Reply to: 231 W. Main, Suite 1E Carbondale, IL 62901 (618) 457-0137 (618) 457-0513/fax

Main Office: 18 Tremont Street, Suite 530 Boston, MA 02108 (617) 624-0234 (617) 624-4933/fax www.catf.us

August 29, 2006

Mr. Richard Fristik

USDA Rural Development Utilities Programs

1400 Independence Ave, SW

Mail Stop 1571, Room 2237

Washington, DC 22050-1571

Re: Comments of the Draft EIS for the Highwood Generating Station

Dear Mr. Fristik:

The Clean Air Task Force is a national environmental group headquartered in Boston Massachusetts and operating nationwide. We use advocacy, education and research to promote and restore healthy air. We welcome the opportunity to submit comments on the draft Environmental Impact Statement for the Highwood Generating Station.  The Draft EIS is deficient because it eliminates from detailed consideration many of the alternatives that are available to replace the proposed CFB plant. These alternatives, which are listed in pages ES-3 and ES-4, should have been included in the detailed EIS analysis. For all practical purposes, the EIS is little more than a comparison of the proposed CFB plant to no action.

In particular, the IGCC alternative to CFB merits detailed evaluation in the EIS. The EIS

incorrectly states that IGCC is not cost effective, needs more research to attain higher

availability, and does not enjoy significant emission advantages over CFB. As more fully

described below, each of these conclusions is incorrect. Therefore, the EIS should not

have eliminated IGCC from detailed review. We respectfully request that the EIS be

revised, adding IGCC to the options evaluated in the detailed analysis.

In July 2006, USEPA released a report entitled, ÒEnvironmental Footprints and Costs of Coal-based Integrated Gasification Combined Cycle and Pulverized Coal Technologies.Ó1 The report presents a ÒsnapshotÓ of evolving costs and performance of IGCC plants.  While the report does not directly compare IGCC to CFB plants, many of the general conclusions of the report still hold. In particular, the report concludes that IGCC plants offer significant air emissions, water use, and solid waste benefits when compared to conventional coal plants. This conclusion is in stark contrast to the draft EIS. The table below compares the USEPA reportÕs emission rates for a subbituminous IGCC plant to the permit limits for the Highwood Generating Station:

1 Available at http://www.epa.gov/airmarkets/articles/control.html Page 2 As the table above shows, IGCC technology is anywhere from 1.7 to 10 times cleaner than CFB technology.

The USEPA report also concludes that an IGCC plant using subbituminous coal produces about 5.9 lbs of solid waste per MMBtu.2 The EIS estimates that the Highwood plant would produce 223 tons of fly ash and bed ash.3 Depending upon the assumptions about the coal used at Highwood, the amount of solid waste generated would be between 7 and 9 lbs of solid waste per MMBtu.

Water use is also significantly lower with an IGCC. The USEPA report notes that for a 500 MW subbituminous IGCC plant (about twice the size of Highwood), raw water use is about 5,764 gpm.4 Cutting this value in half yields about 2800 gpm, or about 10% less water than the 3200 gpm that the EIS estimates is needed for Highwood.5 2 USEPA, ÒEnvironmental Footprints and Costs of Coal-based Integrated Gasification Combined Cycle and Pulverized Coal TechnologiesÓ at page 3-36 3 EIS page 4-110.

4 USEPA, ÒEnvironmental Footprints and Costs of Coal-based Integrated Gasification Combined Cycle and Pulverized Coal TechnologiesÓ at page 3-38.  5 EIS page 4-22.

Pollutant

IGCC

Subbituminou s Coal (1)

Highwood

CFB, 250

MW

Size of IGCC Advantage (in lb/MMBtu)(in lb/MMBtu)

SO2 0.012 0.038

IGCC 3 times better

than CFB

NOx 0.044 0.07

IGCC 1.6 times better

than CFB

Mercury .42x10-6 1.5 x 10-6

IGCC is 3.6 times

better than CFB

PM/PM10 negligible 0.026

VOCs 0.0017 0.003

IGCC is 1.7 times

better than CFB

Sulfuric Acid Mist 0.0005 0.0054

IGCC is 10 times

better than CFB

CO 0.03 0.1

IGCC is 3.3 times

better than CFB

Notes:

1. USEPA Exhibit 3-10, page 3-10

Page 3

The failure to accurately characterize the environmental benefits of IGCC over CFB is a major deficiency of the EIS report.

