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WO1997039235A1 - Synergistic integration of physical solvent agr with plants using gasification - Google Patents

Synergistic integration of physical solvent agr with plants using gasification Download PDF

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Publication number
WO1997039235A1
WO1997039235A1 PCT/US1997/005715 US9705715W WO9739235A1 WO 1997039235 A1 WO1997039235 A1 WO 1997039235A1 US 9705715 W US9705715 W US 9705715W WO 9739235 A1 WO9739235 A1 WO 9739235A1
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WO
WIPO (PCT)
Prior art keywords
unit
gas
turboexpander
fuel gas
ofthe
Prior art date
Application number
PCT/US1997/005715
Other languages
French (fr)
Inventor
Ashok Rao
Original Assignee
Fluor Corporation
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Filing date
Publication date
Application filed by Fluor Corporation filed Critical Fluor Corporation
Priority to AU24440/97A priority Critical patent/AU2444097A/en
Publication of WO1997039235A1 publication Critical patent/WO1997039235A1/en

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B43/00—Engines characterised by operating on gaseous fuels; Plants including such engines
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04527—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general
    • F25J3/04539—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general for the H2/CO synthesis by partial oxidation or oxygen consuming reforming processes of fuels
    • F25J3/04545—Integration with an oxygen consuming unit, e.g. glass facility, waste incineration or oxygen based processes in general for the H2/CO synthesis by partial oxidation or oxygen consuming reforming processes of fuels for the gasification of solid or heavy liquid fuels, e.g. integrated gasification combined cycle [IGCC]
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04563—Integration with a nitrogen consuming unit, e.g. for purging, inerting, cooling or heating
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04563—Integration with a nitrogen consuming unit, e.g. for purging, inerting, cooling or heating
    • F25J3/04575—Integration with a nitrogen consuming unit, e.g. for purging, inerting, cooling or heating for a gas expansion plant, e.g. dilution of the combustion gas in a gas turbine
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04593—The air gas consuming unit is also fed by an air stream
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04593—The air gas consuming unit is also fed by an air stream
    • F25J3/04606—Partially integrated air feed compression, i.e. independent MAC for the air fractionation unit plus additional air feed from the air gas consuming unit
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04612—Heat exchange integration with process streams, e.g. from the air gas consuming unit
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J3/00—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification
    • F25J3/02—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream
    • F25J3/04—Processes or apparatus for separating the constituents of gaseous or liquefied gaseous mixtures involving the use of liquefaction or solidification by rectification, i.e. by continuous interchange of heat and material between a vapour stream and a liquid stream for air
    • F25J3/04521—Coupling of the air fractionation unit to an air gas-consuming unit, so-called integrated processes
    • F25J3/04612—Heat exchange integration with process streams, e.g. from the air gas consuming unit
    • F25J3/04618—Heat exchange integration with process streams, e.g. from the air gas consuming unit for cooling an air stream fed to the air fractionation unit
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F25—REFRIGERATION OR COOLING; COMBINED HEATING AND REFRIGERATION SYSTEMS; HEAT PUMP SYSTEMS; MANUFACTURE OR STORAGE OF ICE; LIQUEFACTION SOLIDIFICATION OF GASES
    • F25J—LIQUEFACTION, SOLIDIFICATION OR SEPARATION OF GASES OR GASEOUS OR LIQUEFIED GASEOUS MIXTURES BY PRESSURE AND COLD TREATMENT OR BY BRINGING THEM INTO THE SUPERCRITICAL STATE
    • F25J2260/00—Coupling of processes or apparatus to other units; Integrated schemes
    • F25J2260/42—Integration in an installation using nitrogen, e.g. as utility gas, for inerting or purging purposes in IGCC, POX, GTL, PSA, float glass forming, incineration processes, for heat recovery or for enhanced oil recovery
    • F25J2260/44—Integration in an installation using nitrogen, e.g. as utility gas, for inerting or purging purposes in IGCC, POX, GTL, PSA, float glass forming, incineration processes, for heat recovery or for enhanced oil recovery using nitrogen for cooling purposes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00—Combustion technologies with mitigation potential
    • Y02E20/16—Combined cycle power plant [CCPP], or combined cycle gas turbine [CCGT]
    • Y02E20/18—Integrated gasification combined cycle [IGCC], e.g. combined with carbon capture and storage [CCS]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/30—Use of alternative fuels, e.g. biofuels

Definitions

  • the present invention relates to integrated gasification power generation plants.
  • Coal gasification plants offer numerous benefits relative to plants which utilize direct combustion of coal.
  • Two promising technologies which integrate coal-gasification with power production include the Integrated Coal Gasification Combined Cycle (IGCC) design and the Integrated Coal Gasification Fuel Cell (IGFC) design.
