Power Generation
Gasification: Status, Outlook and
Technical Developments
Frank Hannemann,
Siemens Fuel Gasification Technology GmbH & Co.KG
Copyright © Siemens AG 2009. All rights reserved.
Content
Energy and Gasification Market Trends
Status of Siemens Gasification Projects
SFG Technology / R&D and new Products
Polygeneration Concepts
Copyright © Siemens AG 2008. All rights reserved.
Energy Sector
Siemens Energy Sector –
Answers for Energy Supply
Energy products and solutions - in 6 Divisions
Oil & Gas
Fossil Power
Generation
Renewable
Energy
Energy
Service
Power
Transmission
Power
Distribution
Copyright © Siemens AG 2008. All rights reserved.
Energy Sector
Global Energy Market Trends and Primary
Energy Consumption
Primary energy demand by types
Total Primary Energy Demand (Gtoe)
12.0
Renewables
Hydro
Nuclear
Gas
1.3
0.7
8.8
0.9
1.7
0.2
0.5
0.3
1.5
0.8
0.3
4.1
0.3
4.2
4.4
0.9
0.4
1.0
0.4
Despite a significant expansion of renewables
fossil energy carrier will keep covering the
highest share of total energy supply
3.6
3.3
3.0
2.8
2.5
0.9
2.0
1.8
1.7
Continue grow with an average rate of 1.5%/a in
total and even 1.9%/a in power sector up to 2030
16.8
15.6
14.4
13.5
Global Energy Market Trends
5.0
4.7
Oil
3.2
3.8
4.1
4.5
2.2
3.2
4.9
Coal
1990
2007
2015
2020
2025
2030
The strongest growth in energy demand is
expected to take place in China and India
Energy consumption in West Europe and the
Americas will stay flat because of efficiency gains
and demand saturation
Primary energy demand by regions
Total Primary Energy Demand (Gtoe)
Africa
12.0
Middle East
Asea/Pacific
Latin America
North America
Eastern Eur./CIS
Western Europe
0.6
8.8
0.4
0.2
4.6
14.4
13.5
0.7
0.7
0.8
0.5
5.7
6.3
16.8
15.6
0.8
0.9
7.1
0.8
1.0
7.8
2.4
0.3
2.2
0.6
0.6
0.7
0.7
0.8
2.8
2.8
2.8
2.9
3.0
1.5
1.6
1.1
1.8
1.2
1.8
1.2
1.8
1.3
1.8
1.4
1990
2007
2015
2020
2025
2030
1.9
Source: IEA WEO 2009
0.9
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 critical
stage. 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
Copyright © Siemens AG 2008. All rights reserved.
Energy Sector
Gasification Market Today
EUROPE
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
Only funded IGCC projects with
90% CCS discussed and one IGCC
project seriously ongoing
IGCC gets strong competition by post
combustion
EU selected 6 CCS projects for
funding: 1 bio EUR
Few biomass gasification activities
ASIA
China:
Largest gasification market
3.000MW IGCC program
Mega CtX projects under development
India:
Gasification for steel industry and CtX
under consideration
Rest: (e.g. South-Korea, Indonesia)
Couple of coal projects under
development (mainly CtX)
AUSTRALIA
BRAZIL
Rising interest in biomass and coal
gasification
AFRICA
Small number of CTL projects under
discussion
Successful implementation
depends on CO2 legislation
2 governmental funded IGCC
projects
Large CTL and fertilizer projects
under development
Due to pending CO2 legislation and high IGCC invest gasification projects difficult to realize
But: Increasing fuel prices (crude oil), security of supply andCopyright
beginning
recovery of economy
© Siemens AG 2008. All rights reserved.
starts driving new gasification projects primarily in Asia
Energy Sector
ia
M
ber
Sa
kh
ali
n
Ea
Si st
be
ria
We
st S
i
id
dl
e
As
ia
Coal Gasification Marketing Potentials in
China
Urumchi
JiLin
鄯善
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
Beijing
Hohhot
• New CTO and MTO extension
rising up due to 40% shortage
imported
YinChuan
• 1 ongoing CTL demonstration
project driven by government
Legend
ShangHai
Existing NG pipeline
NG pipeline planed
Lignite
• Reluctant IGCC demonstration
Sub-bituminous
Bituminous
`
Lean and anthracite
(red-approved and yellow-serious)
Coal to Liquid
(red-operation/construction and yellowapproved)
Coal to Olefins
(red-operation/construction and
yellow-approved)
[Mtons Coal]
SNG
CTL
CTO
CTG
Methanol
DME
a
rm
Bu
Coal to SNG
• Coal to glycol as a new
opportunity supported by
Chinese self proprietary techn.
