overview of the kemper igcc trig project
TRANSCRIPT
Overview of the Kemper County IGCC Project Using TRansport Integrated Gasification (TRIGTM)Randall Rush GM Gasification Technology Southern Company RECS 2012 5 June 2012
Gasification is Not New Technology n First gasifiers were air-blown First gasifiers were air-blown n n
First chartered gasification companies in England in 1812 and 1816 in the U.S. Primarily product was town gas for street lighting and home heating Primarily product was town gas for street lighting and home heating Gasification produces synthesis gas (syngas) comprised mainly of hydrogen (H2) and carbon Gasification produces synthesis gas (syngas) comprised mainly of hydrogen (H2) monoxide (CO) and carbon monoxide (CO) synthesize any hydrogen/carbon based chemical or burned to This syngas can be used to make syngas can be used to synthesize any hydrogen/carbon based chemical or This power burned to make power was developed by Texaco in the 1940s to produce more Oxygen-based gasification concentrated hydrogen for use in oil refineries Oxygen-based gasification was developed by Texaco in the 1940s to produce more concentrated hydrogenwas Coolwater (110 refineries The first coal-based IGCC for use in oil MW) in the mid-1980s an EPRI led demonstration of the Texaco (now GE) gasifier Today only five (5) gasifiers world-wide use coal to produce electricity in an IGCC mode of operation United States (GE & Conoco Phillips) Belguim (Shell) Spain (Shell) Japan (MHI)
First chartered gasification companies in England in 1812 and 1816 in the U.S.
Four (4) new coal-based IGCC units are currently in construction world-wide China (DongGuan and GE-based) US (Ratcliffe and GE-Edwardsport)
Petcoke Gasification to Produce H2 (Kansas)
Kemper County IGCCCoal Loading Hoppers Water Supply Pond Warehouse Process Air Compressors Gasifier Structure: Gasifiers, Syngas Cooling/Filtration Control/Admin Bldg. Coal Prep
Coal Dome
Water Treatment
Flare
Electrical Switchyard 2 x 1 Combined Cycle Sulfur/CO2 Removal
Sulfuric Acid Production
Cooling Towers
Kemper County IGCC Project Map ~70 miles transmission ~ 60 miles CO2 pipeline (for EOR) ~5 miles natural gas pipeline ~31,000 acre mine site ~2,900 acres plant site ~ 30 miles treated effluent lineNew CO2 Pipeline Meridian
Plant Site
Kemper County IGCC Overviewn
2x1 Integrated Gasification Combined Cycle (IGCC)
2 TRansport Integrated Gasifiers (TRIG) 2 Siemens SGT6 - 5000F CTs 1 Toshiba Steam Turbine (Tandem Compound Double Flow) 582 MW peak and 524 MW on syngas Heat Rate 11,708 Btu/kWh (29.5% HHV Efficiency w/ CO2 control and 40+% moisture coal) Selexol for H2S and CO2 removal 65+% CO2 capture (~800 lb/mWh emission rate) Mine Mouth Lignite
Plant Site
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Owner & Operator: Mississippi Power Over $2 billion capital investment Commercial Operating Date: May 2014 Use treated effluent from Meridian as makeup water Operate with Zero Liquid Discharge (ZLD) By-Products (TPY)
~3,000,000 - Carbon dioxide used for EOR ~135,000 - Sulfuric acid Kemper Lignite Composition ~20,000 - Ammonia Average MinHeat Content Moisture Ash Sulfur btu/lb % % % 5,290 45.5 12.0 1.0 4,765 42 8.6 0.35
Max 5,870 50 17 1.7
Development of TRIG for Power and Chemical ProductionTRIGTM Leverages Long History of KBR Fluid Catalytic Cracking (FCC) ExpertiseFirst Commercial FCC Unit for Exxon Orthoflow A Design Orthoflow C Design Resid FCCs
Late 30's 1942
1951
Early 1960's 1976 1980'sDesign Based on FCC Technology
Orthoflow F Design
1990Pilot Plant Tech Center
1996Grand Forks, ND 2,600 Hours Test Run