  • IGCC Integrated Coal Gasification Combined Cycle
  • IGFC Integrated Coal Gasification Fuel Cell
  • fuel gas is produced by partial oxidation of coal, and the fuel gas is then cleaned through reduction of particulates and sulphur containing compounds.
  • the cleaned fuel gas is then combusted in a combustion turbine to generate electric power
  • a typical IGFC plant the cleaned fuel gas is oxidized in the fuel cell to generate the electric power.
  • the term IGCC shall be used generically hereinafter to include all manner of gasification power plants, including both IGCC and IGFC plants, and plants which gasify fuels other than coal.
  • IGCC plants Three important objectives in designing IGCC plants are (1) minimization of pollution; (2) maximization of plant reliability and (3) maximization of energy production relative to capital and fuel costs.
  • H 2 S hydrogen sulfide
  • SO 2 sulfur sulfide
  • both H : S and SO 2 are considered pollutants, and their release into the atmosphere is often restricted by regulation. Since H 2 S in a gasifier effluent typically reaches several thousand parts per million (ppm), and may reach levels of 10,000 to 30.000 ppm or more, some method of desulphurization must be used.
  • IGCC designs have been proposed in which high pressure gasification is combined with direct contact cooling (water quenching) ofthe raw gasifier effluent, and a hot gas turboexpander (which may also be referred to herein simply as an expander) to develop additional power by expanding the gas upstream ofthe combustion turbine.
  • a hot gas turboexpander which may also be referred to herein simply as an expander
  • Such systems can be broadly classified into two categories, (A) those in which the turboexpander is positioned upstream ofthe AGR (the so-called Texaco design of Anand, Jahnke and Olson.
  • a sulphur containing fluid is desulphurized in a desulphurization unit to produce a clean gas.
  • the clean gas is power producingly expanded in an expander to provide refiigeration to the desulpherization unit, and there is at least one intervening process unit other than a heat exchanger with the sulphur containing fluid functionally positioned between the desulphurization unit and the expander.
  • the intervening process unit comprises a membrane separator, synthesis unit or other device involved in coproduction.
  • the intervening process unit comprises a heat exchanger with cold nitrogen expanded downstream of an elevated pressure air separation unit.
  • Figure 1 is a simplified block flow diagram of an IGCC plant according to the present invention.
  • Figure 2 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having a two-stage turboexpander.
  • Figure 3 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having an air separation unit.
  • Figure 4 is a simplified block flow diagram of an IGCC plant according to the present invention.
  • Figure 5 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having a two-stage turboexpander.
  • Figure 6 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having an air separation unit.
  • Figure 1 generally depicts an IGCC plant 1 comprising a feed line 10 containing high pressure raw scrubbed fuel gas, a low temperature gas cooling unit 20, an acid gas removal unit 30, intervening drying unit 40, a turboexpander 50 with associated electrical generator 55, a solvent chiller 60, a humidification/ preheating unit 70, and a combustion turbine 80.
  • Line 10 contains raw scrubbed fuel gas from a gasifier unit (not shown).
  • the gasifier gasifies coal, coke or oil, but in alternative embodiments it may gasify other substances.
  • Many different gasifiers could be utilized, including Texaco, Shell and Noell.
  • the fuel gas in line 10 preferably has a pressure of about 900 - 1200 PSIA, in the case of an IGCC and a temperature of about 300 to 500 °F.
  • Low temperature gas cooling unit 20 cools the high pressure gas from line 10 to about
  • Preferred gas cooling units include a series of heat exchangers.
  • Line 22 carries the cooled high pressure fuel gas from the gas cooling unit 20 to a cold-type, solvent based acid gas removal unit (AGR) 30.
  • AGRs remove at least 98% ofthe sulphur from the fuel gas, and include those utilizing Selexol, Rectesol or Purisol solvents because these utilize a refrigerated physical solvent.
  • preferred AGR units include absorber(s) and stripper(s). Sulphur is preferably recovered from the acid gas produced in the AGR using a sulphur recovery unit (not shown), thereby regenerating the solvent.
  • Line 32 carries the high pressure sweet fuel gas from the AGR 30 to the drying unit 40 when required, where humidity is reduced to a dew point temperature which is lower than the exhaust temperature ofthe turboexpander.
  • Preferred drying units include molecular sieves.
  • Dried fuel gas leaving the drying unit 40 preferably has a pressure of about 800 to 1100 PSIA. and is carried to the turboexpander via line 42.
  • the dried fuel gas is then expanded in turboexpander 50. which produces usable power by driving generator 55. Rather than producing electricity, generator 55 could, for example, be replaced with a compressor.
