siemens global gasification and integrated … o&m services state-of-the-art gas turbines ......

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Siemens Global Gasification and IntegratedGasification Combined Cycle Update

Harry MoreheadManager, IGCC Marketing

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Siemens Global Gasification and IGCC Update2006 Gasification Technologies Conference Power Generation 2

Agenda

• Siemens Power Generation

• Future Energy Acquisition

• Power Island Update

• O&M

• Projects in Development

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PowerGeneration

Power Generation Group Executive Management

Regional Offices Worldwide

• Gas turbines and combined-cycle power plants

• Steam turbines and powerplants

• Electrical generators

• Plant Diagnostics

• Operating Plant Service

Instrumentation& Controls

• Instrumentation and controlsystems

• IT solutions for power plantmanagement

IndustrialApplications

• Industrial size turbines andpower plants

• Turbo compressors• Oil and Gas Sector• Service

StationaryFuel Cells

Joint Venture

Framatome AdvancedNuclear Power(Siemens stake 34%)

Voith Siemens Hydro(Siemens stake 35%)

Siemens Power GenerationProduct and Service Businesses

Integrated global network for power generation

Wind Energy• On shore and off shore

renewable wind energysolutionsGasification

• SFG Gasifiers

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IGCC Plant Instrumentationand Control Systems

Steam TurbineGenerators

Air / N2 / O2 / CO2 / SyngasCompressor Trains

Siemens O&M Services

State-of-the-ArtGas Turbines

IGCC Power IslandReference Plant

SFGGasifiers

Siemens Solutions for Today’s IGCC Plants

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Agenda




• O&M


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The acquisition focuses on gasification technology

SustecHolding AG

FUTURE ENERGYGmbH Sustec AG

SustecIndustries AG

Sustec GSPChina Corp., Ltd.

100% 100%100%

50%

SustecSchwarze Pumpe GmbH

(50% Ningxia Coal Group)

Scope of Acquisition Not included

Siemens Fuel Gasification Technology GmbH

Scope of Acquisition

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Siemens Gasification Business Status

• Siemens SFG gasifiers have been inoperation since 1984 processing a widerange of feedstock from lignite to wastetars and oils

• Siemens has an Engineering group andGasification Center in Freiberg, Germanyand also people in Beijing supporting theJoint Venture

• Siemens Gasification Group’s recent focushas been on the use of coal for productionof synfuel, methanol and ammonia

• Major projects have been awarded inChina, and several feasibility studies areunder way for projects in South Africa,Canada, Australia and USA

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V esová

SchwarzePumpe

Seal-Sands

SiemensTest Center

methanolor NH3

Bituminouscoal

contractawarded

2x200MWth

Anhui(China)

Methanolor NH3

Bituminouscoal

contractawarded

2x200MWth

Linggu(China)

DMEBituminouscoalQ2/20082x

500MWth

Ningxia(China)

syngasfor IGCC

tar oils,liquid

residuals2006175 MWth

esová(CZ)

Fuel Gasliquid

chemicalresiduals

200130MWthBASF Seal-Sands(UK)

Syngashard coal,

lignite,slurries

19965MWthSiemens Test Center(Freiberg, Germany)

Syngasfor

methanoland

power

Lignite,natural gas,tar oils, and

waste

1984200MWthSchwarze Pumpe SZV(Germany)

ProductsFuelStart-upGasifierSize

Projects

Siemens Gasification Experience

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Technology OverviewSiemens SFG Gasification Technology

SFG Gasifier Highlights

This multi-fuel gasifier accepts a wide variety offeedstocks (e.g., bituminous coal, sub-bituminouscoal, lignite, biomass and liquid wastes)

Siemens design & manufacture the gasificationequipment

Technology development started in mid-1970s

Siemens has more than 20 years of successfuloperating experience with SFG gasificationtechnology

Major features include dry feed, a reliable coolingscreen design, high carbon conversion, andoperating pressure up to 40 bar

