Mr. Daniel Tse - · PDF fileRefinery Polygen Chemicals Electricity Synthetic Natural Gas Transportation Fuels GE’s Gasification Technology GE’s Petcoke Gasification Technology

Mr. Daniel Tse

Gasification ExpertGE

Holding a B.S. degree in Electrical Engineering from the University ofHouston, Mr. Daniel has 17 years of experience in the gasificationindustry including roles such as Pricing Leader and Commercial Leaderfor GE’s gasification business.

Mr. Daniel has authored a gasification patent and represents GE on theGasification Technologies Council.

Prior to the start of his GE career, he worked for Texaco andChevronTexaco in various commercial, project management, andtechnical roles wherein he directly managed projects related togasifiers, refineries, and petrochemical plants.

Refinery Polygen

Chemicals Electricity

Synthetic Natural Gas

Transportation Fuels

GE’s Gasification TechnologyGE’s Gasification Technology

GE’s Petcoke Gasification Technology Ready to meet today’s feedstock challenge

Daniel Tse, Manager Gasification SolutionsPetroleum Conclave l March 2013

GE Power & Water

© 2013, General Electric Company. Proprietary Information. All Rights Reserved.


2

Natural gas historical pricing

3


LNG prices expected to remain above $15 in the foreseeable future

• India’s gas utilization policy will not allow domestic gas to flow into “industry”• NG demand growing at 19% compound annual growth rate (CAGR); 10 LNG

terminals planned – currently only 2• Naptha when used for power generation translates to very high costs per unit of

power produced ($1000/t translates to $26/mmbtu)

Source: Credit Rating and Information Services of India Ltd. (CRISIL)


4

Steam Methane Reformer (SMR) economics

Source: US DOE/NETL, Current (2005) Hydrogen from Natural Gas without CO2 Capture and Sequestration, updated by

NREL 2008 and GE Internal Calculations

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Refineries

Chemicals

Coal to liquids

Ammonia

Oxochemicals: Butanol, Ethylhexanol

Hydrogen

Steam

Power

Methanol

Formaldehyde

MTBEAcetic acid

Amine

DME

Urea

Ammonia nitrate/sulfate

Syngas out

(H2 + CO)

Power (IGCC)

Greenfield

Polygen

Refueling

Site repowering

Transportation fuels

Gasification technology

Methanation Substitute natural gas

Feedstock in• Coal

• Pet coke

• Asphalt

• Heavy Oil

• Vacuum Residue

• Natural Gas

• Process gas

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Two configurations

QuenchRadiant Syngas Cooler

Partial Quench (RSC/PQ)

• Hot syngas immediately quenched by direct water contact

• Syngas is warm and saturated with water… ideal for sour CO shift

• Commercial application 12 to 86 bar

• Proven gasifier sizes up to nominal 900ft3

• Typical applications: chemicals, hydrogen, refinery polygen

• Lower capital cost than RSC

• Shorter construction cycles than RSC

• Hot syngas first cooled by radiant cooling before quenching

• Generates high pressure steam to ~135 bar

• Limits pressures to ~45bar

• Proven up to nominal 1800ft3

• Typical applications: power generation, refinery polygen

• Better efficiency than quench

• Construction cycle more complex than quench

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Installed fleet by the numbers

GE has gasifiers in commercial

operation … the largest fleet in the

industry … with additional

gasifiers in development, engineering,

or construction at plants …

and a global presence in

different countries.

155

95

2515

Petroleum Coke Gasification

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GE’s Petroleum coke gasification history

1970s Research, pilot study & semi-commercial testing began

1980s Early industrial scale test at Eastman/Ube

1992 100% petroleum coke to power industrial demo unit built within the El Dorado, KS. Refinery

More industrial applications: Coffeyville: Urea/Refinery H2 & Delaware: IGCC

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GE’s Petroleum coke experience

GE has licensed (7) 100% petroleum coke gasification plants since 1982

• USA: (4) plants with (2) in operation, (1) shut down & the other one in EPC phase

• Asia: (2) built in Japan with (1) still operating

• Euro: (1) in Russia in EPC phase

GE has licensed multiple partial petroleum coke mixing with coal plants around the world including refineries in China

