2. Agenda
GE leadership & experience
Important design characteristics
Process description
Critical process elements
Project complexities
+/- of Illinois #6 coal
Key results/data
Summary
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4. GE Energy: gasification leadership
GE Energy’s Experience
• Gasification leader since 1948
• 65 facilities worldwide (+19 under construction)
• ~120 gasification vessels in operation
• 1966: first heavy fuel oil gasification
• 27 plants today on liquid fuels
• 27 turbines with syngas
• 1MM+ operating hours
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• 33 projects globally that separate CO2 GE /
5. Continuing to invest in technology
Dr / etInj
y W ect HPCoa F
l eed Injection
Ba l e
ngaor Sha i
ngha Technologies
Operability &
Controls
Fuel Flexibility
Dr T F na
op ube ur ce
Caifor
l nia
Conversion Heating Rate
Controls Residence Time
(5s)
Quench FowF cil y
l a it Residence Time
(40s)
NewY k
or
Proposed R r Cent
eseach er
Conversion Wyoming
~ 100 Mt/hr
Foulinglb/hr
~ 15
Fuel Flexibility
Entrainment
Stability & Control Adv Technologies
Quench Chamber Design Operability &
Controls
Fuel Flexibility
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6. The HPG-ATC at the U of Wyoming
High Plains Gasification Advanced Technology Center:
Developing the next generation of gasification technologies
• PRB & other coals
• Scaled facility
• Commercial level gasification
– Dry feed (pressure/metering)
– Dry injection (spray dispersion)
– Dry gasification (O/C ratio)
• Complete process blocks Status
– Coal feeding system • Site Selection…May ‘09
– Gasification island
– Carbon capture systems • Start PreFEED…May ‘09
– Water treatment systems • COD 2012
– Data acquisition & controls
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8. Configuration basis for presentation
• Note: GE does not own F-T technology
• Gasification to support 40,000 bpd CTL plant
• Choice of feedstock: Illinois #6 coal
• Diesel: 28,000 bpd
• Naphtha/LPG: 14,000 bpd
• Plant location: US
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10. Indirect CTL with F-T superior fuels
Coal Oxygen
Power block
Fischer-Tropsch
synthesis
Sour S yngas Cleanup Sweet
Gas ification Syngas Proces s Syngas
Proces s
CO2 Clean Fuels
Sulfur
Stream
• Proven, commercial process, operating in South Africa
• F-T diesel high cetane, low aromatics, near zero sulfur
• Naphtha straight chain paraffinic, near zero sulfur
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11. Process visual model of IGCC plant
Click for visual model
Today’s discussion focus is here 11 /
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13. GE’s quench system
configuration
GRINDING AND SLURRY GASIFICATION AND
GAS COOLING GAS SCRUBBING
PREPARATION
Oxidant
Particulate Free
Water Synthesis Gas
PARTICULATE
SCRUBBER
Coal Feed
GASIFIER
GRINDING
MILL
Recycle Quenched Syngas
SLURRY
TANK
QUENCH
SLURRY CHAMBER
PUMP Char Purge Water
LOCKHOPPER Clarifier
Slag
SLAG Separator
SUMP
Coarse Slag to Recycle
Sale/Disposal
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15. Syngas quality & treatment are critical
Key needs GE Energy’s
Oxidant
Fuel
Quench
Simple Entrained flow
Reliable Refractory-lined
High H2:CO Slurry feed
Product
Syngas
Reactor
Solids removal Quench configuration
Water for shift Saturated syngas
Min. compression Up to 1200 psig
Fuel flexibility
Fuel flexibility
Water use
minimization Water recycle
Cost effective solution for hydrogen, CTL & chemicals
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19. The results/performance
Overall balance
• CO2 production in tons/bbl? 0.23 Tonnes/ Coal feed 18,000 Tpd
bbl CTL*
• Needs of water in tons/bbl? 2.3 bbl Products
water/bbl CTL D ie se l 26,700 b p d
Nap h th a 9,500 b p d
• Can biomass be added? Up to what %? LPG 3,800 b p d
Our customers have tested up to 5% …
not in our current process design Total 40,000 bpd
• CAPEX $ for this 40,000 BPD plant (inside Power
battery limits) Recent, public estimates Gross Powe r 620 MW
$60-105k/bpd capacity1 Export 45 MW
•CO2 from gasification step only
1
SSEB 2005, DOE 2007, RAND 2008
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21. Summary
GE leadership & experience
Important design characteristics
Process description
Critical process elements
Project complexities
+/- of Illinois #6 coal
Key results/data
Summary
www.ge-energy.com/gasification
robert1.carpenter@ge.com
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Why not leverage the existing infrastructure that we have today? Oil refineries make a variety of liquid fuels, many of which are highly valued in the global market. But, we are typically left with heaver fuels, with little external market value. Why not leverage these for power? Instead of tying to mix these heavier liquids to make a fuel suitable for power generation, why not use the heavier ends directly. Describe schematic: 1. To deal with these heavier liquid fuels, we offer a new concept …. Split or separate the heavy liquid ends from the refinery. Once split, the lighter liquids could be sent to a gas turbine … these liquids are well within current gas turbine capabilities, especially as most of the contaminants will end up in the heavier fraction. (Need emphasis here) The heavier fuel fraction can then be gasified. This is a chemical process in which the fuel is partially oxidixed and produces a hydrogen based fuel (syngas), which can be cleaned and burned in a gas turbine. This is a well known process …. GE has more than 1 million gas turbine operating hours on these types of fuels; Once example is a plant in Italy which is gasifying petrolelum (pet) coke to produce syngas which is used to fuel a set of gas turbines, producing 500 MW (net power). This slide strengthens the idea of direct firing of GT’s , as a higher performing platform than a traditional steam boiler. And the right side promotes the years of gasification experience, numbers of value streams; syngas, metals, sulfur, CO2.
CTL block diagram
Slurry/liquid feed simple, safe, versatile, efficient, Reactor design downflow, simple, good solids removal, Wide range of possible operating variables pressure, feeds, optimize overall system, Gas Cooling by either water quench or high pressure steam generation. After the gasification reaction, the gas is cooled and scrubbed free of particulates in a water scrubbing system. This generates a hot clean syngas, saturated with water, and still containing H2S. Ash settles in the water bath and is removed from the high pressure reaction area via a lockhopper. Soot or char high in carbon is concentrated in a settler and recycled to the gasifier. Low carbon ash is sold or disposed of offsite. For solid feeds, the feedstock is ground with water to form a slurry. The slurry is then pumped to the gasifier. For oil feeds, the grinding mill is eliminated and the oil is pumped to the gasifier. Because of the similarity in feed systems for both solids and oil, we have great feedstock flexibility and some commercial units have changed feedstocks as the cost of feedstock has changed.
Turndown issues – refineries have daytanks. These don’t can’t.