GE Energy. Advances in IGCC projects & Technology for the next generation of IGCC & Carbon Capture CC(+S) plants. Marcus Scholz 2010

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1 GE Energy Advances in IGCC projects & Technology for the next generation of IGCC & Carbon Capture CC(+S) plants Marcus Scholz 2010

2 Agenda IGCC Project experience & current activity Lessons learnt & technology improvements GE s Carbon Island technology Carbon Capture levels Gas Turbine hydrogen fuel flexibility

3 GE s leadership & experience Leadership Gasification leadership since 1948 with >70 facilities operating worldwide >130 gasification vessels in operation Experience First coal gasification plant in 1978 First pet coke gasification plant in gas turbines operating on syngas > 1 million operating hours IGCC leader > 3 GW with GE technologies - Cool Water technology demo plant TECO commercial demonstration plant present - DUKE Energy commercial plant COD 2012

4 Diverse Solutions based on Gasification Feedstocks: Coal Pet coke Asphalt Heavy Oil Vacuum Residue Transportation Fuels Jet Diesel Refinery Polygeneration Hydrogen Steam Power Power Generation Electricity Steam Hydrogen + CO 2 Chemicals Ammonia Methanol Oxo-chemicals > 60 years! Substitute Natural Gas SNG

5 Syngas to Hydrogen (CO 2 separation) GE Carbon Island* option Gasification Partial oxidization Shift - Process Water-Steam / Syngas Reactor Copper or Zinc Basis CO 2 Capture + Compression AGR & CO 2 Compression Selexol Refrigeration: >90% Removal Power GT Diffusion burner Diluent (N 2, Steam) H 2 H 2 & CO CO + H 2 O > CO 2 + H 2 H 2 & CO 2 CO 2 Syngas shift & extract carbon photos courtesy of Air Products, Baytown, TX facility. * Carbon Island is a trademark of the General Electric Company.

6 IGCC Plants evolution Pilot Commercial ( ) (1996 today) Large Commercial ( tomorrow) Coolwater 120 MW IGCC 7E Gas Turbine development project Tampa Electric 250 MW IGCC 7FA Gas Turbine 5 Year Construction Duke Energy 630 MW IGCC 7FB Gas Turbine 3 Year Construction

7 IGCC Polygeneration SARLUX 550MW Licensee/Owner: Sarlux S.r.l Operator: SARAS S.p.A. Location: Sardinia, Italy Startup: 2001 Feedstock: Visbreaker tar Design Capacity: 1,200 mtpd Operating Pressure: 38 bar Gasifier Size: 3 x 900 ft³ Power Block: 3 x GE 9E GT s, 3 x GE Steam turbines EPC Contractor : Snamprogetti S.p.A. Oxygen Visbreaker Teer 3,600 t/day Gasification & Carbon Extraction 90+% availability (no spare) Gas Cooling & COS Hydrolysis Steam export refinery MP = 100 t/h; LP =85 t/h Sulfur Claus & Recovery GE Combined Cycle Power to Grid 551 MW Steam to export Black Water Treatment Filtration cake Metal recovery Elemental Sulfur Hydrogen Production H2 to Refinery 40,000 Nm3/h

8 Duke Energy Edwardsport IGCC Nominal 630MW, 207FB CCGT COD in 2012 Construction on-track 2x RSC + gasifier shipped in F Syngas turbines ship in 2010 Wide coal & pet coke fuel envelope Duke Energy Edwardsport site construction, Sept. 2009

9 Gasifier & Radiant syngas cooler sections Gasifier production Italy, 2009 Transport in 2 sections each.

10 Duke Edwardsport IGCC July 2009 Coal unloading Area COAL Harbour Gasification Area RSC assembly area Gasification Island Construction Gasifier Section assembly

11 Take aways: IGCC is about integration Value proposition: 48 month cycle (FEED to COD) Eliminate 1 yr. from custom IGCC sched. Wide bituminous fuel envelope (ash+s) Carbon capture ready Fully integrated Mark VIe control system with 12 mo. factory accept. test Virtual plant simulator Failure modes mitigated, Operators trained before startup

12 Radiant syngas cooler 1996: First application: TECO 2006: Lessons learned Detailed analysis Improved design meth. Availability & performance improvmt. 30% better perform.; 30% lower cost; higher reliability versus TECO configuration Today: Detailed design complete Components at site On-site assembly in process

13 Integrated controls and simulation #%!" #!$%! " #$ #& &'( )*% # $ % ( ( +)*% #', )* ( $ - # 2006: NPI Project 2008: Detailed Validation Plan Physics based - emulated Stage testing Field validation Operator training simulator Today: Stage testing in process Simulators in operation Operators in training Design validation Next Steps: Site transition ICS delivery

14 Simulation reduces time to maturity Syngas Tube Metal Wall Water Tube +!,,+- Engineering Class Simulation for Controls Operability & Operator Training Instructor Station Operability Optimization Enhance Start-up Times and Trip Avoidance Operational Flexibility Emissions, Heat Rate Plant-wide Availability/ Reliability Studies Improved Transient Performance Customer Training Engineering Simulator Simulation Model Control Software Control Hardware Emulator Operator Training Simulator Generate Physics Based Transient Equipment Models

