gasification: status, outlook and technical developments · technical field assistance feedstock:...
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Copyright © Siemens AG 2009. All rights reserved.
Power Generation
Gasification: Status, Outlook and Technical DevelopmentsFrank Hannemann, Siemens Fuel Gasification Technology GmbH & Co.KG
Energy Sector
Copyright © Siemens AG 2008. All rights reserved.
Energy and Gasification Market Trends
Status of Siemens Gasification Projects
SFG Technology / R&D and new Products
Polygeneration Concepts
Content
Energy Sector
Copyright © Siemens AG 2008. All rights reserved.
Energy products and solutions - in 6 Divisions
Oil & Gas Renewable
Energy
Fossil Power
Generation
Energy
Service
Power
Distribution
Power
Trans-
mission
Siemens Energy Sector –Answers for Energy Supply
Energy Sector
Copyright © Siemens AG 2008. All rights reserved.
Global Energy Market Trends and Primary Energy Consumption
Primary energy demand by types
Primary energy demand by regions
Source: IEA WEO 2009
Nuclear
Hydro
Renewables
2030
16.8
4.9
5.0
3.6
1.00.4
2.0
2025
15.6
4.5
4.7
3.3
0.90.4
1.8
2020
14.4
4.1
4.4
3.0
0.90.3
1.7
2015
13.5
3.8
4.2
2.8
0.80.3
1.5
2007
12.0
Coal
4.1
2.5
0.7 0.31.3
1990
8.8
3.2
3.2
1.70.50.20.9
Oil
Gas
2.2
Total Primary Energy Demand (Gtoe)
Western Europe
Eastern Eur./CIS
North America
Latin America
Asea/Pacific
Middle East
Africa
2030
16.8
1.9
1.4
3.0
0.8
7.8
1.00.9
2025
15.6
1.8
1.3
2.9
0.7
7.1
0.90.8
2020
14.4
1.8
1.2
2.8
0.7
6.3
0.80.8
2015
13.5
1.8
1.2
2.8
0.6
5.7
0.70.7
2007
12.0
1.8
1.1
2.8
0.6
4.6
0.50.6
1990
8.8
1.6
1.5
2.2
0.3
2.4
0.20.4
Total Primary Energy Demand (Gtoe)
Global Energy Market Trends
Continue grow with an average rate of 1.5%/a in total and even 1.9%/a in power sector up to 2030
Despite a significant expansion of renewables fossil energy carrier will keep covering the highest share of total energy supply
The strongest growth in energy demand is expected to take place in China and India
Energy consumption in West Europe and theAmericas will stay flat because of efficiency gains and demand saturation
Enormous unconventional gas resources in the US combined with lower demand pressed US gas prices down below $ 5/mmBt in 2008/2009
CCS technology demonstration enters a criticalstage. Weak base load, challenging financing and pending legislation challenge new build CCS.
G8 meeting in June 2009 agreed on goal for 20 full-scale CCS demo projects announced by 2010
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Gasification Market Today
USA / CAN
Market slow down due to economic recession, lack of financing and uncertainties about CO2 legislation
Funding and loan guarantees released in USA/CAN > 5 bio USD
7 IGCC projects and 3 CtX projects supported by US government
EOR opportunities
Due to pending CO2 legislation and high IGCC invest gasification projects difficult to realize
But: Increasing fuel prices (crude oil), security of supply and beginning recovery of economy starts driving new gasification projects primarily in Asia
Only funded IGCC projects with90% CCS discussed and one IGCCproject seriously ongoing
IGCC gets strong competition by post combustion
EU selected 6 CCS projects for funding: 1 bio EUR
Few biomass gasification activities
EUROPE
China:
Largest gasification market
3.000MW IGCC program
Mega CtX projects under development
India:
Gasification for steel industry and CtXunder consideration
Rest: (e.g. South-Korea, Indonesia)
Couple of coal projects underdevelopment (mainly CtX)
ASIA
Successful implementation depends on CO2 legislation
2 governmental funded IGCC projects
Large CTL and fertilizer projects under development
AUSTRALIA
Small number of CTL projects under discussion
AFRICA
Rising interest in biomass and coal gasification
BRAZIL
Energy Sector
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West Siberia
鄯善
YinChuan
BeijingHohhot
Urumchi
Fuzhou
ShangHai
Guangzhou
NanNing
JiLin
Mid
dle
Asi
a
Sakhalin
Burm
a
Coal Gasification Marketing Potentials in China
Market Trend and Conclusion
• Excessive coal to methanol
and ammonia production in
2009
• New government policy
promotes mega scale to
improve competitiveness
• Super scale Coal to SNG will
soar along with the possible
rising up of natural gas price
• New CTO and MTO extension
rising up due to 40% shortage
imported
• 1 ongoing CTL demonstration
project driven by government
• Coal to glycol as a new
opportunity supported by
Chinese self proprietary techn.
