Gasification Technologies 200715 Oct 2007, San Francisco
Nuon MagnumElectricity of the futureRien van Haperen Director Nuon Magnum IGCC projectRobert de Kler Head Engineering Services Nuon TPD
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Düsseldorf
Amsterdam
BrusselsBelgium (120 FTE):• (Selective) production and sales
Netherlands (9,000 FTE):• Generation, trading, distribution, sales
Germany (250 FTE):• Management of industry parks, and public lighting activities (eg. Berlin), (selective) production, sales
‘Grey’ generation assets Renewables
Nuon is an independent, international energy company based in the Netherlands, with focus on North West Europe, striving for balanced growth for all stakeholders. Nuon is a frontrunner in sustainability.
Europe:• Trading and renewable production
Frontrunner highlights:• Nuon Magnum – 1200 MW multifuel plant (2010)• Buggenum – coal gasification, syngas development• Gas – gas storage development• CO2 – storage + first forward deal with Shell • Norway – first mover in wind market with Statkraft• NoordzeeWind – 108 MW first offshore wind farm in NL• Renewable – 410 MW installed capacity in 7 EU countries• “Grey” – 3500 MW installed capacity, dominantly gas fired
Overview Nuon
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Lim
it en
ergy
dem
and
Use renewableenergy
Use fossil fuels as efficiently and cleanly as possible
Smart metersDemand Response
Energy advice
Education Wind
Biomass co-firing
Stimulate green demand
SolarHydro
Technology development:
- Multi-fuel (coal and biomass)
- Gasification technology
- CO2 in house abatement
- Potential for CO2 capture & storage
Nuon’s sustainable strategy based on Trias Energetica
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Nuon’s choice for gasification
• Replacement of existing older assets•Several older units will come at the end of their lifecycle during the next decade•Further development of a sustainable power generation fleet•Nuons investment choice will be Best Available Technology of the future
• Gasification is one of the most versatile and clean ways to generate energy from solid and/or liquid fuels
•High efficiency due to integration with combined cycle technology•Ability to fire a large range of fuels including biomass•Emissions significantly lower than for conventional coal fired units: future-proof
• Gasification is advanced coal technology of the (near) future
•Nuon has extensive Engineering and Operational knowledge in the field of (coal) gasification technology and low caloric fuel fired (dual fuelled) gas turbines;
•Nuon is still developing gasification in Buggenum: modifications, biomass, syngas-start-up, secondary fuels, CO2 capture, ..
Nuon´s competitive edge: the Buggenum experience
Buggenum is the first fully integrated gasification plant with a Combined Cycle. The unit has been commissioned in 1994. In the first years the unit served as a demonstration plant from which it switched smoothly into commercial operations starting in 2001. In the time span 2001-2004 the unit was operating predominately as a swing unit, optimising Nuon´s power position (long or short). As from 2005 the unit will be fuelled with biomass up to 30% (mass) bases.
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Buggenum Performance
Commissioning date: 1993Fuel input:
Up to 2000 t/d of coal Up to 20% of biomass
Plant electric capacity: 253 MWe
Electric efficiency (LHV): 43%
Plant statistics:
0
2000
4000
6000
8000
1993 1995 1997 1999 2001 2003 2005 2007
hou
rs /
yea
r
5000 plant modifications
1 23
4
0
20
40
60
80
100
%
Mercury
Dust particles
Acidification
SO2
NOx
CO2
22% less CO2 when co-gasifying biomass
1. Old generation coal-fired power plants
2. Current generation coal-fired power plants
1. Buggenum power plant (natural gas)
2. Buggenum power plant (coal gas)
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Nuon is developing a multi-fuel power plant, Nuon Magnum, based on coal
gasification technology in the Eemshaven (Groningen, Northern Netherlands).
