GASIFICATION FOR COMBINED PRODUCTION OFELECTRIC POWER AND CHEMICALSELECTRIC POWER AND CHEMICALS
R. Domenichini - Technical Director Foster Wheeler Italiana - Power Division
Gasification Technology Conference, October 2008 – Washington (USA)
Gasification for Combined Production of Electric Power and Chemicals
A G E N D A
• INTRODUCTION INTRODUCTION
• BASES OF DESIGN AND PLANT ALTERNATIVES
• PROCESS DESCRIPTION
• PERFORMANCE DATA
• INVESTMENT COSTS
• COST OF ELECTRICITY (C.O.E.) AND COST OF CHEMICALS (C.O.C)
• SENSITIVITY ANALYSIS
• SUMMARY FINDINGS
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Gasification for Combined Production of Electric Power and Chemicals
INTRODUCTION
The target of this study is to investigate the technical-economical feasibility of capture-ready IGCCplants, designed for the combined production of electric power and chemicals, from coal and petcokeplants, designed for the combined production of electric power and chemicals, from coal and petcoke
Two main case studies are developed:
Co-production of methanol and electric power from coal gasification (IGCC-MeOH)
Co-production of urea and electric power from petcoke gasification (IGCC-Urea)p p p g ( )
Overall performances and investment costs are evaluated and shown through:
• A sensitivity analysis on Cost of Electricity and Cost of Chemicals
• Performance and cost penalties due to the CO2 capture retrofit
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Gasification for Combined Production of Electric Power and Chemicals
IGCC Electrical Energy and Methanol Co-productiongy p
Air Separation Unit
Air
Electric Power
Nitrogen
GasificationIsland
Syngas treatment (CO shift)
Gas Turbine
HRSGCoal Syngas
Electric Power
Steam / BFW
Oxygen
Acid GasRemoval
Sulphur Recovery Unit
Steam TurbineSlag / Filter Cake
SulphurClean Syngas
CO2 drying and i
UtilitiesMethanol Plant
Methanol
CCS case
compression
CO2
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Gasification for Combined Production of Electric Power and Chemicals
IGCC Electrical Energy and Urea Co-production
Air Separation Unit
Gas TurbineAir Electric PowerNitrogen
Unit
GasificationIsland
Syngas treatment (CO shift)
HRSG
Steam TurbineCoal Syngas
Steam / BFWOxygen
Island ( )
Acid GasRemoval
Sulphur Recovery Unit
Slag / Filter Cake
Sulphur Clean Syngas Offgas toPostfiring
CO2 drying and Utilities
y
H2
Urea
Ammonia Plant
Urea
PSACCS case
compressionUtilities
CO2
Plant
CO2
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Gasification for Combined Production of Electric Power and Chemicals
BASES OF DESIGN AND PROCESS ALTERNATIVES
Case Feedstock CO2 capture GT Methanol / Urea production, t/d p
IGCC-MeOH Bitumious Coal No 250 MWe F-class 5,000
IGCC-MeOH Bitumious Coal Yes 250 MWe F-class 5,000
IGCC-Urea Petcoke No 120 MWe E-class 3 400 IGCC-Urea Petcoke No 120 MWe E-class 3,400
IGCC-Urea Petcoke Yes 120 MWe E-class 3,400
i i i E l i i d d di i• Location is a generic European coastal site at iso-standard conditions
• Gaseous emissions (mg/Nm3 @ 15% O2 vol. dry):- NOx : < = 50
GASIFIERS CAPACITY IS FIXED TO PRODUCE REQUIRED SYNGASFOR THE TARGETED CHEMICAL PRODUCTION
- SOx : < = 10
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FOR THE TARGETED CHEMICAL PRODUCTIONAND TO SATISFY THE APPETITE OF THE SELECTED GAS TURBINE
Gasification for Combined Production of Electric Power and Chemicals
PERFORMANCE DATA
MeOH / Urea G Net Power Overall carbon
CASE Fuel MeOH / Urea production
Gross Power Output
Net Power Output
CO2 emission removal efficiency *
t/h t/d MWe MWe t/h %
IGCC-MeOH 474.5 5,000 563.3 253.7 782.8 26.8
IGCC-MeOH with CCS 474.5 5,000 563.3 212.4 183.5 82.8
IGCC-Urea 174.8 3,400 303.5 132.6 414.6 20.0
IGCC-Urea with CCS 174.8 3,400 303.5 110.8 70.6 86.4
* Including carbon present in the chemicals produced (methanol or urea).
Petcoke case meets the target of a modern refinery (delayed coker capacity 100,000 BPSD and internal electrical cons.)
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g y ( y p y , )
Gasification for Combined Production of Electric Power and Chemicals
INVESTMENT COSTS
The overall investment cost includes:
Di t t i l ( i t d b lk t i l )• Direct materials (equipment and bulk materials)• Construction (mechanical erection, instrument and electrical installation, civil
works and site preparation)
• Other costs (temporary facilities, solvents, catalysts, etc.)
