New Gas Turbine Integration Options for ITM Oxygen in ...¾ITM Oxygen plant capacity: 4,550 sTPD oxygen + 13,200 sTPD diluent IGCC Specific Capital Cost ($/kW) 1,500 1,368 -9 Oxygen

New Gas Turbine Integration Optionsfor ITM Oxygen in

Gasification Applications

VanEric SteinPhil Armstrong

Ted FosterAir Products and Chemicals, Inc.

Gasification Technologies 2007San Francisco, CA17 October 2007

3 © Air Products and Chemicals, Inc. 2007

Mature, reliabletechnologyEnergy intensiveRequires 100’s ofequilibrium stagesRepresents ~15% of IGCC capital costConsumes ~15% of IGCC gross power output

Cryogenic Distillation is state-of-the-art for tonnage oxygen


• Mixed-conducting ceramic membranes (non-porous)

• Typically operate at 800-900 °C

• 100% selective for O2

• O2 flux ∝

Ion Transport Membranes (ITMs) produce high-purity oxygenat high flux

''2

'2ln1

⎟⎟⎟

⎠

⎞

⎜⎜⎜

⎝

⎛

OPOP

L

O2- electrons

compressed air

oxygen

P’

P’’O2

O2

O2- ½O2 + 2e-

½O2 + 2e- O2-

L


We are building ½-ton/day commercial-scale ITM modules …

Single-stage air separation yields compactdesigns

Low ΔP on the air side

All-ceramic construction

High-tempprocess has better synergy w/ gasification systems


… and testing them in pilot plant

Heater

Control Room

Heat Exchangers

VacuumPumps

Make-up Streams

ITM Vessel

6 IndependentProduct Trains

Flow Duct Installed

2 Modules Installed

ITM Vessel Internals


Initial pilot plant testing highly successful

Several trials with ½-ton/day modules during the last yearDemonstrated >99% oxygen purity from commercial-scale module and sealOxygen flux consistently met or exceeded expectations and has remained steady over multi-week testsJust completed retrofit of advanced control system to improve reliability during startup/shutdown cycles


ITM Oxygen integrates well with gas turbine power cycles

SYNGAS

OXYGENSUPPLY toGASIFIER

OXYGENCOOLING

IONTRANSPORTMEMBRANE

OXYGENCOMP’R

OXYGEN

VITIATED AIR

NON-PERMEATE

AIRHRSG

STEAM

ELECTRICPOWER

SYNGASe.g., SiemensSGT6-6000G

~300 MW


Full integration with advanced gas turbine poses challenges …

SYNGAS


OXYGENCOOLING


OXYGENCOMP’R

OXYGEN

VITIATED AIR

800 – 900 °C

AIRHRSG

STEAM

ELECTRICPOWER

SYNGAS

ITM-SPECIFICGAS TURBINE

e.g., SiemensSGT6-6000G

~300 MW

RECUPERATOR ?

ΔP

ΔPΔP

ΔP

Air extractionlimitations


Multi-dimensional evaluation determined optimum configuration

With Boost Compressor

No Boost Compressor

NoRecuperator

With Recuperator

Vitiated Air

ReturnTemp

NoRecuperator

With Recuperator

717 oC717 oC

600 oC600 oC

445 oC445 oC

BC-wR-445

BC-wR-600

BC-wR-717

NB-NR-717

NB-NR-600

BC-NR-717

BC-NR-600BC-NR-650

NB-wR-717

NB-wR-600

NB-wR-456

Ref: “Integrated ITM Oxygen – Gas TurbineSystem for IGCC,” presented at FreibergConference on IGCC, May 2007.


Boost compressor / recuperatoryields best overall IGCC

0.92

0.93

0.94

0.95

0.96

0.97

0.98

0.99

1

1.01

1.02

36.5% 37.0% 37.5% 38.0% 38.5% 39.0% 39.5% 40.0% 40.5%

HHV Efficiency

Rel

ativ

e Pl

ant C

ost p

er k

ilow

att BC-NR-600

BC-NR-650BC-NR-717BC-wR-445BC-wR-600BC-wR-717NB-NR-600NB-NR-717NB-wR-456NB-wR-600NB-wR-717

No BoostCompressor

WithBC

With Recuperator


Boost compressor / recuperatorminimizes GT design impact

AIRHRSG

STEAM

ELECTRICPOWER

SYNGAS

ITM-SPECIFICGAS TURBINE

SiemensSGT6-6000G

~300 MW

SYNGAS


OXYGENCOOLING


OXYGENCOMP’R

OXYGEN

VITIATED AIR

RECUPERATOR

BOOST COMP’R


SGT6-6000G gas turbine modifications for ITM Oxygen

Compressor Section:Compressed air extraction (55%)