15 Improving initial availability TECO Polk Unit 1 IGCC Availability Gasifier on Stream Factor Combined Cycle Availability Factor Reference plant Goal: initial availability of 85%

16 IGCC flexibility for carbon value 80 Lowest capital cost CO 2 Avoided Cost $/ton Lowest operating penalty Highest avoided cost CCS Ready meets proposed EU regulation Flexible NGCC CO2 Performance EOR or High CO2 Value 0 Entitlement 5% Capture Eintitlement 20% Capture NG Equivalent Retrofit 60% Capture NG Equivalent Greenfield 65% Capture Greenfield 90% Capture 1 Capture with compression to 150 bar, excludes T&S Avoided Cost ($/ton) = COE cc ($/MWh) COE base ($/MWh) CO2 base (ton/mwh) CO2 cc (ton/mwh) Source: GE Energy internal data

17 GE s Carbon Island TM Greenfield Retrofit Minimal cost/availability impact Integrated with existing Acid Gas Removal (AGR) Installed during turbine maintenance Multiple carbon capture capability options Commercial technologies 33 GE-licensed units operating worldwide using shift reaction. High purity CO 2. Small footprint 2 acres. Reliable CO 2 separation process. Install as greenfield or as an economical retrofit for 65% CO 2 capture

18 IGCC CO 2 Capture Readiness Oxygen, Feedstock Water Gas Shift (50%-65% capture) Process Gas Only High P, Low Vol High Driving Force Diffusion Combustor Diluent NOx Control Gasification Optional Shift AGR / SRU H 2 Power Slag Proven Gasification Hg Proven Process S CO 2 Proven Turbines 70 GE Licensed Gasification Plants operating worldwide 33 GE Licensed Gasification Plants operating worldwide removing CO2 and producing H2 27 GE Gas Turbines operating at 50%-95% H 2

19 Carbon capture technology maturity Commercial Status Low 3 Med 2 Full 1 Chemical Looping Me/MeO ox/red Bench scale Post-Combustion (Powerspan) Slipstream pilot (1MW) Post-Combustion (Chilled Ammonia) Slipstream Pilot (5MW) Oxy-combustion 30MW pilot Post-Combustion (Amine) Slipstream NG & coal (Max ~60MWt NGCC) Pre-combustion (IGCC) Commercial plants (up to 450MW t >90% CC) 1Commercially offered guaranteed cost & performance 2 Requires shared risk & cost for scale-up to pre-or-full commercial 3 Technical feasibility only unknown cost, performance & integration barriers Bench Feasibility (1-5MW t ) Scale-up Pilot (10-30MW t ) Small Commercial (50-100MW t ) Large Commercial (>350MW t ) Experience

20 Hydrogen Combustion in Gas Turbines Hydrogen has been used in Gas Turbines for over 30 years, primarily in Refinery applications.. Combustion System Hot Gas Path Axial Exhaust Cold End Drive Small Modifications to existing Gas Turbine Platform

21 B/E-class High Hydrogen Experience Project / Site GT Model No. Units Fuel Gas Features Geismer, US MS6001B 1 PG up to 80% H2 Refinery, US MS6001B 1 RFG 12-50% H2 Korea MS6001B 1 PG up to 95% H2 Tenerife, Spain MS6001B 1 RFG ~70% H2 Cartagena, Spain MS6001B 1 RFG 66% H2 San Roque, Spain MS6001B 2 RFG 70% H2 Antwerpen, Belgium MS6001B 1 RFG 78% H2 Puertollano, Spain MS6001B 2 RFG up to 60% H2 La Coruna, Spain MS6001B 1 RFG up to 52% H2 Rotterdam, NL MS6001B 1 RFG 59% H2 Schwarze Pumpe, GER MS6001B 1 IGCC 62% H2 Fleet Leader avg. 90% H 2 more than 10 yrs Vresova, CZ MS9001E 2 IGCC 46.8% H2 Fawley, UK MS9001E 1 RFG ~50% H2 Georgia Gulf, US MS7001EA 3 Blend Methane + 50% H2 Milazzo, ITA MS5001P 1 RFG 30-50% H2 Ref., India MS5001P 1 RFG 50% H2 Paulsboro, US MS5001P 2 RFG 20-60% H2 Ref., Int'l MS5001P 1 RFG Propane + 60% H2 Reutgerswerke, US MS3002J 1 PG 60% H2 NUP MS3002J 1 TG ~60% H2 Donges, US GE10 1 RFG 76% H2 Refinery, Jordan PGT10 1 RFG 82% H2 RFG = Refinery Gas, TG = Tail Gas, PG = Process Gas, IGCC = Syngas

22 F-class Hydrogen Experience PSI Wabash Tampa Polk Exxon Singapore Valaro Delaware Turbine 7FA 7FA 2x6FA 2x6FA H 2 (% vol) CO CH CO N 2 +Ar H 2 O LHV BTU/ft kj/m 3 8,224 9,962 9,477 9,768 T fuel F/C 570/ / / / 299 H 2 /CO Ratio Diluent Steam N 2 Steam H 2 O/ N 2 Equiv BTU/ft kj/m 3 5,910 4,649 4,600 5,910

23 Summary 60 years of experience in gasification operation and innovation 25 years of IGCC experience Significant investments in design methods; tools; and validation facilities 16 months from first fire of Duke Energy IGCC facility Investing in next generation industrial and power gasification technology