GE IGCC Gas Turbine Experience

g GE Power Systems Economic Viability and Experience of IGCC From a Gas Turbine Manufacturers Perspective Klaus Brun, Ph.D. - Manager Process Power Plant Product & Market Development Robert M. Jones - Project Development Manager Process Power Plants Power Systems General Electric Company ASME - IGCC Turbo Expo June 2001 g ABSTRACT High natural gas fuel gas prices combined with new technology developments have made IGCC a competitive option when compared to conventional combined cycle or coal steam turbine cycles. Although the initial investment costs for an IGCC plant are still comparatively high, the low level and stability of petroleum coke, coal, and oil/tar residue feedstock prices can be shown to easily overcome this disadvantage when a plant’s life cycle costs are compared over an extended time period. The ability of new IGCC technology to use a mix of low or negative value opportunity fuels has played a significant role in the commercial introduction of these systems. Co-production of Hydrogen, sulfur, Ammonia, Methanol, etc. and/or using IGCC to upgrade existing refinery products can furthermore enhance the economic viability of IGCC. Finally, a dual- or co-fired IGCC plant with natural gas and Syngas (derived from petroleum coke, coal, or residues) as the fuels can be effectively employed by power producers as a financial hedge against exaggerated fuel market price fluctuations. General Electric has developed the technology to provide power producers with a range of gas turbines that can be efficiently integrated with IGCC to generate least cost electricity while meeting environmental regulatory requirements. Today there are over five (5) GW of IGCC plants in operation or under design. IGCC gas turbines are a mature product line with a total of 34 General Electric units sold of which 19 have accumulated over 340,000 hours of operation on Syngas. The IGCC technology has reached the point where systems are commercially competitive, technologically low risk, and offer exceptional environmental performance. The introduction of the next generation of advanced gas turbines will propel IGCC systems to a previously unobtainable level of performance while simultaneously realizing a step change improvement in capital cost. GE Power Systems Economic Viability and Experience of IGCC From a Gas Turbine Manufacturers Perspective g What is IGCC? Fue ls q q q GE Power Systems Integrated Gasification Combined Cycle Products Gas ificaton Syngas Gas ifier HX Cle anup Slag Sulfur Bituminous Coal Sub Bitum inous Coa l Lignite q q q q Orimulsion Residual O ils Refinery Bottoms Pet role um Cole Slag Oxidant Supply Sys tem 2 Stage Co mb ustion Par tial in Gasifier Complete i n G as Turbine 5 Te chn ologies Oxidan t Suppl y Gasificatio n Clean Up Combined Cycle Inte gration Air or Oxygen CO + H2 Sulfur Syngas Synergy Cle an Fue l Com bined Cycle Hydrogen Ammonia Methanol Che micals q q Bioma ss Wastes Electricity q q g What is IGCC? GE Power Systems Typical Coal IGCC g 1878 1930 1940 1950 - Lurgi Gasifier - Coal Gasification - Town Gas Applications - Gasification for Hydrogen Production in the Chemical Process Industry - Coal Tested as Fuel for Gas Turbines (Direct Burning) - IGCC Studies - First Pilot IGCC (Coolwater) - Commercial IGCC Plants - IGCC Accepted Coal Plant Option GE Power Systems IGCC - A Brief Industry History 1960 1970 1980 1990 2000 g • Over 22 Years Experience Testing Low Btu Fuels • First IGCC Plant Commissioned in 1984 •17 Units Currently Operating on Synthetic Gas • Over 340,000 Operating Hours on Synthetic Gas • 19 Additional Units Scheduled to Start 2001-2006 • IGCC Units Include GE10, 6B, 7EA, 9E, 9EC, 6FA, 7FA, 9FA GE Power Systems General Electric IGCC Technical