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TRIG™ Commercialization Status Update · •OTS •OMS •Technical Services Proprietary ......
Transcript of TRIG™ Commercialization Status Update · •OTS •OMS •Technical Services Proprietary ......
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TRIG™
Commercialization
Status Update
Manoj Nagvekar
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KBR at a Glance
• Technology-based EPC & O&M Company
• 100+ Years of Operation
• Listed on the NYSE
• FY 2014 Revenue ~ $6.0 Billion
• Headquartered in Houston, TX
• 27,000 employees worldwide
• Local in 65+ countries
• 3 Primary Business Groups: – Engineering and Construction
– Technology and Consulting
– Government Services
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KBR Technology Portfolio
Refining • ROSE®
• FCC
• VCC™
• K-SAAT™
• HydroProcessing
• Dividing Wall Column
Automation and Process Technologies • InSite™ Performance
Monitoring
• OTS
• OMS
• Technical Services
Proprietary Equipment
• Refining
• Coal Monetization
• Olefins
• Chemicals
• Ammonia and Syngas
Olefins
• SCORE™
• K-COT™
Ammonia and Syngas • Ammonia
• Fertilizers
• Syngas
• Hydrogen
• Methanol
• TRIG™ Applications
• Power
• Industrial
• Energy & Chemicals
Coal Monetization
Chemicals • Phenol/Acetone
• BPA
• PVC
• Acetyls
• NExOCTANE™ and NExETHERS™
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TRIG developed by KBR, Southern
Company with support from U.S. DOE
Collaborative blending of skills and strengths of each company
Technology available for Industrial and Power applications of TRIG using low-rank coals
KBR leads marketing and licensing activities
KBR-Southern Alliance: TRIG
TRIG™ Technology
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TRIG™ Global Footprint
Kemper TRIGTM
IGCC Project
UND Pilot
PSDF Demo SKI Pilot
Berun TRIGTM
DongGuan TRIGTM IGCC
Yanchang Demo
PSDF Demo
50 MTPD
1996 2012 2013 2015 2016 2017 2018 2019
Kemper TRIGTM IGCC 582 MW
2011
DongGuan IGCC 1600 MTPD
Berun TRIGTM 1000 MTPD
2014
UND Pilot
3 MTPD SKI Pilot
3 MTPD
Yanchang Demo 100 MTPD
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Kemper County IGCC Project Overview
● 2x1 Integrated Gasification Combined Cycle (IGCC)
– 2 Transport Gasifiers
– 2 Siemens SGT6 - 5000F CTs
– 1 Toshiba steam turbine
– 582 MW peak and 524 MW on syngas
– Heat rate 12,150 Btu/kWh
– 28.1% HHV efficiency w/ CO2 control and >40% moisture coal
– Selexol for H2S and CO2 removal
– >65% CO2 capture (~800 lb/MWh emission rate)
– Mine mouth lignite
● Owner and Operator:
Kemper Lignite Composition
Average Min Max
Heat Content btu/lb 5,290 4,765 5,870
Moisture % 45.5 42 50
Ash % 12.0 8.6 17
Sulfur % 1.0 0.35 1.7
Plant Site Plant Site
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● Commercial Operating Date: First Half 2016
– Combined cycle in-service August 2014
● Zero Liquid Discharge.
– Make-up water from City of Meridian treated
effluent.
