Upload
others
View
3
Download
0
Embed Size (px)
Citation preview
Energy Sector© Siemens AG 2011© Siemens AG 2012. All rights reserved.
5th International Freiberg Conference on IGCC & XtL Technologies
Conference 21. May to 24. May 2012,
Leipzig - Germany
Development and Engineering of a Synthetic Gas Cooler Concept
Integrated in a Siemens Gasifier Design
Ulrich Guenther (presenter) Siemens Fuel Gasification Technology GmbH & Co. KG
Energy Sector© Siemens AG 2011© Siemens AG 2012. All rights reserved.
“A technical invention obtains importance and significance, if
the technology itself is advanced so far that the
invention has become feasible and a general need”
Werner von Siemens 1892
21. May 2012, FreibergPage 3© Siemens AG 2011
Energy Sector
Agenda
Siemens Strategy and Place of GasificationSiemens Strategy and Place of Gasification
Main Project Landscape SFGTMain Project Landscape SFGT
Application Fields and Business ModelApplication Fields and Business Model
TEIMAB Project TEIMAB Project OverviewOverview
Conclusion and Conclusion and Future OpportunitiesFuture Opportunities
21. May 2012, FreibergPage 4© Siemens AG 2011
Energy Sector
The planned structure as of October 1, 2011
Industry Infrastructure & Cities Energy Healthcare
■ Industry Automation■ Drive Technologies■ Service
■ Power Distribution/Smart Grid Applications
■ Building Technologies■ Mobility
■ Fossil Power Generation
Siemens Fuel Gasification■ Renewable Energy■ Power Transmission■ Oil & Gas■ Energy Service
■ Imaging & Therapy■ Clinical Products■ Diagnostics■ Customer Solutions
Industry Solutions ■ Osram Power Distribution
OsramBuilding Technologies
Mobility
Siemens AG – Strategy Reorganization in order to better serve our customers
New Sector
21. May 2012, FreibergPage 5© Siemens AG 2011
Energy Sector
Siemens Energy Sector –Newly focused on the markets of tomorrow
Solar & Hydro
Power Transmission
Oil & Gas Fossil PowerGeneration
Wind Power
Energy Service
Energy products and solutions – in 6 Divisions
Siemens FuelGasification
21. May 2012, FreibergPage 6© Siemens AG 2011
Energy Sector
9 SFG-500 gasifiers shipped / installed for 3 projects8 SFG-500 gasifier under manufacturing and additional 22 SFG-500 (CtL) under contract
SIEMENS SFGT Main Project Landscape
Siemens OfficesOperating UnitsCurrent ProjectsTechnology Selected
HQ FreibergTest Facility
JinChengAmmonia
Shenhua Ningxia Coal Group
(NCPP)Polypropylene
COD 2011
Secure Energy Transportation Fuel
Capital PowerPower
AEC Ammonia
Summit PowerPower + Ammonia
GSP China Beijing
VresovaPower
COD 2008
Schwarze PumpeSyngas for Chemical Industry
1984 - 2007
Tenaska Inc. SNG/Power
Ukraine ClientSyngas for
Chemical Industry
Syngas Ltd.Transportation Fuel
Orlando
Japanese ClientChemicals
Shanghai
CPI YinanSNG
21. May 2012, FreibergPage 7© Siemens AG 2011
Energy Sector
China NCPP Project Site Impression
Gasifier building
Slag formation on cooling screen
Entire gasification unit with gasifier building CO shift and black water treatment plant
21. May 2012, FreibergPage 8© Siemens AG 2011
Energy Sector
Siemens Fuel Gasification Technology: Application Fields - Cooling screen reactor
HighlightsSFG Gasifier
o ve rflo wW a te r
G a s o u tle t
C o o lin g ja c ke t
O xy g e n , s te a mF u e l
P re ssu r. w a te ro u tle t
B u rn e r
G ra n u la te d s la g
C o o lin g sc re e n
P re s su r. w a te r
Q u e n chw a te r
in le t
Multi-fuel gasifier (standard 500 MWth) accepts a wide variety of fuels with ash content of > 3%compact size compared to other gasifiersAbility to supply syngas at higher pressuresNo ash to handle (only solid slag as saleable by-product)
Dry feeding (entrained flow)high efficiencyhigh carbon conversion rate (> 98%)
Cooling screenshort start-up / shut-down low maintenance (lifetime > 10 years)high availability
Full quenchsimple and reliableideal for CO sour shiftHigh syngas quality (free of tar)Minimal efforts in gas cleaning
21. May 2012, FreibergPage 9© Siemens AG 2011
Energy Sector
New Application Fields and Business Model with HRSG
FT Synthesis
Methanol Synthesis
Ammonia Production
Syngas(CO + H2)
Power
Transportationfuels
Methanol
Ammonia / Fertilizer
SNG
Coal
Lignite
Power Island
Chemicals and Synfuel Production
Fuel Gas Island Applications
Fuel preparation
Petcoke
Air Separation Unit
Gasifier Island
Gasifier
CO Shift(optional)
Sulfur Removal
CO2 Removal(optional)
Refinery residues
Biomass
Siemens Basic Engineering & Design Siemens Supply of Key Equipment Siemens EPC
Hydrogen
SNG Production
Third Party Scope for FEED and EPC
Gas turbineSteam turbine
Generator
Combined Cycle
Steam Drum and Steam Circuit incl.