  • the fuel gas in line 52 would preferably have a temperature of less than 0°F.
  • Lines 34 and 36 carry solvent between the AGR unit 30 and the chiller 60.
  • heat from the solvent in line 36 is transferred to the fuel gas from line 52, increasing the temperature ofthe fuel gas to about 60 °F.
  • the temperature ofthe solvent is reduced from about 90°F to about 25 °F in the case of Selexol.
  • Line 54 carries fuel gas from the chiller 60 to the humidification/preheating unit 70.
  • This unit is optional, and may perform either or both of humidification and preheating functions.
  • Preferred units include a countercurrent packed column and a heat exchanger.
  • Line 72 carries the fuel gas from the humidification/ preheating unit 70 to the combustion turbine 80 where it is combusted, and the combustion products are expanded to produce usable work.
  • the fuel gas may be shghtly preheated before entering the expander such that the gas leaving the chiller does not remain at very low temperatures. This allows optimizing the power developed by the expander and the amount of refrigeration developed.
  • FIG. 2 shows an alternative IGCC design in which the single stage turboexpander 50 of figure 1 has been replaced by a two-stage turboexpander having first stage turboexpander 150A and second stage turboexpander 150B.
  • high pressure scrubbed raw fuel gas would still be produced by a gasifier (not shown), the scrubbed raw fuel gas would enter a low temperature gas cooling unit 120 through line 110, be transferred to an AGR unit 130 via line 122, and then be transferred to an intervening drying unit 140 (when required) via line 132.
  • the fuel gas would then be expanded in the first stage turboexpander 140A, and then transferred to a first solvent chiller 160A.
  • first chiller 160A the fuel gas would undergo heat exchange with solvent flowing through lines
  • an another alternative IGCC plant generally comprises a gasifier unit (not shown), an elevated pressure air separation unit (EP ASU) 211, a physical solvent acid gas removal unit 230, a saturator 270 and a combustion turbine 280.
  • Air separation unit 21 1 produces predominantly oxygen (O 2 ) and nitrogen (N 2 ) streams.
  • the oxygen stream is carried to the gasifier unit (not shown) via line 212.
  • the nitrogen stream is carried along line 214, with a portion ofthe nitrogen being compressed by compressor 215, and then fed into the combustion turbine 280 via line 216.
  • the remainder of the nitrogen is expanded in the nitrogen expander 250, run through a heat exchanger 250, and then either vented to the atmosphere or drawn into the air inlet 282 ofthe combustion turbine 284
  • Raw scrubbed gas from the gasifier unit enters the AGR unit 230 along line 210.
  • the AGR solvent is carried along lines 234 and 236 to the heat exchanger, where it is cooled by heat exchange against the expanded nitrogen. Sulphur removal is provided along line 238.
  • the cleaned (desulphurized) fuel gas is then carried along line 232 to humidifier (saturator) 270, if so desired, where it picks up humidity. Circulating water for the saturation step is carried by line 271A and 271B. Following humidification, the fuel gas is then carried along line 272 to heat exchanger 275 where it is preheated with boiler feed water or other means, and finally carried to the combustor 281 ofthe combustion turbine 280.
  • humidifier saturatedator
  • Combusted gases are expanded by turbine 280 to produce electrical power using power using generator 290.
  • a portion ofthe air compressed by compressor 282 can be shunted via line 217 through one or more heat exchangers such as heat exchanger 218A and 218B. and then carried to the air separation unit 211 via line 219.
  • FIG. 3 has many similarities to the embodiments of figures 1 and 2.
  • a working fluid is expanded to a low temperature, and then reheated using heat from the hot solvent ofthe AGR
  • a working fluid already present in the system such as the fuel gas or the nitrogen from an air separation unit
  • a separate refrigeration unit is obviated and increased efficiency and/or reduced capital costs can be realized.
  • the embodiment of Figure 4 is similar to the embodiment of Figure 1 except that the intervening process unit comprises a membrane separator.
  • raw syn gas (used herein interchangeably with fuel gas) enters a desulphurization unit 330 through line 310, and cleaned syn gas would then pass along line 332 to membrane separator 390.
  • Separator 390 could be used to separate out many different compounds, but here membrane separator is used to separate out a low purity H 2 stream.
  • the H 2 stream then proceeds along line 391 to a pressure swing adsorbtion unit 392, which further separates out H 2 from remaining fuel gas.
  • Clean syn gas which was not separated out in the membrane separator 390 passes along line 392 to turboexpander 350 which provides shaft power to generator 355.