Combustion Section:Vitiated air injectionSyngas combustion with vitiated air

Casings & Structural:Hot gas piping & manifolding


Partial integration with standard GT also achievable …


OXYGENCOOLER

HRSGAIR

STEAM

OXYGENCOMP’R

SYNGAS

ELECTRICPOWER

OXYGEN

VITIATEDAIR

SYNGAS

AIR

AIRCOMP’R

STANDARD OEMGAS TURBINE

DILUENT (N2)

TO HRSGITM

SYSTEM

Ref: “Novel Integrated Oxygen Supply Technologyfor Gasification,” published at Power-Gen, November 2006.


… while preserving significant benefits for IGCC

Integration with modified ITM Oxygen cycle can reduce IGCC specific capital cost by 9% and increase efficiency by 1.2%, with 25% capital savings in oxygen production

ITM Oxygen plant capacity: 4,550 sTPD oxygen + 13,200 sTPD diluent

- 91,3681,500IGCC Specific Capital Cost ($/kW)

- 2518,70025,000Oxygen Plant Cost ($/sTPD O2)

+ 1.238.938.4IGCC Net Efficiency (% HHV)

+ 15627543IGCC Net Output (MW)Δ ( %)ITM O2Cryo O22-on-1 GE 7FA+e design basis


DEDICATEDGT FOR

O2 PROD’N

Minimal integration using dedicated ITM GT offers flexible flowsheet

HRSGAIR

STEAM

ELECTRICPOWER

FUEL

BASELOADGAS TURBINE

AIR

FUEL

OXYGEN

VITIATED AIR

AUX. ELECTRICPOWER

FUEL (optional)OXYGENCOOLER

OXYGENCOMP’R OXYGEN

SUPPLY toAPPLICATIONITM

“Stand-alone” ITM Oxygen plant with minimal power co-production:10 MWe per 1000 TPD Oxygen60 MWe per 4500 TPD Oxygen(e.g., with Siemens GT35P, GT140P)

Oxygen-consuming application, e.g., IGCC, oxycoal combustion, etc…


GT35P/GT140P developed for full air extraction and off-board combustion

6 GT35P PFBC installations world-wide (’89-’98)1 GT140P PFBC installation (’99)


ITM dev’t plan meets FutureGenschedule and market timing

5

150

2000

Phase 2

Phase 3

FutureGen

500

5000+

Cap

acity

(TPD

)

2000 2005 2010 2015 2020

(large energy applications)


The future remains bright for ITM Oxygen

Commercial-scale ITM Oxygen modules are being built and tested successfullyConceptual full integration with SGT6-6000G maximizes ITM benefits while minimizing GT design / development impact

– Partial integration with standard OEM gas turbine preserves significant benefits

– Minimal integration using dedicated ITMGT offers good early entry prospects

Air Products and the DOE are accelerating development of ITM Oxygen to reach large-tonnage scale for FutureGen plant


A significant portion of this report was prepared by Air Products and Chemicals, Inc. pursuant to a Cooperative Agreement partially funded by the United States Department of Energy, and neither Air Products and Chemicals, Inc. nor any of its contractors or subcontractors nor the United States Department of Energy, nor any person acting on behalf of either:

1. Makes any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this report, or that the use of any information, apparatus, method, or process disclosed in this report may not infringe privately owned rights; or

2. Assumes any liabilities with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, or process disclosed in this report. Reference herein to any specific commercial products, process, or service by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Department of Energy. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Department of Energy.

This paper was written with support of the U.S. Department of Energy under Contract No. DE-FC26-98FT40343. The Government reserves for itself and others acting on its behalf a royalty-free, nonexclusive, irrevocable, worldwide license for Governmental purposes to publish, distribute, translate, duplicate, exhibit and perform this copyrighted paper.

Acknowledgment: DOE/NETL

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New Gas Turbine Integration Options for ITM Oxygen in ...¾ITM Oxygen plant capacity: 4,550 sTPD oxygen + 13,200 sTPD diluent IGCC Specific Capital Cost ($/kW) 1,500 1,368 -9 Oxygen