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IGCC Gas Turbines For Refinery Applications
GE Power Systems
GE Company Proprietary
2002 Gasification Technologies ConferenceSan Francisco, California, October 27–30
Robert M. JonesManager, Process Power Marketing
Norman Z. ShillingProduct Line Leader, IGCC
Refinery Drivers• Environmental Legislation Proposed to Reduce Sulfur in
Transportation Fuels from >250 ppm to <15 ppm by ‘06• Incremental Capital Cost is Projected to be $8B that Will
Add 6¢/Gallon to Current Fuel Prices
30.5
31.0
31.5
32.0
32.5
API
Gra
vity
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
Crude Quality
0.9
1.0
1.1
1.2
1.3
Wt %
Sul
fur
1987
1989
1991
1993
1995
1997
1999
Sulfur Content
Higher Sulfur Residuals Favor IGCC
$B %
ROIC
SPENDING
• Increasing demand for middle distillates at same time that crude quality is deteriorating
• Hydrotreatment to increase light production requires hydrogen from expansion of coking facilities
Crude Quality to US Refiners
Increased Petroleum Coke Production
• Pet coke now either stockpiled or handled by middlemen for fuel blending to export as saleable fuel
• Several countries are preventing new coking capacity until a solution is implemented.
Current Coke Market is Saturated
Kyoto & Enviro Concerns Shrinking Market for Pet Coke
Refinery Competitive AssessmentAir Emissions IGCC vs. CFBCSource Volume Reduction
Annual Disposal Costs
IGCC Technology Provides Superior Environmental
Benefits To Refineries
■ Higher Efficiency ( 5%)
■ Environmental Performance
■ “Siteability” and Image
■ Experience
~~
Gasificaton
Gasifier HX
OxidantSupply System
Combined Cycle
Cleanup
Sulfur
SlagSyngas
CleanFuel
SlagHydrogenAmmoniaMethanolChemicals
Electricity
ProductsFuels
Bituminous CoalSub Bituminous CoalLignite
OrimulsionResidual OilsRefinery BottomsPetroleum CokeRefinery Gas
BiomassWastes
2 Stage CombustionPartial in GasifierComplete in Gas Turbine
5 Technologies Oxidant SupplyGasificationClean UpCombined CycleIntegration
- Air or Oxygen - CO + H2 - Sulfur - Syngas - Synergy
Steam
IGCC Process
Opportunity Fuels to Clean Electricity
GE Gas Turbines In Refinery IGCCs
Exxon Singapore (Heavy Oil)
Exxon Singapore (Heavy Oil)
Motiva Delaware (Petroleum Coke)
Motiva Delaware (Petroleum Coke)
Sarlux (Heavy Oil)
Sarlux (Heavy Oil)
Shell Pernice(Heavy Oil)
Shell Pernice(Heavy Oil)
180 MW
2 x 6FA
180 MW
2 x 6FA
240 MW
2 x 6FA
240 MW
2 x 6FA 550 MW
3 x 109E
550 MW
3 x 109E
80 MW
2 x 6B
80 MW
2 x 6B
Texaco El Dorado (Petroleum Coke)
Texaco El Dorado (Petroleum Coke)
40 MW
1 x 6B
40 MW
1 x 6B
GE Gas Turbine Syngas ExperienceGE Syngas Hours of Operation
SyngasStartDate
Cool WaterPSITampaTexaco El DoradoSierra PacificSUV VresovaSchwarze PumpeShell PernisISE / ILVAFife EnergyMotiva DelawareSarluxPiombinoExxon Singapore
107E7FA
107FA6B
106FA209E
6B2x6B
3x109E6FA
2x6FA3x109E
109E2x6FA
120262250
40100350
4080
54080
240550150180
5/8411/959/969/96
-12/96 9/9611/9711/96
-8/0010/0010/003/01
27,00024,50033,50030,660
090,04037,60058,250
141,0000
45033,10012,4009,700
-1,800
-56,37248,4381,715
-22,6874,732
26,220--
2,93012,776
1,0004,1007,101
---
3,800---
5,29010,500
-921
Customer
Totals 499,100
Type MW Hours of OperationSyngas N.G. Dist.