  • the turboexpander 350 reduces the temperature ofthe fuel gas, which then proceeds along line 354 to solvent chiller (heat exchanger) 360 which cools solvent a ⁇ iving from the acid gas removal unit 330 along line 336. Cooled solvent then passes back to the acid gas removal unit 330 along line 334.
  • Fuel gas heated up in solvent chiller 360 then passes along line 362 to humidification and preheating units collectively designated 370, and thence along line 372 to a gas turbine or fuel cell.
  • raw syn gas enters a desulphurization unit 430 through line 410. and cleaned syn gas would then pass along line 332 to synthesis unit 495.
  • Synthesis unit 495 can be used to synthesize many different co-products, and can advantageously be used to synthesize hydrocarbons, including oxygen containing hydrocarbons such as methanol.
  • Unconverted clean syn gas passes along line 492 to turboexpander 450 which provides shaft power to generator 455.
  • the turboexpander 450 reduces the temperature ofthe fuel gas, which then proceeds along line 454 to solvent chiller (heat exchanger) 460 which cools solvent arriving from the acid gas removal unit 430 along line 436.
  • Cooled solvent then passes back to the acid gas removal unit 430 along line 434, and fuel gas heated up in solvent chiller 460 passes along line 462 to humidification and preheating units collectively designated 470, and thence along line 472 to a gas turbine or fuel cell.
  • raw syn gas enters a desulphurization unit 630 through line 610, and cleaned syn gas passes along line 632 to first heat exchanger 518.
  • Refrigeration in first heat exchanger 518 is preferably provided by expanding high pressure nitrogen (N 2 ) from an elevated pressure air separation unit (not shown) along line 514, expanding the high pressure
  • the intervening process unit is a heat exchanger intended to pre-cool the fuel gas before it is introduced into the expander
  • the present invention advantageously reduces the gasifier pressure for a given acid gas removal refrigeration duty requirement and a given expanded fuel gas pressure requirement set by the gas turbine model.
  • This fiiel gas pre-cooling feature is expected to become especially useful as the gas turbine technology advances with a resultant increase in the gas turbine pressure ratio.
  • This pre-cooled expansion configuration is also expected to broaden the lower operating range ofthe gasifier pressure and thus, increase the number of gasification technologies or gasifier heat recovery options that may take advantage ofthe cold expander invention.
  • the minimum gasifier pressure required without cooling the syn gas prior to expansion is 1080 psia, whereas by cooling it to 45° F, the gasifier pressure is reduced to about 890 psia.
  • the mmimum gasifier pressure required without cooling the syn gas prior to expansion is approximately 1390 psia, whereas by cooling it to 45° F, the gasifier pressure is reduced to about 1140 psia
  • Texaco recommends 1215 psia as the maximum gasifier pressure

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Power Engineering (AREA)
  • Engine Equipment That Uses Special Cycles (AREA)

Abstract

The gasification portion of an IGCC plant has a desulpherization unit (30) which produces a clean gas (42) which is expanded (50) to provide refrigeration (60) to the desulpherization unit (30). Preferred embodiments include an intervening process unit which comprises a membrane separator (390), synthesis unit (391, 495), or a heat exchanger (260) with cold nitrogen expanded (250) downstream of an air separation unit (211).

Description

SYNERGISTIC INTEGRATION OF PHYSICAL SOLVENT AGR WITH PLANTS USING GASIFICATION
I. FIELD OF THE INVENTION
The present invention relates to integrated gasification power generation plants.
H. BACKGROUND OF THE INVENTION
Coal gasification plants offer numerous benefits relative to plants which utilize direct combustion of coal. Two promising technologies which integrate coal-gasification with power production include the Integrated Coal Gasification Combined Cycle (IGCC) design and the Integrated Coal Gasification Fuel Cell (IGFC) design. In such plants, fuel gas is produced by partial oxidation of coal, and the fuel gas is then cleaned through reduction of particulates and sulphur containing compounds. In a typical IGCC plant the cleaned fuel gas is then combusted in a combustion turbine to generate electric power, whereas in a typical IGFC plant the cleaned fuel gas is oxidized in the fuel cell to generate the electric power. For the sake of convenience, the term IGCC shall be used generically hereinafter to include all manner of gasification power plants, including both IGCC and IGFC plants, and plants which gasify fuels other than coal.
Three important objectives in designing IGCC plants are (1) minimization of pollution; (2) maximization of plant reliability and (3) maximization of energy production relative to capital and fuel costs.
