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March 14, 2001
GTC Gasification Workshop for Environmental Regulators
1
The Wabash River IGCC Project
THE WABASH RIVER IGCC PROJECT
REPOWERING COAL FIRED POWER PLANTS
PHIL AMICK
VICE PRESIDENT, COMMERCIAL DEVELOPMENT
GLOBAL ENERGY, INC.
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
March 14, 2001
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The Wabash River IGCC Project
Our company:
• Project Developer for Gasification Facilities
• Environmentally Driven
• A Founder of Gasification Technologies Council
• Develop, Build, Own & Operate Strategy
• Two Technologies
• British Gas Lurgi (BGL)
• E-Gas (Dow / Destec Gasification Process)
DOWDeveloped Technology, Proto Plants & LGTI
1973 - 1989
Spun off from Dow in 1989, 80% Dow Ownership
Wabash River 1989-1997
NGC Corporation
Purchased Destec from Dowin June 1997
NGC changed its name toDynegy in June 98
“E-GAS” GASIFICATION PROCESS HERITAGE
2000
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
TECHNOLOGY COMPARISONE-Gas “Destec” BGL
Type Entrained Flow Fixed BedSlagging SlaggingSlurry Fed, O2 Dry Feed, O2
Feedstocks Tested Coal, Lignite Coal, Pet CokePet Coke AFT Fuel Briquette
w/ biomass, sludge
Module Size 120/250/500 MW 120/400 MW
Products Power, Steam, H2 Power, GasChemical Feedstock Transportation Fuel
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
E-GAS GASIFIER
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The Wabash River IGCC Project
EGAS TECHNOLOGY HISTORY
PILOT PLANT 36 TPD 1975
PROTO 1 400 TPD 1979
PROTO 2 1600 TPD 1983
LGTI 2400 TPD 1987
WABASH 2550 TPD 1995
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Wabash River Project Overview• E- Gas Technology Gasification Process• Coal Gasification Combined Cycle Repowering
• Operational since 1995
• 262 MWe Net Output
• Bituminous Coal and Petcoke, up to 7 % S
• Cleanest Coal/Coke Fired Power Plant in the World
• Greatest Petcoke Throughput Demonstrated in Single Gasifier
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Wabash River Project Overview• E- Gas Technology Gasification Process
– Oxygen Blown, Slurry Fed– Continuous Slag Removal ( No lock hoppers)
• High Temperature Heat Recovery (~ 1000 DegC)• Medium Temperature Char Filtration (~ 450 DegC)
– Metallic Elements, Dry Filtration
• COS Catalyst, MDEA Acid Gas Removal• Claus based Sulfur Recovery• Recycle of SRU Tailgas and Char to gasifier• General Electric 7FA Gas Turbine, Dual Fuel (Oil/Syngas)
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
WABASH REPOWERING
SlurryPrep
ASU
Slag / Frit
Handling
Gasifier
HTHR
Filtration
Sulfur
Recovery
Sulfur
Removal
GT
HRSG
Water
Treatment
Switch
Yard
Fuel
Handling
STG &
Aux
Existing
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
WABASH RIVER ENERGY LTD.
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
WABASH RIVER ENERGY LTD.
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
PROJECT SITE
Repowering Unit 1 (90 MW) of Six Unit 888 MW PC plant
Approximately 40 Acres on existing powerplant and coal mine property
Site located on reclaimed mine entrance area
Viking and Saxton coal mines (abandoned) underly the site
Nearest residence one half mile away (nearer existing plant)
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
WABASH RIVER PROJECT SCHEDULE91 92 93 94 95
MILESTONESProposal for Clean Coal IVDOE SelectionIURC Approval
ENVIRONMENTAL PERMITSEnvironmental Information VolNEPA Process
MAJOR EQUIPMENT FABRICATION
CONSTRUCTION
START-UP
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
AIR EMISSION POINTS
Gas Turbine/HRSG Stack 225 Ft. Elevation
Auxiliary Boiler Stack 50 Ft.
Tail Gas Incinerator Stack 310 Ft.
Flare 180 Ft.
Cooling Tower 30 Ft.
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The Wabash River IGCC Project
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
EMISSIONS COMPARISON
Emissions, lb/MWh
SO2 NO x CO PM-10 VOC
Unit 1 before Repower 38.2 9.3 0.64 0.85 0.03
IGCC 1.35 1.1 1.37 nil 0.02
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
SO x Control
IGCC is permitted for 0.25 lb SO2/MMBtu (split between GT and TGI stacks)
Sour syngas goes through a COS catalyst and then an amine based acid gasremoval stage.
Normally running at 0.10 lb SO2/MMBtu
As low as 0.03 lb SO2/MMBtu has been achieved
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
SO2 EMISSIONS
E x is tin g 1 9 5 3S ta tio n
N e w S o u rc eP e rfo rm a n c e
S ta n d a rd s
W a b a s h0
0 .5
1
1 .5
2
2 .5
3
3 .5
4
4 .5
LBS.
SO
2 / M
MB
tu o
f Coa
l Fee
d
E x is tin g 1 9 5 3S ta tio n
N e w S o u rc eP e rfo rm a n c e
S ta n d a rd s
W a b a s h
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
NO x Control
GE 7FA combustion turbine with steam injection (1992 purchase order)
Guaranteed for 25 ppm NO x
Has run as low as 18 ppm
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
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LBS.
NOX
/ M
MBt
u of
Coa
l Fee
dLB
S. N
OX /
MM
Btu
of C
oal F
eed
LBS.