• Reluctant IGCC demonstration
due to high investment
• Poly-generation might be a
trend due to mega chemical
plants and need for CO2
reduction30.6CTG
3.64.1642.16CTO
36.8 (capacity until 2010)DME19.2( capacity until 2010 )Methanol
722.41.269.24CTL
41.3136.72SNG
Serious
considered
Approved
Projects
Under
Constr.In
Operation[Mtons Coal]`
Coal to Liquid(red-operation/construction and yellow-approved)
Legend
NG pipeline planedLignite
Sub-bituminous
Existing NG pipeline
Bituminous
Lean and anthracite
Coal to SNG(red-approved and yellow-serious)
Coal to Olefins(red-operation/construction andyellow-approved)
Eas
t Sib
eria
Energy Sector
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Siemens OfficesOperating UnitsCurrent ProjectsTechnology Selected
HQ FreibergTest Facility
JinChengCoal to Ammonia
NCPP I Coal to Polypropylene
Secure Energy Coal to Chemicals
Capital Power270 MWe IGCC
AEC Coal to UREA
Summit Power400 MWe IGCC + Ammonia
China JVGSP China
9 SFG-500 Gasifiers (incl. other key equipment) shipped
Technology selected and pre-selection in further projects
VresovaIGCCLiquid feedstockCOD 2008
Sustec, Schwarze Pumpe1984 - 2007
Siemens main Gasifier Activity Landscape
Tenaska Coal to SNG/Power
Calgary
Orlando
Energy Sector
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DOE supported IGCC projects using SFG Technology
Tenaska Taylorville Energy Center
Customer: Tenaska Inc.Nebraska, USA
Location / Fuel: Illinois, USA / Illinois coal #6
Power output: 500 MW (net)
Siemens scope: 2 x SFG-500 Gasifier and 1x SGT6-5000F
CCS capture rate: > 50% used for EOR
Time schedule: Financing until end of 2010Operation total plant: 2015
DOE support: loan guarantee
IGCC Concept with intermediateSNG production and natural gas
fired standard Gas Turbine
Summit Texas Clean Energy Project
Customer: Summit Power Group, Inc.Washington, USA
Location / Fuel: Midland Odessa, Texas, USA / PRB
Power output: 400 MW (gross) and 270k t/a NH3
Siemens scope: PowerBlock (1 x SGCC6-5000F) 2 x SFG-500 Gasifier
CCS capture rate: ca. 90% used for EOR
Time schedule: Financing until mid of 2011Commercial operation 2014
DOE support: 350‘ USD funding
IGCC Concept with H2 fired GTand NH3 co-production
Energy Sector
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NCPP I: Largest Coal to Chemical Plant in China5 x SFG-500 class gasifier: Coal to Polypropylen plant
Siemens Scope:
Engineering
Equipment Supply
Gasifiers, Burners, Feeder Vessels, ...
Training (Freiberg Simulator)
Technical Field Assistance
Feedstock:
Subbituminous Coal
Ash: ~ 7 wt%
Moisture: ~ 2 wt%
Status
Engineering Completed
All Gasifiers shipped and erected
Piping installation in progress
Start up Year: 2010
Gasification Unit
(5xSFG-500 class gasifiers)
Air Separation Units
Black Water
Treatment
Power Station
Methanol to
Polypropylene
Energy Sector
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Beginning 2010Civil construction continuing and
piping pre fabrication started
Mid 2009Steel construction in progress
Heavy equipment such as coal bunkers and
K/O drums erected by cranes with 1600t capacity
January, 2009
First batch of gasifiers erected
NCPP / Site Construction Progress
March, 2010Piping installation in progress
90% pipes for BWTP installed
Energy Sector
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Current and New Products of SFG Technology
Cooling Screen Gasifier
ash content > 1,5 – 2%
Refractory Lined Gasifier
ash content < 1,5 – 2%
Higher Efficiency
Economy of Scale
Existing 500MW gasifier
Radiant Cooler Heating surface
Proven 500MW Quench design
BMWI funded program
Radiant Cooler selected dueto robustness and limited modification of current design
IGCC w/o CO2 capture
Plant net efficiency + > 3.5 %
IGCC with CO2 capture
Plant net efficiency + > 1.5 %
> 30% water content to benefit CO shift and downstr. synthesis
Optional HP or IP steamproduction
SFG- 850 MW / 1200MW
20% cost reduction
3 burner application
Design features of 500MW retained
Biomass
Liquid fuel
Petcoke
Lignite
Sub-Bitum.
