Adaptation and Scale-Up of the Enefit Technology

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1 Adaptation and Scale-Up of the Enefit Technology Richard Sherritt, Hermann Sieger, Agnes von Garnier, Taavi Lauringson, Alo Kelder Enefit Outotec Technology 32 nd Oil Shale Symposium Golden CO USA 15-17Oct

2 Contents EOT joint venture Enefit technology Adapting for shale moisture content Reducing water consumption Reducing CO 2 emissions Scale-up R&D Centre 2

EOT Joint Venture 15 M t oil shale annually

s largest oil shale fired power plants 1.

Technology supplier for mining and metals

bed technologies for over 50 years Global

implementation Enefit Outotec Technology

3 EOT Joint Venture 15 M t oil shale annually from open cast and underground mines World s largest oil shale fired power plants 1.2 M bbl annual shale oil production Technology supplier for mining and metals industries Leading provider of fluidized bed technologies for over 50 years Global presence and experience in project implementation Enefit Outotec Technology Joint venture since 2009 Develop, improve and supply Enefit technology Offers consultancy, design, engineering, and construction Start-up and operational support 3

Enefit Technology Narva Enefit140 2 140 t/h oil shale

2 million bbl/year (2011) Narva Enefit280 280 t/h oil

4 Enefit Technology Narva Enefit t/h oil shale Constructed in million bbl/year (2011) Narva Enefit t/h oil shale Construction completed million bbl/year 18 MWe (net) Currently in commissioning 4

5 Enefit280 Narva Estonia Oil shale < 6 mm 375 C BFW Steam 800 C Electrostatic precipitator Feed bin 160 C Venturi Dryer Waste heat boiler 480 C vapor Circulating Fluidized Bed 800 C Air BFW Steam BFW Steam Recycle cooler Stack Water 375 C Air Ash cooler 150 C Ash slurry 5

Adapting for moisture content Oil shales vary significantly in

process needs to be adapted to handle the extremes of moisture

Estonia - Narva 12 Jordan - Attarat 16 Morocco Tarfaya 17

6 Adapting for moisture content Oil shales vary significantly in moisture content Energy is required to vaporize the moisture The process needs to be adapted to handle the extremes of moisture content Location - Deposit Moisture, wt% Utah - Mahogany 1 Estonia - Narva 12 Jordan - Attarat 16 Morocco Tarfaya 17 Australia - Stuart 23 Colorado Oil Shale Estonian Oil Shale Australian Oil Shale 6

7 Adapting for wet oil shale (Jordan) The WHB exit temperature can be increased to supply more heat to the dryer However, the hot gas to dryer must be below 500 C to prevent overheating of oil shale One solution is to temper the gas to the dryer by recycling stack gas Another solution is to burn a supplementary fuel (retort gas) in the CFB. Oil shale 160 C Dryer 500 C 600 C WHB 1. Decrease size of waste heat boiler 480 C 800C vapor CFB 800C ESP 2. Add fan to recycle gas RC AC To stack Cooled ash 7

8 Adapting for dry oil shale (Utah) The dryer is no longer needed and can be removed. The WHB exit temperature is reduced and air preheating is added to maintain thermal efficiency. The net result is increased steam/ power generation without the dryer. Oil shale 1. Remove dryer and dryer cyclone 480C vapor CFB 800 C Other advantages without dryer are: Higher O 2 in CFB OK No raw shale dust in fly-ash No fly-ash to retort Power production independent of retorting Able to process oil shale with free bitumen 2. Increase size of waste heat boiler 800 C RC AC 8 WHB 240 C Cooled ash 160C 3. Add air preheater ESP To stack

9 Reducing water consumption Estonian plants have an abundant supply of water, but other oil shale projects are in areas where access to water is restricted. Three ways to significantly reduce water consumption are: Dry air cooling Dry ash disposal Steam dryer with condensation 9

10 Reducing water consumption by dry air cooling Narva plants employ once-through cooling using river water Alternatives are evaporative, dry air and hybrid cooling. Dry air cooling consumes the least amount of water but is more expensive to build and operate. Dry air cooling reduces steam turbine efficiency during high ambient temperature Once-through cooling - Narva Dry air cooling Steam from boiler Steam turbine G Steam from boiler Steam turbine G Condenser Condenser BFW BFW to river from river Air 10

11 Reducing water consumption by dry ash disposal Narva plants employ slurry transport of ash to settling ponds Clarified water is recirculated to slurry mixing tanks Dry ash disposal uses only enough water to control dust Dry ash is pneumatically conveyed to dry silos Ash is moistened in mixers as it is loaded into trucks or onto conveyors Slurry ash disposal - Narva Dry ash disposal - Narva Water Ash cooler Slurry tank Ash slurry Dry ash silo Water Ash cooler Mixer 11