Leadership General Electric IGCC Combustion Laboratory We are Committed to IGCC Gas Turbine Developments g GE Power Systems IGCC - Major Technological Milestones - Cool Water Demonstration Plant 1984 First Large Scale IGCC. Demonstrated IGCC Technical Feasibility. - Polk Tampa Electric 1996 Succesful Nitrogen Injection for NOx Control. Demonstrated IGCC Commercial Feasibility. - Exxon Singapore 2000 Widest Variety of Gas Turbine Fuels. g Customer C.O. Date SCE Cool Water - USA 1984 LGTI - USA 1987 Demkolec - Nethe rlands 1994 PSI/Destec - US A 1995 Tampa Electric - USA 1996 Texaco El Dorado - US A 1996 SUV - Cze ch. 1996 Schwarze Pumpe - Germany 1996 Shell Pernis - Ne therlands 1997 Puertollano - Spain 1998 Sierra Pacific - USA 1998 ISAB - Italy 1999 API - Italy 2000 MOTIVA - Delaw are 2000 Sarlux/Enron - Italy 2000 EXX ON - S inga pore 2000 Bio E lectrica - Ita ly 2001 FIFE - Scotland 2001 EDF - Total 2003 FIFE E lectric - Scotland 2003 Nihon Seki yu - Japan 2004 IOC Paradip 2004 Confidential 2004 PIEMSA 2004 Confidential 2004 TPS/Lake Charle s 2005 MW 120 160 250 260 260 40 350 40 120 320 100 500 250 240 550 180 12 120 400 400 350 180 750 800 800 700 8252 GE Power Systems IGCC - World Experience Application Power/Coa l Cogen/Coal Power/Coa l Repower/Coal Power/Coa l Cogen/Pet Coke Cogen/Coal Power/Methanol/Lignite Cogen/H 2/Oil Power/Coa l/Pet Coke Power/Coa l Power/H2 /Oil Power/H2 /Oil Repower/P et Coke Cogen/H 2/Oil Cogen/H 2/Oil Power/Biomass Power/Sludge Power/H 2/Cogen/Oil Power/Coa l/RDF Power/Oil Power/Pet Coke Power/Coa l Power/H 2/Oil Power/Coa l Power/H 2/Oil Gasifi er Texaco - O2 Destec - O2 Shell - O2 Destec - O2 Texaco - O2 Texaco - O2 ZUV - O2 Noell - O2 Shell - O2 Prenflow - O2 KRW - Air Texaco - O2 Texaco - O2 Texaco - O2 Texaco - O2 Texaco - O2 Lurgi - Air BGL - O2 Texaco - O2 BGL - O2 Texaco - O2 Shell O2 Texaco - O2 Texaco - O2 Texaco - O2 Texaco - O2 g Syngas Hours of Operation December 2000 Customer Cool Water PSI Tam pa Texaco El Dorado Sierra Pacific SUV Vresova Schwarze Pumpe Shell Pernis ISE / ILVA Fife Energy Motiva Delaware Sarlux Piom bino Exxon Singapore * as of 1/ 01 ** as of 2/ 01 *** as 3/01 GE Power Systems General Electric Gas Turbine Syngas Experience Type 107E 7FA 107FA 6B 106FA 209E 6B 2x6B 3x109E 6FA 2x6FA 3x109E 109E 2x6FA MW 120 262 250 40 100 350 40 120 540 80 240 550 150 180 Syngas Start Date 5/84 11/95 9/96 9/96 12/96 9/96 11/97 11/96 8/00 10/00 10/00 - Hours of Operation Syngas N.G. Dist. 27,000 21,700 *23,200 22,800 0 63,700 26,700 40,300 98,900 0 ***100 **4,400 0 0 1,000 3,000 5300 17,100 20,500 1,200 3,400 17,900 2,200 5,600 ***1300 10,500 400 0 50 Totals 328,800 g Gasifiers & Clean-Up: - Texaco - Shell - Global / E-Gas - Lurgi - Noel GE Power Systems Major IGCC Market Players Air Separation Units: - Air Products International - BOC Group - Praxair - Air Liquide Power Block (GT&ST): - General Electric - Siemens-Westinghouse - MHI - Alstom EPC Contractors: - Bechtel - Krupp-Uhde - Fluor Daniel - Foster Wheeler - Snamprogetti g GE Power Systems IGCC Gas Turbine State-of-the-Art Combustion System Developments Same IGCC Combustor Design for 6FA, 7FA, 9FA, 9EC g IGCC Output Enhancement Natural Gas 2% Syngas 16% Air - 100% NG Exhaust 102% SG Exhaust 116% GE Power Systems IGCC Gas Turbine State-of-the-Art Gas Turbine Output vs Ambient Temperature Gen 7FA (MWe) Ne ar Fu tu re To rque L imit 7FA/9FA Cu rrent To rque /IGCC Li mit 7F A/9F A - Na tu ral G as 20% Extra Output -20 0 20 40 60 80 Ambient Temp. (Deg. F) 100 -10 0 10 20 30 40 Ambient Temp. (Deg. C) Model 6FA 7FA 9EC 9FA 9FA (MWe) Gas Turbine Syng a s GT3 005 3 ppt All Units MW NG-SC 70 172 170 256 Syngas-SC 90 197 215 286 Net-IGCC 126 280 300 420 g GE Power Systems IGCC Gas Turbine State-of-the-Art