Bituminous
Anthracite
Energy Sector
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New Design Features and Capabilities
Process Simulator and I&C System in Freiberg
Real plant data and operatoractivitiesOperational
Data transfer
Diagnostic and trouble-shooting
Process Simulator and real plant I&C system in combination with
OPC interface
• Offers realistic Operator Training
• Remote Monitoring and Diagnostic
• Operational analysis and validation of I&C modifications on simulator
Advanced sensoring and CFD analysis
Advanced ph sensoring, spectroscopicalflame analysis, advanced coal feed and raw gas dust sensoring, online coal humidity sensor
CFD analysis to optimise reactor and quench geometrie and to calculate heat flux
200 400 600 800 1000
0
2000
4000
6000
8000
10000
12000
14000
16000
Inte
nsität
[a.u
.]
Wellenlänge [nm]
11:24:3111:29:3611:35:4111:43:49
SFGT_280607_008.xls
Flame analysis by spectroscopy to determine temperature and ash content
SFG Design Improvements
• Standardisation and optimisation of plant layout to reduce investment
• Advanced Feeding System for cost reduction
• Design improvements to minimise utilityconsumptions
3000K
300K
CFD analysis of pilot plant
Isokinetic dustsampling
Flüssigkeit
Membran-weg
Filter
Kohlestaub-Saugseite
Kohlestaub-Druckseite
Membran
Druckbehälter
Kohlestaub
Flüssigkeits-pumpe
Be-/Entspannung
Be-/EntspannungAuflockerung
Energy Sector
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Basic IGCC Concepts with CCS
Standard CCPP
GasIsland
CO2 for sequestration
Water/Steam
Integrated Gasification Combined Cycle
IGCC-CCS
H2-rich SG
(Air to ASU)
Diluent N2
Syngas/H2
CCPP
GasIsland
Gasification Combined Cycle
GCC-CCS
H2-rich SG
GasIsland
incl. Methanation
Synthetic Natural Gas Combined Cycle
SNG-CC
SNG
CO2 for sequestration
CO2 for sequestration
(CO2)
(CO2)
CO2
NaturalGas Net
Real low-CO2 option (capture up to ~90%; ~100 g/kWh)High efficiency (especially for gasifier with HRSG) Water/steam-side integration low challenging (at least for SFG with full quench) No or partial air-side integration with Siemens GT
Immanent partial CO2 capture for optional retrofit(capture up to ~55%; ~350 g/kWh)High operational flexibility as a proven “standard” CCHigh product flexibility and thus capacity utilization (power and/or SNG)
Real low-CO2 option (capture up to ~90%; ~100 g/kWh)Only one interface lower complexityClear responsibilities (project execution)Option for phased construction(power from NG from beginning)
Flexibility
Established technology
Coal-to-power-
efficiency
CO2 captureAttractive for European power market with its CO2 regulations and potential funding options
Attractive when setting up SNG infrastructure and for intermediate load power generation
Attractive also in connection with polygeneration
Siemens Fuel
Gasifier(SFG)
broadvariety of
feedstocks
Syngas/H2
CCPP(lower
interfaces)
Energy Sector
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IGCC concepts using SFG Technology
Raw
CoalCO2
Flue
GasASU
IGCC with high carbon capture
Gasifier with full quench
net η (LHV) > 34%
Lower integration level
No steam import to CO-Shift due
to high raw gas water content
Gasifier with radiant cooler and heat
utilization
net η (LHV) > 35,5%
Higher integration level
Higher efficiency
IGCC with low/no carbon capture
Gasifier with radiant cooler is preferred
due to optimal heat utilization
High efficiency > 40%
Raw
CoalCO2
Flue
GasASU
Raw
CoalCO2
Flue
GasASU
Bypass
Energy Sector
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~770 MW aux. power**Excluding utility systems
CO2
Polygeneration Plant Concept for Mega SNG
SFG-Gasifier with full quench system
robust and cost-effective
SFG-Gasifier with radiant cooler
high efficient
High feedstock flexibility
Optimized water consumption
E-class gas turbine
Superheated IP-Steam to steam turbine
Net efficiency* (LHV): >0,56
*without power export
(GJ SNG)/ (GJ Raw Coal)
Superheated IP-Steam
Raw Coal SNG
Power
4 billion Nm³/a
16 x SFG-500
Saturated IP-Steam
Alternative concept
Superheated IP-Steam to ASU
Mechanical drives
~370 MW aux. power**Excluding utility systems
Energy Sector
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Methanol Polygeneration Plant Concept
SFG-Gasifier with full quench system
High feedstock flexibility
E-class gas turbine fired with offgas
and syngas
… Saturated IP-Steam
Offgas
(GJ MeOH)/ (GJ Raw Coal)
Net efficiency* (LHV): ~0,53
*without power export
Energy Sector
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Conclusion
• Increasing oil price and continues primary energy growth stillfavour gasification
• SFG gasification is on track: New products, extended scope andnew features enhance attractiveness
• IGCC demonstration projects with CCS under development
• Large scale CTX are the main focus today
• Mega CTX combined with poly-generation concepts benefitsefficiency
• Growing renewable power production requires energy storage andpeak load and flexible fossil power generation. Poly-generation isthe only practical solution.
Energy Sector
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