• Gasified cokes from both fluid coking & delayed coking process

• High sulfur shot coke was the feed in Delaware IGCC units

Case Study: Coal to Petroleum Coke

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Original IGCC configuration

• 5 Year U.S. Department of Energy (DOE) obligation:

• Only coal feedstock (no petroleum coke)

• Slag stored on-site for later disposition

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1999 – Petroleum coke was blended offsite (port of New Orleans) & shipped as a blend to Tampa

Petcoke blend limits

Recycle fines

Sulfur & chlorides in feedstock

Ash fusion temperature/refractory life

Petroleum coke introduction

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Coke blend variations

Current blend; 60% petroleum coke 40% coal

Demonstrated petroleum coke/coal blends up to 100% petroleum coke

% blend depends on several factors:

• Cost of fuels

• Available fuels

• % Sulfur & ppm chlorides in fuel

Case Study: Plant Relocation Conversion to Petroleum Coke


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Barstow, CaliforniaCoolwater IGCC

• Plant mothballed after 5-year Department of Energy demonstration • Combined cycle plant repurposed to natural gas• Gasification equipment sat idle until mid 90’s

Location: Barstow, California, USA

Startup: 1984

Feedstock: Coal

Capacity: 1,150t/d

Operation Pressure: 41bar

Gasifiers: 1×900ft³ Radiant Syngas Cooler/Convective Syngas Cooler; 1×600ft³ Quench

Gas Turbines: 107E; 110MW

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Equipment relocated to new fertilizer project site

1,900 km

Barstow, CA

Coffeyville, KS

New Orleans, LA

200km

400km

600km

800km

1,000km

Coffeyville Site:• Co-located at delayed coking refinery• In middle of farm country

• Located far enough away from NOLA to benefit from transportation costs

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Coffeyville, Kansas, USA

Location: Coffeyville, Kansas, USA

Startup: 2000

Feedstock: Petroleum Coke

Capacity: 1,180t/d (per gasifier)

Operation Pressure: 43bar

Gasifier Size: 2×900ft³ Quench

GE Gasification & Syngas

Scrubbing

CO Shift& Cooling

Oxygen

Petcoke

1300 t/d

Acid Gas Removal

Pressure Swing

Absorption

Ash / Slag

Handling

>90% availability

(no spare)CO2

Separation

Sulfur Recovery

CO2

Purification

Ammonia Synthesis

NH₃ Product

1,100 sTPD

Syngas & high H2 capable turbines


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9E (50 Hz)

7E (60 Hz)

9F (50 Hz)

7F (60 Hz)

6F (50/60 Hz)

Fuel Heating ValueLow

Air IGCC Syngas

Blast Furnace Gas

High

High H2 for CCS

High H2 for EOR

Medium

O2 IGCC Syngas

GTL Off-gas

6B (50/60 Hz)

Syngas turbines: fuel applications

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Low-BTU gas turbines

6F

7E

9F

7F

9E

232 MW187 MW

285 MW256 MW

140 MW126 MW

92 MW77 MW

85 MW85 MWSimple cycle output (MW)

Natural Gas

Syngas

natural gas syngas

6B46 MW42 MW

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Syngas turbine controls & accessories

Ventilation modifications

Inlet filter house

Inlet duct & plenum

Gas fuel module

Water injection skid

Exhaust system

Controls hardware & software

Accessory module

Liquid fuel and atomizing air

Static starter

Inlet bleed

heat system

N2/Steam injection skid1

Syngas fuel skid with N2 purge

Optional air extraction skid1

Enclosure

modifications:• Piping for syngas, diluent, etc.

