TECO to Today: An IGCC Design Improvement Case Study
Dr. Klaus PayrhuberEnergy Applications & Systems EngineeringGE Energy Europe
Kent Dawson60Hz IGCC Product ManagerGE EnergyHouston, Texas
2 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Tampa Electric Co. 1996-Present• Feedstock: Coal, Pet Coke, Biomass
• GE Gasifier/RSC
• 250 MW net IGCC output
• GE 7FA Gas Turbine
• GE Steam Turbine
13 years of operation84,000 operating hours
High availabilityLower emissionsLow cost electricity
Courtesy: Tampa Electric Company
3 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
AERIAL PHOTO
ControlRoom
Air Separation Unit (ASU)
Gasifier/RSC Coal Silos
Slurry Preparation
Sulfuric Acid Plant
HRSG
Combustion turbineSteam turbine
, Courtesy: Tampa Electric Company
4 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
TEC Process Flow Diagram
• Slurry Preparation
• Gasification/ High-temp. gas cooling (HTGC)
• Solids/Water handling
Main AirCompressor
32 MW
Dryers
Coal &Pet Coke2300 TPD
Rod Mills
Water &Recycled Char
SlurryTanks
SlurryPump
ProductCompressors
18 MW
Oxygen2100 TPD
ColdBox
LockhopperChar &
Slag
Char & Cl
Compressor Turbine
Combustor
Generator192 MW
CleanStackGas Air
Condenser
CondensatePump
1600 psigSaturated
Steam
7000 KSCFHClean Syngas
Diluent Nitrogen5250 TPD
RadiantSyngasCooler
Gasifier
SyngasCooler
Final Filter
CoolingWater
MDEA Acid Gas RemovalAcid GasH2S + CO2
CoolingWater
55 psigSteam
EconomizedBoiler
Feedwater
BFW Pump
Heat RecoverySteam Generator
(HRSG)
Generator123 MW
Steam Turbine
Raw Syngas
COSHydrolysis
(COS H2S)
Convective
CombustionTurbine
Saturator
WaterScrubbers
400psigSteam
450 gpmSlurry
Backup/StartupDistillate Fuel
To SulfuricAcid Plant
LPSteam
BFW
2 independent trains
5 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Slurry Preparation Subsystem
Coal Slurry toGasif ier
Rod Mill
MillDischargeTank
RecycledFines
GreyWater
Agitator
Coalfrom
Storage
Slurry Run Tank
Agitator
CoarseTrommelScreen
Slurry Charge Pump
FineScreen
2 independent trains
6 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Slurry Charge PumpChallenge• Corrosion/Erosion of carbon
steel in contact with coal/water slurry5 outages (3.8 days) over 2 years
Solution• Pump contact components
coated with duplex stainless steel
• Check valves coated with an epoxy material
Photos Courtesy: Tampa Electric Company
7 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Low-Pressure Slurry PipingChallenge• Corrosion/Erosion of carbon
steel in contact with coal/water slurryUnacceptable parts lifetime
Solution• Carbon steel slurry pipe
replaced with PE pipe• Slurry transitions extended/
treated with chromium-carbide weld overlay
Photos Courtesy: Tampa Electric Company
8 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Slurry Run Tank Agitator
Courtesy: MetalCoat, Inc.