Fuzhou
due to high investment
Under
Approved
Serious
In
Constr.
Projects
considered
Operation
• Poly-generation might be a
Guangzhou
36.72
41.31
trend due to mega chemical
9.24NanNing1.26
22.4
7
2.16
4.164
3.6
plants and need for CO2
0.6
3
reduction
19.2( capacity until 2010 ) Copyright © Siemens AG 2008. All rights reserved.
36.8 (capacity until 2010)
Energy Sector
Siemens main Gasifier Activity
Landscape
Capital Power
270 MW e IGCC
Sustec, Schwarze Pumpe
NCPP I
1984 - 2007
Coal to
Polypropylene
Calgary
Secure Energy
China JV
GSP China
Coal to Chemicals
Orlando
Summit Power
400 MW e IGCC + Ammonia
Vresova
Tenaska
IGCC
Liquid feedstock
COD 2008
Coal to SNG/Power
JinCheng
Coal to Ammonia
HQ Freiberg
Test Facility
Siemens Offices
Operating Units
Current Projects
Technology Selected
AEC
Coal to UREA
9 SFG-500 Gasifiers (incl. other key equipment) shipped
Technology selected and pre-selection in further projects
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Energy Sector
DOE supported IGCC projects using
SFG Technology
Tenaska Taylorville Energy Center
Summit Texas Clean Energy Project
Customer:
Tenaska Inc.
Nebraska, USA
Customer:
Summit Power Group, Inc.
Washington, USA
Location / Fuel:
Illinois, USA / Illinois coal #6
Location / Fuel:
Midland Odessa, Texas, USA / PRB
Power output:
500 MW (net)
Power output:
400 MW (gross) and 270k t/a NH3
Siemens scope:
2 x SFG-500 Gasifier and
1x SGT6-5000F
Siemens scope:
PowerBlock (1 x SGCC6-5000F)
2 x SFG-500 Gasifier
CCS capture rate:
> 50% used for EOR
CCS capture rate:
ca. 90% used for EOR
Time schedule:
Financing until end of 2010
Operation total plant: 2015
loan guarantee
Time schedule:
Financing until mid of 2011
Commercial operation 2014
350‘ USD funding
DOE support:
IGCC Concept with intermediate
SNG production and natural gas
fired standard Gas Turbine
DOE support:
IGCC Concept with H2 fired GT
and NH3 co-production
Copyright © Siemens AG 2008. All rights reserved.
Energy Sector
NCPP I: Largest Coal to Chemical Plant in China
5 x SFG-500 class gasifier: Coal to Polypropylen plant
Siemens Scope:
Feedstock:
Status
Engineering
Subbituminous Coal
Engineering Completed
Equipment Supply
Ash:
All Gasifiers shipped and erected
Gasifiers, Burners, Feeder Vessels, ...
~ 7 wt%
Moisture: ~ 2 wt%
Training (Freiberg Simulator)
Piping installation in progress
Start up Year: 2010
Technical Field Assistance
Power Station
Air Separation Units
Methanol to
Polypropylene
Gasification Unit
(5xSFG-500 class gasifiers)
Black Water
Treatment
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Energy Sector
NCPP / Site Construction Progress
January, 2009
First batch of gasifiers erected
Mid 2009
Steel construction in progress
Heavy equipment such as coal bunkers and
K/O drums erected by cranes with 1600t capacity
Beginning 2010
Civil construction continuing and
piping pre fabrication started
March, 2010
Piping installation in progress
90% pipes for BWTP installed
Copyright © Siemens AG 2008. All rights reserved.
Energy Sector
Current and New Products of SFG
Technology
Cooling Screen Gasifier
ash content > 1,5 – 2%
Existing 500MW
gasifier
Anthracite
BMWI funded program
Radiant Cooler selected due
to robustness and limited
modification of current design
Higher Efficiency
Bituminous
Radiant Cooler
Heating surface
Sub-Bitum.
Lignite
Refractory Lined Gasifier
ash content < 1,5 – 2%
Proven 500MW
Quench 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 steam
production
Petcoke
Liquid fuel
Economy of Scale
Biomass
SFG- 850 MW / 1200MW
20% cost reduction
3 burner application
Design features of 500MW
retained
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Energy Sector
New Design Features and Capabilities
Process Simulator and real plant
I&C system in combination with
OPC interface
Process Simulator and I&C
System in Freiberg
Real plant data and operator
activities
Operational
Data transfer
• Offers realistic Operator Training
• Remote Monitoring and Diagnostic
Diagnostic
and troubleshooting
• Operational analysis and validation of I&C
modifications on simulator
3000K
16000
Intensität [a.u.]
