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Gasification Plant Cost and Performance Optimization.
Final Report - September 2003

Bechtel Corporation
Global Energy Inc.
Nexant Inc.

In this pdf format, this document has 79 pages and is 2.6MB.

Table of Contents

EXECUTIVE SUMMARY

 

Executive Summary

ES-1
 

INTRODUCTION

I

Background

1
 

1.1

Introduction

1

1.2

Contract Overview

2
 

EXPERIMENTAL

II

Methodology

8
 

II.1

The Wabash River Repowering Project

8

II.2

Optimization Methodology

9

II.3

Availability Analysis

9

II.4

Commodity Pricing

11

II.5

Financial Analysis

13
 

RESULTS AND DISCUSSION

III

Task 1 Gasification Plants

14
 

III.1

Wabash River Greenfield Plan

14

III.2

Petroleum Coke IGCC Coproduction Plant

15

III.3

Optimized Petroleum Coke IGCC Coproduction Plan

15

III.4

Next Optimized Petroleum Coke IGCC Coproduction Plant

16

III.5

Advanced IGCC Coal Power Plant

17

III.6

Single Train Coal and Coke IGCC Power Plants

17

III 7

Nominal 1,000 MW Coal IGCC Power Plant

18

III 8

Coal to Hydrogen Plant

19

IV

Task 2 Gasification Coproduction Plants

23
 

IV.1

Non-Optimized Coke Gasification Power Plant with Liquids Coproduction

23

IV.2

Optimized Coke Gasification Power Plant with Liquids Coproduction

24

IV.3

Optimized Coal Gasification Power Plant with Liquids Coproduction

25

V

Emissions

28

VI

Financial Results

31
 

VI.1

Introduction

31

VI.2

Petroleum Coke IGCC Coproduction Plants

31

VI.3

Coal and Petroleum Coke IGCC Power Plants

35

VI.4

Coal to Hydrogen Plant

40

VI.5

Petroleum Coke IGCC Power Plants with Liquids Coproduction

41

VI.6

Coal IGCC Power Plant with Liquids Coproduction

45
 

CONCLUSION

VII

Summary, Conclusions and Recommendations

50
 

VII.1

Summary

50

VII.2

Conclusions

55

VII.3

Recommendations

56
 

REFERENCES

VIII

References

57

IX

List of Acronyms and Abbreviations

58

X

Acknowledgements

61
 

LIST OF TABLES

I.1

Task 1 Coal and Coke Gasification Plant Case Summaries

5

I.2

Task 2 Coal and Coke Gasification Plant Case Summaries

6

II.1

Basic Economic Parameters

12

VI.1

Comparison of the Subtask 1.2 and Subtask 1.3 Petroleum Coke IGCC Coproduction Plants

33

VI.2

Design and Daily Average Feed and Product Rates for the Subtask 1.1, 1.4 1.5A and 1.6 Coal IGCC Power Plants

37

VI.3

Design and Daily Average Feed and Product Rates for the Subtask 1.5A Coal and Subtask 1.5B Coke IGCC Power Plants

38

VI.4

Return on Investment and Required Power Selling Prices for the Subtask 1.3 Next Plant, Subtask 2.1 and Subtask 2.2

43

VI.5

Required Power Selling Prices for the Subtask 1.6 Power Plant and the Subtask 2.3 Optimized Coal Gasification Power Plant with Liquids Coproduction with and without Backup Natural Gas

47
 
LIST OF FIGURES

I.1

Schematic Diagram Showing the Chronological Development of the Gasification Plant Designs

7

III.1

Subtask 1.1 Wabash River Greenfield Plant - Simplified Block Train Diagram

20

III.2

Subtask 1.2 Petroleum Coke IGCC Coproduction Plant - Simplified Block Train Diagram

20

III.3A

Subtask 1.3 Optimized Petroleum Coke IGCC Coproduction Plant - Base Case Simplified Block Train Diagram

20

III.3B

Subtask 1.3 Optimized Petroleum Coke IGCC Coproduction Plant - Minimum Cost Case - Simplified Block Train Diagram

21

III.3C

Subtask 1.3 Optimized Petroleum Coke IGCC Coproduction Plant - Spare Train Case - Simplified Block Train Diagram

21

III.4

Subtask 1.3 Next Optimized Petroleum Coke IGCC Coproduction Plant - Simplified Block Train Diagram

21

III.5

Subtask 1.4 Advanced IGCC Coal Power Plant - Simplified Block Train Diagram

22

III.6

Subtask 1.5 Single-Train Coal or Coke IGCC Power Plant - Simplified Block Train Diagram

22

III.7

Subtask 1.6 Nominal 1,000 MW Coal IGCC Power Plant - Simplified Block Train Diagram

22

III.8

Subtask 1.7 Coal to Hydrogen Plant - Simplified Block Train Diagram

22

IV.1

Subtask 2.1 Coke Gasification Power Plant with Liquids Coproduction

26

IV.2

Subtask 2.2 Optimized Coke Gasification Power Plant with Liquids Coproduction

27

IV.3

Subtask 2.3 Optimized Coal Gasification Power Plant with Liquids Coproduction

27

VI.1

Design and Daily Average Coke Consumptions for Subtask 1.2 and Subtask 1.3 Petroleum Coke IGCC Coproduction Plants

34

VI.2

Return on Investment vs. Power Selling Price for the Subtask 1.2 and Subtask 1.3 Petroleum Coke IGCC Coproduction Plants

34

VI.3

Return on Investment vs. Power Selling Price for the Subtask 1.1, 1.4, 1.5A and 1.6 Coal IGCC Power Plants

39

VI.4

Effect of Syngas Availability on the Required Power Selling Price for a 12% Return on Investment for the Subtask 1.6 Coal IGCC Power Plant

39

VI.5

Return on Investment vs. Hydrogen selling Price for the Subtask 1.6 Coal to Hydrogen Plant

40

VI.6

Effect of Hydrogen Availability on the Required Hydrogen Selling Price for a 12% Return on Investment for the Subtask 1.6 Plant

41

VI.7

Return on Investment vs. Power Price for the Subtask 2.1 [Non-optimized] and Subtask 2.2 Optimized Coke Gasification Power Plants with Liquids Coproduction and the Subtask 1.3 next Optimized Petroleum Coke IGCC Coproduction Plant

44

VI.8

Return on Investment vs. Power Price Showing the Effect of the Liquids Price for the Subtask 2.2 Optimized Coke Gasification Power Plant with Liquids Coproduction

44

VI.9

Return on Investment vs. Syngas Availability for the Subtask 2.1 [Non-optimized] and Subtask 2.2 Optimized Coke Gasification Power Plants with Liquids Coproduction and the Subtask 1.3 Next Optimized Petroleum Coke IGCC Coproduction Plant

45

VI.10

Return on Investment vs. Power Price for the Subtask 2.3 Optimized Coal Gasification Power Plant with Liquids Coproduction and the Subtask 1.6 Nominal 1,000 MW Coal IGCC Power Plant

48

VI.11

Return on Investment vs. Power Price Showing the Effect of the Liquids Price for the Subtask 2.3 Optimized Coal Gasification Power Plant with Liquids Coproduction and the Subtask 1.6 Coal IGCC Power Plant

48

VI.12

Effect of Syngas Availability on the Required Power Selling Price for a 12% Return on Investment for the Subtask 2.3 Optimized Coal Gasification Power Plant with Liquids Coproduction and the Subtask 1.6 Power Plant

49