Mr. Daniel Tse Gasification Expert GE Holding a B.S. degree in Electrical Engineering from the University of Houston, Mr. Daniel has 17 years of experience in the gasification industry including roles such as Pricing Leader and Commercial Leader for GE s gasification business. Mr. Daniel has authored a gasification patent and represents GE on the Gasification Technologies Council. Prior to the start of his GE career, he worked for Texaco and ChevronTexaco in various commercial, project management, and technical roles wherein he directly managed projects related to gasifiers, refineries, and petrochemical plants.
GE Power & Water GE s Petcoke Gasification Technology Ready to meet today s feedstock challenge Daniel Tse, Manager Gasification Solutions Petroleum Conclave l March 2013 GE s Gasification Technology Chemicals Synthetic Natural Gas Transportation Fuels Refinery Polygen Electricity
Natural gas historical pricing 2
LNG prices expected to remain above $15 in the foreseeable future Source: Credit Rating and Information Services of India Ltd. (CRISIL) India s gas utilization policy will not allow domestic gas to flow into industry NG demand growing at 19% compound annual growth rate (CAGR); 10 LNG terminals planned currently only 2 Naptha when used for power generation translates to very high costs per unit of power produced ($1000/t translates to $26/mmbtu) 3
Steam Methane Reformer (SMR) economics Source: US DOE/NETL, Current (2005) Hydrogen from Natural Gas without CO2 Capture and Sequestration, updated by NREL 2008 and GE Internal Calculations 4
Gasification technology Power (IGCC) Greenfield Polygen Refueling Site repowering Syngas out (H 2 + CO) Feedstock in Coal Pet coke Asphalt Heavy Oil Vacuum Residue Natural Gas Process gas Refineries Chemicals Methanation Coal to liquids Hydrogen Steam Power Formaldehyde MTBE Methanol Acetic acid Amine DME Ammonia Urea Ammonia nitrate/sulfate Oxochemicals: Butanol, Ethylhexanol Substitute natural gas Transportation fuels 5
Radiant cooler Gasifier Chamber Two configurations Quench Quench Quench Radiant Syngas Cooler Partial Quench (RSC/PQ) Hot syngas immediately quenched by direct water contact Syngas is warm and saturated with water ideal for sour CO shift Commercial application 12 to 86 bar Proven gasifier sizes up to nominal 900ft 3 Typical applications: chemicals, hydrogen, refinery polygen for heat recovery Gasifier Chamber Hot syngas first cooled by radiant cooling before quenching Generates high pressure steam to ~135 bar Limits pressures to ~45bar Proven up to nominal 1800ft 3 Typical applications: power generation, refinery polygen Better efficiency than quench Lower capital cost than RSC Shorter construction cycles than RSC Construction cycle more complex than quench 6
Installed fleet by the numbers GE has 155 gasifiers in commercial operation the largest fleet in the industry with additional gasifiers in development, engineering, or construction at 95 and a global presence in different countries. 25 15 plants 7
Petroleum Coke Gasification
GE s Petroleum coke gasification history 1970s Research, pilot study & semi-commercial testing began 1980s Early industrial scale test at Eastman/Ube 1992 100% petroleum coke to power industrial demo unit built within the El Dorado, KS. Refinery More industrial applications: Coffeyville: Urea/Refinery H 2 & Delaware: IGCC 9
GE s Petroleum coke experience GE has licensed (7) 100% petroleum coke gasification plants since 1982 USA: (4) plants with (2) in operation, (1) shut down & the other one in EPC phase Asia: (2) built in Japan with (1) still operating Euro: (1) in Russia in EPC phase GE has licensed multiple partial petroleum coke mixing with coal plants around the world including refineries in China Gasified cokes from both fluid coking & delayed coking process High sulfur shot coke was the feed in Delaware IGCC units 10
Case Study: Coal to Petroleum Coke
Original IGCC configuration 5 Year U.S. Department of Energy (DOE) obligation: Only coal feedstock (no petroleum coke) Slag stored on-site for later disposition 12
Petroleum coke introduction 1999 Petroleum coke was blended offsite (port of New Orleans) & shipped as a blend to Tampa Petcoke blend limits Recycle fines Sulfur & chlorides in feedstock Ash fusion temperature/refractory life 13
Coke blend variations Current blend; 60% petroleum coke 40% coal Demonstrated petroleum coke/coal blends up to 100% petroleum coke % blend depends on several factors: Cost of fuels Available fuels % Sulfur & ppm chlorides in fuel 14
Case Study: Plant Relocation Conversion to Petroleum Coke
Barstow, California Coolwater IGCC Location: Barstow, California, USA Startup: 1984 Feedstock: Coal Capacity: 1,150t/d Operation Pressure: 41bar Gasifiers: 1 900ft³ Radiant Syngas Cooler/Convective Syngas Cooler; 1 600ft³ Quench Gas Turbines: 107E; 110MW Plant mothballed after 5-year Department of Energy demonstration Combined cycle plant repurposed to natural gas Gasification equipment sat idle until mid 90 s 16
