Presentation is loading. Please wait.

Presentation is loading. Please wait.

CFB Firing of Petcoke for Repower Applications By Scott L

Similar presentations


Presentation on theme: "CFB Firing of Petcoke for Repower Applications By Scott L"— Presentation transcript:

1 CFB Firing of Petcoke for Repower Applications By Scott L
CFB Firing of Petcoke for Repower Applications By Scott L. Darling Commercial Director Foster Wheeler North America Corporation

2 Fuel Use In Electricity Generation
Increasing Natural Gas Demand Driven By Utilities For Electricity Generation Fuel Use In Electricity Generation Note that US has significant coal reserves, our largest domestic energy resource.

3 Number of Producing Natural Gas Wells in U.S.
“The number of producing gas wells has tripled since 1971, while production has declined, clear indication that existing basins are becoming tired…” Natural gas deregulated Source: EIA Drilling has responded to the market, increasing with demand and rising prices.

4 U.S. Dry Natural Gas Production
“Domestic production peaked back in 1971…” 1994 2002 Source: EIA Despite increased drilling, we are actually producing less gas than we did in 1970. Why?

5 Natural Gas Price Is Rising
Floor above $4 Floor below $2 The floor price is rising and pricing is becoming more volatile. What we are seeing is the end of the gas surplus unleashed by the 1978 deregulation. Volatility driven by utilities who will on the spot market at any price since they pass it in to consumers in rates. No longer long term pricing contracts – long term supply contracts with gas prices based on monthly index. The recovery in manufacturing and the winter season will drive up gas demand, sending prices even higher. Sources: EIA, Wall Street Journal

6 Gas-Fired Boilers: High Operating Costs
High Fuel Price Gas is a premium fuel Increased demand, limited supply has increased gas prices Typical gas price; $4-6/mm Btu Volatile Fuel Price Weather and other effects can produce significant gas price spikes Low Boiler Efficiency High H2 content means high H2O vaporization losses KEY TOPICS TO DISCUSS ORGANIZATIONAL REVIEW AND PRODUCT RANGE MOST IMPORTANT SELLING FEATURES KEY DIFFERENTIATIORS KEY WEAKNESSES BUSINESS OPPORTUNITIES TO PURSUE EXPECTATIONS

7 Coke-Fired CFB Boilers: Low-Cost Fuel Provides Low Operating Costs
Low Fuel Price Coke is a refinery byproduct Coke price close to delivery cost Typical coke price < $1.00/mm Btu Relatively Stable Fuel Price Similar to coal Broad Fuel Flexibility Can co-fire opportunity fuels such as biomass, etc. High Boiler Efficiency Low H2 content means low H2O vaporization losses KEY TOPICS TO DISCUSS ORGANIZATIONAL REVIEW AND PRODUCT RANGE MOST IMPORTANT SELLING FEATURES KEY DIFFERENTIATIORS KEY WEAKNESSES BUSINESS OPPORTUNITIES TO PURSUE EXPECTATIONS

8 CFB Repowering Requires Low Investment Cost
Replace gas-fired boilers with CFB boilers, by adding the following equipment; New CFB boiler w/ baghouse Solid fuel storage, handling Limestone and ash storage, handling Foundations, electrical, controls Re-use existing turbine-generator, balance of plant equipment KEY TOPICS TO DISCUSS ORGANIZATIONAL REVIEW AND PRODUCT RANGE MOST IMPORTANT SELLING FEATURES KEY DIFFERENTIATIORS KEY WEAKNESSES BUSINESS OPPORTUNITIES TO PURSUE EXPECTATIONS

9 CFB Repowering Requires Low Investment Cost

10 Coke-Fired CFB Repowering: Operating Cost Savings Provide Rapid Payback of Investment Costs
Payback Calculations Based on: Gas Price Range: $4 – 7/mm Btu Coke Price: $0.75/mm Btu Boiler (Plant) Size: 35 – 100 MWe (net) Capital Cost: $960 - $1250/low Payback: Simple Payback

11 Coke Fired CFB Repowering Provides Rapid Payback of Investment Cost

12 Petcoke Fired CFB: Lower Power Cost Than NGCC
20 Year Levelized COE 6.19 3.82 ($4.00/mmBtu) ($.75/mmBtu)

13 Leading the World in CFB Technology

14 CFB Technology Is Mature: Over 480 CFB Boilers Worldwide*
Number of CFB Boilers Year of Sale * Equivalent to over 27,500 MWe Excludes CFB’s Designed in China Source: McCoy Power Reports

15 Foster Wheeler: Market Leader In CFB Technology 1977 - 2003
47% B&W 2% Babcock Borsig 2% Kvaerner 7% Lurgi/Lentjes 12% Alstom 30% Based on MWe Source: McCoy Power Reports

16 Foster Wheeler: Leading The World In CFB Technology
Over 200 Units in Design/Operation 300 MWe Units in Operation 460 MWe Unit in Design Units in Service Over 24 Years Experience with a Range of Fuels High Availability Demonstrated Sizes to 600 MWe Offered

17 CFB Technology Offers Fuel Flexibility
 Coal – Anthracite – Bituminous – Sub-Bituminous – Lignite  Waste Coal – Bituminous Gob – Anthracite Culm  Petroleum Coke – Delayed – Fluid  Oil Shale  Oil  Refinery Bottoms  Natural Gas  Peat  Agricultural Waste – Woodwaste – Rice Husks – Bagasse Pith  Tires  Sludge  Refuse Derived Fuel

