SiemansGasification PDF

Siemens Power Generation 2004.
All Rights Reserved

Siemens Global Gasification and Integrated
Gasification Combined Cycle Update
Harry Morehead
Manager, IGCC Marketing
Agenda
• Siemens Power Generation
Siemens Power Generation 2004. All Rights Reserved

• Future Energy Acquisition
• Power Island Update
• O&M
• Projects in Development
Siemens Global Gasification and IGCC Update

2006 Gasification Technologies Conference Power Generation 2
Siemens Power Generation
Product and Service Businesses
Power Generation Group Executive Management

Power Industrial Instrumentation
Generation Applications & Controls
• Gas turbines and combined- • Industrial size turbines and • Instrumentation and control
cycle power plants power plants systems
• Turbo compressors • IT solutions for power plant
• Steam turbines and power management
plants • Oil and Gas Sector
• Electrical generators • Service
• Plant Diagnostics
Wind Energy Joint Venture
• Operating Plant Service • On shore and off shore Framatome Advanced
renewable wind energy Nuclear Power
Gasification solutions (Siemens stake 34%)
• SFG Gasifiers Voith Siemens Hydro

Stationary
Fuel Cells (Siemens stake 35%)
Regional Offices Worldwide
Integrated global network for power generation

Siemens Solutions for Today’s IGCC Plants
State-of-the-Art IGCC Plant Instrumentation

Gas Turbines and Control Systems
IGCC Power Island

Reference Plant
SFG
Gasifiers
Air / N2 / O2 / CO2 / Syngas

Compressor Trains
Steam Turbine
Generators Siemens O&M Services
Agenda

• O&M

Scope of Acquisition

Scope of Acquisition
Sustec Not included
Holding AG
100% 100% 100%

FUTURE ENERGY Sustec
Sustec AG Industries AG
GmbH
50% (50% Ningxia Coal Group)

Sustec GSP Sustec
China Corp., Ltd. Schwarze Pumpe GmbH
Siemens Fuel Gasification Technology GmbH
The acquisition focuses on gasification technology

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

Siemens Gasification Experience
Projects

Gasifier
Start-up Fuel Products
Size
Syngas
Lignite,
for
Schwarze Pumpe SZV natural gas,
200MW th 1984 methanol
(Germany) tar oils, and
and
waste
power
hard coal,
Siemens Test Center
5MW th 1996 lignite, Syngas
(Freiberg, Germany)
slurries
Schwarze Seal-Sands
liquid Pumpe
BASF Seal-Sands
30MW th 2001 chemical Fuel Gas
(UK)
residuals
tar oils,
esová syngas
175 MW th 2006 liquid
(CZ) for IGCC
residuals
Anhui 2x contract Bituminous methanol

(China) 200MW th awarded coal or NH3
Ningxia 2x Bituminous
Q2/2008 DME
(China) 500MW th coal
Linggu 2x contract Bituminous Methanol
(China) 200MW th awarded coal or NH3
V esová Siemens
Test Center
Technology Overview
Siemens SFG Gasification Technology
SFG Gasifier Highlights

This multi-fuel gasifier accepts a wide variety of
feedstocks (e.g., bituminous coal, sub-bituminous
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
SFG Technology Feedstock
Operating and Testing History
Year Fixed-bed gasification
1956

24 gasifiers constructed in the gas combine „Schwarze Pumpe“ DBI
1977
Entrained-flow gasification
Demonstrations plants Freiberg Commercial plants
1978 DBI
1979 Lignite 3 MW
1980
1981 Saliferous lignite
1982
1983 200 MW
1984 42 lignite varieties Lignite
1985 15 hard coal varieties Schwarze Pumpe
1986 (international) Saliferous lignite
1987 Pulverized hard coal and lignite
1988
1989 Petcoke, flue ash Natural gas
1990 15 municipal and industrial Waste oil, tar oil Noell

1991 sewage sludges, MSW, waste
1992 oil, wood, straw
1993 Slurry
1994 Slurry, flue ash Tar oil/solid sludges
1995 Industrial waste and residues
1996 5 MW
1997 Chlorinated organics
1998 Nitrogen waste organics Nitrogen waste organics
1999 Black liquor 13 t/h Seal Sands
2000 Babcock
2001
2002 Bioslurry, coal Tar oil
Hard coal FUTURE
2003 esová
2004 ENERGY
2005
Hard coal
2006
Anhui Huainan Project
2007
NingMei DME Project
2008