• Explosion proofing

• Hazardous gas detection

• Fire protection

IGCC Controls

with added I/O

1Fuel and diluent skids/modules may need to be customized for specific fuel/plant configurations

Achieving RAM Targets with Polygeneration

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Plant configurationsPolygeneration• Produces H2 for refinery

• Produces power & steam

• No unused spares• Can achieve H2 availability up to 99.9%

• Higher efficiency than traditional quench

with RSC configuration

Traditional Quench• Produces only H2

• Spares for availability (either 1+1 or

2+1)

• Can achieve H2 availability up to

98.8%

MP and LP Steam

Coke

Grind

Sulfur

Recovery

Sulfur

Handling

OXYGENSLURRY

ASU

Waste

Water

Treat

Slag/

Fines

Handle

SLAG WATERBLOWDOWN

Slag

Crusher

Fines

Handle

PSAAGRShift/

LTGC

Gasification

(Quench Gasifier)

ACID GAS

Gas Turbine

HRSGSteam

Turbine

MP and LP Steam

Coke

Grind

Sulfur

Recovery

Sulfur

Handling

OXYGENSLURRY

ASU

Waste

Water

Treat

Slag/

Fines

Handle

SLAG WATERBLOWDOWN

Slag

Crusher

Fines

Handle

PSAAGRShift/

LTGC

Gasification(Quench or RSC

Gasifiers)

ACID GAS

TAIL GASSYNGASHP Steam

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Economics of reliability/availability

0.5

0.55

0.6

0.65

0.7

0.75

0.8

0.85

0.9

0.95

1 2 3 4 5 6 7 8 9 10

Av

ail

ab

ilit

y

0.4

0.45

0.5

0.55

0.6

0.65

0.7

0.75

0.8

0.85

0.9

1 2 3 4 5 6 7 8 9 10

Av

ail

ab

ilit

yCCF - Yr 1-5 NPV CCF - Yr 1-5 NPV

Poor time to maturity can result in 60% decrease in early

year cash flow and 35% decrease in project NPV

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RAM expertise

GE Reliability Centers of Excellence

• Warsaw, Poland

• Schenectady, NY

• Greenville, SC

Capabilities

Analysis of reliability, availability, streams throughput, configuration of process units, streams & critical equipment, enhancing planned maintenance strategy & sparing philosophy

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Typical availability (no spare)

• Chinese coal plants benchmarked for equivalent availability over 3 years

• Equivalent availability was for the total syngas plant not just the gasifiers

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Planned maintenance

Best-in-class petroleum coke 900 ft³ maintenance schedule

Refractory• Repair cone/throat: 7 days, every 18 months

• Repair neck/dome/sidewall: 17.5 days, every 24 months

• Replacement: 25 days, every 72 months

Other Gasification• 2.5 days, every 6 months

• 5 days, every 12 months

Leveled annual maintenance: 16.8 days• Total availability impact: 4.6%

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Availability comparisons

Typical Best

Planned Maintenance -7% -5%

Unreliability -4% -4%

Equivalent Availability 89% 91%

• Polygeneration typically includes hydrogen, power & steam production

• Very high hydrogen availability can be achieved

•Calculated from single train availability using a binomial distribution

•Syngas turbines are backed up with back-up fuels, power availability will be higher

Equivalent

Availability

Typical Best

1+0 (1×100%) 89.0% 91.0%

1+1 (2×100%) 98.8% 99.3%

2+1 (3×50%) 98.2% 98.9%

3+0 (3x33⅓%) H2 99.9% 99.9%

3+0 (3x33⅓%)Coke/MW

83.5% 90.8%

A Perspective on Capital Expenditures from China

Background

• Primary Objective: Assess technical & economic viability of China IGCC using GE technology

• Joint study w/ China Power Engineering Consulting Group Corporation (CPECC)

• Technology selections enhance efficiency while reducing capital expenditure

• Create plan for future efficiency & cost improvements


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IGCC study results

Study Parameter Target Result

41-43% LHV Efficiency 42.2% LHV

Output 800MW net 870 MW net

Cost 8000-10000 RMB/KW (Gross Output Basis) 8928 RMB/KW (~$1380/KW)

Meet IGCC Emissions Standards Key Area Standard met

Water Consumption at a Maximum of 0.6 m3/GWs Maximum met


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Gasifier economics

Source: Internal GE calculation

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Thank you

Documents

Mr. Daniel Tse - · PDF fileRefinery Polygen Chemicals Electricity Synthetic Natural Gas Transportation Fuels GE’s Gasification Technology GE’s Petcoke Gasification Technology