The EIS also mischaracterizes the commercial status of IGCC. On page 2-31, the EIS attributes the following claims to the USDOE: 1) IGCC has insufficient operating experience; 2) That major components of IGCC have not been integrated into power applications, and 3) that the technology has been demonstrated at only a handful of facilities worldwide. Attachment 1 is the DOE reference cited by the report. These conclusions attributed to DOE by the EIS are not found in the article and should not form the basis for rejecting IGCC from detailed review.

The EIS claims that IGCC systems cost 20% more than PC systems. 6 Even if this capital cost premium estimate is true, some utilities find IGCC flexibility benefits outweigh these costs. For example, AEP has proposed an IGCC plant before the Ohio Public Service Commission. Attachment 2 is the testimony of AEPÕs Michael Mudd on behalf of the companyÕs IGCC plant. In his testimony, Mr. Mudd assumed that the capital cost of an IGCC plant is 20% higher than a PC. Next, he modeled the impact of future carbon dioxide regulations by preparing a simple option value analysis of IGCC and SCPC under varying carbon scenarios. The model weighted three scenarios each at 30% probabilityÑ no carbon dioxide requirements, low carbon dioxide prices, and high carbon dioxide prices. The remaining scenario, weighted at 10%, required CO2 controls by 2020. Even assuming a 20% capital cost premium for IGCC over conventional coal plants, IGCC had about the same NPV as the PC project.

By failing to look at total costs, and by focusing exclusively on todayÕs costs and not future costs, the EIS reaches the wrong conclusion that IGCC is not cost effective.  The EIS also incorrectly concludes that IGCC plants do not achieve acceptable levels of reliability. This conclusion is not supported by the facts. Three of the newer IGCC plants are found at Italian refineries. Attachment 3 is a recent Gas Turbine World article that reports that the capacity factors of these three plants are between 90% and 94%. Only one of these plants operates with a spare gasifier. All three IGCC plants utilize liquid refinery wastes not coal. But to use coal in most gasifiers, the coal must be slurried to a liquid, so the gasifier, and all the key downstream equipment, is exactly the SAME as the ones found in the Italian refineries. As noted in the Turbine World article, US power companies overly focus on Wabash and Polk plants. These older plants have availabilities that donÕt exceed 85%.

In conclusion, the EIS cited several key reasons for eliminating IGCC from the EIS detailed evaluation. A more careful consideration of these issuesÑenvironmental benefits, costs, and availabilityÑshow that IGCC has important benefits over CFB technology. We respectfully request that the EIS be revised to include IGCC in the detailed evaluation of alternatives to the proposed CFB plant.  6 EIS page 2-31.

Page 4

Sincerely,

John W. Thompson

Director of the Coal Transition Project

Page 5

Attachment 1

08/29/2006 04:06 PM DOE - Fossil Energy: Pioneering Coal Gasification Plants

Page 1 of 2 http://www.fossil.energy.gov/programs/powersystems/gasification/gasificationpioneer.html

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You are here: Clean Coal & Natural Gas Power Systems > Coal Gasification R&D > Pioneering Gasification

Plants

Pioneering Gasification Plants

In the 1800s, lamplighters once made their rounds down the streets of many of AmericaÕs largest cities lighting street lights fueled by Òtown gas,Ó the product of early and relatively crude forms of coal gasification.  (Town gas is still used extensively in some parts of the world, such as China and other Asian countries). Once vast fields of natural gas were discovered and pipelines built to transport the gas to consumers in the 1940s and 50s, the use of town gas phased out.

In the 1970s, interest in coal gasification

revived, due largely to concerns that the U.S.

supply of natural gas was waning. The

massive Great Plains Coal Gasification Plant in

Beulah, North Dakota, was built with federal

government support to use coal gasification

to produce methane, the chief constituent of

natural gas. When government price controls

on natural gas were lifted, however, large

quantities of natural gas became available,

and no other coal-to-methane gasification

plants have been built to date in the United

States.

Coal gasification, however, found its most

important market application in the 1980s and

90s. Driven primarily by environmental

concerns over the traditional burning of coal, gasification emerged as an extremely clean way to generate electric power. By turning coal into a combustible gas that could be cleansed of virtually all of its pollutantforming impurities and burned in a gas turbine, coal could rival natural gas in terms of environmental performance.

The first major use of coal gasification to generate electric power in the United States took place in the mid-1980s at Southern California EdisonÕs experimental Cool Water demonstration plant near Barstow, California. The 110-megawatt Cool Water plant established the early technical foundation for future integrated gasification combined cycle (IGCC) power plants.