September 2002
IGCC Product Technology IGCC Product Technology –– ProvenProvenThrough Operating ExperienceThrough Operating Experience
GE Gas Turbine Syngas Capabilities
H2
CO
CH4
CO2
N2 + AR
H2O
LHV, - Btu/ft3
Syngas
37.2
46.6
0.1
13.3
2.5
0.3
253
Tampa
35.4
45.0
0.0
17.1
2.1
0.4
242
El Dorado
34.4
35.1
0.3
30.0
0.2
--
210
Pernis
14.5
23.6
1.3
5.6
49.3
5.7
128
SierraPacific
8.6
26.2
8.2
14.0
42.5
--
183
ILVA
61.9
26.2
6.9
2.8
1.8
--
317
SchwarzePumpe
22.7
30.6
0.2
5.6
1.1
39.8
163
SarluxPSI
24.8
39.5
1.5
9.3
2.3
22.7
209
34.4
55.4
5.1
1.6
3.1
--
319
Fife
44.5
35.4
0.5
17.9
1.4
0.1
241
ExxonSingapore
32.0
49.5
0.1
15.8
2.15
0.44
248
MotivaDelaware
35.68
43.94
0.03
18.96
1.20
0.19
239.6
CitgoL. Char.
42.3
47.77
0.08
8.01
2.05
0.15
270.4
PIEMSA
10.3
22.3
3.8
14.5
48.2
0.9
134.6
Tonghua
- kJ/m3 9962 9528 8274 5024 7191 12,492 64038224 12,568 9,477 9,768 9,442 10,655 5304
Tfuel F/C
H2/CO Ratio
Diluent
Equivalent LHV
700/371
.80
N2
250/121
.79
N2/Steam
200/98
.98
Steam
1000/538
.61
Steam
400/204
.33
--
100/38
2.36
Steam
392/200
.74
Moisture
570/300
.63
Steam
100/38
.62
H2O
350/177
1.26
Steam
570/299
.65
H2O/N2
300/149
0.81
N2
338/170
.89
N2
-
.46
n/a
* Always co-fired with 50% natural gas
- Btu/ft3
- kJ/m3
1184649
113*4452
1987801
1104334
----
2007880
----
1505910
*--
1164600
1505910
126.54985
1295083
134.65304
Demonstrated: Syngas Fuel FlexibilityDemonstrated: Syngas Fuel Flexibility
Refinery Projects
IGCC Penetration
22 Global IGCC Plants
Customer C.O. Date MW Application GasifierSCE Cool Water - USALGTI - USADemkolec - NetherlandsPSI/Global - USATampa Electric - USATexaco El Dorado - USASUV - Czech.Schwarze Pumpe - GermanyShell Pernis - NetherlandsPuertollano - SpainSierra Pacific - USAISAB - ItalyAPI - ItalyMOTIVA - DelawareSarlux/Enron - ItalyEXXON - Singapore
FIFE - ScotlandEDF/ Total - GonfrevilleFIFE Electric - ScotlandNihon Sekiyu - JapanCitgo Lake CharlesPIEMSA
1984198719941995199619961996199619971998199819992000200020002000
200120032003200420052006
120160250260260
40350
40120320100500250240550180
120400400350500800
Power/CoalCogen/CoalPower/CoalRepower/CoalPower/CoalCogen/Pet CokeCogen/CoalPower/Methanol/LigniteCogen/H2/OilPower/Coal/Pet CokePower/CoalPower/H2/OilPower/H2/OilRepower/Pet CokeCogen/H2/OilCogen/H2/Oil
Power/Sludge Power/ H2/Cogen/OilPower/Coal/RDFPower/OilCogen/Pet CokePower/H2/Oil
Texaco - O2Destec - O2Shell - O2Destec - O2Texaco - O2Texaco - O2ZUV - O2Noell - O2Shell - O2Prenflow - O2KRW - AirTexaco - O2Texaco - O2Texaco - O2Texaco - O2Texaco - O2
BGL - O2Texaco - O2BGL - O2Texaco - O2Texaco - 02Texaco - 02
6,310
6FA IGCC Multi-Nozzle Combustion Systems
Same System Design for 6FA, 7FA, & 9FASame System Design for 6FA, 7FA, & 9FA
Natural Gas
Steam
EndcoverCombustion
Casing
Transition Piece(Differs For 9FA)
FlowsleeveFuel Nozzles
Stage 1 Nozzle(Nozzle Box For Test)
BlendedFuel
Emissions Sample
Combustion Liner
T/C Rake Location
Dynamic PressureLocations
Full Scale Combustion Testing
GE Investment in IGCC– State-of-the-art combustion
development facility at Greenville, S.C.
