Norman Shilling Leader Process Power Plants Understanding the NG to IGCC Conversion Option GE Energy
2 / AEIC2004.ppt
LongLong--Term
TermNG Prices
NG Prices Permitting
Permitting
Public
Public
AcceptanceAcceptance
Coal
Coal
Avai
labi
lity
Avai
labi
lity
To R
efue
l to Refuel
SiteSiteSuitabilitySuitability
Existing
Existing
Agreements
Agreements
Asset
Asse t
Recove ry
Recove ry
StrategyStrategy
Or Not
Revisiting The Decision
3 / AEIC2004.ppt
• Natural Gas Price Volatility
Gas
LNG
WindOil
20
40
60
80
100
120
91 92 93 94 95 96 97 98 99 00 01 02 03
GW
Coal0
Gas
LNG
WindOil
20
40
60
80
100
120
91 92 93 94 95 96 97 98 99 00 01 02 03
GW
Coal0
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
$9.00
$10.00
Dec-90 Apr-92 Aug-93 Jan-95 May-96 Oct-97 Feb-99 Jul-00 Nov-01 Mar-03
$/M
MB
tu
• Above COE parity with coal
• Sharply falling NGCC investment
• Diminishing capacity factors for NGCC
Current Status
Source:US DOE EIA, Monthly Energy Review, August, 2004
Global Greenfield Investments
Utility Sector NG Cost
Source: Cambridge Energy Research Associates
Refueling Decision Factors
4 / AEIC2004.ppt
Financial EnvironmentalTreatment of residual value of NG plant Permittability of coal vs. NGCoal source & cost Legacy permitting & public relations for NG plantBase load demand vs. cycling Site environmental recharacterizationExisting demand contract arrangements Revised air modelingByproduct sales Local impact of coal and byproduct transportRevised contract services agreement SCR/ammonia system capabilityExisting NG supply contracts Higher exhaust flowOver-the-fence vs. on-the-books 15 ppm syngas & 25 ppm NG cofiringOutage/interruption for conversion Ammonia injection system
Site Suitability Reduced exhaust temperatureSpace for retrofit Sulfur & trace metals impact on catalyst
Distance from gasification to GTCC Accessibility for cleaningLarger GT enclosure & BOP Wash water treatment & dischargeArea for gasification plant CO catalyst capabilityAccessibility for GT modification PerformanceAccessibility for plant construction Level of GTCC integration
Coal availability and accessibility HRSG sizingMaterials logistics Rebalancing of ST
Coal transport means & delivery Generator capacity for higher outputCoal handling & storage OtherByproduct handling and storage System Interconnect re-applicationReagent sourcing, handling & storage Sulfur impact on downstream components
Site utilities Reclassification of operating staffAdditional cooling water Additional operating staff and craftsProcess water consumption New HAZOPS procedures
Financial
• Treatment of residual value of NG plant• Coal source & cost• Base load demand vs. cycling• Existing demand contract arrangements• Byproduct sales• Revised contract services agreement• Existing NG supply contracts• Over-the-fence vs. on-the-books• Outage/interruption for conversion
5 / AEIC2004.ppt
Financial Drivers
6 / AEIC2004.ppt
Power Block39%
Cleanup12%
Oxidant/ASU10%Gasification
39%
Power Block is major cost component of IGCC plant
Potential fornet coal plant
Cost <$1,000/kw
2.8
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6
GreenfieldIGCC
Refuel100%
Residual
Refuel90%
Residual
Refuel80%
Residual
Refuel70%
Residual
Refuel100%
Writeoff
1st Y
ear C
OE
(c/k
W-h
r)
ASSUMPTIONS$1.25/MMBtu Coal$1,450/kW IGCC
$25/kW SCR Upgrade92% CF IGCC
16% Fixed Rate10% Discount Rate
EconomicsAppropriate financial treatment will vary with utility
Example: Increase of depreciable asset or carryover of residual (undepreciated value) into new project.