Siemens comprehensive gasification test facilityavailable to confirm feedstock characteristics, ifneeded

Siemens will provide key components for gasification inpower generation and other applications

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Year

197819791980198119821983198419851986198719881989

1990199119921993199419951996199719981999

200020012002

200320042005200620072008

Fixed-bed gasification

Entrained-flow gasification

Commercial plants

Lignite

Saliferous lignite

42 lignite varieties15 hard coal varieties

(international)Pulverized hard coal and lignite

Petcoke, flue ash

15 municipal and industrialsewage sludges, MSW, wasteoil, wood, straw

Slurry, flue ashIndustrial waste and residues

Chlorinated organicsNitrogen waste organicsBlack liquor

19561977

Lignite

Saliferous lignite

Natural gas

Waste oil, tar oil

SlurryTar oil/solid sludges

Nitrogen waste organics13 t/h

Tar oil

DBI

DBI

Noell

Babcock

FUTUREENERGY

200 MW

3 MW

5 MW

Schwarze Pumpe

Seal Sands

Bioslurry, coalHard coal

Demonstrations plants Freiberg

esová

Hard coalAnhui Huainan ProjectNingMei DME Project

24 gasifiers constructed in the gas combine „Schwarze Pumpe“

SFG Technology FeedstockOperating and Testing History

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Agenda




• O&M


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320,000+ Operating H

oursCustomer/Plant(Location)

ElectricalOutput(net)

GasTurbine Main Features Start-up

Hörde Steelworks(Dortmund, Germany)

Handan Iron & Steel(Handan, P.R. China)

8 MW VM5 Blast-furnace-gas-fired, gas turbine ascompressor drive

1960/

2000

U. S. Steel Corp.(Chicago, USA) 20 MW CW201 Blast-furnace-gas-fired gas turbine 1960

STEAG/Kellermann(Lünen,Germany) 163 MW V93 First CC plant in the world with integrated

LURGI coal gasification (hard coal) 1972

DOW Chemicals(Plaquemine, USA) 208 MW 1) 2 x W501D5 CC plant with integrated DOW coal

gasification 1987

Nuon Power Buggenum(Buggenum, Netherlands) 253 MW V94.2 CC plant with integrated SHELL coal

gasification (hard coal and biomass blend)1993 2)

1994/95HRL(Morwell, Australia) 10 MW Typhoon CC plant with integrated drying gasification

process (lignite) 1996

Sydkraft(Värnamo, Sweden) 6MW Typhoon First CC plant in the world with integrated

biomass gasification 1996

ELCOGAS(Puertollano, Spain) 300 MW V94.3 CC plant with integrated PRENFLO coal

gasification (coal and petroleum coke blend)1996 2)

1997/98ISAB Energy(Priolo Gargallo, Italy) 521 MW 2 x V94.2K CC plant with integrated TEXACO heavy-oil

gasification (asphalt)1998 3)

1999ELETTRA GLT(Servola, Italy) 180 MW V94.2K CC plant with steel-making recovery gas 2000

ARBRE(Eggborough, UK) 8 MW Typhoon CC plant with integrated biomass gasification 2002

EniPower(Sannazzaro, Italy) 250 MW V94.2K CC plant with integrated SHELL heavy-oil

gasification 20061) 160 MW from syngas and 48 MW from natural gas; 2) Natural gas firing; 3) Oil firing

Syngas Experience at Modern IGCC Plants

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IGCC Plant Instrumentationand Control Systems

Air / N2 / O2 / SyngasCompressor Trains

Customer/Plant (Location) Siemens Scope Start-up

DOW Chemicals(Plaquemine, USA) ASU main air compressor 1987

Nuon Power Buggenum(Buggenum, Netherlands)

ASU air compressor (for start-up)N2 compressors, O2 compressor

1993 2)

1994/95Global Energy/Wabash River(West Terre Haute, USA)