1996PSDF-Wilsonville, AL. >15,600 hrs in gasification >2,200 hrs on Mississippi Lignite thru July 11
China 2011 USA 2014TRIGTM In Kemper County, MS, USA & Dong Guan, China
TRIGTM Attributes/Advantagesn n
Simple, well established design
Based on technology in use for 70 years Air for power Oxygen for liquid fuels and chemicals Non-slagging design:l Provides 10-20 year refractory life, l Eliminates black water system l Provides non-fouling syngas cooler operation
Either Air- or Oxygen-blown High Reliability Design
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No burners to fail and be replaced Dry dust removal eliminates gray water system Coarse, dry coal feed allows:l Fewer, lower power pulverizers, and l Less drying than other dry-feed gasifiers
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Lower Fuel Costs
Cost-effective using high moisture, high-ash, low rank coals (PRB and lignite). Lower water use compared to pulverized coal (PC) Excellent emissions performance Easier to permit compared to PC Lower cost carbon capture compared to PC
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Excellent Environmental Performance
Kemper County IGCC 3-DGas Turbines HRSGs Nitrogen Plant CO2 and H2S Removal Steam Turbine Air Compressors HP Coal Feeders
Gasifiers (2) Fluid Bed Dryer System
Sulfuric Acid Production Ammonia Production
Kemper County IGCC 3-DFlare Derricks Sour Water/NH3 Recovery System H2S Absorbers (2) CO2 Absorbers (6) Dry Ash Filters (4)Particulate Collection Device (PCD)
AGR Regenerators (2)
Gasifiers (2) Crushed Coal Silos CO2 Compressors
HP Coal Feeders (12)
Main Syngas Coolers (4) Back-pulse Coal Mills (6) Surge Drums Mercury Adsorbers NH3 Removal Admin. Bldg. Syngas Humidifiers
CO2 Flash Drums (8)
To CT s
COS Hydrolysis
WGS Reactors
Steam Turbine
Warehouse
Process Air Compressors (4)
Kemper County IGCC 3-D
Kemper County IGCC 3-D
Kemper County IGCC 3-D
Kemper County IGCC 3-D
(All Process Steps except Selexol and WSA are simple fixed bed reactors or packed columns)Process Step Humidification / Contaminant Removal Water Gas Shift Process Equipment Packed Bed Column Description Syngas i s contacted with heated water to humidify the gas and to remove halogens (Chlorides, Fluorides, e tc.) Carbon Monoxide (CO) and water (H2O) i n Designer/Supplier KBR
Kemper County Wet Gas CleanupFixed Bed Reactors
COS Hydrolysis
Fixed Bed Reactors
Ammonia Removal CO2 and H2S Removal
Packed Bed Column Packed Bed Columns via UOP's Selexol Process
Catalyst V endor supplies catalyst Syngas are converted to Carbon Dioxide (CO2) and reactor dimensions, KBR designs vessel and Hydrogen (H2)to facilitate carbon capture in subsequent process steps. Carbonyl Sulfide also called Carbon-Oxy- Catalyst V endor supplies catalyst Sulfide (COS) i n Syngas i s converted to and reactor dimensions, KBR Hydrogen Sulfide (H2S) to facilitate sulfur designs vessel removal i n subsequent process steps. Syngas i s contacted with water to remove KBR ammonia (NH3). CO2 and H2S i n Sygnas are removed using UOPs proprietary solvent i n a series of absorbers. UOP supplies process information i ncluding equipment design specifications, KBR designs vessels, piping, e tc. Catalyst V endor supplies bed material and reactor dimensions, KBR designs vessel KBR
Mercury Removal
Packed Bed Adsorber
Mercury (Hg) i s removed on a fixed bed of activated adsorbent. H2S and Ammonia are stripped from sour water collected throughout the facility i n a series of columns. Ammonia i s further purified for sale on commercial market. H2S i s recycled within the process.