Challenge• Erosion grove on slurry run
tank agitator bladesUnacceptable parts lifetime
Solution• Rubber membrane coating• Coating must be reapplied
every few years
9 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Original TEC HTGC Subsystem
Gasifier
RadiantSyngasCooler
H PSteam
H PSteam
Scrubbed Raw SyngasTo Low Temp Cooling
SyngasScrubber
SyngasScrubber
Scrubbed Raw SyngasTo Low Temp Cooling
Clean Syngas toCombutstion Turbine
Diluent N2 toCombutstion Turbine
Clean Syngas fromAcid Gas Removal
Diluent N2 fromOxygen Plant
Oxygen Coal/Water Slurry
Raw Gas/DGANExchanger
Raw Gas/Clean GasExchanger Slag + Char to
Lockhopper
CSC CSC
Challeng e
RGE plugging caused 7 shutdowns, 139 days outage
CSC plugging caused 13 shutdowns, 95 days outage
Solution Removed RGEs, Sacrificed < 40 MMBtu/hr (<2% Fuel HHV)
Proactively detect plugging/ Periodic cleanings
10 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner. Courtesy: Tampa Electric Company
11 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner. Courtesy: Tampa Electric Company
12 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Improved TEC HTGC Subsystem
Gasifier
RadiantSyngasCooler
H PSteam
H PSteam
Syngas +Char toSyngas
Scrubber
Oxygen Coal/Water Slurry
Syngas +Char toSyngas
Scrubber
Slag + CharTo Lockhopper
ConvectiveSyngas Cooler
ConvectiveSyngas Cooler
H PSteam
Water Pool
Regular CSC cleaning reduced CSC forced outages to a manageable level
13 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
RSC SootblowersChallenge• 122 sootblowers in TEC RSC
– Six required for normal operation– Four used for startup/shutdown N2
purging• Several excess sootblowers leaked
– Syngas/nitrogen flange– Lance/RSC penetration
3 outages over 4 years
Solution• Excess blowers removed in mid-2001
Cooling water
Nitrogen
Penetration of Sootblower through RSC waterwall
Sootblower Lance
Photos Courtesy: Tampa Electric Company
14 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Syngas PipingChallenge• Corrosion/Erosion of
transitions in contact with raw syngas7 outages (14 days) over 5 years
Solution• Streamlined piping• Erosion resistant (Densit) liner
Photos Courtesy: Tampa Electric Company
15 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Solids and Water Handling
SyngasScrubbers
VacuumFlash
COSHydrolysis
KODrum
KODrum
KODrum
RSC Sump
Settlers
Recycle FlyashTo Slurry
Preparation
Coarse Slag(<10% LOI)
To Sales Clean CondensateTo Pump Seals andInstrument Purges
Brine Crystals(Ammonium Chloride)
To Disposal
Final Evaporatorand Crystallizer
Vapor CompressionEvaporator
Flash GasToSulfuric Acid Plant
SlagDrag Conveyor
and Screen
Lockhopper
CSCs
Trim CoolerSteamCondensate
Heater
Clean GasPreheater
Syngas ToAcid GasRemoval
Ammonia ToSulfuric Acid
Plant
AmmoniaStripper
ProcessCondensate
Drum
Steam
Slag +Flyash
KODrum
Grey WaterTankSettler
FeedTank
SteamCondensate To
Power Plant
Steam Condensate From Power Plant
Vacuum FlashOverheadCondenser
SlagCrusher
16 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Syngas Scrubber SystemChallenge• Erosive particles/high
volumes of water resulted in scrubber leaks
14 outages (21 days) over 5 years
Solution• Corrosion resistant coatings
(weld overlay in background)
• Proactive inspection and maintenance
Courtesy: Tampa Electric Company
17 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Fine Slag Disposal/Marketable SlagChallenges• Fine slag filter cake difficult to
handle, wet or dry• Consistent marketable slag
- Low (< 10%) Carbon- Free of Chlorides, Ammonia
Solutions• Recycled 100% of the residual
char to the slurry prep. unit• Added wet screening to
effectively separate char from marketable slag
Courtesy: Tampa Electric Company
18 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Time to Maturity
0%
20%
40%
60%
80%
100%
0 12 24 36 48 60 72Months
TEC
0%
20%
40%
60%
80%
100%
0 12 24 36 48 60 72
Another SolidsIGCC Plant
Months
4 years
5 years
• It takes 4-5 years for FOAK plants to reach availability maturity
• Reference plant integration, control system, and simulator are aimed at reducing Time to Maturity
Source: Plant run logs, 12 Month Rolling Average
19 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
IGCC Deployment HistoryTechnical Feasibility
Coolwater (1984-89)
• 120 MW IGCC
• 7E Gas Turbine
• N/A time to maturity
TEC (1996 – Present)
• 250 MW IGCC
• 7FA Gas Turbine
• 5 yr time to maturity
Duke Edwardsport (2012 - )
• 630 MW IGCC
• 7FB Gas Turbine
• 1 yr time to maturity
CommercialFeasibility
CommercialDeploymentReference Plant
