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Current Challenges and Opportunities in IGCC Design

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Current Challenges & Opportunities in IGCC DesignIGCC Design Challenges & OpportunitiesIGCC Design Challenges & OpportunitiesGas Turbine Current Status, Planned and Future ImprovementsGas Turbine Challenges in IGCC ApplicationGas Turbine Challenges in IGCC Application with CCSSlurry Fed Entrained Flow Gasification Technology-Status and Potential ImprovementsDry Coal fed Entrained Flow Gasification Technology –Status and Potential ImprovementsFluidized Bed Gasification Technology – Status and Potential ImprovementsShift & Gas Clean up for IGCC + CCS Applications- Challenges and OpportunitiesChallenge – Definition of IGCC CCS Design BasisTogether…Shaping the Future of ElectricityCurrent Challenges & Opportunities in IGCC DesignJoint US/China Workshop on IGCC/Co- Production/CCSHarvard Kennedy School April 16-17, 2009Neville Holt Technical Fellow - EPRI2© 2009 Electric Power Research Institute, Inc. All rights reserved.IGCC Design Challenges & Opportunities• Better Availability• Lower Capital Cost• Higher Efficiency• Reduction of Power and Efficiency loss when incorporating CCS• Clarification of Design Basis and Emission rules for CCS3© 2009 Electric Power Research Institute, Inc. All rights reserved.IGCC Design Challenges & Opportunities• Better availability• Lower Capital Cost• Higher Efficiency• Improved refractory and injector life, Gas turbine availability, shorter start ups • Larger gasifiers and gas turbines provide economies of scale.(50 Hz GT ~40% larger than 60 Hz – China is 50 Hz US 60 Hz). Lower cost ASU (e.g. ITM). Lower auxiliary power usage• Higher firing temperature gas turbines, Lower auxiliary power usage. GT air extraction. Separation process for CO2 at higher pressure. Advanced cycles.4© 2009 Electric Power Research Institute, Inc. All rights reserved.Gas Turbine Current Status, Planned and Future ImprovementsGT Manufacturer (OEM)Current IGCC ApplicationPlanned or Commercially OfferedFuture ImprovementsGE7 E CoolWater 7 FA Wabash, Tampa 9 E (Saras) 6 FA Valero7 FB Duke 9 FA 9 FB HatfieldHydrogen firing without derate.G or H?Siemens6-3000 E Dow V 94.2 Nuon V 94.2K ISAB V 94.3 Elcogas5 -5000 F 6 -4000 F V 94 2K GreenGenHydrogen firing without derate. G or H?MHIM 701D Nakoso M 701F4 NegishiM 701 F4 Nuon M 701G M 501 F M 501 GM 701 J (2011?)M 501 J5© 2009 Electric Power Research Institute, Inc. All rights reserved.Gas Turbine Challenges in IGCC Application• To date F GTs have lower availability than earlier E types• China IGCC Phase 1 demonstration plants currently plan E type GTs. Need to move to higher efficiency and larger size 50 Hz GTs and incorporate CCS.• GE 7 FB (60 Hz) to be demonstrated in IGCC at Duke Edwardsport 2012. • Siemens 6-5000 F and 5-4000 F yet to be demonstrated in IGCC• Both GE & Siemens need IGCC demonstration of F class 50 Hz GTs• MHI has F class IGCC 50 Hz experience. Offers G (and later J?) GTs for IGCC. Yet to be deployed for IGCC.6© 2009 Electric Power Research Institute, Inc. All rights reserved.Gas Turbine Challenges in IGCC Application with CCS• The high Hydrogen content syngas in the CCS IGCC application needs demonstration for all manufacturers. Currently it appears that the suppliers will offer guarantees for IGCC CCS (Hydrogen) applications by reducing firing temperature.• All GT suppliers are striving for higher firing temperatures and efficiencies without the firing temperature derate. DOE has programs on this with GE & Siemens.• The ability to extract air from the gas turbine compressor improves efficiency and reduces auxiliary power consumption (Lowers ASU Main Air compressor size). In some designs this ability is constrained by ambient conditions and elevation.7© 2009 Electric Power Research Institute, Inc. All rights reserved.Slurry Fed Entrained Flow Gasification Technology- Status and Potential ImprovementsGasification TechnologyCurrent Status in IGCC Application Planned or Commercially offeredPotential ImprovementsGE (single stage downflow, single injector, refractory lined)1800 ft3 gasifier with Radiant Syngas Cooler (SGC) and Convective SGC 450 psig (3.2 MPa) (Tampa) ~2000 mtpd coal. Bituminous coals & Petcoke. Prefer < 20% ash. Lock hopper slag removal. 900 ft3 Quench1800 ft3 Radiant SGC at 600 psig (being built at Duke Edwardsport).Offer 1800 ft3 1000 psig (7 MPa) Quench gasifiers for China but maybe not US Power ? but US Polygen?Longer life injectors & refractory. Extend to lower rank coals and lignite (dry feed & membrane wall ?). Scale up to larger gasifiers to match larger 50 Hz GTs. Lower cost Radiant syngas cooler. Continuous slag removal (replace lock hoppers). Higher carbon conversion.ConocoPhillips (Two stage upflow, refractory lined. Stage 1 two opposed injectors, Stage 2 single injector)~ 2200 mtpd at Wabash. Continuous slag removal. Pet coke, bituminous & sub-bituminous coalsOffers Higher efficiency Full Slurry quench (FSQ) design up to ~ 3000 mtpd. Modified design For CCSLonger life injectors & refractory. Extend to lignites. Scale up to larger gasifiers to match larger 50 Hz GTs. Lower cost quench design for CCS. Non fouling SGCECUST OMB (single stage downflow with four horizontal opposed injectors, refractory lined)2200 tpd, 3.8 m diameter, 6.5 MPa. No IGCC230 MW, 2200 tpd IGCC with radiant cooler. Startup scheduled for 2010. (Huadian)Longer life injectors & refractory Extend to low rank coals (Planned). Scale up to larger gasifiers to match larger 50 Hz GTs. Continuous slag removal.8© 2009 Electric Power Research Institute, Inc. All rights reserved.Dry Coal fed Entrained Flow Gasification Technology – Status and Potential ImprovementsGasification TechnologyCurrent Status in IGCC ApplicationPlanned or Commercially offeredPotential ImprovementsShell (Single stage upflow)2000 mtpd coal 250 MW Nuon. 3300 mtpd (1000 MWth).China up to 35% ash. All coals. Lock hoppers for feed and slag removal.500-800 MW Sized to match 50 Hz GTs. (Nuon, Hatfield)Lower cost coal drying. Quench design. Scale up to larger 50 Hz GTs. Continuous coal feeder and slag removal.Siemens (single stage downflow)No IGCC. 200 MWth in 1980’s. 500 MWth now being supplied. All coals. Lock hoppers for feed and slag removal.500 MWth offered. 1000 MWth planned?Lower cost coal drying.Scale up to larger 50


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