7 / AEIC2004.ppt
8 / AEIC2004.ppt
• Space for retrofit• Distance from gasification plant to GTCC• Larger GT enclosure & BOP• Area for gasification plant• Accessibility for GT modification• Accessibility for plant construction• Coal availability and accessibility• Materials logistics
- Coal transport means & delivery- Coal handling & storage- Byproduct handling and storage- Reagent sourcing, handling & storage
• Site utilities- Additional cooling water- Process water consumption
Site Suitability
Refueling Configurations
Configuration BenefitsSyngas supply only Commercially simpleNon-HR gasification
ORProcess Steam Utilization
Maximum siting flexibility
Steam diluent NOx control
Lowest capital costCentral gasification
Syngas and N2 supply Steam/water consumptionNon-HR gasification Improved HR
OR Flexible sitingProcess steam utilization Central gasification
Syngas and N2 supply Reduced steam consumptionNon-HR gasification Maximum GT output
OR Reduced ASU MAC & capitalProcess steam utilization Improved HRAir Extraction
Syngas and N2 supply Lowest HRHR gasification Highest GTCC outputGT/ASU Integration
Over-the-Fence
Nitrogen Return
GT/ASU integration
Full Integration
Other ConsiderationsRebalancing of steam cycleLowest efficiency, outputMaintenance of syngas superheatSteam diluent/water consumptionGT compressor limitationsShutdown and purge
Rebalancing of steam cycleGT compressor limitationsMaintenance of syngas superheatShutdown & purge
Rebalancing of steam cyclePlant retrofit spaceSystem controls lag
Rebalancing of steam cycleHighest capital costPlant retrofit space
10 / AEIC2004.ppt
11 / AEIC2004.ppt
Gasification IslandCoal Storage, Grinding, & HeatingSlurry Preparation & PumpingGasif ier UnitSyngas Cooling/Saturation/HeatingSyngas CleaningSulfur RecoveryProcess Island Sub-StationSyngas FlareAsh Handling SystemMain Process Contingency & Safety SystemProcess Island Interconnecting Piping & Cabling
Air Separation UnitMain Air CompressorOxygen CompressorNitrogen CompressorGas Turbine Ext/N 2 Heat ExchangerNitrogen SaturationASU AuxiliaryASU Control SystemASU Sub Station
Power IslandGas TurbineSteam TurbineGeneratorHRSGCondenserExpander Turbine GeneratorDemineralizerBoiler Feedw ater PumpsAuxiliary Cooling Water SystemPow er Island Sub-StationDistributed Control SystemTurbine BuildingPow er Island Interconnective Piping & Cabling
Pow er InputSyngas
HP SteamMP SteamLP Steam
LP Condensate Return
LP Feedw aterDemineralized Make-up Water
HP Economizer Water
Auxiliary Cooling Water Return
Process Condensate
MP Feedw ater
LP Condensate
Auxiliary Cooling Water
CoalConveying
RawW
ater
NaturalG
as
Power
Input
CirculatingW
ater
CirculatingW
ater
HP N 2Purge
HP O 2
Sulfur
Slag
Pow er Input
Air ExtractionHP N 2 Injection
Circulated WaterCirculated Water Return
Auxiliary Cooling Water
Auxiliary Cooling Water ReturnAuxiliary Steam to ASU
NaturalG
as
MunicipalW
ater
Pow
er
Output
LP O 2
What the Designer Would
Like
Gasification IslandCoal Storage, Grinding, & HeatingSlurry Preparation & PumpingGasif ier UnitSyngas Cooling/Saturation/HeatingSyngas CleaningSulfur RecoveryProcess Island Sub-StationSyngas FlareAsh Handling SystemMain Process Contingency & Safety SystemProcess Island Interconnecting Piping & Cabling
Air Separation UnitMain Air CompressorOxygen CompressorNitrogen CompressorGas Turbine Ext/N 2 Heat ExchangerNitrogen SaturationASU AuxiliaryASU Control SystemASU Sub Station
Power IslandGas TurbineSteam TurbineGeneratorHRSGCondenserExpander Turbine GeneratorDemineralizerBoiler Feedw ater PumpsAuxiliary Cooling Water SystemPow er Island Sub-StationDistributed Control SystemTurbine BuildingPow er Island Interconnective Piping & Cabling