– Standard machines with optimal integration of turbine and gasification plant with gasification developers
– Program to develop fuel-tolerant, lean-pre-mix combustor for <=9 ppm NOx
– At GE’s Global Research Laboratory -advanced concepts for single-digit NOx
Validation of Performance at Full Flow and Geometry
IGCC Implementation in Refinery
SulfurRemovalSulfur
RemovalShift
ReactorShift
ReactorGasifierGasifier HCUHCU
HRSGHRSG
SteamTurbine
Petroleum Cokevis Breaker Tars
ResidualsAsphalts
ASUASU
H2 Manu-facture
H2 Manu-facture
~~
ProcessSteam
CO2
Air
O2
Air
Syngas
H2
IGCC Provides “Poly-Generation” Benefits With Cost Effective CO2 Separation Capability
Hydrogen Combustion
Video Capture of Flame Structure - 85-90% H2
1.0
10.0
100.0
1000.0
100 150 200 250 300
LHVeq, Btu/SCF
Equivalent Heating Value = Heating Value of Mixture of Syngas and Injected Steam
50 50 -- 95% H95% H22 By Volume, Bal. NBy Volume, Bal. N22, N, N22 + H+ H2200
LHV, kJ/m3
4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000
NO
x @
15%
O2,
ppm
vd
GT Hydrogen Combustion Capability for CO2 Removal
Mixed Fuel Capability (Syngas/Distillate)Dual Fuel Capability
Gas/Distillate Operation
20
% Load
100
0 10 40 50 70 100 % Distillate% Split
100 90 60 50 30 0 % Syngas
Shaded: MixNot Permitted
Mix Permitted(Allowable Splits)
• % Split Is in Terms of % GT Total Heat Consumption
SteamDistillate
Syngas
Atomizing Air
IGCC Fuel Flexibility Critically Important to Refinery Operations
Type Operational capabilities for IGCC systems* Fuel Operability Range
1 Baseline Distillate/SG system
- Similar to other dual fuel standard combustor machine except inert purge on SG side.- Cofiring capability provided for Singapore (ADO/Syngas)
100% SG100% DIST
90% SG/ 10% dist30% SG/ 70% dist
2 Baseline NG/SG system - NG and syngas travel down separate paths- Simplest, least expensive
100%SG100% NG
65% SG/ 35% NG35% SG/ 65% NG
3 Extended Turndown system
- Verified at Exxon-Singapore- Manifolds interconnect via transfer valves- Exclusion zone 10% wide from 15% to 30% NG
100%SG100%NG
90% SG/ 10%NG10% SG/ 90%NG
4 Simplified Extended Turndown System
- Same as #3 except 35% min SG- Eliminates exclusion zone- Simplifies control logic
100% SG100% NG
90% SG/ 10% NG35%SG/ 65% NG
* All assumed to provide for maintaining load set point using NG modulation.