Coal gasification-based power concepts got their biggest boost in the 1990s when the U.S. Department of EnergyÕs Clean Coal Technology Program provided federal cost-sharing for the first true commercial-scale IGCC plants in the United States.

Tampa ElectricÕs Polk Station

The Polk Power Station near

Mulberry, Florida, is the NationÕs

first ÒgreenfieldÓ (built as a brand

new plant) commercial gasification

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08/29/2006 04:06 PM DOE - Fossil Energy: Pioneering Coal Gasification Plants

Page 2 of 2 http://www.fossil.energy.gov/programs/powersystems/gasification/gasificationpioneer.html

Tampa ElectricÕs Polk Power Station

MORE INFO

DOE Fact

Sheet

1/10/97 Plant

Dedication

Announcement

Powerplant of

the Year

Announcement

Topical Report

á      1996 [660KB PDF] Topical Report

á      2000 [1.2MB

PDF]

The Wabash River Clean Coal Power

Plant

MORE INFO

DOE Fact Sheet

11/8/95

Dedication

1/18/97

Powerplant

Award

Announcement

Topical Report

á      1996 [605KB PDF] Topical Report

á      2000 [941KB

PDF]

new plant) commercial gasification

combined cycle power station.

Capable of generating 313

megawatts of electricity - 250

megawatts of which are supplied to

the electric grid - the power plant is

one of the worldÕs cleanest. The

plantÕs gas cleaning technology removes more than 98 percent of the sulfur in coal, converting it to a commercial product. Nitrogen oxide emissions are reduced by more than 90 percent.

The project was presented the 1997

Powerplant Award by Power magazine. In

1996 the project received the Association of

Builders and Contractors Award for

construction quality. Several awards were

presented for using an innovative siting

process in which a local citizens group

evaluated candidate sites and made the final

selection: 1993 Ecological Society of America

Corporate Award, 1993 Timer Powers Conflict

Resolution Award from the State of Florida,

and the 1991 Florida Audubon Society

Corporate Award.

The Wabash River Repowering Project

The Wabash River Coal Gasification

Repowering Project is the first fullsize

commercial gasificationcombined

cycle plant built in the

United States. Located outside

West Terre Haute, Indiana, the

plant started full operations in

November 1995.

The plant can generate 292

megawatts of electricity -- 262

megawatts of which are supplied to

the electric gridÑmaking it one of the worldÕs largest single train gasification combined cycle plants operating commercially.

Destec Energy and CINergy Corp./PSI Energy

received the 1996 Powerplant Award from

Power magazine. Sargent & Lundy, engineer

for the combined-cycle facility, won the

American Consulting Engineers CouncilÕs 1996

Engineering Excellence Award.

Page owner: Fossil Energy Office of Communications Page updated on: June 27, 2006

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Page 6

Attachment 2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 7

Attachment 3

EniPower is commissioning a 250

MW IGCC plant that will burn

syngas produced by gasification of

residues at an adjacent Eni Sannazzaro

refinery in north central Italy.

Based on commercial experience

with earlier plants, project engineers

predict the annual capacity factor

(measure of profitability) of the Sannazzaro

plant should match if not outperform

them, especially in the critical

early years. Specifically:

ISAB Energy. Asphalt-based 520

MW plant built by Ansaldo Energia

went from a capacity factor of 61% in

2000, first year of commercial operation

on syngas, to 93% in 2004.

Sarlux Saras. Residues-based

545 MW plant went from a capacity

factor of 55% in 2001, first year of

commercial operation on syngas, to

90% in 2004.

Api Energy. Residues-based 280

MW plant went from a capacity factor

of 66% in 2001, first year of commercial

operation on syngas, to 94% in

2004.

The Eni Sannazzaro IGCC plant,

nominally rated at 250 MW net ouput,

is designed around a multi-shaft

1 x 1 Ansaldo manufactured Siemens

V94.2K combined cycle module and

Shell Global Solutions gasification

process.

The combined cycle unit is located

at EniPowerÕs 1050 MW station in

Ferrera Erbognone along with two

400 MW natural gas-fired Ansaldo

V94.3A.2 combined cycle (multi-shaft

1x1 configurations) plants.

Ansaldo Energia re-designed and

tested the original Siemens burner design

in two different test programs,

at AnsaldoÕs combustion center and

the Enel Laboratories R&D center in

Italy.

Startup date

The IGCC combined cycle has been

operating on natural gas while the

gasification system is undergoing

commissioning and testing within the

refinery battery limits.

The gas turbine recently began

commissioning and was expected to

begin commercial operation on syngas

in mid-2006 selling electricity into the

national grid.

