Conceptual IGCC Design

Dipl.-Ing. Karsten Huschka, Thermoflow Inc., Allendorf, Germany

Dr.-Ing. Johannes Kowoll, Uhde GmbH, Dortmund, Germany

THERMOFLOW, Inc

Content Page 2 Introduction: Conceptual IGCC Design Page 3 GT PRO Program Philosophie Page 4 GT PRO Simulation of IGCC Power Plant

Puertollano* Page 5 Gasifier Technologies in GT PRO Page 8 Other Features, Hardware Details and Cost

Estimation Page 10 Contacts * Dr.-Ing. Johannes Kowoll, Uhde GmbH, Dortmund, Germany

Page 1 of 10

THERMOFLOW, Inc

Introduction: Conceptual IGCC Design Today IGCC is not yet a standard technology for power production. To reach a market breakthrough and to gain acceptance, IGCC technology must be comparable in performance and cost with prevailing technologies. The new IGCC option in GT PRO/GT MASTER1 allows a typical user to rapidly create a first order power plant design, as well as obtain a budgetary cost estimate, without necessarily being an expert on this specialised technology. Even users who have IGCC expertise will be able to exploit these new features to save time in their preliminary engineering and conceptual proposal activities. GT PRO lets the user define the major parameters for a gasification plant, focusing on system integration and overall costs. It allows the user to apply several different types of gasifiers. The software has been used by several key players in the IGCC community to develop case studies. This paper is based on a plant model (in GT PRO) of the Puertollano IGCC provided by Uhde GmbH, Dortmund. 1 Commercially available CC design and simulation software by Thermoflow, Inc

Page 2 of 10

THERMOFLOW, Inc

GT PRO Program Philosophie

Pic. 3

Pic. 2

Pic. 1

In Application-Specific programs like GT PRO (Pic. 1), the plant model is built from the outside in. The highest level selections are made first, such as overall configuration. The user then proceeds to lower level decisions, such as selecting the types of subsystems to be included. Finally, the lowest level decision are made, such as the fine details within the various subsystems. The structured approach automatically considers all interactions between the subsystems. It also allows many lower level inputs to be logically generated by the program, depending upon the user´s higher level selections. At any level, however, the user is free to alter any or all of the program´s automatic selections. Pic. 2 displays the fully-flexible philosophie of Thermoflow´s program THERMOFLEX. The plant is built from inside out. The user constructs the subsystems from their basic elements, then the overall scheme emerges from the interconnected subsystems. The Bi-Directional Link (Pic. 3) allows the user to implement own developments (gasifier etc.) to the Application Specific programs as described on page 6.

Page 3 of 10

THERMOFLOW, Inc

GT PRO Simulation of IGCC Power Plant Puertollano* The power plant Puertollano is the world’s largest IGCC. The entrained flow gasifier is operating at 25 bar and approx. 1600 °C. The feedstock is a 50/50 mixture of a local high ash coal and petroleum coke containing 5.5% sulfur. The produced gas has to be cooled down and cleaned up before it can be supplied to the gas turbine. Following as-build configuration was simulated with GT PRO:

- Gasification of milled and dried feedstock mixture - Oxygen from Air Separation Unit (ASU) for the gasification - Air to ASU extracted from the gas turbine compressor - Nitrogen from ASU compressed and supplied to the gas turbine - HP and IP steam generation in gas coolers - Scrubber for removal of water soluble components, e.g. Cl - COS hydrolysis in a catbed - MDEA for H2S removal - Clean gas humidification - Siemens V94.3 gas turbine - 3 pressure HRSG - HP, IP and LP steam injection in the steam turbine - Cooling tower.

The required time for flow sheet configuration in GT PRO and filling out all necessary input data was less than one working day. Results:

The obtained simulation results are close to the real figures. • •

•

The gas composition is realistic and all thermodynamically relevant process units are reasonable taken into account. The calculated power output is very close to the nameplate gross capacity of 318 MW.

The modelling of the gasification section is user friendly and possible with basic knowledge only. Of course the gasification model is simplified, therefore only the main thermodynamically relevant factors can be considered and only the main streams are calculated. The successful simulation shows that GT PRO is suitable for estimation of IGCC performance or for preliminary investigation of alternative configurations.