• EPC services CASE Total Investment Cost
106 € • Land purchase
• Technology fees
106 €
IGCC-MeOH 2,051
IGCC M OH ith CCS 36 (d lt ) • Contingencies
IGCC-MeOH with CCS + 36 (delta)
IGCC-Urea 1,558
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IGCC-Urea with CCS + 26 (delta)
Gasification for Combined Production of Electric Power and Chemicals
PRODUCTION COSTS
Main Economic Data:
• Methanol selling price: 380 €/t (Sensitivity to 250÷450 €/t)
• Urea selling price: 260 €/t g p(Sensitivity to 230÷300 €/t)
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Graphs from “nitrogen + syngas” - September / October 2008
Gasification for Combined Production of Electric Power and Chemicals
PRODUCTION COSTS
Main Economic Data:
C t f t k 35 €/t (S iti it t 20 50 €/t)• Cost of petcoke: 35 €/t (Sensitivity to 20÷50 €/t)
• Cost of coal: 85 €/t (Sensitivity to 60÷110 €/t)( y )
• 7,621 syngas equivalent operating hours (87% equivalent availability)
• 10% discount rate on the investment cost over 25 years
• Maintenance cost: approx 3.0% of the total capital costs
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Gasification for Combined Production of Electric Power and Chemicals
COST OF ELECTRICITYCOST OF ELECTRICITY
CASE MeOH / Urea prod. t/d
Cost of Coal / Petcoke €/t
Cost of MeOH / Urea €/t
C.O.E. cent€/kWh
IGCC-MeOH 5,000 85 380 3.6
IGCC-MeOH with CCS 5,000 85 380 4.7
IGCC-Urea 3,400 35 260 2.8
IGCC-Urea with CCS 3,400 35 260 3.9
© Foster Wheeler. All rights reserved
Gasification for Combined Production of Electric Power and Chemicals
IGCC-MeOH
SENSITIVITY TO COAL COST(MeOH price = 380 €/t)
0.1
0.12
0.06
0.08
O.E
. (€/
kWh)
0.02
0.04C.
060 65 70 75 80 85 90 95 100 105 110
Coal Cost (€/t)
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no CCS CCS
Gasification for Combined Production of Electric Power and Chemicals
IGCC-Urea
SENSITIVITY TO PETCOKE COST(Urea price = 260 €/t)
0 05
0.06
0.07
0.03
0.04
0.05
O.E
. (€/
kWh)
0.01
0.02
C.O
020 25 30 35 40 45 50
Petcoke Cost (€/t)
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no CCS CCS
Gasification for Combined Production of Electric Power and Chemicals
IGCC-MeOH
SENSITIVITY TO MeOH SELLING PRICE(Coal cost = 85 €/t)
0.16
0.18
0.2
0.1
0.12
0.14
O.E
. (€/
kWh)
0 02
0.04
0.06
0.08
C.O
0
0.02
250 270 290 310 330 350 370 390 410 430
MeOH Price (€/t)
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no CCS CCS
Gasification for Combined Production of Electric Power and Chemicals
IGCC-Urea
SENSITIVITY TO UREA SELLING PRICE(Petcoke cost = 35 €/t)
0 06
0.07
0.08
0.04
0.05
0.06
O.E
. (€/
kWh)
0.01
0.02
0.03C.O
0230 240 250 260 270 280 290
Urea Price (€/t)
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no CCS CCS
Gasification for Combined Production of Electric Power and Chemicals
IGCC-MeOH
SENSITIVITY TO CARBON TAX – no-CCS vs. CCS(Coal cost = 85 €/t; MeOH price = 380 €/t)
0.14
0.16
0.18
0.08
0.1
0.12
.E. (
€/kW
h) 18 Euro/t (CCS with 10€/t)
0.02
0.04
0.06C.O
.
5 Euro/t (CC only)
0
0.02
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0
Carbon Tax (€/t CO2 )
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CCS no CCS CCS incl. transport & storage
Gasification for Combined Production of Electric Power and Chemicals
IGCC-Urea
SENSITIVITY TO CARBON TAX – no-CCS vs. CCS(Petcoke cost = 35 €/t; Urea price = 260 €/t)
0.14
0.16
0.18
0.08
0.1
0.12
O.E
. (€/
kWh)
16 Euro/t (CCS with 10€/t)
0.02
0.04
0.06C.O
4 Euro/t (CC only)0
0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0
Carbon Tax (€/t CO2 )
( y)
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CCS no CCS CCS incl. transport & storage
Gasification for Combined Production of Electric Power and Chemicals
SUMMARY FINDINGS
• Capture-ready IGCC with electric power and chemicals co-production showsattractive COE especially for a low value feedstock like petcokeattractive COE, especially for a low value feedstock like petcoke
• IGCC-MeOH case is significantly affected by coal cost and MeOH price.98 €/t (b 85€/t) f C l> 98 €/t (base 85€/t) of Coal
< 350 €/t (base 380 €/t) of MeOHnon-competitive COE values
for European electrical market
• IGCC-Urea case is less affected by the petcoke cost and Urea price.
> 60 €/t (base 35 €/t) of Petcoke< 230 €/t (base 260 €/t) of Urea
non-competitive COE valuesfor European electrical market
© Foster Wheeler. All rights reserved
Gasification for Combined Production of Electric Power and Chemicals
SUMMARY FINDINGS
CO t t fit i hi bl ith l f d t• CO2 capture retrofit is achievable with low performance and costpenalties.
• CCS alternatives are economically viable even at a very low level ofcarbon tax (> 18 €/t for IGCC-MeOH and > 16 €/t for IGCC-Urea, assuming10 €/t for CO2 transport and storage)
• Improvements in the main areas like GT, gasifiers and ASU are expectedin the next years, thus making IGCC’s more and more attractive
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THANK YOUTHANK YOU
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Gasification Technology Conference, October 2008 – Washington (USA)
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