ASU main air compressorO2 compressor 1995

Tampa Electric/Polk County(Mulberry, USA)

ASU main air compressorN2 compressors, O2 compressor 1996

ELCOGAS(Puertollano, Spain)

IGCC plant Instrumentation & control systemClaus gas compressorIGCC plant optimization and integration study

1996 2)

1997/98

NPRC/Negishi(Negishi/Japan)

ASU main air compressorN2 /air compressors, O2 compressor 2003

Opti/Long Lake(Alberta, Canada) ASU main air compressor 2006

Compressors, Instrumentation & ControlSystems Experience for IGCC Applications

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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 offeedstocks

SGCC6-5000F 2X1- 630 MW Reference Plant Concept Being

Developed Based on Standard SCC6-5000F 2X1

60 Hz IGCC Power Island Solutions

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Gas Turbines for IGCC Applications

60 Hz Applications 50 Hz Applications

SGT6-3000E

SGT6-5000F

SGT6-6000G

SGT5-2000E

Applications Include:• Coal, Petcoke, or Residual Oil Based

IGCC• Small Coal or Biomass Based IGCC• Other Low-BTU or Med-BTU Applications• Greenfield IGCC or Repowered NGCC

SGT-100

Geared Units

SGT5-4000F

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Diluents: Natural Gas – Steam, Syngas – NitrogenEstimates based on SGT6-5000F with Syngas Combustion System, SGT6-5000F Emissions Verified in 2005

SGT6-5000F SGT6-6000G

Gas Turbine IGCC Performance Estimates[ISO Conditions] (Preliminary Study)

NOx, ppmvd @ 15% O2 (w/o SCR)

Gross GT Output, MW

15

296

Syngas

25

279

Nat. Gas

15

232

Syngas

25

210

Nat. Gas

SGT6-6000GSGT6-5000F

Higher Output From Proven Gas Turbine Technology

SGT6-3000E

60 Hz Gas Turbines for IGCC Applications

SGT6-3000E

15

135

Syngas

25

135

Nat. Gas

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Developments for the Future• Siemens developing catalytic/H2/syngas combustion

systems and integrating advanced gas turbines into IGCCunder EU and US DOE sponsorship

Developments for the Future• Siemens developing catalytic/H2/syngas combustion

systems and integrating advanced gas turbines into IGCCunder EU and US DOE sponsorship

SGT6-5000F Combustion Test Results• <15 ppm NOx and <10 ppm CO on variety of syngas

compostions• <25 ppm NOx and <10 ppm CO on NG with steam injection• Stable combustion and excellent operability demonstrated

during fuel transfers and co-firing

SGT6-5000F Combustion Test Results• <15 ppm NOx and <10 ppm CO on variety of syngas

compostions• <25 ppm NOx and <10 ppm CO on NG with steam injection• Stable combustion and excellent operability demonstrated

during fuel transfers and co-firing

Reduced Emissions with Fuel and Operational Flexibility

SGT6-5000G Combustion Test Results• Initial testing indicated that emissions targets can be

achieved with stable operation

SGT6-5000G Combustion Test Results• Initial testing indicated that emissions targets can be

achieved with stable operation

SGT5-4000F Combustion Test Results• < 15 ppm NOx and < 10 ppm CO on a variety of different

syngas fuels• No impact on dry emissions performance on NG• Stable premixed combustion on selected syngas fuels was

demonstrated

SGT5-4000F Combustion Test Results• < 15 ppm NOx and < 10 ppm CO on a variety of different

syngas fuels• No impact on dry emissions performance on NG• Stable premixed combustion on selected syngas fuels was

demonstrated

AirAir

Air

Syngas 2/ NG(diffusion)

Fuel Oil(diffusion)

Fuel Oil(premix)

Natural Gas(premix)

Syngas 1(premix)

Siemens Global Gas TurbineCombustion Test Programs

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Today’s Fuel Flexible SGT6-5000F