The sulphur content in coal and other carbonaceous fuels poses significant problems with respect to all three objectives. In gasification plants sulfur is largely converted to hydrogen sulfide (H2S)which is subsequently converted to SO2 in the combustor ofthe combustion turbine. This is problematic in that most fuel cells cannot tolerate any sulfur compounds in the fuel gas. Moreover, both H:S and SO2 are considered pollutants, and their release into the atmosphere is often restricted by regulation. Since H2S in a gasifier effluent typically reaches several thousand parts per million (ppm), and may reach levels of 10,000 to 30.000 ppm or more, some method of desulphurization must be used. Finally, desulphurization imposes significant costs on the system, both in terms ofthe capital costs of sulphur removal equipment and in terms of overall operating efficiency. In the last few years IGCC designs have been proposed in which high pressure gasification is combined with direct contact cooling (water quenching) ofthe raw gasifier effluent, and a hot gas turboexpander (which may also be referred to herein simply as an expander) to develop additional power by expanding the gas upstream ofthe combustion turbine. Such systems can be broadly classified into two categories, (A) those in which the turboexpander is positioned upstream ofthe AGR (the so-called Texaco design of Anand, Jahnke and Olson. High Efficiency Quench Gasification Combine-Cycles with Integrated Air Separation, presented at an EPRI conference), and (B) those in which the turboexpander is positioned downstream ofthe AGR (the so-called Humphreys and Glasgow (H&G) design of EP patent no. 384,781). Both the Texaco and H&G designs, however, contain unnecessary inefficiencies in that additional energy is brought into the system to refrigerate the AGR solvent, and the fuel gas is preheated using hot boiler feed water or a hot process stream prior to being expanded in the turboexpander.
A recent improvement describes the expansion of desuphurized gas directly downstream ofthe desulphurizing column, and using the cold gas thus produced to cool the washing hquid and/or the gas which is to be cleaned. (Metallgeselschaft design of EP 0 707 880 Al). This embodiment eliminates some inefficiencies, but fails to consider efficiencies resulting from intermediate process steps between the acid gas removal unit and the expander.
In still other embodiments, it is known to combine an elevated pressure air separation unit (EP ASU) with an IGCC. and to expand a portion ofthe nitrogen to provide shaft power or refrigeration. (U.S. patent no. 5.081.845 to Allam & Topham) There is, however, no disclosure or suggestion in the prior art of using the refrigeration thus obtained to cool the solvent of an acid gas removal unit. The '845 patent, for example, does not even reference the use of an acid gas removal unit.
Thus, there still exists a need to optimize IGCC plants which incorporate a cold type, physical solvent AGR unit.
EQ. SUMMARY OF TELE INVENTION
In the present invention, methods and systems are provided in conjunction with an IGCC plant in which a sulphur containing fluid is desulphurized in a desulphurization unit to produce a clean gas. the clean gas is power producingly expanded in an expander to provide refiigeration to the desulpherization unit, and there is at least one intervening process unit other than a heat exchanger with the sulphur containing fluid functionally positioned between the desulphurization unit and the expander.
In particular preferred embodiments the intervening process unit comprises a membrane separator, synthesis unit or other device involved in coproduction. In other preferred embodiments the intervening process unit comprises a heat exchanger with cold nitrogen expanded downstream of an elevated pressure air separation unit.
IV. BRIEF DESCRIPTION OF THE DRAWING
The present invention will become better understood through a consideration ofthe following description taken in conjunction with the drawing in which:
Figure 1 is a simplified block flow diagram of an IGCC plant according to the present invention.
Figure 2 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having a two-stage turboexpander.
Figure 3 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having an air separation unit.
Figure 4 is a simplified block flow diagram of an IGCC plant according to the present invention.
Figure 5 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having a two-stage turboexpander.
Figure 6 is a simplified block flow diagram of an alternative IGCC plant according to the present invention having an air separation unit.
V. DETAILED DESCRIPTION OF THE DRAWING
Turning now to the drawing, Figure 1 generally depicts an IGCC plant 1 comprising a feed line 10 containing high pressure raw scrubbed fuel gas, a low temperature gas cooling unit 20, an acid gas removal unit 30, intervening drying unit 40, a turboexpander 50 with associated electrical generator 55, a solvent chiller 60, a humidification/ preheating unit 70, and a combustion turbine 80.
Other than the novel configuration shown, the various components and their respective functions will be well-known to those in the art. Line 10 contains raw scrubbed fuel gas from a gasifier unit (not shown). In preferred embodiments, the gasifier gasifies coal, coke or oil, but in alternative embodiments it may gasify other substances. Many different gasifiers could be utilized, including Texaco, Shell and Noell. The fuel gas in line 10 preferably has a pressure of about 900 - 1200 PSIA, in the case of an IGCC and a temperature of about 300 to 500 °F.
Low temperature gas cooling unit 20 cools the high pressure gas from line 10 to about
100 °F. Preferred gas cooling units include a series of heat exchangers.