The gasification system also will

export superheated steam and hydrogen

within the refinery.

Originally, the switchover to syngas

operation was to take place by the

end of 2005. However, an apparent

delay in commissioning, along with

other refinery modifications, pushed

the date off. The actual switchover is

to take place in March 2006.

ShellÕs gasification process has

been widely used for industrial applications

worldwide; eight coal gasification

units are under construction in

China alone.

It was selected for the coal-based

IGCC demo plant at the Nuon Buggenum

power station, The Netherlands,

which has been operating for about 12

years. Also for the commercial Pernis

refinery IGCC project in The Netherlands

that started operations in 1997.

Shell gasifier trains

At the Sannazzaro plant, two 50%

oxygen-blown gasifiers will process

about 600 tons a day of refinery residues

from the Eni Refinery (formerly

Agip Petroli).

According to project engineers,

Eni chose the Shell gasification process

in the interest of achieving higher

net plant efficiencies for the intended

cogeneration of electricity and steam.

Unlike the Texaco quench-type

gasifiers (now GE Energy) used by

the other IGCC plants in Italy, the

Shell gasifiers are fitted with a heat

recovery unit that produces high pressure

(84 barg) superheated steam for

use in the refinery.

Following heat recovery, the syngas

goes through a catalytic hydrolysis

unit where COS and HCN are converted

to H2S and NH3, respectively.

After this, the syngas is washed

in a water-spray column, to absorb

the ammonia, and the H2S is then removed

in the acid gas removal unit

IGCC and Gasification

Refinery IGCC plants are exceeding

90% capacity factor after 3 years

By Harry Jaeger

Steep learning curves for commercial IGCC plants in Italy show annual capacity factors of 55-60% in the first year of service and improvement to over 90% after the third year.

20 GAS TURBINE WORLD: January-February 2006

using a chemical solvent absorption

process (MDEA-Dow).

Resultant hydrogen sulfide-rich

waste gas is sent to a Claus sulfur recovery

unit at the refinery to produce

a solid sulfur product.

Following acid gas removal, the

desulfurized syngas is forwarded to a

hydrogen removal and recovery unit

that produces pure hydrogen which

the refinery uses to produce cleaner

fuels.

Co-firing option

Final composition of

the syngas, and, therefore

its heating value

and Wobbe index,

will vary depending

upon the amount of

hydrogen off-take for

refinery use.

When the ratio of

hydrogen to carbon

monoxide is too low

(depending on gas

turbine combustion

system design specs)

up to about 10% of

natural gas fuel can

be added for operation

in a co-firing

mode.

The syngas modified

V94.2K gas turbine

is equipped with

a dual fuel combustor

to operate on natural gas alone as a

backup fuel when the gasifier is shut

down for scheduled maintenance or

service.

Although a Siemens design, the

gas turbine was built by Ansaldo (under

license) and equipped with its

own designed and patented burners.

The ÒKÓ designation indicates the

addition of one compressor stage to

meet requirements of operating with

syngas with no (or only partial) integration

of the air separation unit.

Ansaldo Energia notes that it performed

all of the combustion and fuel

system modifications needed to burn

and operate on the syngas fuel.

For NOx control purposes, to

meet a local 25 ppm environmental

limit, dilution steam from the combined

cycleÕs heat recovery steam

generator is injected into the syngas

before it is fed to the gas turbine.

At an H2 to CO ratio of approximately

1 to 1, and with water vapor

comprising about 35% of the gas by

volume, the as-delivered lower heating

value of the fuel gas is on the order

of 175 Btu/scf.

Europe forging ahead

Although many utilities and state regulatory

commissions in the U.S. regard

IGCC as ÒemergingÓ technology,

Europe has already acquired a solid

base of commercial IGCC design and

operating experience (lessons learned)

for future projects.

Since 1995, about 2500 MW of

IGCC capacity using heavy petroleum

residues in a refinery environment has

been installed worldwide.

Italy, with IPP partners from the

U.S., has commissioned four refinerybased

IGCC plants for commercial

operation since 2000 with an installed

generating capacity of about 1600

MW.

Two of those plants, rated over

500 MW each, use gasification technology

supplied by Texaco (now GE

Energy) and were built by EPC teams

that included Snamprogetti and Foster

Wheeler Italiana of Milan.

Commercial IGCC plants

First of the large Italian IGCC plants,

owned and operated by ISAB Energy

(51% Erg Petroli and 49% Mission

Energy), came on-line in 2000. It is

located at the Erg refinery in Priolo,

Sicily.

