Gasification: Status, Outlook and Technical Developments · Technical Field Assistance Feedstock: Subbituminous Coal Ash: ~ 7 wt% Moisture: ~ 2 wt% Status Engineering Completed All

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Power Generation

Gasification: Status, Outlook and Technical DevelopmentsFrank Hannemann, Siemens Fuel Gasification Technology GmbH & Co.KG

Energy Sector


Energy and Gasification Market Trends

Status of Siemens Gasification Projects

SFG Technology / R&D and new Products

Polygeneration Concepts

Content

Energy Sector


Energy products and solutions - in 6 Divisions

Oil & Gas Renewable

Energy

Fossil Power

Generation

Energy

Service

Power

Distribution

Power

Trans-

mission

Siemens Energy Sector –Answers for Energy Supply

Energy Sector


Global Energy Market Trends and Primary Energy Consumption

Primary energy demand by types

Primary energy demand by regions

Source: IEA WEO 2009

Nuclear

Hydro

Renewables

2030

16.8

4.9

5.0

3.6

1.00.4

2.0

2025

15.6

4.5

4.7

3.3

0.90.4

1.8

2020

14.4

4.1

4.4

3.0

0.90.3

1.7

2015

13.5

3.8

4.2

2.8

0.80.3

1.5

2007

12.0

Coal

4.1

2.5

0.7 0.31.3

1990

8.8

3.2

3.2

1.70.50.20.9

Oil

Gas

2.2

Total Primary Energy Demand (Gtoe)

Western Europe

Eastern Eur./CIS

North America

Latin America

Asea/Pacific

Middle East

Africa

2030

16.8

1.9

1.4

3.0

0.8

7.8

1.00.9

2025

15.6

1.8

1.3

2.9

0.7

7.1

0.90.8

2020

14.4

1.8

1.2

2.8

0.7

6.3

0.80.8

2015

13.5

1.8

1.2

2.8

0.6

5.7

0.70.7

2007

12.0

1.8

1.1

2.8

0.6

4.6

0.50.6

1990

8.8

1.6

1.5

2.2

0.3

2.4

0.20.4

Total Primary Energy Demand (Gtoe)

Global Energy Market Trends

Continue grow with an average rate of 1.5%/a in total and even 1.9%/a in power sector up to 2030

Despite a significant expansion of renewables fossil energy carrier will keep covering the highest share of total energy supply

The strongest growth in energy demand is expected to take place in China and India

Energy consumption in West Europe and theAmericas will stay flat because of efficiency gains and demand saturation

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 criticalstage. 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

Energy Sector


Gasification Market Today

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

Due to pending CO2 legislation and high IGCC invest gasification projects difficult to realize

But: Increasing fuel prices (crude oil), security of supply and beginning recovery of economy starts driving new gasification projects primarily in Asia

Only funded IGCC projects with90% CCS discussed and one IGCCproject seriously ongoing

IGCC gets strong competition by post combustion

EU selected 6 CCS projects for funding: 1 bio EUR

Few biomass gasification activities

EUROPE

China:

Largest gasification market

3.000MW IGCC program

Mega CtX projects under development

India:

Gasification for steel industry and CtXunder consideration

Rest: (e.g. South-Korea, Indonesia)

Couple of coal projects underdevelopment (mainly CtX)

ASIA

Successful implementation depends on CO2 legislation

2 governmental funded IGCC projects

Large CTL and fertilizer projects under development

AUSTRALIA

Small number of CTL projects under discussion

AFRICA

Rising interest in biomass and coal gasification

BRAZIL

Energy Sector


West Siberia

鄯善

YinChuan

BeijingHohhot

Urumchi

Fuzhou

ShangHai

Guangzhou

NanNing

JiLin

Mid

dle

Asi

a

Sakhalin

Burm

a

Coal Gasification Marketing Potentials in China

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

• New CTO and MTO extension

rising up due to 40% shortage

imported

• 1 ongoing CTL demonstration

project driven by government

• Coal to glycol as a new

opportunity supported by

Chinese self proprietary techn.

