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Integrated Gasification Combined Cycle
Gasification and IGCC: Status and Readiness
Wyoming Coal Gasification SymposiumCasper, Wyoming
February 28, 2007
Elaine Everitt, Project Manager – Gasification & Fuels Division National Energy Technology Laboratory, US Department of Energy
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Presentation Outline
• Why the Interest in Gasification• Status of Gasification
Technology• Clean Coal Demonstrations • FutureGen• Systems Studies
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Why the Interest in Gasification?• Continuing high price of fuels
− Natural gas for home heating and industrial uses− Highway transportation fuels (gasoline and diesel)
• Excellent environmental performance of IGCCs for power generation
• Growing environmental community view of IGCCs as best technology option for coal systems
• Gasification is baseline technology for H2, SNG, fuels from coal and capture of CO2 for sequestration
• Consolidation of IGCC development companies• Uncertainty of carbon management requirements and
potential suitability of IGCC for CO2 controls
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Gasification
A Commercial Reality Sarlux
Polk Wabash
Buggenum
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Sulfur By-Product
Sulfur By-Product
Fly Ash By-ProductFly Ash
By-Product
Slag By-Product
Slag By-Product
Gasification-Based Energy Production System Concepts
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
History of IGCC Plants in the U.S.
• Southern California Edison− 100 MWe Cool Water Coal Gasification
Plant (1984-1988)• Dow Chemical's Louisiana Gasification
Technology Inc (LGTI) Project− 160 MWe (1987-1995)
• Wabash River Coal Gasification Repowering Project− 262MW – Coal/Coke (1995 - present)
• Tampa Electric Polk Power Station− 250MW - Coal/Coke (1996 - present)
• Valero (Premcor) Delaware City− 160 MW - Pet Coke
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Cumulative Worldwide GasificationCapacity and Growth
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
1970 1975 1980 1985 1990 1995 2000 2005 2010
PlannedOperating
MWth Syngas
Planned
Operating
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Gasification by Primary Feedstock
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
MW
th S
ynga
s
Coal Petroleum Gas Petcoke Biomass/Waste
Planned
Operating
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Gasification by Product
0
5,000
10,000
15,000
20,000
25,000
30,000
MW
th S
ynga
s
FT liquids Chemicals Power Gaseousfuels
Not specified
Planned
Operating
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Summary of Gasification Projects
• 160 commercial projects -- in operation/ constructions/design
• 450 gasifier vessels in 28 countries• 68,000 MW thermal energy• 430 million normal cubic meter per day of
syngas • 770,000 barrels of oil equivalent energy per
day
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
US Gasification Development Coast to Coast, and North to South
• American Electric Power OH, WV• Agrium/Blue Sky AK• Baard Generation OH• BP/Edison Mission CA• Cash Creek Generation KY• Clean Coal Power IL• DKRW WY• Duke/Cinergy IN• Energy Northwest WA• Erora Group IL• Excelsior Energy MN• First Energy/Consol OH• Leucadia National LA
• Madison Power IL• Mountain Energy ID• NRG Energy DL• Orlando Util/Southern FL• Otter Creek MT• Power Holdings IL• Rentech MS• Royster Clark/Rentech IL• Southeast Idaho ID• Steelhead Energy IL• Synfuel OK• WMPI PA• Xcel Energy CO
Courtesy of Burns and Roe
Most large projects are for power, but also substitute natural gas and liquid fuels.
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Operating IGCC Projects
Total IGCC Megawatts – 3,880 MWTotal Experience, Operating Hours on Syngas = Almost 1,000,000 hours
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Clean Coal Technology Demonstrations
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Technology in Early CommercializationCompleted Clean Coal Projects
• Wabash River − 1996 Powerplant of the Year Award*− Achieved 77% availability **
• Tampa Electric− 1997 Powerplant of the Year Award*− First dispatch power generator− Achieved 90% availability **
Nation’s first commercial-scale IGCC plants, each
achieving > 97% sulfur removal > 90% NOx reduction
*Power Magazine ** Gasification Power Block
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Wabash River Clean Coal ProjectA Case Study for Cleaner Air
0
1
2
33.1
0.1
0.8
Emis
sion
s, P
ound
s pe
r M
illio
n B
TUs
BEFORECCT
BEFORECCT
AFTERCCT
SO2
NOx
AFTERCCT
0.15
The Wabash River Plant in Terre Haute, Indiana, was repowered with gasification technology
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Tampa Electric (TECO) Clean Coal ProjectA Case Study for Cleaner Air
OlderCoalPlant
SO2
NOx0.5
0
1.0Em
issi
ons
(Pou
nds
per M
illio
n Bt
us)
1.5
2.0
2.5
OlderCoalPlant
FleetAvg.