18 CFB Process Design Offers Significant Advantages
15-16 ft/sec Air Limestone 1/20” x 0 Flue Gas Fuel 1/2” x 0 Feature Low Furnace Temps. Hot Circulating Solids Long Solid Residence Time Benefit Low NOx Low SO2 Fuel Flexibility Handles Poor Fuels Simple Feed Systems Good Fuel Burnout Good Sorbent Utilization

19 Foster Wheeler CFB: Improved Performance With Less Equipment
Backpass Furnace Cyclone

20 Foster Wheeler Has Significant Experience With CFB Repowering
Plant Size Fuel Remarks NISCO 2 x 120 MWe Pet Coke Replaced Gas-Fired (Louisiana) Boilers Turow 3 x 235 MWe Brown Coal Replaced Coal-Fired (Poland) PC Boilers Centerior-Bay Shore 1 x 180 MWe Pet Coke Replaced Coal-Fired (Ohio) PC Boilers JEA-Northside 2 x 300 MWe Pet Coke Replaced Oil/Gas Fired (Florida) Boilers SIPC 1 x 120 MWe Waste Coal Replaced Coal-Fired (Illinois) Cyclone Boilers

21 NISCO: First Petcoke Repower
Location Westlake, Louisiana (USA) Unique Features IPP Project With EPC Contractor Repowering of 25+ Year Old Gas Fired Plant 2 x 120 MWe CFB Boilers World’s Largest Petcoke-fired CFB’s IPP Project Based on Petcoke From Nearby Refineries (Citgo, Conoco) Low Cost Fuel and Commercial Uses for CFB Ash

22 NISCO: First Petcoke Firing
Capacity, Mwe (g) 2 x 120 Steam Flow, (SH/RH) 825/727 Steam Pressure, psig (SH/RH) 1625/464 Steam Temperature, °F (SH/RH) 1005/1005 Major Dimensions Furnace Height, ft. 112 Furnace Width, ft. 42 Furnace Depth, ft. 20 Cyclone Diameter, ft. 18.7

23 NISCO: First Petcoke Repower
Fuel Coke Moisture, % wt 10.6 Ash, % wt 0.3 Sulfur, % wt 4.5 HHV, Btu/lb 13,454 Schedule Contract Award November 1989 Start of Erection June 1990 Commercial Operation August 1992 Availability Boiler Availability, 96.1%

24 NISCO: First Petcoke Repower
Parameters Guarantee Test Capacity, klb/hr Boiler Efficiency, % NOx, lb/106 Btu SO2, % Removal (lb/106 Btu) (0.39) > 91 (0.38) CO, lb/106 Btu Hydrocarbons, lb/106 Btu Limestone Flow, klb/hr < 38 < 19.5

25 JEA: Utility CFB Repower
Location Jacksonville, Florida, USA Unique Features – Replaces Two 275 MWe Oil/Gas-Fired Boilers With two MWe Coal/Petroleum Coke Fired CFB Boilers (Northside Units 1 and 2) – World’s Largest CFB Boilers in Operation – DOE Cost Sharing For Unit 2 (Part of Clean Coal Technology Program) – After Repower, Northside Emissions Will Be 10% Lower Than Current (Even Though Unit 2 Currently Out of Service)

26

27

28 JEA: Utility CFB Repower
Capacity, Mwe (g) 2 x 300 Steam Flow, klb/hr (SH/RH) 1991/1771 Steam Pressure, psi (SH/RH) 2620/580 Steam Temperature, °F (SH/RH) 1005/1005 Major Dimensions Furnace Height, ft 115 Furnace Width, ft 85 Furnace Depth, ft 22 Cyclone Diameter, ft 3 x 24

29 JEA: Utility CFB Repower
Fuel Petcoke Coal Moisture, % wt Ash, % wt Sulfur, % wt Volatiles, % wt HHV, Btu/lb 14, ,690 Emissions SO lb/106 Btu NOx 0.09 lb/106 Btu Schedule Contract Award August 1999 Start of Erection June 2000 Commercial Operation May/July 2002

30 JEA: Utility CFB Repower
PARAMETERS GUARANTEE TEST Capacity, klb/hr (SH/RH) 1993/ /1734 Boiler Efficiency, % (Coke/Coal) 90.16/ /88.20 SO2 Capture, % (Coke/Coal) Boiler 90/ /99.4 Boiler & Scrubber 98/ /99.7 SO2, lb/106 Btu (Coke/Coal) Boiler 0.75/ /0.023 Boiler & Scrubber 0.15/ /0.010 NOx, lb/106 Btu (Coke/Coal) 0.09/ /0.04 CO, lb/106 Btu (Coke/Coal) 0.22/ /0.06

31 Repowering with Foster Wheeler CFB Boilers: A Key Strategy to Reduce Costs
Natural gas prices are high and likely to remain high Switching from gas to solid fuel drastically reduces operating costs Repowering with CFB boilers minimizes investment cost Reduced operating cost rapidly pay back the repowering investment FW has the most CFB experience in the industry FW has the most mature, efficient, reliable CFB design in the industry


Download ppt "CFB Firing of Petcoke for Repower Applications By Scott L"

Similar presentations


Ads by Google