Sour Water Treatment / Fixed Tray and Packed Bed Columns Ammonia Recovery
Sulfuric Acid Production H2S burners / Fixed Bed Reactors / Acid Condensers via H2S i s converted i n a series of steps to highly Haldor Topsoe supplies process Haldor Topsoe's Wet Sulfuric Acid (WSA) Process concentrated sulfuric acid (H2SO4) product for information i ncluding equipment design commercial sale. specifications, and some specialized e quipment, KBR designs vessels, piping, e tc.
Kemper CO2 Capture SchemeRefrig.
Two Stages WGS Selexol Physical Solvent Refrigerated to 40F Carbon Capture: 65+% CO2 Emissions: 800 lb CO2/MWh Yield: >3 MM Tons/yr CO2
Refrig. CO2 Absorbers Product CO2
CO2 Compression And Drying CO2 Flash Tanks To Sulfuric Acid CW
Water Gas Shift Reactors
H2S Absorber
Steam Cond Cond H2S Stripper
Recycle Gas Compressor Acid Gas Concentrator Sour Syngas From Gasifier Steam
Syngas To Turbine
To Gasifier
Selexol: Practicality and Experiencen
Stable, well-proved process uses a single physical solvent to remove both CO2 and H2S from syngas. Selexol has a high affinity for CO2 and sulfur compounds. No chemical reactions, only solubility. Solvent was developed over 50 years ago for natural gas treatment. Process was developed for IGCC over 30 years ago. 50 units are in operation worldwide, many for natural gas purification, about 10 worldwide treat syngas or heavy oil.
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Coal-based IGCC Applications 100 MW EPRI Cool Water IGCC Demonstration Plant (Mid1980s) Removed both CO2 and H2S. Extremely high reliability over 5 year plant life. Also experienced high reliability over 5 year demonstration period. Produced low sulfur syngas and a purified CO2 stream for a urea plant. Removes both CO2 and sulfur from syngas for fertilizer production. Selexol process is reliable, automatic, and low maintenance.
TVA/Muscle Shoals Gasifier Demonstration Plant (Early 1980s)
Coffeyville Resources (2000-present)
WSA Process: Practicality and Experiencen n n n n n
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WSA Condenser
The Wet gas Sulfuric Acid process recovers sulfur emissions as high quality, commercial grade H2SO4. Developed by Haldor-Topsoe A/S. Mature technology commercially available since 1980. 75 units operating worldwide (21 more in design/construction). 14 gasification applications treating H2S waste gases. 11 units operating that are similar size or larger than the Kemper design. (Largest is 9x.) Advantages include very low outlet emissions, high reliability, no waste streams, and significant energy recovery as steam.
Lignite Mining Surface mine Multiple seams Typically 2 - 10 feet thick 30-150 feet deep
Surface Mine: Red Hills Mine
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Reclamation: Red Hills MineActive Mine
Pasture New Timber
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New Pond
Project Schedule
Be Aware of Your Surroundings March 2012
Safety
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Goal Zero, No Accidents, No Recordables Target RIR 0.50 Total Project Hours 2,470,754 Recordables 8 RIR Project to Date 0.65 Personnel on Site 1937
Recordable Incidents
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Laborer Carpenter Lead Carpenter Lead Electrician Driller Ironworker Carpenter Driller
Slipped and fell scrapping his leg Fracture - Finger Fracture - Ankle Laceration to Thumb Bee Sting Sutures to Lip Cut Hand Amputated Thumb
Be Aware of Your Surroundings April 2012
Water Reservoir Lignite Delivery Area