Agenda

• O&M

Syngas Experience at Modern IGCC Plants
Electrical

Customer/Plant Gas
320,000+ Operating Hours

Output Main Features Start-up
(Location) Turbine
(net)
Hörde Steelworks
(Dortmund, Germany) 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.
20 MW CW201 Blast-furnace-gas-fired gas turbine 1960
(Chicago, USA)
STEAG/Kellermann First CC plant in the world with integrated
163 MW V93 1972
(Lünen,Germany) LURGI coal gasification (hard coal)
DOW Chemicals 1) CC plant with integrated DOW coal
208 MW 2 x W501D5 1987
(Plaquemine, USA) gasification
2)
Nuon Power Buggenum CC plant with integrated SHELL coal 1993
253 MW V94.2
(Buggenum, Netherlands) gasification (hard coal and biomass blend) 1994/95
HRL CC plant with integrated drying gasification
10 MW Typhoon 1996
(Morwell, Australia) process (lignite)
Sydkraft First CC plant in the world with integrated
6MW Typhoon 1996
(Värnamo, Sweden) biomass gasification
2)
ELCOGAS CC plant with integrated PRENFLO coal 1996
300 MW V94.3
(Puertollano, Spain) gasification (coal and petroleum coke blend) 1997/98
3)
ISAB Energy CC plant with integrated TEXACO heavy-oil 1998
521 MW 2 x V94.2K
(Priolo Gargallo, Italy) gasification (asphalt) 1999
ELETTRA GLT
180 MW V94.2K CC plant with steel-making recovery gas 2000
(Servola, Italy)
ARBRE
8 MW Typhoon CC plant with integrated biomass gasification 2002
(Eggborough, UK)
EniPower CC plant with integrated SHELL heavy-oil
250 MW V94.2K 2006
(Sannazzaro, Italy) gasification
1) 160 MW from syngas and 48 MW from natural gas; 2) Natural gas firing; 3) Oil firing

Compressors, Instrumentation & Control
Systems Experience for IGCC Applications
Customer/Plant
Siemens Scope Start-up
(Location)

DOW Chemicals
ASU main air compressor 1987
(Plaquemine, USA)
2)
Nuon Power Buggenum ASU air compressor (for start-up) 1993
(Buggenum, Netherlands) N2 compressors, O2 compressor 1994/95
Global Energy/Wabash River ASU main air compressor
1995
(West Terre Haute, USA) O2 compressor
Tampa Electric/Polk County ASU main air compressor
1996
(Mulberry, USA) N2 compressors, O2 compressor
IGCC plant Instrumentation & control system 2)
ELCOGAS 1996
Claus gas compressor
(Puertollano, Spain) 1997/98
IGCC plant optimization and integration study
NPRC/Negishi ASU main air compressor
2003
(Negishi/Japan) N2 /air compressors, O2 compressor
Opti/Long Lake
ASU main air compressor 2006
(Alberta, Canada)
IGCC Plant Instrumentation Air / N2 / O2 / Syngas

and Control Systems Compressor Trains

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

Gas Turbines for IGCC Applications
60 Hz Applications Geared Units 50 Hz Applications

SGT6-3000E
SGT5-2000E
SGT-100
SGT6-5000F
SGT5-4000F
Applications Include:
• Coal, Petcoke, or Residual Oil Based
SGT6-6000G IGCC
• Small Coal or Biomass Based IGCC
• Other Low-BTU or Med-BTU Applications
• Greenfield IGCC or Repowered NGCC

60 Hz Gas Turbines for IGCC Applications
SGT6-3000E SGT6-5000F SGT6-6000G

Gas Turbine IGCC Performance Estimates
[ISO Conditions] (Preliminary Study)
SGT6-3000E SGT6-5000F SGT6-6000G
Syngas Nat. Gas Syngas Nat. Gas Syngas Nat. Gas
Gross GT Output, MW 135 135 232 210 296 279
NOx, ppmvd @ 15% O2 (w/o SCR) 15 25 15 25 15 25
Diluents: Natural Gas – Steam, Syngas – Nitrogen
Estimates based on SGT6-5000F with Syngas Combustion System, SGT6-5000F Emissions Verified in 2005
Higher Output From Proven Gas Turbine Technology