Syngas
CoalConveying
RawW
ater
NaturalG
as
Power
Input
CirculatingW
ater
CirculatingW
ater
HP N 2Purge
HP O 2
Sulfur
Slag
Pow er Input
NaturalG
as
MunicipalW
ater
Pow
er
Output
LP O 2
Gasification IslandCoal Storage, Grinding, & HeatingSlurry Preparation & PumpingGasif ier UnitSyngas Cooling/Saturation/HeatingSyngas CleaningSulfur RecoveryProcess Island Sub-StationSyngas FlareAsh Handling SystemMain Process Contingency & Safety SystemProcess Island Interconnecting Piping & Cabling
Air Separation UnitMain Air CompressorOxygen CompressorNitrogen CompressorGas Turbine Ext/N 2 Heat ExchangerNitrogen SaturationASU AuxiliaryASU Control SystemASU Sub Station
Power IslandGas TurbineSteam TurbineGeneratorHRSGCondenserExpander Turbine GeneratorDemineralizerBoiler Feedw ater PumpsAuxiliary Cooling Water SystemPow er Island Sub-StationDistributed Control SystemTurbine BuildingPow er Island Interconnective Piping & Cabling
Syngas
CoalConveying
RawW
ater
NaturalG
as
Power
Input
CirculatingW
ater
CirculatingW
ater
HP N 2Purge
HP O 2
Sulfur
Slag
Pow er Input
NaturalG
as
MunicipalW
ater
Pow
er
Output
LP O 2
What the Utility Would
Like
Configuration
Integration
Extraction Air
Air Separation Unit
HP Oxygen
LP Oxygen
Clean Syngas
Nitrogen HumidifiedNitrogen
Steam
LP Steam / BFW
Exhaust
PowerNitrogen
Moisturizationand Heating
Gas Turbine -Steam Turbine -Generator Block
Supplemental Air Air Extraction0% -------------- Case A-------------- 100%50% -------------- Case B-------------- 50%100%-------------- Case C-------------- 0%
Supplemental Air Air Extraction0% -------------- Case A-------------- 100%50% -------------- Case B-------------- 50%100%-------------- Case C-------------- 0%
12 / AEIC2004.ppt
13 / AEIC2004.ppt
Gas Turbine Output vs. Ambient Temperature
0 20 40 60 80 100Ambient Temp. (Deg. F)
9FA
(MW
e)
7FA/9FACurrent Torque/IGCC Limit
Near Future Torque Limit
-20 -10 0 10 20 30 40Ambient Temp. (Deg. C)
Syngas
7FA/9FA - Natural Gas
7FA
(M
We)
Additional Output
Gas Turbine Output vs. Ambient Temperature
0 20 40 60 80 100Ambient Temp. (Deg. F)
9FA
(MW
e)
7FA/9FACurrent Torque/IGCC Limit
Near Future Torque Limit
-20 -10 0 10 20 30 40Ambient Temp. (Deg. C)
Syngas
7FA/9FA - Natural Gas
7FA
(M
We)
Additional Output
Performance
14 / AEIC2004.ppt
•Permitting of coal vs. NG• Legacy issues with NGCC plant• Site environmental re-characterization• Revised air modeling• Local impact of coal and byproduct transport• SCR/ammonia system capability
- Higher exhaust flow- NG co-firing- Ammonia injection system- SCR temperature- Sulfur & trace metals impact on catalyst- Accessibility for cleaning- Wash water treatment & discharge
• CO catalyst capability
Environmental
Environmental Factors IGCC NGCC CommentsNOx - Diffusion combustor
Syngas lb/MMBtu 0.07 0.01 BACT basis -- coal plant vs. NGCC?NG backup/Cofiring lb/MMBtu 0.11 NA Higher NOx w/ NG operation
NOx - SCR lb/MMBtu 0.02 0.01
SCR requires < 2ppm sulfurSCR temperatureAmmonia system capacitySulfur resistance of catalystSCR sizing for higher flowProvisions for SCR and HRSG wasHRSG materials & dewpoints
SO2lb/MMBtu 0.01 <0.001 Both well below conventional coal
PM lb/MMBtu <0.01 <0.01 Comparable performanceSUSD Emissions Longer time for startup/shutdown
Other Process stack ventsCoal pile
Local Impact Local impact of transport of coal, reagent, byproductIncreased water consumption
15 / AEIC2004.ppt
Size of the Opportunity
16 / AEIC2004.ppt
Bituminous
Sub bituminous
Anthracite
Active MineLignite
Bituminous
Sub bituminous
Anthracite
Active MineLignite
CONNECTICUT
WEST VIRGINIA
VIRGINIA
