IGCC Gas Turbines For Refinery Applications

GE Power Systems

GE Company Proprietary

2002 Gasification Technologies ConferenceSan Francisco, California, October 27–30

Robert M. JonesManager, Process Power Marketing

Norman Z. ShillingProduct Line Leader, IGCC

Refinery Drivers• Environmental Legislation Proposed to Reduce Sulfur in

Transportation Fuels from >250 ppm to <15 ppm by ‘06• Incremental Capital Cost is Projected to be $8B that Will

Add 6¢/Gallon to Current Fuel Prices

30.5

31.0

31.5

32.0

32.5

API

Gra

vity

1988

1989

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

Crude Quality

0.9

1.0

1.1

1.2

1.3

Wt %

Sul

fur

1987

1989

1991

1993

1995

1997

1999

Sulfur Content

Higher Sulfur Residuals Favor IGCC

$B %

ROIC

SPENDING

• Increasing demand for middle distillates at same time that crude quality is deteriorating

• Hydrotreatment to increase light production requires hydrogen from expansion of coking facilities

Crude Quality to US Refiners

Increased Petroleum Coke Production

• Pet coke now either stockpiled or handled by middlemen for fuel blending to export as saleable fuel

• Several countries are preventing new coking capacity until a solution is implemented.

Current Coke Market is Saturated

Kyoto & Enviro Concerns Shrinking Market for Pet Coke

Refinery Competitive AssessmentAir Emissions IGCC vs. CFBCSource Volume Reduction

Annual Disposal Costs

IGCC Technology Provides Superior Environmental

Benefits To Refineries

■ Higher Efficiency ( 5%)

■ Environmental Performance

■ “Siteability” and Image

■ Experience

~~

Gasificaton

Gasifier HX

OxidantSupply System

Combined Cycle

Cleanup

Sulfur

SlagSyngas

CleanFuel

SlagHydrogenAmmoniaMethanolChemicals

Electricity

ProductsFuels

Bituminous CoalSub Bituminous CoalLignite

OrimulsionResidual OilsRefinery BottomsPetroleum CokeRefinery Gas

BiomassWastes

2 Stage CombustionPartial in GasifierComplete in Gas Turbine

5 Technologies Oxidant SupplyGasificationClean UpCombined CycleIntegration

- Air or Oxygen - CO + H2 - Sulfur - Syngas - Synergy

Steam

IGCC Process

Opportunity Fuels to Clean Electricity

GE Gas Turbines In Refinery IGCCs

Exxon Singapore (Heavy Oil)

Exxon Singapore (Heavy Oil)

Motiva Delaware (Petroleum Coke)

Motiva Delaware (Petroleum Coke)

Sarlux (Heavy Oil)

Sarlux (Heavy Oil)

Shell Pernice(Heavy Oil)

Shell Pernice(Heavy Oil)

180 MW

2 x 6FA

180 MW

2 x 6FA

240 MW

2 x 6FA

240 MW

2 x 6FA 550 MW

3 x 109E

550 MW

3 x 109E

80 MW

2 x 6B

80 MW

2 x 6B

Texaco El Dorado (Petroleum Coke)

Texaco El Dorado (Petroleum Coke)

40 MW

1 x 6B

40 MW

1 x 6B

GE Gas Turbine Syngas ExperienceGE Syngas Hours of Operation

SyngasStartDate

Cool WaterPSITampaTexaco El DoradoSierra PacificSUV VresovaSchwarze PumpeShell PernisISE / ILVAFife EnergyMotiva DelawareSarluxPiombinoExxon Singapore

107E7FA

107FA6B

106FA209E

6B2x6B

3x109E6FA

2x6FA3x109E

109E2x6FA

120262250

40100350

4080

54080

240550150180

5/8411/959/969/96

-12/96 9/9611/9711/96

-8/0010/0010/003/01

27,00024,50033,50030,660

090,04037,60058,250

141,0000

45033,10012,4009,700

-1,800

-56,37248,4381,715

-22,6874,732

26,220--

2,93012,776

1,0004,1007,101

---

3,800---

5,29010,500

-921

Customer

Totals 499,100

Type MW Hours of OperationSyngas N.G. Dist.