FleetAvg.
TECOCCTPlant
TECOCCTPlant
2.07
0.6 to 1.21.2
0.47
0.07(15ppm)0.1
TECO’s coal-to-gas plant in Polk County, FL,is the pioneer of a new type of clean coal plant.
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Active Clean Coal IGCC Projects• Demonstration of a 285-MW Coal-based Transport
Gasifier − Southern Company Services, Inc.− In Orange County, Florida − 285 MW (net) of electricity using sub-bituminous coal
• Mesaba Energy Project − Excelsior Energy Inc. − On Minnesota’s Mesaba Iron Range− Installed capacity of 531 MW. − Expected to be in service in 2010
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
285-MWe Transport Gasification ProjectStatus
• All contracts with the Major Participants are in place− EPC subcontract with KBR for Gasifier Island− Commercialization Agreement between Southern
Company and KBR− GE contract for CT supply and syngas testing− All contracts between Orlando Utilities Commission and
Southern Company• Including ownership, capacity purchase and O&M
Conceptual Image
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
285-MWe Transport Gasification ProjectStatus
• OUC's Need for Power Application was approved by the Florida Public Service Commission on 5/24/06
• FEED is complete; received vendor quotes
• Comment period for EIS closing this month; ROD to follow
• Detailed design and equipment procurement will begin in April of 2007
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
CCPI Mesaba Energy ProjectStatus
• 606 MWe (net) IGCC• Excelsior Energy Inc.• $2.1 billion ($36 million federal
cost share)• Status
− Draft Environmental Impact Statement due April 2007
− Project definition and preliminary engineering design underway
− Applications for pre-construction site environmental permits under review by Minnesota Public Utilities Commission (MPUC)
− Power Purchase Agreement request under review by MPUC
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
FutureGen
• Pioneer advanced hydrogen production from coal
• Emit virtually no air pollutants• Capture and permanently
sequester carbon dioxide• Integrate operations at full-
scale – a key step to proving feasibility
World’s first near-zero emission, coal-based power plant to:
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
FutureGen Participants
• Other Participating Countries•India•China
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Coal-Fired IGCC
Refinery
CO2 Pipeline
Oil
Pip
elin
e Electricity
Hydrogen Pipeline
Enhanced Oil Recovery Geologic Sequestration
and / or
Coal-Fired IGCC
Refinery
CO2 Pipeline
Oil
Pip
elin
e Electricity
Hydrogen Pipeline
Enhanced Oil Recovery Geologic Sequestration
and / or
FutureGen Concept
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
FutureGen Will Use Cutting-Edge Technologies
• Can accommodate technology innovations with minimal modifications − Emerging from national or international R&D pipelines− Module and full-scale tests− Over life of project
• Some emerging new technologies− Membrane-based O2 and H2 separation− High-efficiency hydrogen turbines− High-throughput gasifiers− Monitoring systems− Fuel-cells FutureGen will be a global
showcase of very best technology options for coal-based systems with near-zero carbon emissions
FutureGenFutureGen will be a global showcase of very best technology options for coal-based systems with near-zero carbon emissions
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
