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 GenerationFuel Use In Electricity GenerationNote 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 productionhas declined, clear indication that existing basins are becoming tired…”Natural gas deregulatedSource: EIADrilling has responded to the market, increasing with demand and rising prices.
4 U.S. Dry Natural Gas Production “Domestic production peaked back in 1971…”19942002Source: EIADespite increased drilling, we are actually producing less gas than we did in 1970.Why?
5 Natural Gas Price Is Rising Floor above $4Floor below $2The 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 PriceGas is a premium fuelIncreased demand, limited supply has increased gas pricesTypical gas price; $4-6/mm BtuVolatile Fuel PriceWeather and other effects can produce significant gas price spikesLow Boiler EfficiencyHigh H2 content means high H2O vaporization lossesKEY TOPICS TO DISCUSSORGANIZATIONAL REVIEW AND PRODUCT RANGEMOST IMPORTANT SELLING FEATURESKEY DIFFERENTIATIORSKEY WEAKNESSESBUSINESS OPPORTUNITIES TO PURSUEEXPECTATIONS
7 Coke-Fired CFB Boilers: Low-Cost Fuel Provides Low Operating Costs Low Fuel PriceCoke is a refinery byproductCoke price close to delivery costTypical coke price < $1.00/mm BtuRelatively Stable Fuel PriceSimilar to coalBroad Fuel FlexibilityCan co-fire opportunity fuels such as biomass, etc.High Boiler EfficiencyLow H2 content means low H2O vaporization lossesKEY TOPICS TO DISCUSSORGANIZATIONAL REVIEW AND PRODUCT RANGEMOST IMPORTANT SELLING FEATURESKEY DIFFERENTIATIORSKEY WEAKNESSESBUSINESS OPPORTUNITIES TO PURSUEEXPECTATIONS
8 CFB Repowering Requires Low Investment Cost Replace gas-fired boilers with CFB boilers, by adding the following equipment;New CFB boiler w/ baghouseSolid fuel storage, handlingLimestone and ash storage, handlingFoundations, electrical, controlsRe-use existing turbine-generator, balance of plant equipmentKEY TOPICS TO DISCUSSORGANIZATIONAL REVIEW AND PRODUCT RANGEMOST IMPORTANT SELLING FEATURESKEY DIFFERENTIATIORSKEY WEAKNESSESBUSINESS OPPORTUNITIES TO PURSUEEXPECTATIONS
14 CFB Technology Is Mature: Over 480 CFB Boilers Worldwide* Number ofCFB BoilersYear of Sale* Equivalent to over 27,500 MWeExcludes CFB’s Designed in ChinaSource: McCoy Power Reports
15 Foster Wheeler: Market Leader In CFB Technology 1977 - 2003 47%B&W 2%Babcock Borsig 2%Kvaerner7%Lurgi/Lentjes12%Alstom30%Based on MWeSource: McCoy Power Reports
16 Foster Wheeler: Leading The World In CFB Technology Over 200 Units in Design/Operation300 MWe Units in Operation460 MWe Unit in DesignUnits in Service Over 24 YearsExperience with a Range of FuelsHigh Availability DemonstratedSizes to 600 MWe Offered
18 CFB Process Design Offers Significant Advantages 15-16 ft/secAirLimestone1/20” x 0Flue GasFuel1/2” x 0FeatureLow FurnaceTemps.Hot CirculatingSolidsLong SolidResidence TimeBenefitLow NOxLow SO2Fuel FlexibilityHandles PoorFuelsSimple FeedSystemsGood FuelBurnoutGood SorbentUtilization
19 Foster Wheeler CFB: Improved Performance With Less Equipment BackpassFurnaceCyclone
20 Foster Wheeler Has Significant Experience With CFB Repowering Plant Size Fuel RemarksNISCO 2 x 120 MWe Pet Coke Replaced Gas-Fired(Louisiana) BoilersTurow 3 x 235 MWe Brown Coal Replaced Coal-Fired (Poland) PC BoilersCenterior-Bay Shore 1 x 180 MWe Pet Coke Replaced Coal-Fired(Ohio) PC BoilersJEA-Northside 2 x 300 MWe Pet Coke Replaced Oil/Gas Fired(Florida) BoilersSIPC 1 x 120 MWe Waste Coal Replaced Coal-Fired(Illinois) Cyclone Boilers
21 NISCO: First Petcoke Repower LocationWestlake, Louisiana (USA)Unique FeaturesIPP Project With EPC ContractorRepowering of 25+ Year Old Gas Fired Plant2 x 120 MWe CFB BoilersWorld’s Largest Petcoke-fired CFB’sIPP 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 120Steam Flow, (SH/RH) 825/727Steam Pressure, psig (SH/RH) 1625/464Steam Temperature, °F (SH/RH) 1005/1005Major DimensionsFurnace Height, ft. 112Furnace Width, ft. 42Furnace Depth, ft. 20Cyclone Diameter, ft. 18.7
23 NISCO: First Petcoke Repower Fuel CokeMoisture, % wt 10.6Ash, % wt 0.3Sulfur, % wt 4.5HHV, Btu/lb 13,454ScheduleContract Award November 1989Start of Erection June 1990Commercial Operation August 1992AvailabilityBoiler Availability, 96.1%
25 JEA: Utility CFB Repower LocationJacksonville, Florida, USAUnique Features– Replaces Two 275 MWe Oil/Gas-Fired Boilers With two MWeCoal/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)
31 Repowering with Foster Wheeler CFB Boilers: A Key Strategy to Reduce Costs Natural gas prices are high and likely to remain highSwitching from gas to solid fuel drastically reduces operating costsRepowering with CFB boilers minimizes investment costReduced operating cost rapidly pay back the repowering investmentFW has the most CFB experience in the industryFW has the most mature, efficient, reliable CFB design in the industry