Page 4 of 10

THERMOFLOW, Inc

p[bar], T[C], M[kg/s], Steam Properties: Thermoflow - STQUIK

1X Siemens V94.3

182759 kW

0.93 p 15 T 60 %RH 540.6 m 700 m elev.

0.92 p 15 T 540.6 m

Syngas 50.99 m

260 TLHV= 548509 kWth 23.07 p

160 T 64.88 m N2 from ASU

to ASU 13.88 p 389 T 89.22 m

13.88 p 389 T

13.53 p 1252 T

567.2 m 0.97 p 573 T 567.2 M

74.87 %N2 11.54 %O2 7.701 %CO2+SO2 4.992 %H2O 0.9016 %Ar

572 T 567.2 M

572 556 535 509 468 406 345 344 312 311 308 258 258 198 179

101 T 567.2 M

SDP 86 T

138088 kW

0.0869 M

FW

0.07 p 39 T 104.6 M

39 T

5 p 140 T 194.5 M

LTE

39 T 108.1 M

140 T 5 p 152 T

84T

86.46 M

5.385M

6 p 159 T 5.329 M

LPB

2.605M

5.714 p 293 T 2.726 M

LPS

2.726 M 5.291p

292T

105.3M

9.54 MGasifier

34.72 p 237 T 95.73 M

IPE2

9.54 MGasifier

34.05 p 294 T 9.54 M

IPS1

33.38 p 321 T 9.54 M

IPS2

2.916 MGasifier

23.56 MGasifier

121.9 p 292 T 119.3 M

HPE2

120.1 p 320 T 119.3 M

HPE3

88.04 MGasifier

120.1 p 325 T 30.94 M

HPB1

64.48 MGasifier

118.7 p 412 T 95.42 M

HPS0

117.4 p 472 T 95.42 M

HPS1

116 p 512 T 95.42 M

HPS3

113.8 p 510 T 95.42 M

116p

512T

93.07 M 34.72p

341T

32.29 p 452 T 99.69 M

RH1

31.2 p 512 T 99.69 M

RH3

99.69 M 30p

510T

Gross Power 320847 kWNet Power 285481 kWAux. & LossesAux. & Losses 35366 kWGross Heat Rate 7765 kJ/kWhNet Heat Rate 8727 kJ/kWhGross Electric Eff. 46.36 %Net Electric Eff. 41.25 %Fuel LHV Input 692042 kWthFuel HHV Input 712049 kWth

ASU: Air Separation UnitRSC1: Raw Syngas Cooler 1RSC2: Raw Syngas Cooler 2GCS: Gas Cleanup System

33.38 p321.1 T2.916 M

25 T29.16 M

O2

N2to GT

13.88 p389.2 T89.22 M

from GT

10 p15 T0.6531 M

23.07 p160 T64.88 M

31 p191.8 T23.69 M

Slag100 T7.489 M

26.82 p1600 T55.76 M

26.55 p380 T101.4 M

IPS2

120.1 p319.7 T1461 h64.48 M

HPS0120.1 p324.7 T2688.3 h64.48 M

DA35.76 p153.1 T647.8 h9.54 M

IPS1 34.72 p242.1 T2801.8 h9.54 M

53.1 M

26.29 p235 T101.4 M

GCS InletRaw syngas, vol %CO 65.49%CO2 1.01%CH4 0.006%H2 25.01%H2S 1.239%

O2 0%H2O 1.389%COS 0.1234%N2 5.664%Ar 0.0682%

Gasifier

ASU

RSC2RSC1

26.29 p235 T48.28 M

Raw syngas

3.161 M

Clean syngas

33 T46.81 M

Clean syngas to GT23.07 p260 T50.99 M

121.1 T

125 T

Moisturization water4.172 M

HPE2120.1 p319.7 T1461 h23.56 M

HPE1123.7 p240.6 T1042.4 h23.56 M

124.1 T

126.1 T51.44 M

104 T

Drain1.777 M

33 T

Drain1.811 M

H2S1.034 M

Clean syngas, vol %CO 60.66%CO2 1.049%CH4 0.0056%H2 23.17%H2S 0.0009%O2 0%H2O 9.81%COS 0.0003%N2 5.246%Ar 0.0632%LHV = 11093 kJ/kg