Mass Grading Plant Area Complete 3,400,000 cy Construction Laydown Complete 1,100,000 cy Water Reservoir 380,000 of 380,000 cy Lignite Delivery 191,929 of 320,000 Ash Storage 497,884 of 1,300,000 5,569,814 of 6,500,000 Cubic Yards Total 86%
LDF Area Stacker Re-Claimer Foundation
Deep Foundations Auger Cast Piling 158,121 LF of 175,730 LF Installed 90%
Underground Utilities Storm Drains 100% 18,500 of 18,500 LF Fire Protection 84% 20,920 of 24,911 LF Potable Water 64% 12,652 of 19,244 LF Other Pipe 64% 48,828 of 75,718 LF Total U/G Pipe 68% 100,900 of 148,462 LF
LDF Area Concrete Foundations Concrete Foundations 66,618 CY of 103,537* CY Installed 64%
Structural Steel Gasifier 30% 7,224 of 23,874 Tons Gas Clean Up 15% 1,852 of 12,084 Tons Combined Cycle - 25% 356 of 1,421 Tons LDF 0% 0 of 527 Tons BOP 0% 0 of 200 Tons Totals 25% 9,432 of 38,079 Tons
Gasifier Structural Steel
Gas Clean Up and By Products Structural Steel
Combined Cycle Structural Steel
Process Piping Above Ground Gasifier 3% 4,932 of 155,631* LF Gas Clean Up 1% 4,182 of 315,321* LF Combined Cycle 2% 1,102 of 76,237* LF LDF 0% 0 of 21,882 LF BOP 0% 0 of 7,047* LF Totals 2% 20,218 of 576,118 LF
Combined Cycle Structural Steel Combined Cycle
HRSGs
HRSG Erection 42%
Combined Cycle Steam Turbine Erection 25%
Concrete Tanks Fire Protection - 98% Waste Water - 98% Condensate - 85%
Architectural Buildings Warehouse 100% Main Electrical Bldg Admin/Control Bldg Maintenance Shop 100% Main Electrical Bldg 94% Gasifier Elect Bldgs 94% Combined Cycle Elect Bldg 88% Admin/Control Bldg 74% Warehouse
Maintenance Shop
Coal & Ash Silos Fabrication Coal Silos Ash Silos Crushed Ash Total 58% 63% 40% 58%
Treated Effluent Water Line Horizontal Directional Drill
Off Site Pipe Lines Treated Effluent Water Line 65% 111,391 of 170,578 LF Natural Gas Line 0% 0 of 33,125* LF Mobilization June 2012 CO2 Line 0% 0 of 342,202* LF Mobilization June 2012 Total 21% 110,875 of 525,707LF
Hwy 493 Modifications
88% Complete Turn Lanes
June 21, 2010 Day 1
April 30, 2012 - 22 Months Later
Kemper County IGCC 6,287,567 CYn
Earthwork
Dirt Sidewalk 6,287,567 CY 8038.1 Miles
Kemper will have enough cubic yards of earthwork to construct a 4 foot wide by 1 foot deep sidewalk around the US starting in Jacksonville, FL and heading to Los Angeles, CA to Seattle, WA to Augusta, ME and back to Jacksonville, FL.
Deep Foundations Total (Caisson & ACP)Kemper County IGCC 201,800 LF 38.2 miles
Birmingham to Plant Miller 20 miles
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Kemper will have enough linear feet of caissons and auger cast piles to stretch from APCO Headquarters in Birmingham to Plant Miller in Quinton, AL and back!
Kemper County IGCC 93,260 CYn
Concrete
St. Louis Gateway Arch 38,107 CY
Kemper will have enough cubic yards of concrete to construct the foundations and inner structure of the St. Louis Arch twice and still have 17,000 CY left over!630
630
Kemper County IGCC 34,643 tons
Structural Steel
Golden Gate Bridge Main Towers 44,400 tons (Both)
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Kemper will have enough tonnage of steel to build 80% of the main towers of the Golden Gate Bridge in San Francisco.
746
Kemper County IGCC 536,113 SF
Grating
Football Field 57,600 SF
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Kemper will have enough square feet of grating to cover more than 9 football fields!
x9
Kemper County IGCC 75,752 LF
Guardrail & Handrail
Talladega Superspeedway 1 Lap = 2.66 Miles 14,045 LF
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Kemper will have enough linear feet of guardrail & handrail to wrap around the track at Talladega Superspeedway nearly 5 times!