FutureGen Candidate Sites Announced
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
FutureGen Project Schedule
BP- 0 BP- 4BP- 3BP- 2BP- 1 BP- 5
Dec. 2, 2005
Jan 31, 2007
January, 2008
July, 2009
July, 2012July, 2016
July, 2018
Siting, NEPA, and Permitting
Project Structuring
&Conceptual
Design
Phase 2CooperativeAgreement
Negotiations
PreliminaryDesign
Final Design
Facilities Construction
PlantStart-Up
&Shakedown
Initial Full Scale Plant Operations Full Scale Plant Operation Continues
Site MonitoringLimitedCooperativeAgreementAwarded
Full ScopeCooperativeAgreementAwarded
NEPA RODJuly, 2007
Final Site SelectionLong Lead Time OrdersSeptember, 2007
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Systems Studies
IGCC Power PlantCurrent State-of-the-Art
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Study Matrix
PlantType
ST Cond.(psig/°F/°F)
GTGasifier/
BoilerAcid Gas Removal/
CO2 Separation / Sulfur RecoveryCO2
Cap
Selexol / - / ClausSelexol / Selexol / Claus 90%
MDEA / - / ClausSelexol / Selexol / Claus 88%1
Sulfinol-M / - / Claus
IGCC
1800/1050/1050 (non-CO2
capture cases)
1800/1000/1000(CO2 capture
cases) Selexol / Selexol / Claus 90%Wet FGD / - / Gypsum
Wet FGD / Econamine / Gypsum 90%Wet FGD / - / Gypsum
Wet FGD / Econamine / Gypsum 90%
- / Econamine / - 90%NGCC 2400/1050/950 F Class HRSG
3500/1100/1100 Supercritical
2400/1050/1050 SubcriticalPC
Shell
CoPE-Gas
GE
F Class
GEE – GE EnergyCoP – Conoco Phillips
1 CO2 capture is limited to 88% by syngas CH4 content
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Design Basis: Coal Type
Illinois #6 Coal Ultimate Analysis (weight %)As Rec’d Dry
Moisture 11.12 071.725.061.41
Chlorine 0.29 0.33Sulfur 2.51 2.82
Ash 9.70 10.91Oxygen (by difference) 6.88 7.75
100.0 100.0HHV (Btu/lb) 11,666 13,126
Carbon 63.75Hydrogen 4.50
Nitrogen 1.25
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Environmental Targets
PollutantIGCC1 PC2 NGCC3
SO20.0128
lb/MMBtu0.085
lb/MMBtu< 0.6 gr S /100
scf
NOx 15 ppmv (dry) @ 15% O2
0.07 lb/MMBtu
2.5 ppmv @ 15% O2
PM 0.0071 lb/MMBtu
0.017 lb/MMBtu Negligible
Hg > 90% capture 1.14 lb/TBtu Negligible
1 Based on EPRI’s CoalFleet User Design Basis Specification for Coal-Based IGCC Power Plants2 Based on BACT analysis, exceeding new NSPS requirements3 Based on EPA pipeline natural gas specification and 40 CFR Part 60, Subpart KKKK
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Technical Approach
1. Extensive Process Simulation (ASPEN)All major chemical processes and equipment are simulatedDetailed mass and energy balancesPerformance calculations (auxiliary power, gross/net power output)
1. Extensive Process Simulation (ASPEN)All major chemical processes and equipment are simulatedDetailed mass and energy balancesPerformance calculations (auxiliary power, gross/net power output)
2. Cost EstimationInputs from process simulation (Flow
Rates/Gas Composition/Pressure/Temp.)Sources for cost estimation
Parsons Vendor sources where available
Follow DOE Analysis Guidelines
2. Cost EstimationInputs from process simulation (Flow
Rates/Gas Composition/Pressure/Temp.)Sources for cost estimation
Parsons Vendor sources where available
Follow DOE Analysis Guidelines
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Study Assumptions• Capacity Factor = Availability
− IGCC capacity factor = 80% w/ no spare gasifier− PC and NGCC capacity factor = 85%
