Innovative use of Integrated Gasification Combined Cycle...Hot air plus wood chips –exothermic,...
Transcript of Innovative use of Integrated Gasification Combined Cycle...Hot air plus wood chips –exothermic,...
Innovative use of Integrated Gasification Combined Cycle
Evolving an economically viable biomass power solution
R John Thomas
Laura Fell
Environmental Energy Australia Pty Ltd &
Fleurieu Power Company Pty Ltd
Power Plant design evolution• In 2016 EEA responded to “Non Network Options Report” for Kangaroo Island
• Proposed a combustion / steam turbine solution for power plant
• Expensive in terms of use of fuel, needed subsidy to work economically
• Costs of ash management
• Top ranked of all “non network” credible responses to the NNOR
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Biomass as a fuel
• Massive moisture content• At times higher than 50% water;
• Means that much of the combustion energy simply evaporates water.
• Bulky material with moderate calorific value• Need many tons of wood chip to make 1 MW hour of power 24 hours a day,
365 days a year;
• Large materials handling issue.
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Economic & other concerns
• Rate of change of power plant output;
• Network needs rapid demand response;
• In SA at least MUST bring “inertia” to the network;
• Needs to be environmentally friendly; • Low or non existent particle emissions;
• Low NOX, SOx
• Acoustically acceptable.
• Reliability of power production, meet the National Electricity Rules
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Dry the biomass-Torftech Compact Bed Reactor
Wood chips from 50% to 15% moisture, then suitable for syngas generation.
Use waste heat from HRSG exhaust to dry the wood chips.
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Create Syngas -Torftech Expanded Bed ReactorHot air plus wood chips – exothermic, stoichiometry limited O2
Hot gas to cycloneHot gas then to air /gas heat exchanger, heat up incoming air.
Syngas H2, CO, CH4, N2
Low calorific value syngasGas quite dirty
Nutrients in biochar, no ash for disposal. Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Options to use low Calorific Value syngas
1. Burn syngas, raise steam in boiler, use steam turbine generator1. Around 20% - 30% thermal efficiency.2. Lag in turn down / ramp up.
2. Heat an organic Rankine cycle turbine1. Around 14 - 18 % thermal efficiency.
3. Gas spark engine1. Around 30% - 40% thermal efficiency, was in use at Usk (Wales) but maintenance issues.2. Need serious gas clean up plant .3. High maintenance for any reciprocating engine.
4. Gas turbine1. Aero-derivatives 40% efficiency plus; but poor ride through, need clean fuel2. Heavy duty “Frame” units tolerate dirty fuel, massive power system disturbance ride
through, 28% - 32% efficient, Frame 5 in particular is responsive.
3. Add Heat Recovery Steam Generator – use energy in Gas Turbine exhaust1. Thermal efficiency to around 45% - 50% but less responsive than Gas Turbine.
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
RDFdrier
HRSG Exhaust to driers
RDF Gasifier
Gascooling
Dry RDF
Hot Syngas
Extra steam to HRSG system
Gas scrubber
Syngas compressor
Gas cooling
Gas clean up
Gas in pipeline – line pack
Gas Turbine & Generator
To HV switchyard
11kV
Steam Turbine & Generator
Buried length of gas pipeline
Oxygen System
Air in
RDF in
Captured contaminantsCaptured
contaminants
Water, grit
Cool syngas
Cool clean compressed syngas
Gas Turbine &
GeneratorRDP pre-prepared offsiteOxygen by Pressure Swing AdsorptionMultiple drier / syngas / scrubber trainsTwo or three Gas turbine generatorsSingle HRSG Wastes captured in biochar and at scrubber
Hot Syngas
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Plant schematic – RDF as fuel
TORBED®
Gasifier
Char
Feed Surge
Bin
Start up
Burner
Process Air
Fan
Char
Cyclone
Recycle Fan
Dry RDF
Gas
Buffer
Gas
Flare
Outlet
Cleaning Medium
Syn Gas
Booster Fan
GeneratorGas Turbine
Compressor
Excess heat
Heat Recovery
Steam Generator
`
TORBED
Dryer
Oxygen
Wet RDF
Gasifier Module
Gas Cleanup
SteamTurbine Generator
Dryer Module
Powerhouse
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Plant layout
• Woodchip in, to drier.• Drier runs on HRSG
exhaust• Chips to syngas• Syngas to Frame 5 Gas
Turbine• GT exhaust to HRSG• HRSG exhaust to drier• Mass spec for
environmental monitoring.
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Plant characteristics
• Three GE Frame 5-M Gas Turbine Generators at 32 MVA each
• One HRSG, associated Steam Turbine Generator at 32 MVA
• Peak output 110 MW
• Base load output• GTG-1, 2, 3 at 5 MW each, STG-1 at 12MW using approx. 28 tonnes per hour
of biomass (RDF).
• Peak to 25MW per GTG to deliver 60 MW rapid response(Raise 6)
• Approximately 900 - 1,000 MWs of inertia
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Technical compliance challenges
• Suitable connection point• What voltage / MVA capacity, existing protection systems;• Typically not near the biomass!
• Meet the National Electricity Rules• Expensive modelling work to gain a connection agreement;• Flow modelling, ride through capability imperative on skinny
network.
• In SA at least, mandatory inertia requirements.
• EPA requirements• Acoustic• Atmospheric• Water
Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Modelled outcomes
• Power production cost • On woodchip marginal cost of production $108 / MW Hour
• Fuel - woodchip cost $78 / MW Hour
• OPEX – across green output adds $30 / MW Hour
• On RDF, assuming $20 per tonne RDF cost and ash disposal adding $20 per ton to process, marginal cost of production drops to around $80 / MW Hour or less if adequate fuel supply.
• No offset provided in figures above for value of Inertia or FCAS.
• OPEX per MWH costs driven by low base capacity – limited fuel.Environmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd
Acknowledgments • Kangaroo Island Council - Report on Biomass on Kangaroo Island
• Dunstan C., Fattal A., James G., Teske S., 2016, Towards 100% Renewable Energy for Kangaroo Island. Prepared by the Institute for Sustainable Futures, University of Technology Sydney (with assistance from AECOM) for ARENA, Renewables SA and Kangaroo Island Council.
• Innovation and Science Australia – R&D Tax Incentive – Lloyd Thomas Enterprises Pty Ltd & Laura Fell Management Pty Ltd
• Mr Martin Groszek, Torftech
• Fleurieu Power Company as Trustee for Fleurieu Power Unit Trust, Environmental Energy Australia Pty Ltd
Any discussion on supplier selection relates only to the Fleurieu Power ProjectEnvironmental Energy Australia Pty Ltd &Fleurieu Power Company Pty Ltd