Siemens Global Gas Turbine
Combustion Test Programs
SGT6-5000F
SGT6-5000F Combustion
Combustion Test
Test Results
Results

•• <15
<15 ppm
ppm NOx
NOx andand <10
<10 ppm
ppm CO
CO onon variety
variety of
of syngas
syngas
compostions
compostions
•• <25
<25 ppm
ppm NOx
NOx andand <10
<10 ppm
ppm CO
CO onon NG
NG with
with steam
steam injection
injection
•• Stable combustion and excellent operability demonstrated
Stable combustion and excellent operability demonstrated
during
during fuel
fuel transfers
transfers and
and co-firing
co-firing
SGT6-5000G
SGT6-5000G Combustion
Combustion Test
Test Results
Results Fuel Oil
(diffusion)
•• Initial
Initial testing
testing indicated
indicated that
that emissions
emissions targets
targets can
can be
be
Syngas 2/ NG
achieved
achieved withwith stable
stable operation
operation (diffusion)
Air
SGT5-4000F
SGT5-4000F Combustion
Combustion Test
Test Results
Results
•• << 15
15 ppm
ppm NOx
NOx and
and << 10
10 ppm
ppm CO
CO on
on aa variety
variety of
of different
different Natural Gas
(premix)
Fuel Oil
(premix)
syngas
syngas fuels
fuels
Air Air
•• No
No impact
impact on
on dry
dry emissions
emissions performance
performance onon NG
NG
•• Stable
Stable premixed combustion on selected syngas fuels
premixed combustion on selected syngas fuels was
was Syngas 1
(premix)
demonstrated
demonstrated
Developments
Developments for
for the
the Future
Future
•• Siemens
Siemens developing
developing catalytic/H
catalytic/H22/syngas
/syngas combustion
combustion
systems
systems and
and integrating
integrating advanced
advanced gas gas turbines
turbines into
into IGCC
IGCC
under EU and US DOE sponsorship
under EU and US DOE sponsorship
Reduced Emissions with Fuel and Operational Flexibility

Today’s Fuel Flexible SGT6-5000F
Siemens IGCC Experience Base Full Scale Test Facilities

SGT6-5000F for
IGCC Applications
• 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
95%
the basis for new Fleet Availability
technology 189 Units in Operation
improvements

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

DOW Standard
LGTI DF-42
DOW Standard
LGTI DF-42
85,000 Hours of Successful Syngas Operation

2005 Syngas Combustion
Test Results Summary
Emissions at Full Pressure Operability

• Syngas • Syngas - NG Transfer
- NOx < 15 ppm, 50% to 100% load - Successful Both Ways
- CO < 10 ppm, 70% to 100% load - 30% Load and Baseload
• Natural Gas • Syngas - NG Co-Firing
- NOx < 25 ppm, 70% to 100% load - Successful Both Combinations
- CO < 10 ppm, 70% to 100% load - At 30% Load and Baseload
• Ambient Effects
(by Air to Fuel Ratio sweep)
- Minor Impact on Emissions
- NOx Variations < 2 ppm
- CO Variations < 5 ppm
• Combustion Dynamics within limits
Exceeded Emissions Objectives with Stable Combustion

2006 H2 Combustion Testing Update
Range of hydrogen fuel compositions tested

30%-78%, with different diluents levels in pure H2 at
90% carbon capture level
Range of loads tested at full pressure

30%, 50%, 70%, and full load with 45% H2, 30% N2,
and 25% H2O
Diluents used with H2

pure steam, pure N2, mixture of both
Range of heating values tested:

100-260 BTU/scf
Emissions
NOx 15 ppm with N2 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
Advanced Hydrogen Turbine
Development Program Objectives

