Siemens Global Gasification and IGCC Update Harry Morehead, Manager, IGCC Business Development Presented at APPA New Generation Workshop January 11, 2007 Orlando, FL
Agenda Siemens Gasification Technology Acquisition IGCC Power Island Update IGCC O&M Market Issues Conclusions Page 2 January 11, 2007 Harry Morehead
Siemens AG: Active In Six Business Areas $23B $26B $15B $17B $10B $5B Information and Automation Communications and Control Power Transportation Medical Lighting Communications Siemens Business Services Automation and Drives Industrial Solutions and Services Siemens Building Technologies Small IGCC Projects COREX Gasification Process Power Transmission and Distribution IGCC Gasification Transportation Systems Siemens VDO Automotive Broad Infrastructure Provider Medical Solutions OSRAM Page 3 January 11, 2007 Harry Morehead
Siemens Product and Service Businesses Group Executive Management Power Generation Industrial Applications Instrumentation & Controls Gas turbines and combinedcycle power plants Steam turbines and power plants Electrical generators Plant Diagnostics Operating Plant Service Gasification SFG Gasifiers Industrial size turbines and power plants Turbo compressors Oil and Gas Sector Service Wind Energy On shore and off shore renewable wind energy solutions Stationary Fuel Cells Instrumentation and control systems IT solutions for power plant management Joint Venture Framatome Advanced Nuclear Power (Siemens stake 34%) Voith Siemens Hydro (Siemens stake 35%) Regional Offices Worldwide Integrated global network for power generation Page 4 January 11, 2007 Harry Morehead
Benefits of IGCC Lower Air Emissions Future potential to capture CO 2 at a significantly lower cost than today s PC plant because CO 2 can be separated prior to combustion Potential to control mercury at a lower cost than is possible with other coalbased generation technologies Lower Water Use 30-50% less that today s PC plants Less Solid Waste Generated 50% less than today s PC plants Overall More Efficient than today s PC Plant With Currently Required Pollution Control Equipment Results in Lower overall CO 2 emissions Fuel Flexible (including a wide range of Coals and Petroleum Coke) Able to take advantage of a range of domestic fuel sources Potential to tap into future poly-generation capabilities including the coproduction of Fertilizer Transportation fuels Synthetic Natural Gas IGCC is more flexible and cleaner than today s PC plants with the potential to provide electricity at a competitive price PC Pulverized Coal Page 5 January 11, 2007 Harry Morehead
Siemens Solutions for Today s IGCC Plants State-of-the-Art Gas Turbines IGCC Plant Instrumentation and Control Systems IGCC Power Island Reference Plant SFG Gasifiers Steam Turbine Generators Siemens O&M Services Air / N 2 / O 2 / CO 2 / Syngas Compressor Trains Page 6 January 11, 2007 Harry Morehead
Scope of Acquisition Scope of Acquisition Sustec Holding AG Not included 100% FUTURE ENERGY GmbH 100% 100% Sustec AG Sustec Industries AG 50% Sustec GSP China Corp., Ltd. (50% Ningxia Coal Group) Sustec Schwarze Pumpe GmbH Siemens Fuel Gasification Technology GmbH The acquisition focuses on gasification technology Page 7 January 11, 2007 Harry Morehead
Siemens Gasification Business Status Siemens SFG gasifiers have been in operation since 1984 processing a wide range of feedstock from lignite to waste tars and oils Siemens has an Engineering group and Gasification Center in Freiberg, Germany and also people in Beijing supporting the Joint Venture Siemens Gasification Group s recent focus has been on the use of coal for production of synfuel, methanol and ammonia Major projects have been awarded in China, and several feasibility studies are under way for projects in South Africa, Canada, Australia and USA Page 8 January 11, 2007 Harry Morehead
Siemens Gasification Experience Projects Gasifier Size Start-up Fuel Products Schwarze Pumpe SZV (Germany) 200MW th 1984 Lignite, natural gas, tar oils, and waste Syngas for methanol and power Future Energy Test Facility (Freiberg, Germany) 5MW th 1996 hard coal, lignite, slurries Syngas BASF Seal-Sands (UK) 30MW th 2001 liquid chemical residuals Fuel Gas Schwarze Pumpe Seal-Sands esová (Chec Republic) 175 MW th 2007 tar oils, liquid residuals syngas for IGCC Shenhua Ningxia Coal Group Equipment Ordered (China) 2x 500MW th Q1/2009 Bituminous coal DME Confidential Client Selected 4 x 500 MW th 2011 Lignite H 2 Shenhua Ningxia Coal Group In Discussions (China) 4 x 500 MW th 2009 Bituminous coal Polypropylene V esová Siemens Test Center Page 9 January 11, 2007 Harry Morehead