Siemens IGCC Experience Base Full Scale Test Facilities

95%Fleet Availability

189 Units in Operation

• Based on provenstandard product andfleet experience

• Lessons learned fromprior and current IGCCPlants are thefoundation foradaptations for IGCC

• Full scale testing formsthe basis for newtechnologyimprovements

SGT6-5000F forIGCC Applications

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• Syngas combustion system• Based on Proven Syngas

Combustor at DOW, LGTI IGCCProject

• 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

SGT6-5000FGas Turbine Modifications for IGCC Applications

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DOW, LGTI Syngas Combustion System

DOWLGTI

StandardDF-42

DOWLGTI

StandardDF-42

85,000 Hours of Successful Syngas Operation

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2005 Syngas CombustionTest Results Summary

• Syngas- NOx < 15 ppm, 50% to 100% load- CO < 10 ppm, 70% to 100% load

• Natural Gas- NOx < 25 ppm, 70% to 100% load- CO < 10 ppm, 70% to 100% load

• Syngas - NG Transfer- Successful Both Ways- 30% Load and Baseload

• Syngas - NG Co-Firing- Successful Both Combinations- 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

Emissions at Full Pressure Operability

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2006 H2 Combustion Testing Update

Range of hydrogen fuel compositions tested30%-78%, with different diluents levels in pure H2 at90% carbon capture level

Range of loads tested at full pressure30%, 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

EmissionsNOx 15 ppm with N2 and/or steam dilution

Combustor configurationproduction design nozzle

H2 dilution with steam, N2 and a blend of both steam and N2 wassuccessfully demonstrated while achieving 15 ppm NOx emissions

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Siemens / DOE program includes Phases 1 and2 of a 10-year program to develop an advancedGT for IGCC applications.

DOE Advanced Power Systems goal is toconduct R & D for CO2 sequestration readycoal-based power systems with:

45 – 50% HHV plant eff.

<2 ppm NOx @ 15% O2

<$1,000/kW capital cost

Phase 1Technologies identification,R&D Implementation Plan,conceptual designs

Phase 2Advanced technologiesdevelopment / validation,detailed designs

Phase 3 (Not yet awarded)GT-IGCC plant construction,validation / demonstration

Advanced Hydrogen TurbineDevelopment Program Objectives

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Agenda




• O&M


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Siemens O&M Approach for IGCC

• O&M Group is a member of the ReferencePlant Design Team

• Adapt Traditional Siemens O&M Services• 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 CenterOrlando, FL

IGCC Power IslandSFG Gasifier Island (Planned)

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• O&M


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IGCC Projects in Development

606 MW Fuel Flexible IGCC

Siemens / Fluor Consortium

ConocoPhillips Gasification Technology

FEED Expected to Start Shortly

630 MW IGCC

Siemens / Fluor Consortium

ConocoPhillips Gasification Technology

Phase A FEED Completed

E-Gas Consortium Design TemplatesSiemens 3D Reference Power Block Model

Excelsior EnergyMesaba IGCC Project

Steelhead EnergySouthern IL Clean Energy Center

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Conclusion

Siemens is expanding its portfolioof products and services to servethe IGCC and gasificationmarkets

Siemens is leveraging its globalmanufacturing and servicecapabilities to provide OEM levellife cycle support for our SFGgasifiers

Siemens continues to invest inthe key power generation andgasification technologies neededto make IGCC a competitiveoption for the world’s powerindustry

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Questions ?

Puertollano at Night

• IGCC Power Island for60 Hz Applications

• 50 and 60 Hz Gas TurbineGenerators with Syngas /Natural Gas (or Oil)Capability

• SFG Gasifiers

• Steam Turbine Generators

• IGCC Plant Instrumentationand Controls

• IGCC CompressionSolutions

• IGCC Power Block and SFGGasifier O&M Services

siemens global gasification and integrated … o&m services state-of-the-art gas turbines ......

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