The multi-shaft combined cycle

power block, net rated at 520 MW

without deducting for gasification

auxiliary loads such as the air separation

unit, is built around two Ansaldo

Siemens V94.2K gas turbines.

Sarlux, the second Italian plant

rated at 550 MW, is said

to be the largest IGCC

plant in the world. It is

located at the Saras Oil

Refinery, on the island of

Sardinia, which supplies

the heavy residue feedstock

for gasification.

Air Liquide provides

oxygen and nitrogen to

each of those facilities on

an Òover the fenceÓ sales

basis.

Sarlux started commercial

syngas operation

in January 2001. It was

built by Snamprogetti,

Turbotechnica (Nuovo

Pignone) and GE Power

Systems under ownership

of a joint venture between

Enron and Saras.

It contains three 184

MW STAG 109E GE/Nuovo Pignone

single-shaft combined cycle units.

Output power is sold into the local

grid, under a 20-year long term power

purchase agreement with Enel.

The plant also supplies the Saras

refinery with 200 tons per hour process

steam and 1.4 million scf per

hour of hydrogen feedstock.

The third plant, owned by Api Energia,

is located at the Ancona refinery

on the Adriatic coast and entered commercial

operation in April 2001.

It was developed as a joint venture

project by Anonima Petroli Italiana

(51% stake), ABB (25%) and Texaco

(24%), and is now 100% owned by

Api.

The 280 MW combined cycle power

block in this case is built around a

IGCC and Gasification

Eni Power

Ferrera 250 MW

Api Energia,

Falconara 280 MW

Sarlux,

Sardinia 550 MW

ISAB Energy,

Sicily 520 MW

IGCC projects. Refineries are generating electric power, steam and hydrogen from excess low-grade residues. Developed as joint ventures with non-recourse project financing (US$3.1 billion for Sarlux, ISAB, Api Energia).

GAS TURBINE WORLD: January-February 2006 21

syngas modified GT13E2 gas turbine.

Plant design features

Close examination of the ISAB and

Sarlux plants reveals subtle design

differences in plant configuration that

were in large part dictated by plant

owner and operations considerations.

Both plants use Texaco (now GE

Energy) oxygen-blown quench gasification

technology to convert heavy

residual oil feedstock to syngas: two

gasification trains operating at 70 bar

for ISAB versus three, running at only

40 bar, for Sarlux.

Neither has a spare gasifier installed,

so that gasifier capacity effectively

matches combined cycle requirements.

Each gas turbine is fed by

a single gasifier. In both cases the gasification

process takes place at around

1400¡C (2552¡F).

However, they do have different

sulfur removal systems: a ÒhybridÓ

MDEA-Dow Chemical system for

ISAB and a ÒphysicalÓ Selexol-UOP

system at Sarlux.

Perhaps this has something to do

with the different sulfur recovery and

tail-gas treatment (H2S to elemental

sulfur) methods used at the two plants.

At the ISAB plant the tail gas is

treated and incinerated, while at Sarlux

it is compressed and recycled back to

the Selexol unit. Cleaned syngas in both

cases contains about 30 ppm sulfur.

In the case of the ISAB plant, the

clean syngas is sent to an expander,

where the higher pressure is recovered

to produce about 5 MW of additional

power.

Syngas treatment

At Sarlux the syngas goes to a UOP

hydrogen removal and recovery unit

which includes a membrane section

and a pressure swing absorption

(PSA) section to produce pure hydrogen

(over 99% vol) for use within the

refinery.

Both plants ÒmoisturizeÓ the syngas

in saturator units so that it ends

up containing on the order of 35-40%

by volume water vapor, before being

forwarded to the gas turbines.

This steam dilution has the effect

of lowering combustion flame temperature,

and thereby NOx production,

and also adds a bit of a power

boost for the gas turbines.

The fuel gas delivered at around

400¡F temperature has an LHV heating

value on the order of 165 Btu/scf.

Combined cycle modules

At ISAB the combined cycle is a 2 x 1

design comprised of two Ansaldo Siemens

V94.2K gas turbine generators,

two HRSGs with duct firing capability,

and one condensing steam turbine

generator.

For Sarlux, there are three separate

1 x 1 single-shaft GE STAG

109E units, each including one Frame

9001E gas turbine, double-ended generator,

condensing steam turbine and

HRSG.

Although details are not available

from Snamprogetti, they report that

the EPC contract values for the two

plants Òdo not differ substantiallyÓ so

they can be assumed to cost about the

same on a $ per kW basis.