Line 22 carries the cooled high pressure fuel gas from the gas cooling unit 20 to a cold-type, solvent based acid gas removal unit (AGR) 30. Preferred AGRs remove at least 98% ofthe sulphur from the fuel gas, and include those utilizing Selexol, Rectesol or Purisol solvents because these utilize a refrigerated physical solvent. Specifically, preferred AGR units include absorber(s) and stripper(s). Sulphur is preferably recovered from the acid gas produced in the AGR using a sulphur recovery unit (not shown), thereby regenerating the solvent.
Line 32 carries the high pressure sweet fuel gas from the AGR 30 to the drying unit 40 when required, where humidity is reduced to a dew point temperature which is lower than the exhaust temperature ofthe turboexpander. Preferred drying units include molecular sieves.
Dried fuel gas leaving the drying unit 40 preferably has a pressure of about 800 to 1100 PSIA. and is carried to the turboexpander via line 42. The dried fuel gas is then expanded in turboexpander 50. which produces usable power by driving generator 55. Rather than producing electricity, generator 55 could, for example, be replaced with a compressor.
Gas expanded in turboexpander 50 to a pressure of about 300 to 400 PSIA, is then carried to solvent chiller 60 via line 52. The fuel gas in line 52 would preferably have a temperature of less than 0°F.
Lines 34 and 36 carry solvent between the AGR unit 30 and the chiller 60. At chiller 60, heat from the solvent in line 36 is transferred to the fuel gas from line 52, increasing the temperature ofthe fuel gas to about 60 °F. Concurrently, the temperature ofthe solvent is reduced from about 90°F to about 25 °F in the case of Selexol.
Line 54 carries fuel gas from the chiller 60 to the humidification/preheating unit 70. This unit is optional, and may perform either or both of humidification and preheating functions. Preferred units include a countercurrent packed column and a heat exchanger.
Line 72 carries the fuel gas from the humidification/ preheating unit 70 to the combustion turbine 80 where it is combusted, and the combustion products are expanded to produce usable work.
Alternately, the fuel gas may be shghtly preheated before entering the expander such that the gas leaving the chiller does not remain at very low temperatures. This allows optimizing the power developed by the expander and the amount of refrigeration developed.
Figure 2 shows an alternative IGCC design in which the single stage turboexpander 50 of figure 1 has been replaced by a two-stage turboexpander having first stage turboexpander 150A and second stage turboexpander 150B. In this embodiment high pressure scrubbed raw fuel gas would still be produced by a gasifier (not shown), the scrubbed raw fuel gas would enter a low temperature gas cooling unit 120 through line 110, be transferred to an AGR unit 130 via line 122, and then be transferred to an intervening drying unit 140 (when required) via line 132. Following drying in the drying unit 140, the fuel gas would then be expanded in the first stage turboexpander 140A, and then transferred to a first solvent chiller 160A. At first chiller 160A the fuel gas would undergo heat exchange with solvent flowing through lines
134A and 136A. The fuel gas would then be expanded a second time in second stage turboexpander 150B. and then be transferred to a second chiller 160B where it would undergo heat exchange with solvent carried along lines 134B and 136B. Fuel gas would then leave chiller 160B via line 154, possibly be humidified and/or preheated at humidifier/preheating unit 170, and then carried to combustion turbine 180 via line 172.
In Figure 3. an another alternative IGCC plant generally comprises a gasifier unit (not shown), an elevated pressure air separation unit (EP ASU) 211, a physical solvent acid gas removal unit 230, a saturator 270 and a combustion turbine 280.
Air separation unit 21 1 produces predominantly oxygen (O2) and nitrogen (N2) streams. The oxygen stream is carried to the gasifier unit (not shown) via line 212. The nitrogen stream is carried along line 214, with a portion ofthe nitrogen being compressed by compressor 215, and then fed into the combustion turbine 280 via line 216. The remainder of the nitrogen is expanded in the nitrogen expander 250, run through a heat exchanger 250, and then either vented to the atmosphere or drawn into the air inlet 282 ofthe combustion turbine 284
Raw scrubbed gas from the gasifier unit (not shown) enters the AGR unit 230 along line 210. The AGR solvent is carried along lines 234 and 236 to the heat exchanger, where it is cooled by heat exchange against the expanded nitrogen. Sulphur removal is provided along line 238.
The cleaned (desulphurized) fuel gas is then carried along line 232 to humidifier (saturator) 270, if so desired, where it picks up humidity. Circulating water for the saturation step is carried by line 271A and 271B. Following humidification, the fuel gas is then carried along line 272 to heat exchanger 275 where it is preheated with boiler feed water or other means, and finally carried to the combustor 281 ofthe combustion turbine 280.