Technology Overview Siemens SFG Gasification Technology SFG Gasifier Highlights This multi-fuel gasifier accepts a wide variety of feedstocks (e.g., bituminous coal, subbituminous coal, lignite, biomass and liquid wastes) Siemens design & manufacture the gasification equipment Technology development started in mid-1970s Siemens has more than 20 years of successful operating experience with SFG gasification technology Major features include dry feed, a reliable cooling screen design, high carbon conversion, and operating pressure up to 40 bar Siemens comprehensive gasification test facility available to confirm feedstock characteristics, if needed Siemens will provide key components for gasification in power generation and other applications Page 10 January 11, 2007 Harry Morehead
Burner Cooling screen Pressur. water inlet Quench water SFG Entrained-Flow Gasifier Fuel Pressur. water outlet Oxygen, Steam Granulated slag Cooling jacket Gas outlet Water overflow Slag discharge unit Fuel Raw gas Slag Oxygen, Steam Water -cooled cooling screen eliminates the need for refractory lining improving gasifier availability High carbon conversion efficiency of up to >99 % Generation of a raw syngas free from hydrocarbons, i.e. absolutely tar-free No dioxin/furan formation even at high chlorine content in the gasification feed No heed to be given to ash content and ash composition High gasifier performance (short retention time) High availability Quick gasifier startup and shutdown (approx. 1 hour) Multiple-fuel feeding Proven cooling screen life time >10 years Page 11 January 11, 2007 Harry Morehead
Cooling Screen of the Gasification Reactor Liquid slag layer Membrane wall Pressurized water Solid slag layer Ramming mass (SiC) Pipe coil with studs Page 12 January 11, 2007 Harry Morehead
Views of the Cooling Screen after 10 Years in Service Page 13 January 11, 2007 Harry Morehead
Pneumatic Feeding System for Solid Materials Fuel Nitrogen LIA Storage bin PI TI Depressurization M M Depressurization PIC PIC Nitrogen Lock hopper M H LIC L H LIC L Lock hopper M Nitrogen FIC LIC UC Q S Fuel to gasifier Feeding vessel PI Nitrogen M Page 14 January 11, 2007 Harry Morehead
Raw Gas Scrubbing Scrubber water LP steam Raw gas to desulfurization Raw gas from gasification Waste water 1 st Venturi scrubber 2 nd Venturi scrubber Waste heat boiler (partial condensation) Separator (Demister) Page 15 January 11, 2007 Harry Morehead
SFG Technology Feedstock Testing History Year 1956 1977 1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 Lignite Saliferous lignite 42 lignite varieties 15 hard coal varieties (international) Pulverized hard coal and lignite Petcoke, flue ash 15 municipal and industrial sewage sludges, MSW, waste oil, wood, straw Slurry, flue ash Industrial waste and residues Chlorinated organics Nitrogen waste organics Black liquor Fixed-bed gasification 24 gasifiers constructed in the gas combine Schwarze Pumpe Demonstrations plants Freiberg Bioslurry, coal Hard coal Entrained-flow gasification 3 MW 5 MW Lignite Saliferous lignite Natural gas Waste oil, tar oil Commercial plants Slurry Tar oil/solid sludges Nitrogen waste organics 13 t/h Tar oil Hard coal 200 MW Schwarze Pumpe Seal Sands esová Anhui Huainan Project Ningmei DME Project Linggu Project Preussag AG Noell GmbH Babcock Borsig Power GmbH FUTURE ENERGY GmbH Siemens Fuel Gasification Technology GmbH Page 16 January 11, 2007 Harry Morehead DBI DBI Over 90 Feedstocks tested Over 6 Years of Lignite Operation at SVZ Successful Scale up from 3 MW to 200 MW
Gas Turbines for IGCC Applications 60 Hz Applications Geared Units 50 Hz Applications SGT6-3000E SGT-100 SGT5-2000E SGT6-5000F SGT5-4000F SGT6-6000G Applications Include: Coal, Petcoke, or Residual Oil Based IGCC Small Coal or Biomass Based IGCC Other Low-BTU or Med-BTU Applications Greenfield IGCC or Repowered NGCC Page 17 January 11, 2007 Harry Morehead