Siemens / DOE program includes Phases 1 and
2 of a 10-year program to develop an advanced
GT for IGCC applications.
DOE Advanced Power Systems goal is to

conduct R & D for CO2 sequestration ready
coal-based power systems with:
45 – 50% HHV plant eff.
<2 ppm NOx @ 15% O2

<$1,000/kW capital cost
Phase 1 Phase 2 Phase 3 (Not yet awarded)

Technologies identification, Advanced technologies GT-IGCC plant construction,
R&D Implementation Plan, development / validation, validation / demonstration
conceptual designs detailed designs

Agenda

• O&M

Siemens O&M Approach for IGCC
• O&M Group is a member of the Reference

Plant Design Team
• Adapt Traditional Siemens O&M Services

IGCC Power Island
SFG Gasifier Island (Planned)
• 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
Siemens Diagnostics Center

Orlando, FL
Agenda

• O&M

IGCC Projects in Development
Steelhead Energy Excelsior Energy

Southern IL Clean Energy Center Mesaba IGCC Project
E-Gas Consortium Design Templates

Siemens 3D Reference Power Block Model
630 MW IGCC 606 MW Fuel Flexible IGCC
Siemens / Fluor Consortium Siemens / Fluor Consortium
ConocoPhillips Gasification Technology ConocoPhillips Gasification Technology
Phase A FEED Completed FEED Expected to Start Shortly

Conclusion
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

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


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Siemens Power Generation 2004.

All Rights Reserved

• Siemens Power Generation

Siemens Power Generation 2004. All Rights Reserved

Siemens Global Gasification and IGCC Update

Power Generation Group Executive Management

Siemens Power Generation 2004. All Rights Reserved

• SFG Gasifiers Voith Siemens Hydro

Regional Offices Worldwide

Integrated global network for power generation

State-of-the-Art IGCC Plant Instrumentation

Siemens Power Generation 2004. All Rights Reserved

IGCC Power Island

Air / N2 / O2 / CO2 / Syngas

• Siemens Power Generation

Siemens Power Generation 2004. All Rights Reserved

Siemens Global Gasification and IGCC Update

Siemens Power Generation 2004. All Rights Reserved

100% 100% 100%

50% (50% Ningxia Coal Group)

Siemens Fuel Gasification Technology GmbH

The acquisition focuses on gasification technology

• Siemens SFG gasifiers have been in

Siemens Power Generation 2004. All Rights Reserved

• Siemens has an Engineering group and

• Siemens Gasification Group’s recent focus

• Major projects have been awarded in

Siemens Global Gasification and IGCC Update

Siemens Power Generation 2004. All Rights Reserved

Anhui 2x contract Bituminous methanol

SFG Gasifier Highlights

Siemens Power Generation 2004. All Rights Reserved

Siemens design & manufacture the gasification

Siemens will provide key components for gasification in

Siemens Power Generation 2004. All Rights Reserved

Demonstrations plants Freiberg Commercial plants

1990 15 municipal and industrial Waste oil, tar oil Noell

Siemens Global Gasification and IGCC Update

• Siemens Power Generation

Siemens Power Generation 2004. All Rights Reserved

Siemens Global Gasification and IGCC Update

Siemens Power Generation 2004. All Rights Reserved

320,000+ Operating Hours

Siemens Global Gasification and IGCC Update

Siemens Power Generation 2004. All Rights Reserved

IGCC Plant Instrumentation Air / N2 / O2 / Syngas

Siemens Global Gasification and IGCC Update

Siemens Power Generation 2004. All Rights Reserved

Siemens Global Gasification and IGCC Update

60 Hz Applications Geared Units 50 Hz Applications

Siemens Power Generation 2004. All Rights Reserved

Siemens Global Gasification and IGCC Update

SGT6-3000E SGT6-5000F SGT6-6000G

Siemens Power Generation 2004. All Rights Reserved

Higher Output From Proven Gas Turbine Technology

Siemens Power Generation 2004. All Rights Reserved

Reduced Emissions with Fuel and Operational Flexibility

Siemens IGCC Experience Base Full Scale Test Facilities

Siemens Power Generation 2004. All Rights Reserved

Siemens Global Gasification and IGCC Update

• Syngas combustion system

Siemens Power Generation 2004. All Rights Reserved

Siemens Power Generation 2005. All Rights Reserved