Combusted gases are expanded by turbine 280 to produce electrical power using power using generator 290.
Depending on the efficiencies involved, a portion ofthe air compressed by compressor 282 can be shunted via line 217 through one or more heat exchangers such as heat exchanger 218A and 218B. and then carried to the air separation unit 211 via line 219.
It should be apparent, therefore, that the embodiment of figure 3 has many similarities to the embodiments of figures 1 and 2. In all cases a working fluid is expanded to a low temperature, and then reheated using heat from the hot solvent ofthe AGR By using a working fluid already present in the system, such as the fuel gas or the nitrogen from an air separation unit, a separate refrigeration unit is obviated and increased efficiency and/or reduced capital costs can be realized. This contrasts with previously known designs in which the AGR is cooled by a refrigeration unit, the expander of which uses a closed fluid which is not technically upstream ofthe combustion turbine.
The embodiment of Figure 4 is similar to the embodiment of Figure 1 except that the intervening process unit comprises a membrane separator. In this embodiment raw syn gas (used herein interchangeably with fuel gas) enters a desulphurization unit 330 through line 310, and cleaned syn gas would then pass along line 332 to membrane separator 390.
Separator 390 could be used to separate out many different compounds, but here membrane separator is used to separate out a low purity H2 stream. The H2 stream then proceeds along line 391 to a pressure swing adsorbtion unit 392, which further separates out H2 from remaining fuel gas. Clean syn gas which was not separated out in the membrane separator 390 passes along line 392 to turboexpander 350 which provides shaft power to generator 355. The turboexpander 350 reduces the temperature ofthe fuel gas, which then proceeds along line 354 to solvent chiller (heat exchanger) 360 which cools solvent aπiving from the acid gas removal unit 330 along line 336. Cooled solvent then passes back to the acid gas removal unit 330 along line 334. Fuel gas heated up in solvent chiller 360 then passes along line 362 to humidification and preheating units collectively designated 370, and thence along line 372 to a gas turbine or fuel cell.
In Figure 5. raw syn gas enters a desulphurization unit 430 through line 410. and cleaned syn gas would then pass along line 332 to synthesis unit 495. Synthesis unit 495 can be used to synthesize many different co-products, and can advantageously be used to synthesize hydrocarbons, including oxygen containing hydrocarbons such as methanol. Unconverted clean syn gas passes along line 492 to turboexpander 450 which provides shaft power to generator 455. The turboexpander 450 reduces the temperature ofthe fuel gas, which then proceeds along line 454 to solvent chiller (heat exchanger) 460 which cools solvent arriving from the acid gas removal unit 430 along line 436. Cooled solvent then passes back to the acid gas removal unit 430 along line 434, and fuel gas heated up in solvent chiller 460 passes along line 462 to humidification and preheating units collectively designated 470, and thence along line 472 to a gas turbine or fuel cell.
In Figure 6. raw syn gas enters a desulphurization unit 630 through line 610, and cleaned syn gas passes along line 632 to first heat exchanger 518. Refrigeration in first heat exchanger 518 is preferably provided by expanding high pressure nitrogen (N2) from an elevated pressure air separation unit (not shown) along line 514, expanding the high pressure
N2 in a first turboexpander 550 to run generator 555, passing the cold N2 into first heat exchanger 518 in heat exchanging relationship with the clean syn gas in line 532, and exiting via line 553. The further cooled syn gas leaves the first heat exchanger 518 along line 519, and is then expanded in a second turboexpander 550, which drives generator 555. This cools the syn gas still further, and the still further cooled syn gas travels along line 554 to second heat exchanger 560. where it cools solvent passing through line 536. The heat exchange process heats up the syn gas. and the heated up syn gas travels along line 562 to humidification and preheating units collectively designated 470, and thence along line 472 to a gas turbine or fuel cell.
Various embodiments ofthe present invention have distinct advantages. For example, where the intervening process unit is a heat exchanger intended to pre-cool the fuel gas before it is introduced into the expander, the present invention advantageously reduces the gasifier pressure for a given acid gas removal refrigeration duty requirement and a given expanded fuel gas pressure requirement set by the gas turbine model. This fiiel gas pre-cooling feature is expected to become especially useful as the gas turbine technology advances with a resultant increase in the gas turbine pressure ratio. This pre-cooled expansion configuration is also expected to broaden the lower operating range ofthe gasifier pressure and thus, increase the number of gasification technologies or gasifier heat recovery options that may take advantage ofthe cold expander invention.