Equipment relocated to new fertilizer project site 1,900 km Coffeyville Site: Co-located at delayed coking refinery In middle of farm country Located far enough away from NOLA to benefit from transportation costs Barstow, CA Coffeyville, KS 1,000km 800km 600km 400km 200km New Orleans, LA 17
Coffeyville, Kansas, USA Location: Coffeyville, Kansas, USA Startup: 2000 Feedstock: Petroleum Coke Capacity: 1,180t/d (per gasifier) Operation Pressure: 43bar Gasifier Size: 2 900ft³ Quench Oxygen >90% availability (no spare) CO 2 Separation Petcoke 1300 t/d GE Gasification & Syngas Scrubbing CO Shift & Cooling Acid Gas Removal Pressure Swing Absorption Ammonia Synthesis Ash / Slag Handling Sulfur Recovery CO 2 Purification NH₃ Product 1,100 stpd 18
Syngas & high H 2 capable turbines 19
Syngas turbines: fuel applications 6B (50/60 Hz) 7E (60 Hz) 9E (50 Hz) 6F (50/60 Hz) 7F (60 Hz) 9F (50 Hz) Low Air IGCC Syngas Blast Furnace Gas Fuel Heating Value Medium O 2 IGCC Syngas GTL Off-gas High High H 2 for CCS High H 2 for EOR 20
Low-BTU gas turbines 6B 42 MW 46 MW 7E 85 MW 85 MW Simple cycle output (MW) Natural Gas Syngas 6F 77 MW 92 MW 9E 126 MW 140 MW 7F 187 MW 232 MW 9F 256 MW natural gas 285 MW syngas 21
Syngas turbine controls & accessories Inlet bleed heat system Inlet filter house Inlet duct & plenum Ventilation modifications Syngas fuel skid with N2 purge Static starter Gas fuel module Optional air extraction skid 1 IGCC Controls with added I/O Enclosure modifications: Piping for syngas, diluent, etc. Explosion proofing Hazardous gas detection Fire protection Controls hardware & software Accessory module Liquid fuel and atomizing air Water injection skid Exhaust system N2/Steam injection skid 1 1 Fuel and diluent skids/modules may need to be customized for specific fuel/plant configurations 22
Achieving RAM Targets with Polygeneration
Plant configurations Traditional Quench Produces only H 2 Spares for availability (either 1+1 or 2+1) Can achieve H 2 availability up to 98.8% Polygeneration Produces H 2 for refinery Produces power & steam No unused spares Can achieve H 2 availability up to 99.9% Higher efficiency than traditional quench with RSC configuration Coke Grind ASU Coke Grind ASU Gas Turbine HRSG Steam Turbine SLURRY OXYGEN SLURRY OXYGEN HP Steam SYNGAS TAIL GAS Gasification (Quench Gasifier) Shift/ LTGC AGR PSA Gasification (Quench or RSC Gasifiers) Shift/ LTGC AGR PSA SLAG WATER BLOWDOWN ACID GAS MP and LP Steam SLAG WATER BLOWDOWN ACID GAS MP and LP Steam Slag Crusher Fines Handle Sulfur Recovery Slag Crusher Fines Handle Sulfur Recovery Slag/ Fines Handle Waste Water Treat Sulfur Handling Slag/ Fines Handle Waste Water Treat Sulfur Handling 24
Availability Availability Economics of reliability/availability 0.95 0.9 0.85 0.8 0.75 0.7 0.65 0.6 0.55 0.5 1 2 3 4 5 6 7 8 9 10 0.9 0.85 0.8 0.75 0.7 0.65 0.6 0.55 0.5 0.45 0.4 1 2 3 4 5 6 7 8 9 10 CCF - Yr 1-5 NPV CCF - Yr 1-5 NPV Poor time to maturity can result in 60% decrease in early year cash flow and 35% decrease in project NPV 25
RAM expertise GE Reliability Centers of Excellence Warsaw, Poland Schenectady, NY Greenville, SC Capabilities Analysis of reliability, availability, streams throughput, configuration of process units, streams & critical equipment, enhancing planned maintenance strategy & sparing philosophy 26
Typical availability (no spare) Chinese coal plants benchmarked for equivalent availability over 3 years Equivalent availability was for the total syngas plant not just the gasifiers 27
Planned maintenance Best-in-class petroleum coke 900 ft³ maintenance schedule Refractory Repair cone/throat: 7 days, every 18 months Repair neck/dome/sidewall: 17.5 days, every 24 months Replacement: 25 days, every 72 months Other Gasification 2.5 days, every 6 months 5 days, every 12 months Leveled annual maintenance: 16.8 days Total availability impact: 4.6% 28
Availability comparisons Typical Best Planned Maintenance -7% -5% Unreliability -4% -4% Equivalent Availability 89% 91% Polygeneration typically includes hydrogen, power & steam production Very high hydrogen availability can be achieved Equivalent Availability Typical Best 1+0 (1 100%) 89.0% 91.0% 1+1 (2 100%) 98.8% 99.3% 2+1 (3 50%) 98.2% 98.9% 3+0 (3x33⅓%) H 2 99.9% 99.9% 3+0 (3x33⅓%) Coke/MW 83.5% 90.8% Calculated from single train availability using a binomial distribution Syngas turbines are backed up with back-up fuels, power availability will be higher 29
A Perspective on Capital Expenditures from China
Background Primary Objective: Assess technical & economic viability of China IGCC using GE technology Joint study w/ China Power Engineering Consulting Group Corporation (CPECC) Technology selections enhance efficiency while reducing capital expenditure Create plan for future efficiency & cost improvements 31
IGCC study results Study Parameter Target Result 41-43% LHV Efficiency 42.2% LHV Output 800MW net Cost 8000-10000 RMB/KW (Gross Output Basis) Meet IGCC Emissions Standards Water Consumption at a Maximum of 0.6 m 3 /GWs 870 MW net 8928 RMB/KW (~$1380/KW) Key Area Standard met Maximum met 32
Gasifier economics Source: Internal GE calculation 33
Thank you 34