James Childress Executive Director Gasification Technologies Council

The Basics of GasificationThe Basics of Gasification

APPA Utility Education CourseAPPA Utility Education CourseNew Generation Emerging Technologies & FinancingNew Generation Emerging Technologies & Financing

2005 APPA Winter Education Institute2005 APPA Winter Education InstituteFebruary 17, 2005 February 17, 2005 San Antonio, TexasSan Antonio, Texas

James ChildressJames ChildressExecutive DirectorExecutive Director

Gasification Technologies CouncilGasification Technologies Council


GTC MembersGTC Members

AFC Coal PropertiesAFC Coal PropertiesAir Liquide America*Air Liquide America*Air Products and Chemicals, Inc.*Air Products and Chemicals, Inc.*American Electric Power*American Electric Power*Aramco Services Company*Aramco Services Company*Bechtel Corporation*Bechtel Corporation*Black & Veatch Corporation*Black & Veatch Corporation*BOC Gases*BOC Gases*Boeing, Rocketdyne Propulsion & Power*Boeing, Rocketdyne Propulsion & Power*Cinergy Corporation*Cinergy Corporation*ConocoPhillips*ConocoPhillips*Constellation Energy*Constellation Energy*The Dow Chemical Company*The Dow Chemical Company*Eastman Chemical Company*Eastman Chemical Company*Ebara CorporationEbara CorporationEmery Energy CompanyEmery Energy CompanyFluor Corporation*Fluor Corporation*Foster Wheeler Energy International Inc.*Foster Wheeler Energy International Inc.*Gas Technology InstituteGas Technology InstituteGE Energy*GE Energy*

Global Energy, Inc.*Global Energy, Inc.*Kentucky Center for Applied Energy Kentucky Center for Applied Energy ResearchResearchLake Charles Cogeneration, LLCLake Charles Cogeneration, LLCLinde Process PlantsLinde Process PlantsLockwood Greene E&C / CH2M HillLockwood Greene E&C / CH2M HillLurgi Oel Gas Chemie GmbHLurgi Oel Gas Chemie GmbHMitretekMitretekNexant, Inc.Nexant, Inc.Parsons Energy & Chemicals Group Inc.*Parsons Energy & Chemicals Group Inc.*Porvair PLCPorvair PLCPraxair, Inc.*Praxair, Inc.*Sasol TechnologySasol TechnologySempra GenerationSempra GenerationShell Global Solutions B.V.*Shell Global Solutions B.V.*Siemens Westinghouse Power Corporation*Siemens Westinghouse Power Corporation*Snamprogetti S.p.A.Snamprogetti S.p.A.Tennessee Valley Authority* Tennessee Valley Authority* Uhde Corporation of America*Uhde Corporation of America*UOPUOP* Denotes member of Board of Directors* Denotes member of Board of Directors


OverviewOverview

What is gasification?What is gasification?

Gasification is not combustion!Gasification is not combustion!

Environmental performance: Environmental performance: gasification vs. combustiongasification vs. combustion

State of the gasification industryState of the gasification industry

Factors driving gasification trendsFactors driving gasification trends

Is Gasification Ready for Prime Time?Is Gasification Ready for Prime Time?


Gasification is a process Gasification is a process technologytechnology

Gasification is not combustion, it operates in a Gasification is not combustion, it operates in a controlled, oxygen-starved (reducing) atmosphere that controlled, oxygen-starved (reducing) atmosphere that avoids creation of undesirable combustion byproducts. avoids creation of undesirable combustion byproducts. Modern “Slagging Gasification” is the keyModern “Slagging Gasification” is the keyThe high temperature & pressure in the slagging gasifier The high temperature & pressure in the slagging gasifier convert carbon in feedstock to synthesis gas, primarily a convert carbon in feedstock to synthesis gas, primarily a mixture of CO and Hmixture of CO and H2.2. The clean syngas can be combusted to generate The clean syngas can be combusted to generate electricity or used as a feedstock for production of electricity or used as a feedstock for production of chemicals, fuels and fertilizers.chemicals, fuels and fertilizers.


Environmental Benefits

The slagging gasification process allows the use of lower cost, “distressed” feedstocks which would be problemmatic if combusted. (high sulfur coal, petcoke, petroleum residuals, secondary materials)Sulfur in feedstock is converted to HSulfur in feedstock is converted to H22S which is conveted S which is conveted to elemental sulfur or sulfuric acid using commercially to elemental sulfur or sulfuric acid using commercially available processes.available processes.No NOx in syngas. IGCC NOx production relatively low compared to other coal-using processes .Particulate emissions below standards.Organics are undetected, or below limits.Ash and other inert materials captured in slag. >95% mercury capture commercially proven.


Environmental Benefits, contEnvironmental Benefits, cont..

Synthesis gas is cleaned prior to combustion. In PC Synthesis gas is cleaned prior to combustion. In PC plant, cleanup is post-combustion. plant, cleanup is post-combustion.