September 2002

IGCC Product Technology IGCC Product Technology –– ProvenProvenThrough Operating ExperienceThrough Operating Experience

GE Gas Turbine Syngas Capabilities

H2

CO

CH4

CO2

N2 + AR

H2O

LHV, - Btu/ft3

Syngas

37.2

46.6

0.1

13.3

2.5

0.3

253

Tampa

35.4

45.0

0.0

17.1

2.1

0.4

242

El Dorado

34.4

35.1

0.3

30.0

0.2

--

210

Pernis

14.5

23.6

1.3

5.6

49.3

5.7

128

SierraPacific

8.6

26.2

8.2

14.0

42.5

--

183

ILVA

61.9

26.2

6.9

2.8

1.8

--

317

SchwarzePumpe

22.7

30.6

0.2

5.6

1.1

39.8

163

SarluxPSI

24.8

39.5

1.5

9.3

2.3

22.7

209

34.4

55.4

5.1

1.6

3.1

--

319

Fife

44.5

35.4

0.5

17.9

1.4

0.1

241

ExxonSingapore

32.0

49.5

0.1

15.8

2.15

0.44

248

MotivaDelaware

35.68

43.94

0.03

18.96

1.20

0.19

239.6

CitgoL. Char.

42.3

47.77

0.08

8.01

2.05

0.15

270.4

PIEMSA

10.3

22.3

3.8

14.5

48.2

0.9

134.6

Tonghua

- kJ/m3 9962 9528 8274 5024 7191 12,492 64038224 12,568 9,477 9,768 9,442 10,655 5304

Tfuel F/C

H2/CO Ratio

Diluent

Equivalent LHV

700/371

.80

N2

250/121

.79

N2/Steam

200/98

.98

Steam

1000/538

.61

Steam

400/204

.33

--

100/38

2.36

Steam

392/200

.74

Moisture

570/300

.63

Steam

100/38

.62

H2O

350/177

1.26

Steam

570/299

.65

H2O/N2

300/149

0.81

N2

338/170

.89

N2

-

.46

n/a

* Always co-fired with 50% natural gas

- Btu/ft3

- kJ/m3

1184649

113*4452

1987801

1104334

----

2007880

----

1505910

*--

1164600

1505910

126.54985

1295083

134.65304

Demonstrated: Syngas Fuel FlexibilityDemonstrated: Syngas Fuel Flexibility

Refinery Projects

IGCC Penetration

22 Global IGCC Plants

Customer C.O. Date MW Application GasifierSCE Cool Water - USALGTI - USADemkolec - NetherlandsPSI/Global - USATampa Electric - USATexaco El Dorado - USASUV - Czech.Schwarze Pumpe - GermanyShell Pernis - NetherlandsPuertollano - SpainSierra Pacific - USAISAB - ItalyAPI - ItalyMOTIVA - DelawareSarlux/Enron - ItalyEXXON - Singapore

FIFE - ScotlandEDF/ Total - GonfrevilleFIFE Electric - ScotlandNihon Sekiyu - JapanCitgo Lake CharlesPIEMSA

1984198719941995199619961996199619971998199819992000200020002000

200120032003200420052006

120160250260260

40350

40120320100500250240550180

120400400350500800

Power/CoalCogen/CoalPower/CoalRepower/CoalPower/CoalCogen/Pet CokeCogen/CoalPower/Methanol/LigniteCogen/H2/OilPower/Coal/Pet CokePower/CoalPower/H2/OilPower/H2/OilRepower/Pet CokeCogen/H2/OilCogen/H2/Oil

Power/Sludge Power/ H2/Cogen/OilPower/Coal/RDFPower/OilCogen/Pet CokePower/H2/Oil

Texaco - O2Destec - O2Shell - O2Destec - O2Texaco - O2Texaco - O2ZUV - O2Noell - O2Shell - O2Prenflow - O2KRW - AirTexaco - O2Texaco - O2Texaco - O2Texaco - O2Texaco - O2