Syngas Experience at Modern IGCC Plants Customer/Plant (Location) Hörde Steelworks (Dortmund, Germany) Electrical Output (net) Gas Turbine Main Features Start-up Blast-furnace-gas-fired, gas turbine as 1960/ 8 MW VM5 Handan Iron & Steel compressor drive 2000 (Handan, P.R. China) U. S. Steel Corp. (Chicago, USA) 20 MW CW201 Blast-furnace-gas-fired gas turbine 1960 STEAG/Kellermann First CC plant in the world with integrated 163 MW V93 (Lünen,Germany) LURGI coal gasification (hard coal) 1972 DOW Chemicals 208 MW 1) CC plant with integrated DOW coal 2 x W501D5 (Plaquemine, USA) gasification 1987 Nuon Power Buggenum CC plant with integrated SHELL coal 1993 2) 253 MW V94.2 (Buggenum, Netherlands) gasification (hard coal and biomass blend) 1994/95 HRL CC plant with integrated drying gasification 10 MW Typhoon (Morwell, Australia) process (lignite) 1996 Sydkraft First CC plant in the world with integrated 6MW Typhoon (Värnamo, Sweden) biomass gasification 1996 ELCOGAS CC plant with integrated PRENFLO coal 1996 2) 300 MW V94.3 (Puertollano, Spain) gasification (coal and petroleum coke blend) 1997/98 ISAB Energy CC plant with integrated TEXACO heavy-oil 1998 3) 521 MW 2 x V94.2K (Priolo Gargallo, Italy) gasification (asphalt) 1999 ELETTRA GLT (Servola, Italy) 180 MW V94.2K CC plant with steel-making recovery gas 2000 ARBRE (Eggborough, UK) 8 MW Typhoon CC plant with integrated biomass gasification 2002 EniPower CC plant with integrated SHELL heavy-oil 250 MW V94.2K (Sannazzaro, Italy) gasification 2006 1) 160 MW from syngas and 48 MW from natural gas; 2) Natural gas firing; 3) Oil firing 320,000+ Operating Hours Page 18 January 11, 2007 Harry Morehead
Compressors, Instrumentation & Control Systems Experience for IGCC Applications Customer/Plant (Location) DOW Chemicals (Plaquemine, USA) Nuon Power Buggenum (Buggenum, Netherlands) Global Energy/Wabash River (West Terre Haute, USA) Tampa Electric/Polk County (Mulberry, USA) ELCOGAS (Puertollano, Spain) NPRC/Negishi (Negishi/Japan) Opti/Long Lake (Alberta, Canada) IGCC Plant Instrumentation and Control Systems Siemens Scope Air / N 2 / O 2 / Syngas Compressor Trains Start-up ASU main air compressor 1987 ASU air compressor (for start-up) N 2 compressors, O 2 compressor ASU main air compressor O 2 compressor ASU main air compressor N 2 compressors, O 2 compressor IGCC plant Instrumentation & control system Claus gas compressor IGCC plant optimization and integration study ASU main air compressor N 2 /air compressors, O 2 compressor 1993 2) 1994/95 1995 1996 1996 2) 1997/98 2003 ASU main air compressor 2006 Page 19 January 11, 2007 Harry Morehead
60 Hz IGCC Power Island Solutions SGT6-PAC 5000F - Syngas Rating 232 MW at ISO Conditions with 15 ppm NOx - Can be integrated with wide range of gasifiers operating with a broad range of feedstocks SGCC6-5000F 2X1-630 MW Reference Plant Concept Being Developed Based on Standard SCC6-5000F 2X1 Page 20 January 11, 2007 Harry Morehead
60 Hz Gas Turbines for IGCC Applications SGT6-3000E SGT6-5000F SGT6-6000G Gas Turbine IGCC Performance Estimates [ISO Conditions] (Preliminary Study) Gross GT Output, MW NOx, ppmvd @ 15% O2 (w/o SCR) SGT6-3000E Syngas 135 15 Nat. Gas 135 SGT6-5000F Syngas 232 Diluents: Natural Gas Steam, Syngas Nitrogen Estimates based on SGT6-5000F with Syngas Combustion System, SGT6-5000F Emissions Verified in 2005 25 15 Nat. Gas 210 25 SGT6-6000G Syngas Nat. Gas 296 279 15 25 Higher Output From Proven Gas Turbine Technology Page 21 January 11, 2007 Harry Morehead
Siemens Global Gas Turbine Combustion Test Programs SGT6-5000F Combustion Test Results <15 ppm NOx and <10 ppm CO on variety of syngas compositions <25 ppm NOx and <10 ppm CO on NG with steam injection Stable combustion and excellent operability demonstrated during fuel transfers and co-firing SGT6-6000G Combustion Test Results Initial testing indicated that emissions targets can be achieved with stable operation SGT5-4000F Combustion Test Results < 15 ppm NOx and < 10 ppm CO on a variety of different syngas fuels No impact on dry emissions performance on NG Stable premixed combustion on selected syngas fuels was demonstrated Developments for the Future Siemens developing catalytic/h2/syngas combustion systems and integrating advanced gas turbines into IGCC under EU and US DOE sponsorship Fuel Oil (diffusion) Syngas 2/ NG (diffusion) Air Natural Gas (premix) Air Syngas 1 (premix) Fuel Oil (premix) Air Reduced Emissions with Fuel and Operational Flexibility Page 22 January 11, 2007 Harry Morehead