Similar start-up hiccups

Also, according to Snamprogetti engineers,

the ISAB and Sarlux IGCC

plants went through similar commissioning,

startup and performance improvement

experiences.

There were no problems or delays

during initial startup testing and commissioning

on backup fuel oil systems.

However, integrated IGCC commissioning

and startup testing took 10-12

months in each case.

Once in service, both plants also

experienced significant operating

problems that were complicated by the

number of technologies and individual

systems involved. These were the first

large scale 500 MW-plus IGCC projects

commissioned.

During the first year, after the start

of commercial operations, the annual

capacity factor on syngas at ISAB was

down around 61%, and only around

55% for Sarlux.

Even taking into account plant operation

on backup fuel oil, the annual

capacity factor came to only 75% and

79% respectively that first year.

ISAB operating issues

Problems at ISAB reportedly had to

do with severe corrosion in soot water

and gray water circuits, syngas expander

reliability, gasifier refractory

hot spots, and gas turbine combustor

IGCC and Gasification

90%

80%

70%

60%

50%

4 1 2 3

ISAB Energy

Sarlux

Api Energy

Negishi

Annual Availability

Year of Operation

Commercial IGCC availabilty. ISAB Energy went from 61% to 93% in four years, Sarlux from 55% to 90% in three years and Api Energy from 63% to 94% in four years. Nippon Refining plant in Negishi operated at 69% availability on syngas in its first year of operation. Excludes operation on backup fuel.  Recent operating data for Negishi were not available at time of publication.

22 GAS TURBINE WORLD: January-February 2006

Source: EPRI, Snamprogetti / Eni, ERG

deposits.

Project engineers note that the asphaltines

design feedstock was the

heaviest oil feed to be gasified at that

time.

Gas turbine deposits, primarily of

nickel alloy, were apparently caused

by the reaction of CO in the fuel with

nickel in combustion system components.

Detailed investigation traced the

cause of the deposition to the disassociation

of a single contaminant, Nickel

Carbonyl (Ni CO4).

There was also an issue with higher

than expected ratio of H2 to CO in

the syngas, especially with light feedstock,

that caused combustion problems.

Initially, Ansaldo and Siemens

treated this as an out-of-specs fuel

condition and restricted the use of

syngas in the gas turbines.

Adjusting gasifier operating temperature

and reducing the steam-to-oil

feed ratio in the gasifiers solved the

problem, but compromised gasifier

performance.

Ultimately, Ansaldo and Siemens

performed the necessary combustion

testing to demonstrate the capability

to handle the higher syngas hydrogen

levels, resolving the issue and allowing

the gasifiers to run at their design

operating conditions.

Sarlux operating issues

The first year of operation was marked

by a persistent problem of soot carryover

in the syngas, especially during

plant transients, such as load changes

during operation.

This was resolved by modifying

gasifier and syngas scrubber operating

procedures.

There was also a carryover issue

due to the recycling of a small amount

of water containing Selexol solvent.

Eliminating the recycle greatly improved

operation, say project engineers.

Another early problem at Sarlux

involved severe damage to the hydrogen

removal and recovery membrane

system due to contact with some minor

amount of Selexol carryover.

This was solved by adding new

high-efficiency coalescing separators

in lieu of the conventional demisters

used in the original design.

Steady improvement gains

With resolution of initial equipment

problems, and improved operating

procedures, IGCC plant availability

showed steady improvement.

During 2004, with four years of

commercial operation behind it, the

ISAB plant enjoyed around 93% capacity

factor on syngas according to a

report issued by one of the plant owners.

This was up from 89% during the

third year of commercial operation,

and 77% the year before that.

The Sarlux plant also witnessed a

dramatic improvement within the frist

three years of operation.

Capacity factor on syngas improved

to 90%, climbing up from a

lowly 55% the first year.

Adding operating time on backup

fuel brings this figure to a very respectable

88%.

Although detailed data are lacking,

current operation of the Sarlux plant is

said to be quite satisfactory.

Api Energy design

The 280 MW Api Energia plant at

Falconara Marittima differs from the

other two IGCC plants in that it has

two gasifiers feeding one gas turbine.

It features two parallel trains of

Texaco gasifiers (now GE Energy)

producing syngas for a single ABB

GT13E2A gas turbine combined cycle

unit.

Like the arrangement at ISAB, a

syngas expander is used to recover

excess pressure energy upstream of

the gas turbine fuel control valve.

But, unlike the earlier Italian

plants where the syngas is saturated

by steam prior to combustion, compressed

nitrogen from the air separation

unit (ASU) is injected into the

syngas for a 50% dilution for NOx

control.