BGL - O2Texaco - O2BGL - O2Texaco - O2Texaco - 02Texaco - 02

6,310

6FA IGCC Multi-Nozzle Combustion Systems

Same System Design for 6FA, 7FA, & 9FASame System Design for 6FA, 7FA, & 9FA

Natural Gas

Steam

EndcoverCombustion

Casing

Transition Piece(Differs For 9FA)

FlowsleeveFuel Nozzles

Stage 1 Nozzle(Nozzle Box For Test)

BlendedFuel

Emissions Sample

Combustion Liner

T/C Rake Location

Dynamic PressureLocations

Full Scale Combustion Testing

GE Investment in IGCC– State-of-the-art combustion

development facility at Greenville, S.C.

– Standard machines with optimal integration of turbine and gasification plant with gasification developers

– Program to develop fuel-tolerant, lean-pre-mix combustor for <=9 ppm NOx

– At GE’s Global Research Laboratory -advanced concepts for single-digit NOx

Validation of Performance at Full Flow and Geometry

IGCC Implementation in Refinery

SulfurRemovalSulfur

RemovalShift

ReactorShift

ReactorGasifierGasifier HCUHCU

HRSGHRSG

SteamTurbine

Petroleum Cokevis Breaker Tars

ResidualsAsphalts

ASUASU

H2 Manu-facture

H2 Manu-facture

~~

ProcessSteam

CO2

Air

O2

Air

Syngas

H2

IGCC Provides “Poly-Generation” Benefits With Cost Effective CO2 Separation Capability

Hydrogen Combustion

Video Capture of Flame Structure - 85-90% H2

1.0

10.0

100.0

1000.0

100 150 200 250 300

LHVeq, Btu/SCF

Equivalent Heating Value = Heating Value of Mixture of Syngas and Injected Steam

50 50 -- 95% H95% H22 By Volume, Bal. NBy Volume, Bal. N22, N, N22 + H+ H2200

LHV, kJ/m3

4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000

NO

x @

15%

O2,

ppm

vd

GT Hydrogen Combustion Capability for CO2 Removal

Mixed Fuel Capability (Syngas/Distillate)Dual Fuel Capability

Gas/Distillate Operation

20

% Load

100

0 10 40 50 70 100 % Distillate% Split

100 90 60 50 30 0 % Syngas

Shaded: MixNot Permitted

Mix Permitted(Allowable Splits)

• % Split Is in Terms of % GT Total Heat Consumption

SteamDistillate

Syngas

Atomizing Air

IGCC Fuel Flexibility Critically Important to Refinery Operations

Type Operational capabilities for IGCC systems* Fuel Operability Range

1 Baseline Distillate/SG system

- Similar to other dual fuel standard combustor machine except inert purge on SG side.- Cofiring capability provided for Singapore (ADO/Syngas)

100% SG100% DIST

90% SG/ 10% dist30% SG/ 70% dist

2 Baseline NG/SG system - NG and syngas travel down separate paths- Simplest, least expensive

100%SG100% NG

65% SG/ 35% NG35% SG/ 65% NG

3 Extended Turndown system

- Verified at Exxon-Singapore- Manifolds interconnect via transfer valves- Exclusion zone 10% wide from 15% to 30% NG

100%SG100%NG

90% SG/ 10%NG10% SG/ 90%NG

4 Simplified Extended Turndown System

- Same as #3 except 35% min SG- Eliminates exclusion zone- Simplifies control logic

100% SG100% NG

90% SG/ 10% NG35%SG/ 65% NG

* All assumed to provide for maintaining load set point using NG modulation.