Scrubber

COS Hydrolysis

Acid Gas Removal

Cooler 1 Cooler 2

Syngas Heater

Cycle Flow SchemticPuertollano IGCC

THERMOFLOW, INC

HPE3

Gasifier Technologies in GT PRO GT PRO allows the user to apply several different types of gasifiers. Both Oxygen-blown and Air-blown gasifiers can be selected. The Oxygen-blown gasifier has three different predefined types: Type 1 (one stage slurry) similar to the GE / Texaco gasifier, Type 2 (one stage dry) similar to the Shell / Uhde gasifier, and Type 3 (two stage slurry) similar to the E.-Gas gasifier. The predefined types are aimed at helping the user to get started. Beside the predefined types, there is also a user-defined type available. Each of the above gasifiers can…

be fed either a fuel/water slurry or dry fuel with steam addition. gasify both solid and liquid fuels. include high temperature coolers or be of the quench type.

Pic. 4 shows the Gasification Main Inputs screen of the Puertollano IGCC model. The connections to the HRSG (water/steam) and the gasturbine (compressed air/nitrogen) are handled through scroll-down menus.

Pic. 4

Page 5 of 10

THERMOFLOW, Inc

Depending on the gasifier type oxygen or air is fed to the gasifier. For an Oxygen-blown gasifier the oxygen is produced in an Air Separation Unit (ASU), which also may produce usable nitrogen for gas turbine NOx reduction and power augmentation. The ASU consist of air, oxygen and nitrogen compressors and the oxygen and nitrogen producing unit. For the air-blown gasifier GT PRO treats the ASU as a compressor station for compression of air. Two main gas cleanup systems are available in GT PRO, cold gas cleanup and hot gas cleanup. Pic. 5 displays the Gas Cleanup System inputs screen.

Pic. 5

Page 6 of 10

THERMOFLOW, Inc

To close the the gap between the currently available gasifier models in GT PRO and new gasifier developments/innovations, the user has the opportunity to implement his own gasifier model through the fully-flexible program THERMOFLEX as mentioned on page 3. The user can implement his own gasifier model written in a C++, Fortran or Visual Basic source code. Finally, the bi-directional link (Pic. 6) between THERMOFLEX and GTP will be used to connect the gasification plant with the gasturbine (fuel source, compressed air extraction, N2 addition) and the HRSG (steam/water connections).

Pic. 6

Page 7 of 10

THERMOFLOW, Inc

Other Features, Hardware Details and Cost Estimation Gasturbine & Fuel Database GT PRO provides a database with nearly three hundred gasturbine models. Most engines in the GT selection list (Pic. 7) are physically based models which can run with any reasonable fuel, with any preconditioning of inlet air, at part loads, with water or steam injection, and with peak firing. The fuel database includes over 100 typical predefined coals, biomass, etc. from all over the world. Of course, the user can also define an own fuel.

Pic. 7 PEACE – Plant Engineering And Construction Estimator PEACE works seamlessly with GT PRO. It provides additional inputs to automate the preliminary engineering and cost estimation. The logical cost functions for all equipment are derived from the detailed hardware specifications, so that any design change is immediately reflected in corresponding changes in both performance and cost. This allows the techno-economic optimization of all major equipment. Pic. 8 displays a part of the PEACE Hardware Details (Piping), Pic. 9 the PEACE Project Cost Summary.

Page 8 of 10

THERMOFLOW, Inc

Pic. 8

Pic. 9

Page 9 of 10

THERMOFLOW, Inc

Please contact us for further information THERMOFLOW, Inc 29 Hudson Road Sudbury MA 01776 USA Tel: +1 978 579 7999 Email: info@thermoflow.com THERMOFLOW Europe GmbH Gartenstrasse 18 D-35469 Allendorf Germany Tel : +49 6407 906991 Email: huschka@thermoflow.com

Page 10 of 10

THERMOFLOW, Inc