• Reluctant IGCC demonstration

due to high investment

• Poly-generation might be a

trend due to mega chemical

plants and need for CO2

reduction30.6CTG

3.64.1642.16CTO

36.8 (capacity until 2010)DME19.2( capacity until 2010 )Methanol

722.41.269.24CTL

41.3136.72SNG

Serious

considered

Approved

Projects

Under

Constr.In

Operation[Mtons Coal]`

Coal to Liquid(red-operation/construction and yellow-approved)

Legend

NG pipeline planedLignite

Sub-bituminous

Existing NG pipeline

Bituminous

Lean and anthracite

Coal to SNG(red-approved and yellow-serious)

Coal to Olefins(red-operation/construction andyellow-approved)

Eas

t Sib

eria

Energy Sector


Siemens OfficesOperating UnitsCurrent ProjectsTechnology Selected

HQ FreibergTest Facility

JinChengCoal to Ammonia

NCPP I Coal to Polypropylene

Secure Energy Coal to Chemicals

Capital Power270 MWe IGCC

AEC Coal to UREA

Summit Power400 MWe IGCC + Ammonia

China JVGSP China

9 SFG-500 Gasifiers (incl. other key equipment) shipped

Technology selected and pre-selection in further projects

VresovaIGCCLiquid feedstockCOD 2008

Sustec, Schwarze Pumpe1984 - 2007

Siemens main Gasifier Activity Landscape

Tenaska Coal to SNG/Power

Calgary

Orlando

Energy Sector


DOE supported IGCC projects using SFG Technology

Tenaska Taylorville Energy Center

Customer: Tenaska Inc.Nebraska, USA

Location / Fuel: Illinois, USA / Illinois coal #6

Power output: 500 MW (net)

Siemens scope: 2 x SFG-500 Gasifier and 1x SGT6-5000F

CCS capture rate: > 50% used for EOR

Time schedule: Financing until end of 2010Operation total plant: 2015

DOE support: loan guarantee

IGCC Concept with intermediateSNG production and natural gas

fired standard Gas Turbine

Summit Texas Clean Energy Project

Customer: Summit Power Group, Inc.Washington, USA

Location / Fuel: Midland Odessa, Texas, USA / PRB

Power output: 400 MW (gross) and 270k t/a NH3

Siemens scope: PowerBlock (1 x SGCC6-5000F) 2 x SFG-500 Gasifier

CCS capture rate: ca. 90% used for EOR

Time schedule: Financing until mid of 2011Commercial operation 2014

DOE support: 350‘ USD funding

IGCC Concept with H2 fired GTand NH3 co-production

Energy Sector


NCPP I: Largest Coal to Chemical Plant in China5 x SFG-500 class gasifier: Coal to Polypropylen plant

Siemens Scope:

Engineering

Equipment Supply

Gasifiers, Burners, Feeder Vessels, ...

Training (Freiberg Simulator)

Technical Field Assistance

Feedstock:

Subbituminous Coal

Ash: ~ 7 wt%

Moisture: ~ 2 wt%

Status

Engineering Completed

All Gasifiers shipped and erected

Piping installation in progress

Start up Year: 2010

Gasification Unit

(5xSFG-500 class gasifiers)

Air Separation Units

Black Water

Treatment

Power Station

Methanol to

Polypropylene

Energy Sector


Beginning 2010Civil construction continuing and

piping pre fabrication started

Mid 2009Steel construction in progress

Heavy equipment such as coal bunkers and

K/O drums erected by cranes with 1600t capacity

January, 2009

First batch of gasifiers erected

NCPP / Site Construction Progress

March, 2010Piping installation in progress

90% pipes for BWTP installed

Energy Sector


Current and New Products of SFG Technology

Cooling Screen Gasifier

ash content > 1,5 – 2%

Refractory Lined Gasifier

ash content < 1,5 – 2%

Higher Efficiency

Economy of Scale

Existing 500MW gasifier

Radiant Cooler Heating surface

Proven 500MW Quench design

BMWI funded program

Radiant Cooler selected dueto robustness and limited modification of current 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 steamproduction

SFG- 850 MW / 1200MW

20% cost reduction

3 burner application

Design features of 500MW retained

Biomass

Liquid fuel

Petcoke

Lignite

Sub-Bitum.

Bituminous

Anthracite

Energy Sector


New Design Features and Capabilities

Process Simulator and I&C System in Freiberg

Real plant data and operatoractivitiesOperational

Data transfer

Diagnostic and trouble-shooting

Process Simulator and real plant I&C system in combination with

OPC interface

• Offers realistic Operator Training

• Remote Monitoring and Diagnostic

• Operational analysis and validation of I&C modifications on simulator

Advanced sensoring and CFD analysis

Advanced ph sensoring, spectroscopicalflame analysis, advanced coal feed and raw gas dust sensoring, online coal humidity sensor

CFD analysis to optimise reactor and quench geometrie and to calculate heat flux

200 400 600 800 1000

0

2000

4000

6000

8000

10000

12000

14000

16000

Inte

nsität

[a.u

.]