Pumps
Feed Water
Steam
HRSG - Heat Recovery Steam Generator
21. May 2012, FreibergPage 10© Siemens AG 2011
Energy Sector
Project Organization ChartGermany Government ( BMWI / PTJ )
funded R&D Project COORETEC
21. May 2012, FreibergPage 11© Siemens AG 2011
Energy Sector
TEIMAB Project Time Schedule
21. May 2012, FreibergPage 12© Siemens AG 2011
Energy Sector
Step 1: Variation of Main Tech. Sys. Gasification Island
L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
K
J
I
H
G
F
E
D
C
B
A
L
K
J
I
H
G
F
E
D
C
B
A
13 14 15 16
Distribution and reproduction of this document, use and disclosure of the contents are prohibited, unless specifically authorized. Contraventions will be indemnified. All patent rights on registered designs are reserved.
UNID
Checked Date: Name: Approved Date: Name: Scale Drawingdimension
Drawn Date: Name: Prepared Date: Name: Rev.Index
Description Drawing Number
Project Project Number
Customer SIEMENSFuel Gasification
Technology GmbH
2009-02-11
2009-02-11
2009-02-11
2009-02-11
T. Fleischer
R. Schumann
T. Fleischer
C. Reuther
P01
- -
F&E TEIMAB
SIEMENS AG
Index Revisions Drawn Checked Approved Date
P01 Preliminary T. Fleischer R. Schumann C. Reuther 2009-02-11
PRELIMINARY12
1 OSBL2 ISBL (SIEMENS)
Notes:- not all minor equipment is shown on the PFDs
Battery Limit Gasifier IslandCONFIDENTIAL
PFD -Variante A
0009WC UT290-???
Cooling Water2039
0008WCR
290-????
Cooling Water2039
0002WBM UT290-????
0001WBL UT290-????
0014SL Header280-????
0005NH UT
280-????
0006GX UT
280-????
0018BW Flash1261-0001
0017 GR Gas Scrubber
251-0001
0019 WS Slag Discharge
241-???
0007CD Feeding
221-????
13-03
13-05
13-04
13-02
FC
0004FG UT
290-????FC
BCC Fine FilterF-23101
BCC PumpP-23101 A/B
13-19
PC
13-18
LC
CJ PumpP-23104 A,B
LCE
Quench Water FilterF-23103 A/B
0011CG K/O Drum
251-0001
0010WQ Venturi251-0001
Quench Water PumpP-23103 A/B/C
LCD
Gasifier Line 1PROCESS FLOW DIAGRAM
13-25
13-10
13-26
0013SL Heater280-????
FC
GasifierR-23101
0016WBH ????
?????
0015SH ?????????
2310-001
0012WK ????290-???? 2310-015
2310-014
2310-013
Quench Water VesselD-23103
2310-016
2310-017
2310-001
Emergency Quench Water VesselD-23105
CJ CoolerE-23104
CJ DrumD-23104
231 - 0001
2310-030
2310-032
2310-033
0003SI UT
290-????
BURNERB-23101
BCC CoolerE-23101
BCC DrumD-23101
CSC PumpP-23102 A,B/C
CSC Steam DrumE-23102
CSC DrumD-23102
L
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8 9 10 11 12
K
J
I
H
G
F
E
D
C
B
A
L
K
J
I
H
G
F
E
D
C
B
A
13 14 15 16
Distribution and reproduction of this document , use and disclosure of the contents are prohibited , unless specifically authorized . Contraventions will be indemnified. All patent rights on registered designs are reserved .
UNID
Checked Date: Name: Approved Date: Name: Scale Drawingdimension
Drawn Date: Name: Prepared Date: Name: Rev.Index
Description Drawing Number
Project Project Number
Customer SIEMENSFuel Gasification
Technology GmbH
2009-02-11
2009-02-11
2009-02-11
2009-02-11
T. Fleischer
R. Schumann
T. Fleischer
C. Reuther
P01
- -
F&E TEIMAB
SIEMENS AG
Index Revisions Drawn Checked Approved Date
P01 Preliminary T.Fleischer R.Schumann C.Reuther 2009-02-11
PRELIMINARY12
1 OSBL2 ISBL (SIEMENS)
Notes:- not all minor equipment is shown on the PFDs
Battery Limit Gasifier IslandCONFIDENTIAL
PFD -Variante B
Cooling Water????
Cooling Water????
Cooling Water????
Black Water fromGasifier
231-0001
Black Water toBlack Water Treatment
270-0003
Vent Gas toBWT Plant270-0003
Flash Condensate toBWT Plant270-0003
Black Water toBlack Water Treatment
270-0003
Flash System Line 1PROCESS FLOW DIAGRAM
425 861 477
261 - 0001
Cooling Water2039
Cooling Water2039
Vent Gas toBlack Water Treatment
270-0003
Cooling Water????