Today s Fuel Flexible SGT6-5000F SGT6-5000F for IGCC Applications Siemens IGCC Experience Base Full Scale Test Facilities Based on proven standard product and fleet experience Lessons learned from prior and current IGCC Plants are the foundation for adaptations for IGCC Full scale testing forms the basis for new technology improvements 95% Fleet Availability 189 Units in Operation Page 23 January 11, 2007 Harry Morehead
SGT6-5000F Gas Turbine Modifications for IGCC Applications Syngas combustion system Based on Proven Syngas Combustor at DOW, LGTI IGCC Project Dual Fuel Syngas / Natural Gas Flexible On-line Operation Designed for a wide range of syngases Capable of Co-Firing Capable of On-Line Transfers DOW, LGTI Syngas Combustion System Siemens 2005. All Rights Reserved DOW LGTI Standard DF-42 DOW LGTI Standard DF-42 85,000 Hours of Successful Syngas Operation Page 24 January 11, 2007 Harry Morehead
2006 H 2 Combustion Testing Update Range of hydrogen fuel compositions tested 30%-78%, with different diluents levels in pure H 2 at 90% carbon capture level Range of loads tested at full pressure 30%, 50%, 70%, and full load with 45% H 2, 30% N 2, and 25% H 2 O Diluents used with H 2 pure steam, pure N 2, mixture of both Range of heating values tested: 100-260 BTU/scf Emissions NOx 15 ppm with N 2 and/or steam dilution Combustor configuration production design nozzle H2 dilution with steam, N2 and a blend of both steam and N2 was successfully demonstrated while achieving 15 ppm NOx emissions Page 25 January 11, 2007 Harry Morehead
Siemens O&M Approach for IGCC O&M Group is a member of the Reference Plant Design Team SFG Gasifier Island (Planned) Adapt Traditional Siemens O&M Services Long Term Maintenance Programs O&M Advisor + LTMP O&M Management O&M with Pass-through Accounts Full Scope Operation and Maintenance Scope Provide Additional OEM Value OEM Home Office Engineering Support Power Diagnostics HyBrixPower Digital Library IGCC Power Island Siemens Diagnostics Center Orlando, FL 3D Gasifier Island Model developed by Bibb based on design by Siemens Page 26 January 11, 2007 Harry Morehead
Market Introduction Issues & Solutions Cost reduction by 15% to 20% Develop reference plants Build on CCPP reference design experience - 60% replication - 15% modification - 25% custom scopes Use more advanced technologies Scale up projects Risk reduction & allocation FEED study Phased approach to implementation / availability Flexibility from regulator Government incentives Stakeholder risk sharing Capture learning curve Next wave of IGCC plants will require an innovative approach to risk allocation Page 27 January 11, 2007 Harry Morehead
Siemens Approach for IGCC Projects EPA of 2005 Customer Environmental Groups Regulators Turnkey EPC States Siemens Partner(s) Gasifier Technologies Siemens SFG COP E-Gas Shell SCGP ASU Air Products Air Liquide Linde Praxair Gas Cleanup MDEA Selexol Rectisol Power Generation E Class F Class G/H Class Each Project Needs The Best Combination of Partners, Technologies and Steakholder for Success Page 28 January 11, 2007 Harry Morehead
Conclusions Siemens is expanding its portfolio of products and services to serve the IGCC and gasification markets Siemens is leveraging its global manufacturing and service capabilities to provide OEM level life cycle support for our SFG gasifiers Siemens continues to invest in the key power generation and gasification technologies needed to make IGCC a competitive option for the world s power industry Page 29 January 11, 2007 Harry Morehead
Questions? IGCC Power Island for 60 Hz Applications 50 and 60 Hz Gas Turbine Generators with Syngas / Natural Gas (or Oil) Capability SFG Gasifiers Steam Turbine Generators IGCC Plant Instrumentation and Controls IGCC Compression Solutions IGCC Power Block and SFG Gasifier O&M Services Puertollano at Night Page 30 January 11, 2007 Harry Morehead