Proven technology for future steps
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Characteristics Magnum Project
•Clean Coal Technology: Gasification and Combined Cycle
Technology
•Fuel flexibility: Multi Fuel Concept
•Peak and base-load plant
•Net Power output app. 1200 MWe
•Shell Gasification Technology (3 x 2000 tpd)
•3 State of the Art Combined Cycle Units
•Commercial plant from beginning, no Demo
•Proven technology where possible
•CO2 capture ready
•2011 start commercial operation
•Site: Eemshaven
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Simplified flow diagram
By-p
rod
ucts
CO
2
Entrained flow gasifier Wet gas cleaning
Acid removalWaste water treatmentDemi water production
Combined Cycle Dual fuelled Gas Turbines (Syngas, Natural gas fired)
otal heat input 2600 MWthTotal net electrical output 1200 MWe
Oxygen and Nitrogenproduction
Gasifier(3 units)
CC(3 units)
Power
Nat.G
as
Air Separation
Unit
Steam / Heat
Emissions
N2
Syngas
Power
Air
O2
Coal
Sec. Fuels
By-p
rod
ucts
Section 1: Gasification
Section 2: Air Separation
Section 3: CCGT
Gas cleaning
Steam
CO2capture
Solid Biomass
Ch
em
icals
N2
Co
olin
g W
ate
r
Ch
em
icals
/W
ate
r
Em
ission
s/Fla
re
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Tendering: overview
Natural Gas
Power Heat
CCU
CCGT
CCGT
CCGT
Stevedore Gas receiving station
ASU
ASUOTF
CoalBiomass N2 O2
Gas Cleaning
Gasification EPC
Fuel Preparation
Gasifier
Gasifier
Gasifier
Slag Fly-ash Sulphur
Syngas
Steam
ST
MAC
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Market Experiences lead to Phased Approach
Contractor market is difficult:Quotations very highPrice uncertainty is highLonger delivery schedulesSevere constraints in ConstructionMultiple potential critical pathsOriginal LSTK-approach not supported
Nuon has adapted its mindset:More open-book-type of approachEvaluation of Magnum at a higher price-level than expectedStill believer of multi-fuel conceptSeeking a feasible route to realization in a sellers market
Nuon has announced a phased execution of Magnum: CCU first, followed by gasification
+€
FullScope
Phase 1 Phase 2
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Planning for CCU in line with Original Planning
Start comm. operation
Commissioning
Building phase
Detailed design
Permit
Engineering
Site + O&M
Commercial
Site Selection
Project strategy
2011201020092008200720062005PlanningActivities
Nuon invests 60 – 70 million euro in the project development phase
FID
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Outlook Phase 2: Business Case Improvements
Business Case
•Review actual set-up•Plot plan improvements
•MDEA i.s.o. Sulfinol
•BoD-review:•Review original set-up
•Turndown requirements
•CO2-inclusion•Profile IGCC
•More integrated design•European Flagship Programme?
•Revenue improvement•Biomass
•Sale of syngas, CO2, H2•Enhance ASU?
•Contract Structure•Reimbursable i.s.o LS
•Separation of ‘EP’ and ‘C’
•Partnering?
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Original Planning CO2 capture and storage
Design CO2-demo Buggenum
Start CO2-capture Magnum
Building CO2-capture Magnum
Prepare CO2-transport/storage
Commissioning Magnum IGCC
Design review Magnum
Design CO2-capture Magnum
Testing
Building CO2-demo Buggenum
2013201220112010200920082007
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Planning Magnum Phase 2 including CCS
Design & Build CO2-demo Buggenum
Start CO2-capture Magnum
Prepare CO2-transport/storage
Commissioning Magnum Phase 2
Construction Magnum Phase 2 with CCS
Develop Magnum Phase 2 with CCS
Construction Magnum Phase 1 (CCU)
Test CO2-demo Buggenum
2013201220112010200920082007
Present planningRevised planning
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CO2 capture installation CO2 capture installation
Magnum
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Two dynamic simulators of a IGCC power plant (process + controls), 40-100% load
1. Buggenum IGCC , incl. validation with operational data 2. Magnum IGCC design (3 gasifier trains, compressor station,
3 CCU’s), including overall controls (based on syngas demand control)
IGCC simulator Buggenum & Magnum
These simulations comprise:
Gasification: feedstocks: free parameterizable ultimate analysis, incl. minerals, soot and lime, equilibrium chemistry with gas components CO, H2, H2O, CO2, H2S, COS, N2, Ar, NH3, CH4, HCN, radiative heat exchange with reactor membrane wall, slag holdup at membrane wall; slag viscosity, slag flow and thermal conduction
Syngas cooler, fly ash removal, wet scrubbing, syngas recycle, HCN/COS conversion, H2S absorbing, flash gas recycle, saturation
Compressor station, 3 parallel compressors with anti surge
CCU combined cycles running on syngas and NG
Specific simulations are made for:Compressor station responses in case of gasifier / compressor / GT trips Gaseous oxygen buffer dynamics
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Post- vs. Pre-combustion CO2 capture
Fuel
CO2
Pre-combustion Post-combustion
Higher partial pressure of CO2allows for bulk removal methods
Technology already available and proven in chemical industry
Limited impact on a plant
Limited energy consumption
No hazardous wastes
LHV loss (syngas)
Low partial pressure of CO2 requires deep removal methods
Technology requires further development
Significant impact on a plant due to a large unit size and substantial steam off-take
High energy consumption
Large quantities of hazardous wastes
Fuel
CO2
Flue gas Flue gas
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Pre-combustion at Nuon Magnum -- separation
Very expensive, because of large quantity of adsorbent required, no industrial experience.