Another unique feature is the addition

of an auxiliary boiler to supply

plant steam in the event of gas turbine

outage.

During normal operating conditions,

the auxiliary boiler is kept at

minimum load and the steam produced

is recirculated into the steam

and water cycle.

23 GAS TURBINE WORLD: January-February 2006

IGCC and Gasification

280 MW Api Energy IGCC plant. Two parallel train GE gasifiers produce syngas for a single GT13E2A gas turbine. This is a view of the sulfur recovery units (center), sour water stripping towers (right) and the Selexol regenerator and absorber.

GAS TURBINE WORLD: January-February 2006 23

First-year jitters

Like the other plants, equipment and

operating problems at Api seriously

detracted from plant availability during

its initial commercial service.

After about a year the plant owners

awarded a contract to Foster Wheeler

Italiania, the original EPC contractor,

to resolve the problems and bring the

plant up to design performance.

According to project engineers assigned

that task, IGCC plant availability

during the first two years of

operation was in the range of 70% and

caused investor concern.

It also resulted in high maintenance

costs and created problems with

plant neighbors due to excessive flaring

and frequent steam safety valve

discharge noise during plant upsets.

Improvement targets

The main problem areas for the Foster

Wheeler Òavailability improvementÓ

project initiated in 2002 had to do

with low safety system effectiveness;

low instrumentation reliability; metallurgical

inadequacies; equipment performance

limitations.

A reliability, availability and maintainability

(RAM) study was conducted

at the outset to provide a roadmap

for improvements.

The study showed that the theoretical

average equivalent availability

of the plant operating on syngas was

87% -- taking into account the Falconara

plant configuration and utilizing

an industry RAM database relevant to

IGCC and Gasification

Project Startup Rating Feed Product Gasifer Gas Turbine

Nuon (Demkolec), 1994 250 MW coal/biomass power Shell V94.2

Buggenum, The Netherlands

Wabash (Global/Cinergy), 1995 260 MW coal/coke repowering Conoco 1xFr 7FA

Indiana USA Phillips

Tampa Electric, 1996 250 MW coal/coke power GE/Texaco 1xFr 7FA

Polk County, Florida USA

Frontier Oil, 1996 45 MW coke power/steam GE/Texaco 1xFr 6B

El Dorado, Kansas USA

SUV, Czech Republic 1996 350 MW coal/coke power/steam Lurgi 2xFr 9E

Schwarze Pumpe, Germany 1996 40 MW lignite/waste power/methanol Future Energy 1xFr 6B

Shell Refinery, 1997 120 MW visbreaker/tar power/steam/H2 Shell 2xFr 6B

Pernis, The Netherlands

Elcogas S.A., 1998 300 MW coal/coke power Prenflo 1x V94.3

Puertollano, Spain

ISAB Energy, 2000 520 MW asphalt hydrogen/power GE/Texaco 2x V94.2K

ERG/Mission, Italy

Sarlux, Saras/Enron, 2001 545 MW visbreaker/tar power/steam/H2 GE/Texaco 3x Fr 9E

Sardinia, Italy

Exxon Chemical, 2001 160 MW ethylene tar power/steam GE/Texaco 2xFr 6FA

Singapore

Api Energia, 2002 280 MW visbreaker/tar power GE/Texaco 1xKA 13E2

Falconara, Italy

Alstom

Valero (Premcor), 2003 160 MW coke repowering GE/Texaco 2xFr 6FA

Delaware City USA

Nippon Refining (NPRC), 2003 342 MW asphalt power GE/Texaco 1x701F

Negishi, Japan Mitsubishi

Eni Sannazzaro, 2006 250 MW oil residues power/steam/H2 Shell V94.2K

AGIP Petrolia, Italy

Total generating capacity 3872 MW

Commercially Operating IGCC Projects Worldwide .Table lists 14 commercially operating IGCC plants worldwide (including

one now undergoing commissioning) that provide close to 3900 MW of generating capacity. Plants use a variety

of feedstock coals, petroleum coke and other refinery residues. Nuon Buggenum plant recently introduced biomass to

supplment its coal feedstock. The syngas-modified V94 gas turbines are Siemens designs built by Ansaldo. The Frame

machines are GE designs.

Source: Luke OÕKeefe, Burns & Roe

24 GAS TURBINE WORLD: January-February 2006 operating IGCC plants.

Plant owners and the project engineers

took this figure as their reference

target in pursuit of the multi-year

availability improvement project.