For example, for a GE 7FA gas turbine, the minimum gasifier pressure required without cooling the syn gas prior to expansion is 1080 psia, whereas by cooling it to 45° F, the gasifier pressure is reduced to about 890 psia. As another example, for the advanced GE7H gas turbine, the mmimum gasifier pressure required without cooling the syn gas prior to expansion is approximately 1390 psia, whereas by cooling it to 45° F, the gasifier pressure is reduced to about 1140 psia To put this in perspective, Texaco recommends 1215 psia as the maximum gasifier pressure
Thus, improved IGCC and IGFC designs and methods have been disclosed. While specific embodiments and apphcations of this invention have been shown and described, it would be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit ofthe appended claims.

Claims

What is claimed is
1 A method of producing power, comprising in sequence producing a sulphur containing fluid in a gasification unit, desulphurizing the sulphur containing fluid in a desulphurization unit to produce a cleaned gas, passing the cleaned gas through an intervening process unit other than a heat exchanger with the sulphur containing fluid; and power producingly expanding the cleaned gas in an expander to provide refrigeration to the desulpherization unit
2 The method of claim 1 wherein the step of passing the cleaned gas through the intervening process unit comprises passing the cleaned gas through a drying unit
3 The method of claim 1 wherein the step of passing the cleaned gas through the intervening process unit comprises passing the cleaned gas through a second expander.
4 The improved power plant of any of claims 1-3 wherein the plant co-produces at least one of hydrogen, hydrocarbon and oxygenated hydrocarbon
5 The method of claim 1 wherein the step of passing the cleaned gas through the intervening process unit comprises passing the cleaned gas through a membrane separator to separate out a coproduct
6 The method of claim 1 wherein the step of passing the cleaned gas through the intervening process unit comprises passing the cleaned gas through a synthesis unit to produce a coproduct
7 The method of claim 1 further comprising the step of producing nitrogen from an elevated pressure air separation unit, expanding the nitrogen, and wherein the step of passing the cleaned gas through the intervening process unit comprises passing the cleaned gas through a heat exchanger with the expanded nitrogen
8. An IGCC plant which co-produces a chemical product, comprising: a gasification unit which produces a fuel gas; a washing column in direct contact with the fuel gas which produces a cleaned fuel gas; a turboexpander downstream ofthe washing column which expands the cleaned gas in an expander to provide refrigeration to the desulpherization unit; a coproduction unit fluidly interposed between the washing column and the turboexpander.
9. The IGCC plant of claim 8 wherein the coproduction unit comprises a membrane separator.
10. The IGCC plant of claim 9 wherein the membrane separator separates out hydrogen.
11. The IGCC plant of claim 8 wherein the coproduction unit comprises a synthesis unit.
12. The IGCC plant of claim 11 wherein the synthesis unit produces an oxygenated hydrocarbon.
13. An improved IGCC power plant having a gasification unit for producing fuel gas from a carbonaceous fueL and a cold solvent based acid gas removal unit for removing sulphur from the fuel gas, the improvement comprising: a turboexpander which expands a working fluid to provide refrigeration to the acid gas removal unit; an air separation unit which produces nitrogen, wherein the working fluid comprises at least a portion ofthe nitrogen produced by the air separation unit.
14. The improved IGCC plant of claim 13 wherein the refrigeration is applied to cool the fuel gas in a heat exchanger downstream ofthe acid gas removal unit.
15. The improved IGCC plant of claim 14 further comprising a second turboexpander o which expands the fuel gas downstream ofthe heat exchanger to provide additional refrigeration to the acid gas removal unit.
16. A method of increasing the efficiency of an IGCC power plant having a gasification unit which produces a fuel gas through gasification of a carbonaceous feedstock, an acid gas removal unit which uses a physical solvent to remove sulphur containing compounds from the fuel gas, and a working fluid which is expanded in a turboexpander to provide cooling to the solvent, the improvement comprising at least one of: providing at least a portion ofthe working fluid as nitrogen from an air separation unit. and fluidly positioning an intervening process unit between the output ofthe acid gas removal unit and the input ofthe turboexpander. wherein the intervening process unit is not used to cool the working fluid entering the gas removal unit.
17. The method of claim 16 wherein the working fluid comprises the fuel gas.
18. The method of claim 16 wherein the turboexpander has first and second stages, and further comprising passing the working fluid from the first stage ofthe turboexpander through a heat exchanger to the second stage ofthe turboexpander.
19. The method of any of claims 16-18 further comprising providing nitrogen from an air separation unit, and using a portion ofthe nitrogen as the working fluid.
20. The method of claim 16 further comprising coproducing at least one of hydrogen, hydrocarbon and oxygenated hydrocarbon.
PCT/US1997/005715 1996-04-18 1997-04-08 Synergistic integration of physical solvent agr with plants using gasification WO1997039235A1 (en)

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