capacity, Mwe (g) 2 x 120Steam Flow, (SH/RH) 825/727Steam Pressure, psig (SH/RH) 1625/464Steam Temperature, °F (SH/RH) 1005/1005
Major Dimensions Furnace Height, ft. 112Furnace Width, ft. 42Furnace Depth, ft. 20Cyclone Diameter, ft. 18.7
NISCO: First Petcoke FiringNISCO: First Petcoke Firing
Fuel Coke
Moisture, % wt 10.6Ash, % wt 0.3Sulfur, % wt 4.5HHV, Btu/lb 13,454
Schedule
Contract Award November 1989
Start of Erection June 1990
Commercial Operation August 1992
Availability
Boiler Availability, 96.1%
NISCO: First Petcoke RepowerNISCO: First Petcoke Repower
Parameters Guarantee Test
Capacity, klb/hr 825 908
Boiler Efficiency, % 83.7 90.3
NOx, lb/106 Btu 0.6 0.13
SO2, % Removal (lb/106 Btu) 90 (0.39) > 91
(0.38)
CO, lb/106 Btu 0.06 0.01
Hydrocarbons, lb/106 Btu 0.008
0.001
Limestone Flow, klb/hr < 38 < 19.5
NISCO: First Petcoke RepowerNISCO: First Petcoke Repower
LocationJacksonville, Florida, USA
Unique Features– Replaces Two 275 MWe Oil/Gas-Fired Boilers With two 297.5 MWe
Coal/Petroleum Coke Fired CFB Boilers (Northside Units 1 and 2)
– World’s Largest CFB Boilers in Operation
– DOE Cost Sharing For Unit 2 (Part of Clean Coal Technology Program)
– After Repower, Northside Emissions Will Be 10% Lower Than Current
(Even Though Unit 2 Currently Out of Service)
JEA: Utility CFB RepowerJEA: Utility CFB Repower
Capacity, Mwe (g) 2 x 300Steam Flow, klb/hr (SH/RH) 1991/1771Steam Pressure, psi (SH/RH) 2620/580Steam Temperature, °F (SH/RH) 1005/1005
Major Dimensions Furnace Height, ft 115Furnace Width, ft 85Furnace Depth, ft 22Cyclone Diameter, ft 3 x 24
JEA: Utility CFB RepowerJEA: Utility CFB Repower
Fuel Petcoke Coal
Moisture, % wt 9.0 5.2Ash, % wt 0.4 12.8Sulfur, % wt 6.7 2.8Volatiles, % wt 9.0 35.6HHV, Btu/lb 14,000 12,690
EmissionsSO2 0.15 lb/106 BtuNOx 0.09 lb/106 Btu
Schedule
Contract Award August 1999Start of Erection June 2000Commercial Operation May/July 2002
JEA: Utility CFB RepowerJEA: Utility CFB Repower
JEA: Utility CFB RepowerJEA: Utility CFB Repower
PARAMETERS GUARANTEE TEST
Capacity, klb/hr (SH/RH) 1993/1773 1950/1734
Boiler Efficiency, % (Coke/Coal)90.16/87.57 91.04/88.20
SO2 Capture, % (Coke/Coal)
Boiler 90/90 89.5/99.4
Boiler & Scrubber 98/98 98.5/99.7
SO2, lb/106 Btu (Coke/Coal)
Boiler 0.75/0.75 0.96/0.023
Boiler & Scrubber 0.15/0.15 0.134/0.010
NOx, lb/106 Btu (Coke/Coal) 0.09/0.09 0.02/0.04
CO, lb/106 Btu (Coke/Coal) 0.22/0.22 0.02/0.06
Repowering with Foster Wheeler CFB Repowering with Foster Wheeler CFB Boilers:Boilers:
A Key Strategy to Reduce Costs A Key Strategy to Reduce Costs
Natural gas prices are high and likely to remain high
Switching from gas to solid fuel drastically reduces operating costs
Repowering with CFB boilers minimizes investment cost
Reduced operating cost rapidly pay back the repowering investment
FW has the most CFB experience in the industry
FW has the most mature, efficient, reliable CFB design in the industry