• GE gasifier operated in radiant/quench mode• Shell gasifier with CO2 capture used water injection for
cooling (instead of syngas recycle)• Nitrogen dilution was used to the maximum extent
possible in all IGCC cases and syngashumidification/steam injection were used only if necessary to achieve approximately 120 Btu/scf syngasLHV
• In CO2 capture cases, CO2 compressed to 2200 psig and delivered to the fenceline as sequestration-ready
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Power Plant
Current State-of-the-Art
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Current TechnologyIGCC Power Plant
Emission Controls:PM: Water scrubbing and/or candle filters to get 0.0071 lb/MMBtuNOx: N2 dilution to ~120 Btu/scf LHV to get 15 ppmv @15% O2
SOx: AGR design target of 0.0128 lb/MMBtu; Claus plant with tail gas recycle for ~99.8% overall S recovery
Hg: Activated carbon beds for ~95% removalAdvanced F-Class CC Turbine: 232 MWeSteam Conditions:
1800 psig/1050°F/1050°F (non-CO2 capture cases) 1800 psig/1000°F/1000°F (CO2 capture cases)
Emission Controls:PM: Water scrubbing and/or candle filters to get 0.0071 lb/MMBtuNOx: N2 dilution to ~120 Btu/scf LHV to get 15 ppmv @15% O2
SOx: AGR design target of 0.0128 lb/MMBtu; Claus plant with tail gas recycle for ~99.8% overall S recovery
Hg: Activated carbon beds for ~95% removalAdvanced F-Class CC Turbine: 232 MWeSteam Conditions:
1800 psig/1050°F/1050°F (non-CO2 capture cases) 1800 psig/1000°F/1000°F (CO2 capture cases)
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
GE Energy Radiant
Coal
Water
High Pressure
Steam
Radiant Syngas Cooler
Radiant Quench Gasifier
SyngasScrubber
Saturated Syngas 398OF
Quench Chamber
2,500OF
1,100OF
419OF
Coal
Water
High Pressure
Steam
Radiant Syngas Cooler
Radiant Quench Gasifier
SyngasScrubber
Saturated Syngas 398OF
Quench Chamber
2,500OF
1,100OF
419OF
Coal Slurry63 wt.%
95% O2
Slag/Fines
Syngas 410°F, 800 PsiaComposition (Mole%):H2 26%CO 27%CO2 12%H2O 34%Other 1%H2O/CO = 1.3
Design: Pressurized, single-stage, downward firing, entrained flow, slurry feed, oxygen blown, slagging, radiant and quench cooling
Note: All gasification performance data estimated by the project team to be representative of GE gasifier
To Acid Gas Removalor
To Shift
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
ConocoPhillips E-Gas™
Coal Slurry63 wt. %
Stage 2
95 % O2Slag
Quench
Char
Slag/Water Slurry
Syngas Syngas1,700°F, 614 psia
Composition (Mole%):H2 26%CO 37%CO2 14%H2O 15%CH4 4%Other 4%H2O/CO = 0.4
(0.22)
(0.78)
Stage 12,500oF
614 Psia
To Fire-tube boiler
Design: Pressurized, two-stage, upward firing, entrained flow, slurry feed, oxygen blown, slagging, fire-tube boiling syngas cooling, syngas recycle
Note: All gasification performance data estimated by the project team to be representative of an E-Gas gasifier
To Acid Gas Removalor
To Shift
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Shell Gasification
Syngas350°F, 600 Psia
Composition (Mole%):H2 29%CO 57%CO2 2%H2O 4%Other 8%H2O/CO = 0.1
DryCoal
Design: Pressurized, single-stage, downward firing, entrained flow, dry feed, oxygen blown, convective cooler
Soot Quench& Scrubber
95% O2HP Steam
Convective Cooler
Gasifier2,700oF
615 psia
650oF
Steam
Source: “The Shell Gasification Process”, Uhde, ThyssenKrupp TechnologiesSyngasQuench2
Notes: 1. All gasification performance data
estimated by the project team to be representative of Shell gasifier.