Reliability - Availability - Maintenance (RAM) 1 • Need Automatic Fuel Switch/Nitrogen Purge Life Fraction 0 .8 IGCC CONTROL SY STEM • Need Clean Syngas • Reduced Firing Temp to Maintain Design Metal Temp/ 100% Life 0 .6 0 .4 0 .2 0 0 10 20 Vol % H 2O in Exha ust 30 40 Syngas Combined Cycle Can Have Same Performance as Natural Gas Combined Cycle g Emissions GE Power Systems IGCC Gas Turbine State-of-the-Art 1000 N2 H20 Best Available Control Technology: Current IGCC BACT: 15-25 ppm NOx Near Future IGCC BACT: 9-15 ppm NOx • Simulated Coal Gas 2550 F/1400 C Combustor Exit Temperature 100 10 C02 • Long Term IGCC BACT: <9 ppm NOx 1 100 150 200 250 300 LHV, Btu/SCF Full load NOx versus Syngas Heating Value g IGCC Economics GE Power Systems IGCC versus Conventional Natural Gas Combined Cycle First year COE - 60 Hz Ma rk et - Coal Price $ 1.25 /MMBtu IGCC with natural gas in CC operation @ 6% Capacity Factor 6.5 VARIAT ION DRIVEN BY EPC PRICE CC2 07FA -Low EPC 350 $/ kW 6 CC207FA- Actu al EPC-412$/ kW CC207FA-High EPC- 500 $/ kW IGCC2 07FA-Low EPC- 847 $/ kW IGCC - Me dium EPC-1050 $/ kW IGCC- High EPC - 1168 $/ kW P. Coal -L ow E PC - 968 $/ kW P. Coal - High EPC -1168 $/ kW 5.5 First year Cost of Electricity (¢/kWh) 5 4.5 4 3.5 3 Combined Cycle Tec hnology 2.5 IGCC Technology 2 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 First Year Natural Gas Price ($/MMBtu)- HHV g IGCC Economics GE Power Systems IGCC versus Conventional Natural Gas Combined Cycle 20 Year Levelized COE versus Fuel Price 6 .0 Cos t Of Electricity, c/kWh 5 .5 5 .0 4 .5 4 .0 tu Na 3 .5 3 .0 0. 00 0. 50 1. 00 1. 50 2. 00 2. 50 3. 00 3. 50 4. 00 4. 50 5. 00 Fuel (Fe edsto ck) Price , $/MBTU, HHV $3.70/MBTU Natural Gas $4.40/MBTU Natural Gas CC IG $1.23/MBTU Coal FA 07 2 as G ral g IGCC Economics based on 20 year COE for large power plants GE Power Systems IGCC versus Conventional Natural Gas Combined Cycle Economic Comparison of IGCC versus Combined Cycle 2.2 2 IGCC Fuel Price [$/MMBTU] 1.8 1.6 1.4 1.2 1 0.8 0.6 0.4 0.2 0 1.5 2 2.5 3 3.5 4 4.5 5 5.5 Combined Cycle Fuel Price [$/MMBTU] Pet Coke Residues Coa l Orimulsion Combined Cycle Preferred IGCC Preferred Economic Divide g IGCC Economics GE Power Systems US Natural Gas Prices (Henry Hub) US$/MMBTU 6 5 4 3 2 1 0 19 90 19 91 Currently NG is US$ 4.2 / MMBTU 19 92 19 93 19 94 19 95 19 96 19 97 19 98 19 99 20 00 20 01 Cost of Electricity: Coal IGCC Beats Natural Gas Combined Cycle when Natural Gas Prices are Above US$4.1/MMBTU. 20 02 g IGCC Economics GE Power Systems New Power Plant Cost Development US $/KW 3000 2500 2000 1500 1000 500 0 1975 1980 1985 1990 1995 2000 2005 2010 Coal IGCC Currently at US$ 1050-1250 per kW Installed g IGCC Economics GE Power Systems IGCC Versus Other Coal Fired Power Plants g Nominal Efficiency HHV % SO2 Emissions lb/106 Btu NOx Emissions lb/106 Btu Particulate Emissions lb/106 Btu Fuel Type Cost - $/MM Btu Capital Cost 1999 $/kW Cost of Electricity 1999 ✔ /kWh 33 Power Generation Options Actual 1999 PC PC 40 Current 2000 IGCC 43 NGCC 52 PC 44 Future 2005 IGCC 52 NGCC 60 1.3 0.05 0.017 --- 0.025 0.017 --- 0.5 0.15 0.028 0.028 0.07 0.024 0.024 0.05 0.01 0.002 --- 0.01 0.002 --- Coal 1.2 N/A 4.0 Coal 1.2 1050 3.6 Coal 1.2 1100 3.5 Gas 3.5 - 7.5 550 4.0 - 6.8 Coal 1.1 1000 3.4 Coal 1.1 950 3.2 Gas 4.0-7.0 500 3.5-6.0 g 10 Year Outlook New Power Equipment Purchases [GW] GE Power Systems IGCC Projected Energy Market Penetration 120 Natural Gas GT 200 630 60 IGCC Fossil Steam Other IGCC Market Forecast 6000 5000 4000 3000 2000 1000 0 2000 Market Trend: IGCC will be a significant participant in the near future power market. MW 2001 2002 Year Maximum 2003 2004 2005 Minimum g GE Power Systems IGCC is currently the most competitive new Power Plant option in the US.