Much industrial experience exists for various solvents, including syngas applications.
No industrial experience exists with membranes to separate CO2 from syngas.
Cryogenic separation section would not significantly improve the specific energy consumption or allow lower investments, 90 % separation efficiency doubtful
Solids adsorbents Membranes
Cryogenic separation
Solvent absorption
The required solvent properties:Non-corrosive,Stable,Inexpensive,Non-foaming.
Physical or chemical
Physical solvent is found to be the most effective?
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CO2 capture readiness
Capture readiness is not limited to reserving plot space!
One needs to study many more issues:Identify CO2 sinks
Develop technological concept and study impact on a plant
Assess pre-investments
Reserved plot space
Study business case
Identify CO2 sinks
Study design and integration with a plantReserve plot space
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Pre-combustion at Nuon Magnum
Building in stages
100%Overall
0.006%Other
0.867%Ar
7.726%N2
2.017%CO2
28.655%H2
60.212%CO
0.518%H2O
0% CO2 capture
100%Overall
0.005%Other
0.737%Ar
6.567%N2
1.714%CO2
24.359%H2
51.185%CO
15.432%H2O
0% CO2 capture
100%Overall
0.005%Other
0.724%Ar
6.691%N2
2.810%CO2
38.979%H2
35.222%CO
15.569%H2O
27% CO2 capture (1 train)
Sulfinol M Saturator Compressor
CO2 capture unit
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%Sy
nga
s
H2
CO2
0.005%Other
100%Overall
0.712%Ar
6.810%N2
3.868%CO2
53.092%H2
19.813%CO
15.702%H2O
54% CO2 capture (2 trains)
Burner tips replacementProven technology
New burner replacement Being tested
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Pre-combustion at Nuon Magnum
Carbon transport throughout the plant
Gas
ific
atio
n
C in coal
C in biomass
C in limestone
Gas cleanup
Shift Separation
Pressuri-zation
Gas turbines & HRSGs
Sulfur plants & Tail gas
incineration
Raw syngas
60% CO, 30% H2
CO2 in acid gas
CO & CO2 in syngas Capture unit bypass
CO/CO2 lean
CO2 rich
Liquid CO2 for sequestration
CO2 capture unit
CO2 in tail gas
CO2 in flue gas
Emitted CO2
Power & steam
C in natural gas
A minor part of the CO2 travels with the H2S rich stream from the acid gas regenerator to the sulfur plants. The tail gas from these sulfur plants is incinerated, thereby emitting some sulfur as SO2 and all the CO2 present.
The existing Sulfinol unit (selectively absorbing H2S) and the sulfur plants, including tail gas treating, will be used also in case the capture plant is on line.
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Pilot plant
2007 2008 2009 2010
Preparation phase
Building phase
Test phase
Permitting
R&D program
Design Phase
Pilot plant features
Simplified process incl. shift reactors and absorbtion section
Testing catalyst and solvent durability
Testing operation flexibility and performance
Approx. 2.5% of the syngas flow
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Unit integration with the Buggenum plant
SulfinolAbsorber
CO2 demoplant
Saturator
• ~1.0 kg/s taken from the main syngas stream
• Hydrogen rich stream returned to the Buggenum plant
• Hydrogen content of the syngas increased by 4.6% (within limits of the GT)*
• Steam and water taken from the Buggenum utilities
* Limit of GT after dilution 9.9-12.4 mole % H2
syngas 40 kg/s
1 kg/s H2 0.5 kg/s
CO2 1.1 kg/swater 0.6 kg/s
steam 0.6 kg/s waste water 0.6 kg/s (will be reused)
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Cooperation in CCS chain in Northern Netherlands
Nuon is actively searching for cooperation in the CCS chain. Therefore a declaration of intent has been signed with the province of Groningen and the Ministry of Environment (April 27, 2007)
mr. Alders, province of Groningen, mr. Van der VlistMinistry of Environment, mr. Van Halderen, Nuon
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Thanks