20 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Improvements for Reference PlantMitigated• Coated feed pump internals• Improved LP slurry piping• Coated HP slurry transitions• Streamlined slurry piping• Coated run tank/agitator• Coated syngas scrubber
Eliminated• Raw gas exchangers• Convective syngas coolers• RSC Sootblowers
Incorporated• Marketable slag• 100% residual char recycle
TG1Opportunity
TG2Planning
TG3Concept Design
TG4Prelim.Design
TG5Detail
Design
TG6Ship
TG7Validate
TG8Access
GE’s New Product Introduction (NPI) Process Integrates Lessons Learned throughout the Design Process
21 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Lessons learned integrated into Reference Plant
Two trains 630 MW net plant output
Optimized RSC Availability
7FB turbines Efficiency
Higher pressure CAPEX
MkVIe controls Operability
Simulator Reduced time to maturity
Improved refractory Availability
Improved feed injector Efficiency
Slurry preheat Lower O2, Efficiency
Selexol AGR Emissions approaching NGCC
GE’s IGCC
Referenc e Plant
ASU
Steam turbine
RSC
Controls
Gas turbine
Engineering
22 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
HTGC Subsystem
Gasifier
RadiantSyngasCooler
H PSteam
H PSteam
Scrubbed Raw SyngasTo Low Temp Cooling
SyngasScrubber
SyngasScrubber
Scrubbed Raw SyngasTo Low Temp Cooling
Clean Syngas toCombutstion Turbine
Diluent N2 toCombutstion Turbine
Clean Syngas fromAcid Gas Removal
Diluent N2 fromOxygen Plant
Oxygen Coal/Water Slurry
Raw Gas/DGANExchanger
Raw Gas/Clean GasExchanger Slag + Char to
Lockhopper
CSC CSC
RSC Improvements
23 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
RSC Improvements on Reference Plant
TECO Soot blower Deposits
Soot-Blowers – Removed from Reference Plant Design
CSC’s - Removed to Increase RAM
Seal Design/N2 Purge - Optimized for robust operation and RAM
Performance – 30% increase in steam production through surface optimization & increased steam & hot gas pressure
Size – 2 ft smaller diameter9 ft longer, same weight
Internal Quench – Experience based design, Favorable for sealing
TECO Tube Cage Leak RCA
CSC Inlet Fouling – Coating sample
Lessons Learned &
Design Improvements
TECRef. Plan
t
24 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
GE 630MW IGCC Ref. Plant Performance
Source: GE internal data, average of 30 permits granted, applications and publicly reported emissions, Aug 2006
Advanced PC/SCPC
IGCCcapability
NGCC0.00
0.05
0.10
0.15Average recent permit data
Best individual plant
Lb/MMBTU
• 90% + Hg removal• Useful byproducts• 30% less water
• 33% less NOx
• 75% less SOx
• 40% less PM10
IGCC reference plant benefits compared to supercritical pulverized coal
1Plant performance from Illinois #6 commercial match. Performance will vary according to specific coal and site conditions
Net Output1 634 MW
Net HR (HHV)1 8865 Btu/kWhAvailability
Target92%, 85% on
syngas
Net Eff.1 38.5% HHVTurndown 50%Coal type Eastern
Bituminous CoalFuel Envelope Up to 14% Ash
0.8 – 4% Sulfur Chlorides 2500 ppm
NOxSO2PM10
GE Ref. Plant Carbon Capture ready
Precombustiondecarbonization
H2 + CO2
GE Energy• Power• Heat
• Underground storage• Enhanced oil recovery (EOR)
CO2
26 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
GE Carbon Island™• Option for GE’s 630MW
IGCC plant • Allocated in plant layout• $225MM total installed cost• 585 MW output
(from 630 MW)
• 33% HHV efficient (from 38.5%)
• Tie-ins matched GT outages (Minimum plant downtime)
NG Eq. CO2 Footprint• Simple Cycle:
50% carbon capture (~1,100 lb/MWh)
• Combined Cycle: 65% carbon capture (~770 lb/MWh)
Note: Illinois Basin Coal on ISO site with proven technology…Performance and CAPEX are coal- dependant
27 /Coal-Gen 2008
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copiedor distributed in whole or in part, without prior written permission of the copyright owner.
Duke Energy Edwardsport IGCC Reference Plant launch customer• 630MW on Indiana 5 coal• NTP in 2007, COD in 2012• Detailed engineering near completion• Construction on-track • RSC ships in 2009• 7F Syngas turbines ship in 2010Successful siting & permitting• Sited & permitted next to aging PC facility
“ We have an opportunity to make history with the Edwardsport plant. The facility could very well be one of the cleanest coal-fired power plants in the
world. It will produce nearly 10 times as much energy as the existing Edwardsport plant with much less environmental impact.” - Jim Turner,
President & COO, U.S. Franchised Electric and Gas-Duke Energy Duke Energy press release, Jan. 25, 2008
Duke Energy Edwardsport site construction, January 2009