ΔΔ in gas volume: PC plant cleans up 100-160X the gas in gas volume: PC plant cleans up 100-160X the gas volume as an IGCC plant.volume as an IGCC plant.

COCO22 Capture with IGCC is least cost option. Capture with IGCC is least cost option.



(lb/MMBtu)(lb/MMBtu)Coal FiredCoal Fired[2][2]

E-Gas E-Gas GreenfieldGreenfield

IGCCIGCC

E-Gas NGCC E-Gas NGCC ReFuelingReFueling NGCCNGCC

SOSO22 0.15 - 0.180.15 - 0.18 0.0140.014 0.0080.008 0.0030.003[3][3]

NONOXX 0.07 - 0.080.07 - 0.08 0.0590.059 0.0120.012[1][1] 0.0120.012[1][1]

VOCVOC 0.0040.004 0.0030.003 0.0030.003 0.0020.002

COCO 0.11 - 0.120.11 - 0.12 0.0660.066 0.0660.066 0.030.03

PM/PM-10PM/PM-10 0.015 - 0.0180.015 - 0.018 0.0110.011 0.0110.011 0.0070.007

HgHg(lb/10(lb/101212 Btu) Btu) 1.0 - 4.01.0 - 4.0 0.50.5 0.50.5 --

Comparative Air EmissionsComparative Air Emissions

[1] 3 ppmvd @ 15% Oxygen

[2] Range covers recently issued air permits for SCPC, PC, and CFB projects

[3] Based on 1 gr H2S / 100 scf NG spec

Source: ConocoPhillips, 2004 GTCSource: ConocoPhillips, 2004 GTC


The Gasification IndustryThe Gasification Industry2004 World Gasification Survey2004 World Gasification Survey

Summary FindingsSummary Findings Geographical DistributionGeographical Distribution Feedstock DistributionFeedstock Distribution Product DistributionProduct Distribution


World Gasification SurveyOperating Plant Statistics 2001 vs. 2004

20012001

127127 operating plants operating plants

400400 gasifiers gasifiers

Capacity~Capacity~41,82941,829 MWth MWth

FeedsFeeds– Coal Coal 45%,45%, Pet. Resid. Pet. Resid. 38%38%

Products Products – Chemicals Chemicals 43%,43%, F-T F-T 29%,29%,

Power Power 20%20%

Growth Forecast Growth Forecast 7%7%

20042004

118118 Operating Plants Operating Plants

385385 Gasifiers Gasifiers

Capacity~Capacity~45,000 45,000 MWthMWth

FeedsFeedsCoal Coal 49%,49%, Pet. Resid. Pet. Resid. 36%36%

ProductsProductsChemicals Chemicals 37%,37%, F-T F-T 36%,36%,

Power Power 19%19%

Growth Forecast Growth Forecast 5%5%


World Gasification Capacity GrowthWorld Gasification Capacity Growth2000-20102000-2010

35,000

45,000

55,000

65,000

75,000

2000 2002 2004 2006 2008 2010

(MW(MWth Equivalent) Equivalent)

Source: 2004 World Gasification SurveySource: 2004 World Gasification Survey


Geographical Distribution of World Geographical Distribution of World Gasification CapacityGasification Capacity


0

5,000

10,000

15,000

20,000

25,000

30,000

C&SAmerica

NorthAmerica

Europe + Asia/Aust. Afr/ME

Planned (2010)

Operating (2004)


Feedstock Distribution of World Feedstock Distribution of World Gasification CapacityGasification Capacity


0

10,000

20,000

30,000

40,000

Coal Petroleum Gas Petcoke BWO*

Planned (2010)

Operating (2004)

China(US) Europe

Canada

US

MidEast


Product Distribution of World Product Distribution of World Gasification CapacityGasification Capacity


0

5,000

10,000

15,000

20,000

25,000

30,000

Power Chemicals Liquid Fuel GaseousFuel

NotSpecified

Planned (2010)

Operating (2004)


Factors Driving Gasification TrendsFactors Driving Gasification Trends

AsiaAsiaFertilizers & Chemicals (China, poss. India)Fertilizers & Chemicals (China, poss. India)Power (China/Japan future)Power (China/Japan future)Fuels (Longer term)Fuels (Longer term)Wild Card – China, Environmental Issues & Econ. Growth; Japan, Policy Shift Toward Wild Card – China, Environmental Issues & Econ. Growth; Japan, Policy Shift Toward IGCC?IGCC?