Advanced sensoring and CFD
analysis
Advanced ph sensoring, spectroscopical
flame analysis, advanced coal feed and raw
gas dust sensoring, online coal humidity
sensor
14000
12000
10000
8000
6000
4000
11:24:31
11:29:36
11:35:4
11:43:49
1
2000
0
CFD analysis to optimise reactor and quench
geometrie and to calculate heat flux
200
Isokinetic dust
sampling
400
600
800
Wellenlänge [nm]
300K
1000
SFGT_280607_008.xls
Flame analysis by spectroscopy to
determine temperature and ash content
SFG Design Improvements
CFD analysis of
pilot plant
Flüssigkeitspumpe
Druckbehälter
• Standardisation and optimisation of plant
layout to reduce investment
• Advanced Feeding System for cost
reduction
• Design improvements to minimise utility
consumptions
Flüssigkeit
Membranweg
Membran
Kohlestaub
Be-/Entspannung
Filter
Be-/Entspannung
Auflockerung
KohlestaubSaugseite
KohlestaubDruckseite
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Energy Sector
Basic IGCC Concepts with CCS
Integrated Gasification Combined Cycle
(CO2)
IGCC-CCS
Gas
Syngas/H2
Water/Steam
Island
CCPP
H2-rich SG
Siemens
Fuel
Gasifier
(SFG)
Diluent N2
Coal-topowerefficiency
CO2 capture
(Air to ASU)
Attractive for European power market with its
CO2 regulations and potential funding options
CO2 for sequestration
Gasification Combined Cycle
GCC-CCS
Gas
Island
H2-rich SG
(CO2)
Syngas/H2
CCPP
(lower
interfaces)
Synthetic Natural Gas Combined Cycle
CO2
SNG-CC
Gas
Island
incl.
Methanation
SNG
CO2 for sequestration
Standard
CCPP
Natural
Gas Net
Real low-CO2 option (capture up to ~90%; ~100 g/kWh)
Only one interface lower complexity
Clear responsibilities (project execution)
Option for phased construction
(power from NG from beginning)
Attractive also in connection with
polygeneration
CO2 for sequestration
broad
variety of
feedstocks
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
Flexibility
Established
technology
Immanent partial CO2 capture for optional retrofit
(capture up to ~55%; ~350 g/kWh)
High operational flexibility as a proven “standard” CC
High product flexibility and thus capacity utilization
(power and/or SNG)
Attractive when setting up SNG infrastructure
and for intermediate load power generation
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Energy Sector
IGCC concepts using SFG Technology
IGCC with high carbon capture
Flue
Gas
ASU
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
Bypass
Raw
Coal
CO2
Gasifier with radiant cooler is preferred
due to optimal heat utilization
High efficiency > 40%
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Energy Sector
Polygeneration Plant Concept for Mega SNG
~770 MW aux. power*
~370
*Excluding utility systems
CO2
16 x SFG-500
Net efficiency* (LHV): >0,56 (GJ SNG)/
(GJ Raw Coal)
*without power export
Raw
Coal
SNG
4 billion Nm³/a
SFG-Gasifier with full quench system
robust and cost-effective
Power
SFG-Gasifier with radiant cooler
high efficient
High feedstock flexibility
Superheated IP-Steam
Saturated IP-Steam
Optimized water consumption
Alternative concept
E-class gas turbine
Superheated IP-Steam to ASU
Superheated IP-Steam to steam turbine
Mechanical drives
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Energy Sector
Methanol Polygeneration Plant Concept
Net efficiency* (LHV): ~0,53
*without power export
(GJ MeOH)/
(GJ Raw Coal)
SFG-Gasifier with full quench system
High feedstock flexibility
E-class gas turbine fired with offgas
and syngas
…
Saturated IP-Steam
Offgas
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Energy Sector
Conclusion
• Increasing oil price and continues primary energy growth still
favour gasification
• SFG gasification is on track: New products, extended scope and
new 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 benefits
efficiency
• Growing renewable power production requires energy storage and
peak load and flexible fossil power generation. Poly-generation is
the only practical solution.
Copyright © Siemens AG 2008. All rights reserved.
Energy Sector
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Copyright © Siemens AG 2008. All rights reserved.
Energy Sector