Advancements in Slurry Gasification

Transcription

1 Advancements in Slurry Gasification Jason Crew, General Manager GE Power & Water, Gasification International Advanced Coal Technologies Conference 2012 Xi an June 4, 2012

2 Gasification is energy conversion Fuel Gasification system Downstream Solids Coal Pet coke Low rank coal Biomass Fuel Prep Heat Recovery Methanol Oxochemicals Gas Low-cost NG Off-gases Liquids Oil Residues O 2 Cleanup Hydrogen Ammonia Liquid Fuels Substitutes e.g. Direct Liquefaction, SMR 2

3 Installed fleet by the numbers GE has 145 gasifiers in commercial operation the largest fleet in the industry with 85 additional gasifiers in design, engineering, or construction at 25 plants and a global presence in 15 different countries. 3

4 Licensed fleet growth in China since 2010 Methanol & Derivatives Ammonia & Urea Coal Coke Oil Hydrogen & Other In Operation In Design/Construction 4

5 Historical factors driving China growth Low cost, flexible, highly reliable technology Proven at scale & pressure Credible technology introduction process Strong DI relationships Highly localized hardware Broad installed base with capable operators Short build cycle 36 mo contract to first-fire 12FYP all of this + greater capital and operating efficiency more advanced 5

6 Slurry vs. Dry Feed for entrained flow Slurry-Fed Entrained Flow Gasification Coal is ground and mixed with water & additives to form a slurry typical concentrations between 55-70%. Benefits/challenges Highly scalable in pressure & throughput Low cost and highly reliable Highly flexible operating capability Traditional slurry prep technology not well suited for higher moisture coals Higher water consumption Lower thermal efficiency Dry-Fed Entrained Flow Gasification Coal is ground and conveyed directly to the gasifier. Advanced cooling systems manage temp/slagging. Benefits/challenges Higher thermal efficiency Lower water consumption Suitable for higher moisture coals Throughput & pressure scale costly and difficult. Higher capital cost & lower reliability Low operating flexibility particularly sensitive to feedstock changes. How do we enhance slurry-fed technology while retaining its benefits? 6 GE Title or job number 6/15/2012

7 Technology Advancement: Scaled gasifier 450 cuft 900 cuft 1,800 cuft Significant CAPEX reduction Optimized performance Minimized entrainment Proven in US IGCC Can reduce project risk 10-15% reduction in CAPEX 7

8 Technology Advancement: High Pressure Gasification Syngas Compressor Shift / Cooling MeOH Synthesis Acid Gas Remova l AGR MeOH GE s HP Quench Gasification Technology: Pressures up to 87 bar 5 10% reduction in MeOH cost Syngas compression Aux Loads, MP, LP Steam for shift / AGR 5% reduction in coal to MeOH capex Number of trains HFO, Vac Resid, NG, and coal experience Syngas 87 bar GE O&G Expander MeOH Production Syngas 5%-10% MeOH cost 5% capex + Up to 18 MW per train Electricity 5-10% reduction in methanol cost + creation of 18MW of internal power 8

9 Technology Advancement: RSC for HP steam Tamp a Tampa Soot blower Deposits 坦 帕 灰 吹 扫 处 理 Tampa Tube Cage Leak RCA 坦 帕 管 笼 泄 漏 的 故 障 根 源 分 析 Soot-blowers Removed from new configuration 除 灰 器 -- 新 装 置 上 去 除 了 Performance 30% increase in steam production through surface enhancements & increased steam & hot gas pressure 性 能 - 通 过 增 加 换 热, 增 加 蒸 汽 和 热 气 压 力 提 高 30% 的 蒸 汽 产 能 Size 9 ft longer, same weight, and 2ft smaller diameter 尺 寸 - 加 长 了 9 英 尺, 相 同 的 重 量 和 直 径 缩 小 2 英 尺 Seal/N2 Purge - Enhanced for robust operation and RAM 密 封 /N2 吹 扫 - 增 加 了 操 作 性 及 可 靠 性, 可 用 性 及 可 维 护 性 Convective Cooler - Removed to increase availability 取 消 了 对 流 冷 却 器 增 加 可 用 性 Experience Based Improvements 在 经 验 基 础 上 的 改 进 Inlet Fouling Coating sample clean Internal Quench experience based configuration, favorable for sealing 内 部 激 冷 - 基 于 经 验 的 配 置, 有 利 于 密 封 9

10 Control systems 控 制 系 统 Physics-based models for dynamic plant control 机 理 模 型 用 于 工 厂 动 态 控 制 Plant simulator for optimization & operator training 工 厂 模 拟 器 用 来 优 化 和 操 作 员 培 训 Combined hardware + software testing & deployment 整 合 硬 件 + 软 件 测 试 和 调 度 10

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