Pbrkic71/1 DBK 00-10-05

ABB Oil, Gas and Petrochemicals

John L. SpenceVice President Operations

ABB Lummus GlobalTechnology DivisionBloomfield, NJ, USA

api ENERGIA IGCC PlantStatus

by

2000 Gasification Technologies ConferenceSan Francisco, USAOctober 8-11, 2000

ABB Oil, Gas and PetrochemicalsPBrkic71/2 DBK 00-10-04

Outline

n Site location

n Project contractual scheme

n Process scheme

n Plant characteristics

n Overall project history

n Present project status

n Remaining activities to PAC

n Commissioning issues

n Lessons learned

ABB Oil, Gas and PetrochemicalsPBrkic71/3 DBK 00-10-04

Site Location

ABB Oil, Gas and PetrochemicalsPBrkic71/4 DBK 00-10-04

api ENERGIAapi ENERGIA

Shareholder and ancillary agreements

25 % Equity51 % Equity

Technologylicense agreements

24 % Equity

Fuel supply agreement

O & M agreement

Steam purchase agreement

Utilities and service supplyEnergy Sales agreement

Turnkey constructionagreement

Non-recourse debt

Completionundertakings

ABBABB

Texaco DevelopmentTexaco DevelopmentCorpCorp

ANONIMA PETROLI ANONIMA PETROLI ITALIANA, SPAITALIANA, SPA

API REFINERYAPI REFINERY

API GROUPAPI GROUP

LENDERSLENDERS69 BANKS69 BANKS

ABB Sadelmi *ABB Sadelmi *ABB Lummus GlobalABB Lummus GlobalABB Power Generation ABB Power Generation **

ENELENEL

Project Contractual Scheme

* Today: Alstom Power

ABB Oil, Gas and PetrochemicalsPBrkic71/5 DBK 00-10-04

TAR

FILTER

CAKE

STEAM TO

REFINERYSTEAM

POWERPOWERPOWER POWERPOWERPOWEROXYGEN

DEMI

WATER

DEMI

WATER

EXHAUST

SULPHUR

STEAM

WASTE

WATER

NITROGEN

STEAM

AIRAIRSEPARATORSEPARATOR

GASIFICA-GASIFICA-TIONTION

GASGASCOOLINGCOOLING

ACID GASACID GASREMOVALREMOVAL

SULPHURSULPHURRECOVERYRECOVERY

SOOTSOOTRECOVERYRECOVERY

GASGASTURBINETURBINE

STEAMSTEAMTURBINETURBINE

HEATHEATRECOVERYRECOVERY

STEAMSTEAMGENERATORGENERATOR

AUXILIARYAUXILIARYBOILERBOILER

HOT

EXHAUST

Process Scheme

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Syngas Manufacturing Process Plant (SMPP)

n Technology: Texaco, UOP, Parsons, Südchemieand ABB Lummus Global

n Plant size:v 59 t/h of feed

v 130 t/h of syngas

v 127 t/h of Nitrogen

v 62 t/h of Oxygen

v 33 t/h pretreated waste water

v 4 t/h sulfur

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Combined Cycle Power Plant (CCPP)

n Technology: Alstom PowerDry LowNOx , GT13E2 MBTU

n Plant size:vGas Turbine 190 MW

v Steam Turbine 100 MW

v HRSG 280 t/h

v Auxiliary Boiler 140 t/h

v Export steam to refinery 65 t/h

ABB Oil, Gas and PetrochemicalsPBrkic71/8 DBK 00-10-04

Api IGCC Project History

n 1990 Project idea/potential clients

n 1991 Technology selection, licensor, feasibility study

n 1992 License agreement, consortium agreement

n 1993 Basic engineering, nominated subcontractors, cost estimate,authority permitting

n 1994/95 LSTK proposal, feasibility analysis,development of contracts, financing

n November 1996 Signing of contracts, determination ofcontractual value in LIT

n December 2000 Provisional acceptance

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Api Energia IGCCView of (right to left) the

cold box, the incinerator

stack, the grey water

treatment unit, the HRSG

and its stack, the sulfur

recovery units (foreground)

and the Selexol towers

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Api Energia IGCCView of the HRSG

in the direction of

the air separation

compressor building

and the cold box

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Api Energia IGCCGasifier structure

upper deck

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Api Energia IGCCView of the naphtha

stripper and carbon

extraction unit

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Api Energia IGCCView from the gasifier

deck of the acid gas

removal section

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Api Energia IGCCView of the sulfur recovery

units (center), the sour

water stripping towers (right)

and the Selexol regenerator

and absorber

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Api Energia IGCCView of the HRSG

showing the DeNOx

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Api Energia IGCC

View of the GT

building and

air intake

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Plant Performance Highlights

n Both gasifiers have operated at 100% rate

n All upstream and downstream process areashave run successfully

n Process chemistry working well

n SRU’s have operated on oxygen and acid gasat near design efficiency

n Gas turbine has operated at base load ondiluted syngas

n Emissions from gas turbine are lower thanexpected

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Remaining Activities to PAC

n Complete gas turbine testing

n Validate the CEMS

n Operate auxiliary boiler on syngas

n Conduct the 96-hour guaranteeperformance test

n Complete the 30-day reliability run

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Project and Commissioning Issues

n Excessive number of equipment componentfailures

n Gasket upgrading to spiral wound types witha center ring

n Replacement of valves

n Pump outages and pump seal failures

n Operational learning experiences

n Feed injector weld failures and modifications

ABB Oil, Gas and PetrochemicalsPBrkic71/20 DBK 00-10-04

Lessons Learned

n An IGCC plant is a highly integrated facility

n Each facility has its own operatingcharacteristics

n Continuous emissions monitoring systemsare time consuming to obtain certificationby the authorities