PENNSYLVANIA
OHIO
ONTARIO
NORTH CAROLINA
FLORIDA
TENNESSEE
SOUTH CAROLINA
LOUISIANA
Hanging RockHanging RockHanging RockHanging RockHanging RockHanging RockHanging RockHanging RockHanging Rock
ALABAMA
ARKANSAS
DISTRICT OF COLUMBIA
GEORGIA
IOWA
ILLINOIS INDIANA
KENTUCKY
MASSACHUSETTS
MISSOURI
MISSISSIPPI
NEW JERSEY
NEW YORK
Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Bethlehem (CIV)Brunot IslandBrunot IslandBrunot IslandBrunot IslandBrunot IslandBrunot IslandBrunot IslandBrunot IslandBrunot Island
GermanGermanGermanGermanGermanGermanGermanGermanGerman
Grand TowerGrand TowerGrand TowerGrand TowerGrand TowerGrand TowerGrand TowerGrand TowerGrand Tower
Hog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy CenterHog Bayou Energy Center
Reliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw CountyReliant Energy Choctaw County
Near Northern / Central / Southern Appalachian Coal
Basin SourceCONNECTICUT
WEST VIRGINIA
VIRGINIA
PENNSYLVANIA
OHIO
ONTARIO
NORTH CAROLINA
FLORIDA
TENNESSEE
SOUTH CAROLINA
LOUISIANA
Indiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration FacilityIndiantown Cogeneration Facility
Bridgeport HarborBridgeport HarborBridgeport HarborBridgeport HarborBridgeport HarborBridgeport HarborBridgeport HarborBridgeport HarborBridgeport HarborHudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)Hudson (PSEGF)
EddystoneEddystoneEddystoneEddystoneEddystoneEddystoneEddystoneEddystoneEddystoneMuskingum RiverMuskingum RiverMuskingum RiverMuskingum RiverMuskingum RiverMuskingum RiverMuskingum RiverMuskingum RiverMuskingum River
Hatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power StationHatfields Ferry Power Station
River RougeRiver RougeRiver RougeRiver RougeRiver RougeRiver RougeRiver RougeRiver RougeRiver Rouge
Stanton Energy CenterStanton Energy CenterStanton Energy CenterStanton Energy CenterStanton Energy CenterStanton Energy CenterStanton Energy CenterStanton Energy CenterStanton Energy Center
CristCristCristCristCristCristCristCristCrist
Allen (TVA)Allen (TVA)Allen (TVA)Allen (TVA)Allen (TVA)Allen (TVA)Allen (TVA)Allen (TVA)Allen (TVA)
Martin (FPL)Martin (FPL)Martin (FPL)Martin (FPL)Martin (FPL)Martin (FPL)Martin (FPL)Martin (FPL)Martin (FPL)
Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bergen (PSEGF)Bridgeport EnergyBridgeport EnergyBridgeport EnergyBridgeport EnergyBridgeport EnergyBridgeport EnergyBridgeport EnergyBridgeport EnergyBridgeport Energy
Brooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioBrooklyn Navy Yard CogeneratioRavenswoodRavenswoodRavenswoodRavenswoodRavenswoodRavenswoodRavenswoodRavenswoodRavenswood
Liberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectLiberty Electric ProjectWaterford (psegp)Waterford (psegp)Waterford (psegp)Waterford (psegp)Waterford (psegp)Waterford (psegp)Waterford (psegp)Waterford (psegp)Waterford (psegp)
Washington Energy FacilityWashington Energy FacilityWashington Energy FacilityWashington Energy FacilityWashington Energy FacilityWashington Energy FacilityWashington Energy FacilityWashington Energy FacilityWashington Energy Facility
GermanGermanGermanGermanGermanGermanGermanGermanGerman
Dearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLCDearborn Industrial Generation LLC
Hopewell CogenerationHopewell CogenerationHopewell CogenerationHopewell CogenerationHopewell CogenerationHopewell CogenerationHopewell CogenerationHopewell CogenerationHopewell Cogeneration
Bell meadeBell meadeBell meadeBell meadeBell meadeBell meadeBell meadeBell meadeBell meade
StantonStantonStantonStantonStantonStantonStantonStantonStanton
Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)Santa Rosa (SKYSER)
SouthavenSouthavenSouthavenSouthavenSouthavenSouthavenSouthavenSouthavenSouthaven
Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)Chouteau (AECI)
Sugar CreekSugar CreekSugar CreekSugar CreekSugar CreekSugar CreekSugar CreekSugar CreekSugar Creek
ALABAMA
ARKANSAS
DELAWARE
GEORGIA
IOWA
ILLINOIS INDIANA
KENTUCKY
MASSACHUSETTS
MISSOURI
MISSISSIPPI
NEW YORK
ChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfieldChesterfield
Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)Grand River Dam (GRDA)
Wabash RiverWabash RiverWabash RiverWabash RiverWabash RiverWabash RiverWabash RiverWabash RiverWabash River
Within 10 miles of an Eastern Coal Plant >
300MWOr
Co-located at a coal generation facility
0
5
10
15
20
# of Sites 207FA Plants 307FA Plants
#
Near Coal Source Near Coal Plant Co-located with Coal Plant
First Level Screening
7FA EvolutionPG7211(F) PG7221(FA) PG7241(FA)PG7231(FA)
Turbine SC Output, MW 150 159 167.8 171.7
1X CC Output, MW - 253.4 258.8 262.6
1X CC Efficiency, LHV - 55.0 56.0 56.0
Firing Temperature, C 1260 1287 1316 1327
Pressure Ratio 13.5:1 15:1 15:1 15.5:1
Compressor Stages 18 18 18 18
Turbine Stages 3 3 3 3
Combustion Chambers 14 14 14 14
Year of First Shipment 1989 1992 1996 1999
17 / AEIC2004.ppt
18 / AEIC2004.ppt
Air ExtractionSyngas& Diluent
InjectionSkids
Mark VI IGCC Controls
IGCC Combustion System• MNQC Type• SG/ NG or Distillate• N2, Steam or N2+Steam• Air Extraction
Larger Stage 1 Turbine Nozzle• 7211 component• Modified Retaining & Support Ring
Air ExtractionSyngas& Diluent
InjectionSkids
Mark VI IGCC Controls
IGCC Combustion System• MNQC Type• SG/ NG or Distillate• N2, Steam or N2+Steam• Air Extraction
Larger Stage 1 Turbine Nozzle• 7211 component• Modified Retaining & Support Ring
7FA F-F Modifications
19 / AEIC2004.ppt
Inlet Bleed Heat
System
Enclosure Mods:• Piping – SG, Diluent, Air Ext• Explosion Proofing• Hazardous Gas Detection• Fire Protection
Ventilation Mods
Syngas Fuel Skidw/N2 Purge System
Opt. Air Ext. Skid
IGCC Controlsw/Added I/O
N2/StmInjection Skid
Inlet Bleed Heat
System
Enclosure Mods:• Piping – SG, Diluent, Air Ext• Explosion Proofing• Hazardous Gas Detection• Fire Protection
Ventilation Mods
Syngas Fuel Skidw/N2 Purge System
Opt. Air Ext. Skid
IGCC Controlsw/Added I/O
N2/StmInjection Skid
Accessory & Packaging Modifications
20 / AEIC2004.ppt
IGCC Power Eng. & Equipment CycleNTP
Release N.G.
SyngasComm.
Manufactur'gRelease COD
M’facture
4018
CODSyngas
4028
Site Construction
366 12-18 -12 -6 0 18 24
12 18 24 30-6 0 6
CODFEEDPackage
DetailedEngineering
IGCC Process Eng. & Equipment Cycle
36-30 -24 -18 -12 -6 0 6 12
12 18 24 30
MONTHS
MONTHS
LOI SHIPCycleConfig.
-6 0 6
SyngasComm.
Detailed Engineering& Combustion Validate Install
1st
Fire
NTPRelease
IGCC Power Eng. & Equipment CycleNTP
Release N.G.
SyngasComm.
Manufactur'gRelease COD
M’facture
16
CODSyngas
Site Construction
366 120 18 24
12 18 24 306
CODFEEDPackage
DetailedEngineering
IGCC Process Eng. & Equipment Cycle
360 6 12
12 18 24 30
MONTHS
MONTHS
LOI SHIPCycleConfig.
0 6
SyngasComm.
Detailed Engineering& Combustion Validate Install
1st
Fire
NTPRelease
Conceptual Refueling Timeline
FirstShovel
Summary
21 / AEIC2004.ppt
• Refueling is a potential option for recovery of NPV and re-use of strained or impaired assets
• 7FA’s are amenable to conversion for syngasoperation
• Site characteristics are key to determining a refueling strategy and design
• Developing a permitting strategy is a critical factor for sucess
• The number of refueling opportunities will require an in-depth evaluation on a site-by-site basis