● By-Products (TPY)
– ~3,000,000 – Carbon dioxide used for EOR
– ~140,000 – Sulfuric acid
– ~22,000 – Ammonia
Plant Site Plant Site
Project Overview
Kemper Lignite Composition
Average Min Max
Heat Content btu/lb 5,290 4,765 5,870
Moisture % 45.5 42 50
Ash % 12.0 8.6 17
Sulfur % 1.0 0.35 1.7
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Kemper County IGCC – July 2015
Construction >99% Complete
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Construction Update
● 0.46 project recordable incident rate
(7 times safer than construction industry average)
● Construction complete on all plant equipment and piping
● What’s left:
‒ Commissioning support
‒ Punchlist items
‒ Insulation
‒ Painting
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Construction Progress
Selexol unit (acid gas removal)
Entire plant from south
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Construction Progress
Sulfuric acid production unit
Lignite delivery facility
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Commissioning
● Clean-outs: nearing completion
‒ Air/steam blows
‒ Hydrolazing
‒ Flushes
‒ Chemical cleaning
● Initial pressure tests: essentially complete
‒ Refrigeration system - vacuum and pressure test
‒ Gasifier/syngas cooler/particulate control device
‒ Syngas scrubber
‒ Ash silos
‒ Acid gas removal
‒ Wet sulfuric acid
‒ Gasifier lignite feed system
Loading internals in CO2 absorbers
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Commissioning
● Column internal installation: complete
● Filter element installation: complete
‒ Syngas particulate control device
‒ Lignite prep candle filters
‒ Cyclonic baghouse
● Loop checks: essentially complete
● Detailed logic review: nearing completion
Loading internals in CO2 absorbers
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Commissioning Progress
Filter installation in cyclonic baghouse
Steam blows
Syngas cooler tubesheet
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Commissioning Progress
Vacuum testing on ammonia refrigeration system
Internals to be installed in AGR vessels
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Operator Training Simulator
● Has proven to be beneficial for
procedure, DCS controls, SIS, and
interface checkout
● Numerous findings have saved
countless hours that would have
been spent during startup
● Will serve as operator training
platform going forward
Findings DCS SIS Model Procedure Screens Siemens
Test 3 305 12 237 362 280 24
Test 4 97 2 49 106 93 5
DCS COPY
MODEL
SIS EMULATION
VIRTUAL SIEMENS
INSTRUCTOR STATION
WORKSTATIONS
DCS
SIS
Model
Procedure
Screens
Siemens
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Functional Testing
● Functional checks:
– Startup burner
– Coal mills
– Coal dryer fans
– WSA burner
● Air/nitrogen circulation tests:
– Complete gasification loop
from gasifier through syngas
cleanup
– Coal mill loops
– Initial tests on fluidized bed
dryers
Fluid bed dryer circulation tests
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Functional Testing
● Selexol unit:
– Water circulation tests complete
– Internal degreasing underway
● Test fired flares
● WSA
– Initial air circulation
WSA circulation tests Flare test fire
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Functional Testing
● Tempered water:
– Circulation tests complete
– Heating tests underway
● WGS nitrogen circulation and heating test:
– Complete on train A
● Coal feeder filling cycle:
– All 12 commissioned
● Compressors commissioned:
– Process air
– Transport air
– Recycle gas WGS nitrogen circulation
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Process air compressor
Coal feeder filling cycle
Functional Testing
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Fully Operational Systems
• Combined cycle
• Nitrogen plant
• Wastewater plant
• Demineralized water plant
• Instrument air
• LP and IP steam systems
• Lignite delivery facility
• Mill reject removal system
• Auxiliary boiler
Nitrogen plant
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Fully Operational Systems
Wastewater system Inside coal dome
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Operational Equipment
Switchyard
Lignite delivery system
Approximately 1.2 million tons of lignite mined
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Water treatment
Combined cycle
Operational Equipment
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Commercial Operations
● Combined cycle placed in service: August 9, 2014
● Power generated: 3.5 million megawatt-hours
● EFOR: about 1 percent. (Five times better than typical combined cycle of similar size)
Commercial Equipment
● 2 x gas turbines
● 1 x steam turbine
● Auxiliary boiler
● Cooling tower
● SCRs
● Duct burners
● Electrical service
● Utilities
● Transmission
Assets
● Water Storage
Pond
● Treated Effluent
Water Line
● Natural Gas
Pipeline
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Assets in Service
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1. Start solids
circulation
2. Burner light-off and
refractory cure
3. Coal feed
4. Syngas to cleanup
unit
5. Byproduct
generation
6. Syngas to turbine
7. Repeat on train 2
What’s Next
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Thank You