Co-Firing Operational Capability
Dual Fuel Systems Designed For Wide Supply Variation
Cool Water 25PSI - Wabash <25Tampa - Polk <25Texaco - El Dorado <25Motiva - Delaware 9 - 15Sarlux - Italy <30Exxon - Singapore 42
PredictedSierra Pacific - Pinon <42 (<9 Thermal)Gonfreville 35 Citgo Lake Charles 25PIEMSA 30
Typical NOx Emissions from IGCC Plants
Operating N0x PPMVD @15%02
GT24333A
Representative USA IGCC NOx Levels and Permits
Plant Date Fuel NOx(ppmbv@15%O2)
Cool Water 1984 Coal 25
Wabash River 1995 Coal/Pet Coke < 25
Polk 1996 Coal/Pet Coke < 25
Texaco El Dorado 1996Pet Coke/ Refinery Wastes
< 25
Motiva Delaware 2000 Pet Coke 15
PolkBACTRedetermination
2002 Coal/Pet Coke 15
Kentucky Pioneer* 2001 Coal 15**
* Permit issued 6/17/2001** Subject to re-evaluation
Changing NOx Emissions Stds. For US IGCC Plants
\
GE IGCC Gas Turbine and Combined-Cycle Product Line
IGCC 7FA
GAS TURBINESModelSyngas Power RatingGE1010MW (50/60 Hz)6B40MW (50/60 Hz)7EA90MW (60 Hz)9E150MW (50 Hz)6FA90MW (50/60 Hz)7FA197MW (60 Hz)9FA286MW (50 Hz)
IGCCModelNet Plant Power Rating
106B60MW (50/60 Hz)107EA130MW (60 Hz)109E210MW (50 Hz)106FA130MW (50/60 Hz)107FA280MW (60 Hz)109FA420MW (50 Hz)
Dedicated IGCC Gas Turbine Product LineDedicated IGCC Gas Turbine Product Line
GE F Class Advanced Gas Turbine IGCC Refinery Projects
• 6FA (90MW)- Motiva Enterprises Delaware (2-Units w/Ht. Rec. Cogen.)
Petroleum Coke- Exxon Singapore (2- Units w/Ht. Rec. Cogen.)
Heavy Oil
• 7FA (197MW)- Citgo Lake Charles (2-Units w/Combined Cycle Cogen.)
Petroleum Coke
• 9FA (294MW)- PIEMSA (2-Units w/Combined Cycle Cogen.)
Heavy Oil
High Efficiency “F” Class Gas Turbine Performance Drives IGCC Solution
GE 7FA Gas Turbine IGCC Evolution
7FA Natural Gas150–172 MW ISO
7FA+e IGCC197 MW ISO
192 MW ISO7FA IGCC 1995
2000
2006
– IGCC Combustor
– Higher Torque Rotor
– Higher Firing Temperature
– Modified Turbine Nozzle
– Combustor Developments
– Increased Pressure Ratio
7FA Advanced IGCC211 MW ISO
Continued Gas Turbine AdvancesContinued Gas Turbine Advancesto Enhance IGCC Plant Economicsto Enhance IGCC Plant Economics
IGCC Economics
Economic Comparison of IGCC versus Combined CycleEconomic Comparison of IGCC versus Combined Cyclebased on 20 year COE for large power plants
00.20.40.60.8
11.21.41.61.8
22.2
1.5 2 2.5 3 3.5 4 4.5 5 5.5
Combined Cycle Fuel Price [$/MMBTU]
IGC
C F
uel P
rice
[$/M
MB
TU]
Combined CycleCombined CyclePreferredPreferred
IGCCIGCCPreferredPreferred
Pet Coke
Residues
Coal
Orimulsion
COEParity
IGCC Competitive at $2.50 Spread
$3.91H Hub10-9-02
Summary• Current market drivers are favorable for refinery waste fuel conversion
projects
• Contemporary IGCC plant designs are commercially viable with refinery operations
- Broad capability to use opportunity and low value waste fuels
• IGCC technology enjoys compelling environmental advantages for waste fuel conversion to economical poly generation products
- Growth potential to meet future regulatory challenges
• IGCC economics are at parity or better than conventional solid fuel technologies using opportunity fuels
• GE gas turbine IGCC product line is experienced and well matched for refinery syngas applications
- Advanced F Class Gas Turbines: High Output, High Effic. & Specific Work
• Fuel flexibility allowing for high system reliability are critically important to successful IGCC refinery projects