Wash Water from Gas Cleaning
251-0001
E
LC
LC
PC
Flash 1D-2610101
Flash 2D-2610102
Flash Cooler DrumD-2610202
E
PU Flash ValvesPU-2610001
Flash Bypass DrumD-2610402
Flash PumpP-2610103A/B
Flash Bypass CoolerE-2610401A/BFlash Bypass Cooler
E-2610401A/B
2610-008
2610-009
2610-016
2610-007
Flash Cooler 1E-2610201
2610-005
2610-006
2610-013
Vacuum PumpC-2610303A/B
Separator DrumVacuum PumpD-2610304A/B
Cooler Vacuum PumpE-2610305A/B
2610-010
2610-014
Flash Cooler 2E-2610301
2600-009
2600-008
2600-007
PU Flash ValvesPU-2610001
2610-012 2610-015
2610-011
2600-015
2600-010
2610-002
2610-003
2610-004
2610-001
2610-017
PU Flash ValvesPU-2610001
Comparison of ProcessModells:
Variant A:
Variant B:
21. May 2012, FreibergPage 13© Siemens AG 2011
Energy Sector
Step 2 Thermodynamic Investigation
IGCC Performance Data for Heat Recovery Systems (Variants Example)
Results:
• generation of HP steam it’s
a large efficiency advantage
in relation to IP steam
generation
• efficiency improvement
between 1.4 and max. 1.9 %
points for the variants
• comparing the two cooler
types, the radiant cooler
shows a slight efficiency
advantage
Therefore, the thermodynamic results did not lead to a clear decision criterion for concept selection.
21. May 2012, FreibergPage 14© Siemens AG 2011
Energy Sector
HRSG Step 3 Comparison of Design Concepts
Investigation:
• Process integration
• Additional CAPEX
and OPEX
3D Detail studies
21. May 2012, FreibergPage 15© Siemens AG 2011
Energy Sector
Step 4 Technical Assessment and Decision
Development criterias technical evaluation:
• New Equipment necessary ?
• Availibility of new equipment ?
• Range of load control ?
• Risk of fouling and scaling ?
• Cleaning possibilities of new equipment ?
SFGT Gasifier extended by a Radiant Cooler promises
• lowest complexity
• use proven design with full quench and wet gas cleaning
• offers a high efficiency for future IGCC plants ( > 1.5 % )
21. May 2012, FreibergPage 16© Siemens AG 2011
Energy Sector
SFGT Gasifier with Heat Recovery
Radiant Cooler followed by full quench of raw gasEfficient use of the high temperature heat in the steam generator for HP steam generation High raw gas water content benefits CO-shiftProven reactor and quench design extended by Radiant Cooler
Design features
Efficiency improvement potential:IGCC w/o CO2 capturePlant net efficiency ca. + > 3,5 %(depends upon coal type, water/steam condition, gas turbine)
IGCC with CO2 capturePlant net efficiency ca. + > 1.5 %(depends upon process conditions of CO-shift, coal type, water/steam condition)
Fuel, oxygen, steam
Granulated slag
Cooling screen
Quench water
Heating surface
Pressure vessel
Raw Gas outlet
21. May 2012, FreibergPage 17© Siemens AG 2011
Energy Sector
University Partner Scope LUAT CFD Modelling
Verification and Validation of Submodels
100 %70 % 105 %1.00
[-] < 0.01
related heatflux
outer wall
inner walls
0.40
[-] < 0.01
related heatflux
•Selection of suitable material for the walls dependingon heat load
•Find an appropriate cleaning system for the wallsdepending on particle load
• Ensure the process parameter
• Sensitive study on water nozzle angles•Selection of suitable material for the walls dependingon heat load
•Find an appropriate cleaning system for the wallsdepending on particle load
21. May 2012, FreibergPage 18© Siemens AG 2011
Energy Sector
→ Risk and cost reduction of mega coal to chemical plants
→ Where: support of China pioneers mega CTL and CTO technologies
→ Have a possibility to integrate a HRSG in Siemens SFGT Gasifier ifprofitable
→ Maximum product flexibility: chemicals/liquid fuels ↔ electricity
→ Long terme issues: attractive for peak load and energy storage
→ Energy storage by importing renewable power to balance auxiliary power consumption
Conclusion And Siemens SFGT Future Opportunities
Current and future application for coal gasification with polygeneration concepts worldwide with the option to implement a radiant cooler
21. May 2012, FreibergPage 19© Siemens AG 2011
Energy Sector
Thank you for your attention!
NCPP | Large Coal to Chemical Plant in China
“A Winner Is A Dreamer Who Never Gives Up “
Nelson Mandela
21. May 2012, FreibergPage 20© Siemens AG 2011
Energy Sector
This document contains forward-looking statements and information – that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on the SEC’s website, www.sec.gov. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated.
Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.
Disclaimer