Co-Firing Operational Capability

Dual Fuel Systems Designed For Wide Supply Variation

Cool Water 25PSI - Wabash <25Tampa - Polk <25Texaco - El Dorado <25Motiva - Delaware 9 - 15Sarlux - Italy <30Exxon - Singapore 42

PredictedSierra Pacific - Pinon <42 (<9 Thermal)Gonfreville 35 Citgo Lake Charles 25PIEMSA 30

Typical NOx Emissions from IGCC Plants

Operating N0x PPMVD @15%02

GT24333A

Representative USA IGCC NOx Levels and Permits

Plant Date Fuel NOx(ppmbv@15%O2)

Cool Water 1984 Coal 25

Wabash River 1995 Coal/Pet Coke < 25

Polk 1996 Coal/Pet Coke < 25

Texaco El Dorado 1996Pet Coke/ Refinery Wastes

< 25

Motiva Delaware 2000 Pet Coke 15

PolkBACTRedetermination

2002 Coal/Pet Coke 15

Kentucky Pioneer* 2001 Coal 15**

* Permit issued 6/17/2001** Subject to re-evaluation

Changing NOx Emissions Stds. For US IGCC Plants

\

GE IGCC Gas Turbine and Combined-Cycle Product Line

IGCC 7FA

GAS TURBINESModelSyngas Power RatingGE1010MW (50/60 Hz)6B40MW (50/60 Hz)7EA90MW (60 Hz)9E150MW (50 Hz)6FA90MW (50/60 Hz)7FA197MW (60 Hz)9FA286MW (50 Hz)

IGCCModelNet Plant Power Rating

106B60MW (50/60 Hz)107EA130MW (60 Hz)109E210MW (50 Hz)106FA130MW (50/60 Hz)107FA280MW (60 Hz)109FA420MW (50 Hz)

Dedicated IGCC Gas Turbine Product LineDedicated IGCC Gas Turbine Product Line

GE F Class Advanced Gas Turbine IGCC Refinery Projects

• 6FA (90MW)- Motiva Enterprises Delaware (2-Units w/Ht. Rec. Cogen.)

Petroleum Coke- Exxon Singapore (2- Units w/Ht. Rec. Cogen.)

Heavy Oil

• 7FA (197MW)- Citgo Lake Charles (2-Units w/Combined Cycle Cogen.)

Petroleum Coke

• 9FA (294MW)- PIEMSA (2-Units w/Combined Cycle Cogen.)

Heavy Oil

High Efficiency “F” Class Gas Turbine Performance Drives IGCC Solution

GE 7FA Gas Turbine IGCC Evolution

7FA Natural Gas150–172 MW ISO

7FA+e IGCC197 MW ISO

192 MW ISO7FA IGCC 1995

2000

2006

– IGCC Combustor

– Higher Torque Rotor

– Higher Firing Temperature

– Modified Turbine Nozzle

– Combustor Developments

– Increased Pressure Ratio

7FA Advanced IGCC211 MW ISO

Continued Gas Turbine AdvancesContinued Gas Turbine Advancesto Enhance IGCC Plant Economicsto Enhance IGCC Plant Economics

IGCC Economics

Economic Comparison of IGCC versus Combined CycleEconomic Comparison of IGCC versus Combined Cyclebased on 20 year COE for large power plants

00.20.40.60.8

11.21.41.61.8

22.2

1.5 2 2.5 3 3.5 4 4.5 5 5.5

Combined Cycle Fuel Price [$/MMBTU]

IGC

C F

uel P

rice

[$/M

MB

TU]

Combined CycleCombined CyclePreferredPreferred

IGCCIGCCPreferredPreferred

Pet Coke

Residues

Coal

Orimulsion

COEParity

IGCC Competitive at $2.50 Spread

$3.91H Hub10-9-02

Summary• Current market drivers are favorable for refinery waste fuel conversion

projects

• Contemporary IGCC plant designs are commercially viable with refinery operations

- Broad capability to use opportunity and low value waste fuels

• IGCC technology enjoys compelling environmental advantages for waste fuel conversion to economical poly generation products

- Growth potential to meet future regulatory challenges

• IGCC economics are at parity or better than conventional solid fuel technologies using opportunity fuels

• GE gas turbine IGCC product line is experienced and well matched for refinery syngas applications

- Advanced F Class Gas Turbines: High Output, High Effic. & Specific Work

• Fuel flexibility allowing for high system reliability are critically important to successful IGCC refinery projects