12 Reducing water consumption by recovering shale moisture Oil shale 120C CWS CWR Water 2. Add condenser with dry air cooling to recover water 3. Increase size of waste heat boiler 800 C WHB 4. Add air preheater to maintain thermal efficiency Steam Condensate Dryer 240 C 1. The venturi dryer is replaced by a steamfluidized bed dryer. The FBD is heated indirectly with intermediate steam from power turbine. The FBD is fluidized by recompressed dryer effluent. 480 C vapor CFB 800 C RC AC Cooled ash 160 C ESP To stack Applicable to wet oil shales only Many advantages but much more expensive to build

13 CO 2 Emissions CO 2 emissions of shale processing originate from combustion of organic matter carbonate decomposition kerogen decomposition (minor) The type and quantity of carbonates vary for different oil shales Wt% Carbonate type Formula Decomposition temperature, C Estonia Narva China Fushun Jordan Attarat Utah Skyline Australia Rundle Calcite CaCO Dolomite CaCO3.MgCO Siderite FeCO The extent of decomposition depends on type of carbonate, CFB temperature and residence time 13

14 Reducing CO 2 Emissions Carbonate decomposition can be reduced by lowering CFB combustion temperature and residence time Afterburner may be 160 C required to complete CO and THC combustion. A side benefit is Oil shale increased power production. WHB 800 C 2. Add afterburner Fuel gas Air vapor CFB 650C to 750C ESP To stack Dryer 480C RC 375 C 1. Reduce combustion temperature AC Cooled ash 14

Scale-up Current studies are considering scale up to 540 t/h oil shale per unit Still need several units for a commercialscale operation. Number of cyclones and dryers increase.

15 Scale-up Current studies are considering scale up to 540 t/h oil shale per unit Still need several units for a commercialscale operation. Number of cyclones and dryers increase. CFB still smaller than what is build in power plants Rotary retort approaching maximum diameter Preliminary Layout Enefit540 - Jordan Layout Enefit280 - Narva ESP Stack ESP Cooler Cooler Heat Carrier Cyclone CFB Recycle Cyclone Cooler Dryer Cyclone WHB Venturi Dryer WHB Cyclone Cooler Cooler Cooler CFB WHB Feed bin Feed bin 15

16 EOT R&D Centre Located in Frankfurt Germany Shared location with Outotec and other technology development companies Equipment (FB, CFB, cyclones) available to be modified for individual tests (i.e., drying, pyrolysis, combustion) 16

17 Bench-scale retort 10 kg/h oil shale Ash or sand heat carrier Commissioned Nov Tests completed on numerous oil shales Sand or ash prepared in CFB combustor FB heater 800 C Vent Post combustion Oil shale Gas sampling Pyrolysis Rotary kiln Dust chamber Dedusting Condensation I Condensation II Spent shale Dust Heavy oil Light oil and water 17

Bench-scale retort Bench-scale testing is used to determine optimum pyrolysis temperature Heat carrier properties significantly impact oil yield and quality for any particular pyrolysis temperature

18 Bench-scale retort Bench-scale testing is used to determine optimum pyrolysis temperature Heat carrier properties significantly impact oil yield and quality for any particular pyrolysis temperature and residence time. Therefore, it is important to use representative ash heat carrier in bench-scale testing 100 Oil yield in Enefit bench scale unit Yield [% of assay yield] Determine optimum pyrolysis temperature Slight decrease of yield at lower temperatures Strong decrease of yield at higher temperatures API gravity [ ] Viscosity at 40 C [mm²/s] Heat Carrier 3.4 Heat Carrier API gravity [ ] Viscosity at 40 C [mm²/g] Sand Ash temperature [ C] 18

water 300 kg/h oil shale Under-construction Testing

19 Pilot Plant Oil shale Gas Combustion CFB Ash Pyrolysis Rotary kiln Vapor Condensation Spent shale Oil and water 300 kg/h oil shale Under-construction Testing begins 2013 To confirm design data and collect larger samples 19

20 Conclusions The Enefit technology is adaptable to different oil shales and site conditions. Enefit Outotec Technology is well positioned for further development of the technology Experience and know-how both internally and through parent companies Well-equipped test facilities 20

21 Thank you Enefit Outotec Technology Phone: Website: Postal address: Ludwig-Erhard-Str. 21, Oberursel GERMANY Office address: In den Schwarzwiesen 9, Oberursel GERMANY 21

CHP-turbine room. CHP can capture almost EXTRACTED STEAM 20 PSI HIGH-PRESSURE STEAM 1250 PSI HEAT EXCHANGER HOT WATER SUPPLY F

CHP-turbine room. CHP can capture almost EXTRACTED STEAM 20 PSI HIGH-PRESSURE STEAM 1250 PSI HEAT EXCHANGER HOT WATER SUPPLY F 5 6 HIGH-PRESSURE STEAM is routed from the wood-chp boiler to the turbine. TURBINE BLADES spin at nearly 00 revolutions per second. Steam acting on the turbine blades creates mechanical energy in the TURBINE.