2. CO2 capture incorporates full water quench instead of syngas quench.
To Acid Gas Removalor
To Shift
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Performance ResultsNo CO2 Capture
GE Energy E-Gas ShellGross Power (MW) 770 742 748
Auxiliary Power (MW)
Base Plant Load 23 25 21
Total Aux. Power (MW) 130 119 112
Heat Rate (Btu/kWh) 8,922 8,681 8,306
Air Separation Unit 103 91 90
Gas Cleanup 4 3 1
Net Power (MW) 640 623 636
Efficiency (HHV) 38.2 39.3 41.1
Note: Revised technical performance as of January 2007. Final report release date: April 2007
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Power PlantWith CO2 Capture
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Current TechnologyIGCC Power Plant with CO2 Scrubbing
Emission Controls:PM: Water scrubbing and/or candle filters to get 0.007 lb/MMBtuNOx: N2 dilution to ~120 Btu/scf LHV to get 15 ppmv @15% O2
SOx: Selexol AGR removal of sulfur to < 28 ppmv H2S in syngasClaus plant with tail gas recycle for ~99.8% overall S recovery
Hg: Activated carbon beds for ~95% removalAdvanced F-Class CC Turbine: 232 MWeSteam Conditions: 1800 psig/1000°F/1000°F
Emission Controls:PM: Water scrubbing and/or candle filters to get 0.007 lb/MMBtuNOx: N2 dilution to ~120 Btu/scf LHV to get 15 ppmv @15% O2
SOx: Selexol AGR removal of sulfur to < 28 ppmv H2S in syngasClaus plant with tail gas recycle for ~99.8% overall S recovery
Hg: Activated carbon beds for ~95% removalAdvanced F-Class CC Turbine: 232 MWeSteam Conditions: 1800 psig/1000°F/1000°F
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Water-Gas Shift Reactor System
H2O/CO Ratio1
GE 1.3
E-Gas 0.4
Shell 1.5
Design: Haldor Topsoe SSK Sulfur Tolerant CatalystUp to 97.5% CO Conversion2 stages for GE and Shell, 3 stages for E-GasH2O/CO = 2.0 (Project Assumption)Overall ΔP = ~30 psia
775oF 450oF 500oF 450oF Cooling
Steam Turbine Output (MW)
0.9
2.4
1.0
Relative HP* Steam Flow
230Shell
230E-Gas
275GE
455oF
Steam Steam
H2O + CO CO2 + H2
*High Pressure Steam
1 Prior to shift steam addition
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Performance ResultsGE Energy
CO2 Capture NO YES
CO2 Compression - 27
Energy Penalty1 - 5.7
Gross Power (MW) 770 745
Auxiliary Power (MW)
Base Plant Load 23 23
121
18
189
556
10,505
32.5
Total Aux. Power (MW) 130
Heat Rate (Btu/kWh) 8,922
Air Separation Unit 103
Gas Cleanup/CO2 Capture 4
Net Power (MW) 640
Efficiency (HHV) 38.2
1CO2 Capture Energy Penalty = Percent points decrease in net power plant efficiency due to CO2 Capture
in ASU air comp. load w/o CT integration
Steam for Selexol
Includes H2S/CO2Removal in Selexol
Solvent
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Performance ResultsGE Energy E-Gas Shell
CO2 Capture NO YES NO YES NO YES
CO2 Compression - 27 - 26 - 28
Energy Penalty1 - 5.7 - 7.6 - 9.1
Gross Power (MW) 770 745 742 694 748
26 21
90
1
112
636
8,306
41.1
109
15
176
518
10,757
31.7
23
121
18
189
556
10,505
32.5
693
Auxiliary Power (MW)
Base Plant Load 23 25 19
Total Aux. Power (MW) 130 119 176
Heat Rate (Btu/kWh) 8,922 8,681 10,674
Air Separation Unit 103 91 113
Gas Cleanup/CO2 Capture 4 3 16
Net Power (MW) 640 623 517
Efficiency (HHV) 38.2 39.3 32.0
1CO2 Capture Energy Penalty = Percent points decrease in net power plant efficiency due to CO2 Capture
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
Schedule to Complete Study
• Performance Summary Due: 1/31/07− Updated performance results are included in this
presentation
• Cost Summary Due: 3/23/07• Draft Final Report Due: 4/16/07
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
IGCC Key PointsIGCC
• HHV efficiency = 38 – 41% (Supercritical PC is 39.1%)
IGCC with CO2 Capture• Reduces efficiency by 6 – 9 percentage points• IGCC efficiency with CO2 capture is 5-7 percentage points
higher than PC with CO2 capture and 11-12 percentage points lower than NGCC with CO2 capture
R&D can increase competitiveness and reduce costs• Reduced ASU cost (membranes)• Warm gas cleaning for sulfur removal• Improved gasifier performance
- carbon conversion, throughput, RAM
Wyoming Coal Gasification Symposium, Casper, Wyoming, February 28, 2007
SummaryGASIFICATION− Stable, affordable, high-efficiency energy supply with a
minimal environmental impact
− Feedstock Flexibility/Product Flexibility
− Flexible applications for new power generation, as well as for repowering older coal-fired plants
BIG PICTURE
− Energy Security - -Maintain coal as a significant component in the US energy mix
− A Cleaner Environment (reduced emissions of pollutants)• The most economical technology for CO2 capture
− Ultra-clean Liquids from Coal -- Early Source of Hydrogen