NOX
/ M
MBt
u of
Coa
l Fee
dLB
S. N
OX /
MM
Btu
of C
oal F
eed
NOX EMISSIONSNOX EMISSIONSNOX EMISSIONSNOX EMISSIONS
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
PARTICULATE EMISSIONS
NONE MEASURABLE IN HRSG STACK
ZERO OPACITY
March 14, 2001
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The Wabash River IGCC Project
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Steam TurbineCondenser
Gasification Island, ASU, CWT
Power Block
Old Power Plant
New WW Pond
Ash PondOutfall 002
Metering Point
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
WATER BALANCE – NEW USERSCooling Tower BD 0.144 mgd
Flushes & Purges 0.144
Unrecycled slurry water 0.101
Demineralizer Rinse 0.086
Steam Losses 0.072
Filter Backwash 0.065
Clarifier Sludge 0.058
Coal Pile Runoff 0.014
Boiler Blowdown 0.014
Domestic Sewage 0.022
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
WATER BALANCE – OUTFALL 002
Added Discharge from new project 0.72 mgd
Savings from PC Boiler Decommissioning (0.57)
-------
Net Increase to Outfall 002 0.15 mgd
( 2.8 % increase for overall station)
March 14, 2001
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The Wabash River IGCC Project
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Slag
Sulfur
Black, glassy sandlike material
Inert, passes TCLP
Generally 3-10% Carbon
Marketed for asphalt, construction backfill, roofing shingle applications
Production is proportional to ash & flux content in feed
Produced as 99.99% pure elemental sulfur
Leaves plant in railcars
Sold to Broker for agricultural applications, over 40,000 tons to date
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
March 14, 2001
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The Wabash River IGCC Project
Annual output constrained by 100 day combustion turbine outage Reflects restructuring (no contract and no sales for three months)
SYNGAS FACILITY OPERATING STATISTICS
Time PeriodOn Coal(Hrs)
Coal/CokeProcessed(Tons)
On Spec. Gas(MMBtu)
SteamProduced(Mlbs)
ProductSyngasAvailability(%)
1998 5,279 561,495 8,844,902 2,190,393 70
1999 3,496 369,862 5,813,151 1,480,908 69
2000 386,630 6,430,446 1,082,254 75
Overall11/18/1995–12/31/2000
1,936,191
30,321,513
8,010,727 1998-2000
71%
4,191
19,260
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Syngas Production
0
1
2
3
4
5
6
7
8
9
10
Tri
llio
n B
tu o
f S
yng
as P
rod
u
1996 1997 1998 1999 Adjusted 2000 Adjusted
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Syngas Availability
0
10
20
30
40
50
60
70
80
Ava
ilab
ilit
y of
Syn
gas
Del
iver
1996 1997 1998 1999 2000
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
• Gasifier Second Stage at LGTI ~ 1990
• Wabash River 1997 - 20,000 tons from Midwest Refinery
• Wabash River 1999 - 10,000 tons from Gulf Coast Refinery
• 2000 & 2001 - Over 1,000,000 tons from another MidwestRefinery
E-GAS PETCOKE CAPABILTY DEVELOPMENTPROGRAM
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Petroleum Coke Test Results - 1997 & 1999
• Demonstrated plant efficiency, 40.2% (HHV)
• Produced 100% rated output at normal environmental standards
• 99% Carbon Conversion
• No slag tapping problems
• Nickel (80%) and Vanadium (99%) were captured in slag, non-leaching
• No negative impact on equipment
• Refractory wear rates similar to coal operations
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
P E T R O L E U M C O K EA N A L Y S I S T Y P I C A LC O A L 1 9 9 7 1 9 9 9 2 0 0 0
M o istu re , % 1 5 .2 7 .0 1 2 .0 7 .8A sh , % 1 2 .0 0 .3 0 .4 0 .6V o la t i le , % 3 2 .8 1 2 .4 1 1 .2 1 0 .5F ix e d C a rb o n , % 3 9 .9 8 0 .4 7 7 .7 8 1 .1S u lfu r , % 1 .9 5 .2 5 .6 5 .7
M e ta ls in F u e l :N i, p p m , d ry b a s is T ra c e 2 1 0 2 9 0 3 7 0V , p p m , d ry b a s is T ra c e 4 3 0 1 5 0 0 8 9 0
H e a t in g V a lu e , a s re c ’d ,B tu /lb
1 0 ,5 3 6 1 4 ,2 8 2 1 3 ,3 8 0 1 4 ,0 2 6
FEEDSTOCK SPECIFICATIONS
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GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
PRODUCT SYNGAS ANALYSIS
TypicalCoal
PetroleumCoke
N2, % 1.9 1.9Ar, % 0.6 0.6CO2, % 15.8 15.4CO, % 45.3 48.6H2 % 34.4 33.2CH4, % 1.9 0.5Total S, ppmv 68 69HHV, Btu/Scf 277 268
March 14, 2001
GTC Gasification Workshop for Environmental Regulators
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The Wabash River IGCC Project
Performance Variable Typical Coal
Petroleum CokeTest #1
Petroleum CokeTest #2
SO2 Emission, lbs/MMBtu <0.1 <0.1 <0.1
Sulfur Removal Eff., % >99 >99 >99
Carbon in Slag, % <5 <10 <5
Carbon Conversion, % >99 >99 >99
Cold Gas Efficiency, % 71 - 76 71 - 73 72 - 74
Projected Heat Rate, HHV,Btu/kWh
8910 8790 8600 (est.)
Table 3: Petroleum Coke Performance Summary