EuropeEuropeRefinery Models – Environment Driven Toward Cleaner FuelsRefinery Models – Environment Driven Toward Cleaner Fuels

– Pernis (Hydrogen, Power)Pernis (Hydrogen, Power)– Italian Plants (Power)Italian Plants (Power)

COCO2 Concerns

Remote GasRemote GasF-T LiquidsF-T Liquids

North AmericaNorth AmericaNatural Gas Demand in Power Sector > NG PricesNatural Gas Demand in Power Sector > NG Prices↑↑U.S. Coal, Power, Environment (The AEP Model)U.S. Coal, Power, Environment (The AEP Model)U.S. Petcoke in Refineries (Hydrogen, Power)U.S. Petcoke in Refineries (Hydrogen, Power)U.S. Possible Public Sector Incentives ($$ + Regulations)U.S. Possible Public Sector Incentives ($$ + Regulations)Canada – Tar Sands, CoalCanada – Tar Sands, Coal


U.S. Gasification ExperienceU.S. Gasification Experience20 Plants Operating20 Plants Operating

FeedstocksFeedstocks

Coal/Petcoke - 7Coal/Petcoke - 7

Gas - 9Gas - 9

Petroleum - 4Petroleum - 4

ProductsProducts

Chemicals - 14Chemicals - 14

Power - 4Power - 4

Gas - 2Gas - 2


U.S. Gasification PlantsU.S. Gasification PlantsEastman Kingsport 1983 1600000 Coal Chemicals

Great Plains Synfuels Plant 1984 13900000 Coal Gaseous fuels

Polk County IGCC Project 1996 3300000 Coal/Petcoke Power

Houston Oxochemicals Plant 1977 2100000 Gas Chemicals

LaPorte Syngas Plant 1979 4800000 Gas Chemicals

Oxochemicals Plant 1983 400000 Gas Chemicals

Texas City Syngas Plant 1983 830000 Gas Chemicals

Taft Syngas Plant 1995 432000 Gas Chemicals

LaPorte Syngas Plant 1996 1850000 Gas Chemicals

Texas City Syngas Plant 1996 1920000 Gas Chemicals

Oxochemicals Plant 1998 350000 Gas Chemicals

Longview Gasification Plant 2002 1558000 Gas Chemicals

Wabash River Energy Ltd. 1995 4320000 Petcoke Power

Frontier Energy El Dorado 1996 80559 Petcoke Power

Coffeyville Nitrogen Plant 2000 2141200 Petcoke Chemicals

Premcor Refinery Delaware City 2002 3800000 Petcoke Power

Baton Rouge Oxochemicals 1978 570000 Petroleum Chemicals

Oxochemicals Plant 1979 500000 Petroleum Chemicals

Convent H2 Plant 1984 1880000 Petroleum Chemicals

Baytown Syngas Plant 2000 2540000 Petroleum Gaseous fuels


Technology Performance:Technology Performance:

Commercially ViableCommercially Viable


Summary of IGCC Status

IGCC offers SO2, NOx, and particulate emissions below recent pulverized coal plants’ permit limits.

Mercury removal >95% at 1/10th the cost for PC plant.

CO2 capture costs 43% of PC plant (COE basis).

ConocoPhillips, GE, and Shell gasifiers have been successfully operated at commercial size on a variety of feedstocks to produce power, fuels & chemicals.

Existing single train IGCC coal plants have achieved availability of 85% on a quarterly basis. Commercial multi-train plants with spare gasifiers will achieve >90% availability.

IGCC is currently being commercially used in many plants worldwide based on the gasification of petroleum residuals providing power, steam and hydrogen to refineries. These plants provide additional operating experience on key components and unit operations.

Source: Holt, et. al.Source: Holt, et. al.


But is IGCC ready for But is IGCC ready for prime time?prime time?


AEP, Cinergy announce plans to build AEP, Cinergy announce plans to build commercial scale coal-IGCC plants (~600-1,000 commercial scale coal-IGCC plants (~600-1,000 mWe each)mWe each)Feasibility studies underwayFeasibility studies underwayAEP Prelim site selection (OH, KY WV)AEP Prelim site selection (OH, KY WV)St. Legislature/PUC discussions underwaySt. Legislature/PUC discussions underwayDrivers: Drivers: – Expectations of more stringent criteria+Hg limitsExpectations of more stringent criteria+Hg limits– Expectations of COExpectations of CO22 limits limits– Desire to keep coal in their energy mixDesire to keep coal in their energy mix

References:References: http://www.aep.com/environmental/default.htm http://www.aep.com/environmental/default.htm

http://www.cinergy.com/sustain/environmental_improvement.asphttp://www.cinergy.com/sustain/environmental_improvement.asp


““As part of its future plans to mitigate the As part of its future plans to mitigate the economic impacts of its emissions, AEP has economic impacts of its emissions, AEP has committed to accelerating IGCC deployment by committed to accelerating IGCC deployment by building one, or more, commercial-scale, base-building one, or more, commercial-scale, base-load IGCC plants (up to 1,000 megawatts) as load IGCC plants (up to 1,000 megawatts) as soon as 2010.”soon as 2010.”

AEP Press Release, 8/31/04AEP Press Release, 8/31/04


2005 Gasification Technologies 2005 Gasification Technologies ConferenceConference

San Francisco, October 9-12San Francisco, October 9-12


Questions?Questions?

For further information: http://www.gasification.orgFor further information: http://www.gasification.org

Documents

James Childress Executive Director Gasification Technologies Council