Wellenlänge [nm]

11:24:3111:29:3611:35:4111:43:49

SFGT_280607_008.xls

Flame analysis by spectroscopy to determine temperature and ash content

SFG Design Improvements

• Standardisation and optimisation of plant layout to reduce investment

• Advanced Feeding System for cost reduction

• Design improvements to minimise utilityconsumptions

3000K

300K

CFD analysis of pilot plant

Isokinetic dustsampling

Flüssigkeit

Membran-weg

Filter

Kohlestaub-Saugseite

Kohlestaub-Druckseite

Membran

Druckbehälter

Kohlestaub

Flüssigkeits-pumpe

Be-/Entspannung

Be-/EntspannungAuflockerung

Energy Sector


Basic IGCC Concepts with CCS

Standard CCPP

GasIsland

CO2 for sequestration

Water/Steam

Integrated Gasification Combined Cycle

IGCC-CCS

H2-rich SG

(Air to ASU)

Diluent N2

Syngas/H2

CCPP

GasIsland

Gasification Combined Cycle

GCC-CCS

H2-rich SG

GasIsland

incl. Methanation

Synthetic Natural Gas Combined Cycle

SNG-CC

SNG



(CO2)

(CO2)

CO2

NaturalGas Net

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

Immanent partial CO2 capture for optional retrofit(capture up to ~55%; ~350 g/kWh)High operational flexibility as a proven “standard” CCHigh product flexibility and thus capacity utilization (power and/or SNG)

Real low-CO2 option (capture up to ~90%; ~100 g/kWh)Only one interface lower complexityClear responsibilities (project execution)Option for phased construction(power from NG from beginning)

Flexibility

Established technology

Coal-to-power-

efficiency

CO2 captureAttractive for European power market with its CO2 regulations and potential funding options

Attractive when setting up SNG infrastructure and for intermediate load power generation

Attractive also in connection with polygeneration

Siemens Fuel

Gasifier(SFG)

broadvariety of

feedstocks

Syngas/H2

CCPP(lower

interfaces)

Energy Sector


IGCC concepts using SFG Technology

Raw

CoalCO2

Flue

GasASU

IGCC with high carbon capture

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

Gasifier with radiant cooler is preferred

due to optimal heat utilization

High efficiency > 40%

Raw

CoalCO2

Flue

GasASU

Raw

CoalCO2

Flue

GasASU

Bypass

Energy Sector


~770 MW aux. power**Excluding utility systems

CO2

Polygeneration Plant Concept for Mega SNG

SFG-Gasifier with full quench system

robust and cost-effective

SFG-Gasifier with radiant cooler

high efficient

High feedstock flexibility

Optimized water consumption

E-class gas turbine

Superheated IP-Steam to steam turbine

Net efficiency* (LHV): >0,56

*without power export

(GJ SNG)/ (GJ Raw Coal)

Superheated IP-Steam

Raw Coal SNG

Power

4 billion Nm³/a

16 x SFG-500

Saturated IP-Steam

Alternative concept

Superheated IP-Steam to ASU

Mechanical drives

~370 MW aux. power**Excluding utility systems

Energy Sector


Methanol Polygeneration Plant Concept

SFG-Gasifier with full quench system

High feedstock flexibility

E-class gas turbine fired with offgas

and syngas

… Saturated IP-Steam

Offgas

(GJ MeOH)/ (GJ Raw Coal)

Net efficiency* (LHV): ~0,53

*without power export

Energy Sector


Conclusion

• Increasing oil price and continues primary energy growth stillfavour gasification

• SFG gasification is on track: New products, extended scope andnew 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 benefitsefficiency

• Growing renewable power production requires energy storage andpeak load and flexible fossil power generation. Poly-generation isthe only practical solution.

Energy Sector


Disclaimer

This document contains forward-looking statements and information – that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”, “plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on the SEC’s website, www.sec.gov. Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated.

Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.

Documents

Gasification: Status, Outlook and Technical Developments · Technical Field Assistance Feedstock: Subbituminous Coal Ash: ~ 7 wt% Moisture: ~ 2 wt% Status Engineering Completed All