As a result, a plant upgrade program

was initiated, with modifications

to be implemented during each of the

three annual planned maintenance outages

during 2002, 2003, and 2004.

Safety first

Among the plant-wide studies performed

was a Safety Integrity Level

study in accordance with international

standards for more than 300 safety instrumentation

system functions.

All of the specified modifications

related to safety were implemented

along with a number of corrective

measures that were identified for overall

IGCC plant design and operation.

Modifications related to plant reliability

and performance were subjected

to rigorous cost-benefit analyses

and prioritized.

A series of instrumentation and

control system reliability improvement

measures included automated

flow regulators to replace simple orifices,

increased control loop redundancy,

and high-performance CPUs

and operator station controllers to

handle heavy software loads.

Steam cycle

Particular attention was given to the

auxiliary boiler system to insure its

backup supply of steam to the refinery

and to the gasifiers in the event of a

combined cycle trip.

Basically, the burner management

system was simplified and made more

flexible to improve its reliability.

Several measures were taken to

improve the reliability of the steam

and water cycle, according to the project

engineers, the most important of

which included duplication of de-superheating

stations to allow on-line

maintenance.

An automatically actuated control

valve was also installed at the auxiliary

boiler outlet to replace the original

on-off valve.

This was to allow a smooth and

reliable release of high pressure steam

to the atmosphere in the event of a

combined cycle plant or steam turbine

trip.

Materials upgrades

Reliability studies of the Falconara

plant placed focus on two systems

where materials upgrades were indicated,

i.e. the gray water system and

the oxygen system.

In the gray water system, corrosion

and erosion phenomena were evident

in carbon steel piping, equipment and

control valves.

Metallurgical studies indicated that

this was due to the effect of acidic

conditions in the presence of solids

(soot, ash) in these components.

However, initial measures taken to

neutralize the acids did not solve the

problem.

Subsequent change to stainless

steel for parts where the corrosion

and erosion damage was most severe

achieved the desired result.

The focus on the oxygen system

came after a plant shutdown due to

loss of oxygen, and the owner gave

high priority to finding a solution to

assure higher safety and reliability

levels.

As a result, the original stainless

steel material in some portions of the

system handling high velocity oxygen

was replaced with Monel 400 material.

Non-materials modifications to the

oxygen system included adding new

lines and isolation valves to improve

system maintainability.

It involved replacing manual

valves with multi-stage restriction orifices

in each oxygen vent line, installing

new automatic valves, adding instrumentation

and controls for startup

and shutdown of the gasifiers.

Critical equipment

One major equipment upgrade to

achieve targeted RAM performance

was to replace a 23 MW electric motor

drive for the main ASU air compressor

with a more powerful unit.

The original motor had been repaired

after being severely damaged

when a cooling water leak caused an

insulation failure.

In the eyes of the owners and inspection

engineers, the incident and

subsequent repair left this critical

plant item unreliable.

The replacement compressor mo-

25 GAS TURBINE WORLD: January-February 2006

IGCC and Gasification

Proposed 500 MW pet-coke refinery project in the U.S.

Given EuropeÕs example of what can (and should) be done with refinery residuals, and the proven benefits of IGCC in a refinery application, there is growing interest in the U.S. for similar plants.

With new federal incentives for pet-coke IGCC plants now in place under the Energy Policy Act of 2005, plans have been announced for at least one plant and more can be expected to follow.

BP and Edison Mission Group (affiliate of Mission International) recently unveiled plans for a 500 MW pet-coke IGCC plant to be located at the BP refinery near Carson, California, south of Los Angeles. Plant startup date set for 2011.  This first-of-a-kind commercial-scale project will carry the IGCC theme one step further by featuring CO2 separation and sequestration in the form of injection into deep reservoirs for enhanced oil recovery.

Combined cycle power unit will be fired with near-pure hydrogen that will remain from the syngas after it is stripped of about 90% of the CO2 before the gas is fed to the modified gas turbine combustion system.

No information has been disclosed regarding the gasification or combined cycle suppliers. A final decision to go ahead with the proposed project is not expected until 2008.

GAS TURBINE WORLD: January-February 2006 25

tor is rated at 24.5 MW, providing

some margin over the original design.

It also has many electrical and mechanical

design upgrade features such

as titanium water-to-air coolers that

are corrosion resistant to the seawater

coolant.

On top of this, the cooling system

was redesigned in such a way as to

preclude seawater coming in contact

with the windings.

It also is equipped with an on-line

rotor telemetry monitoring system to

allow for thorough remote supervision

of all motor operating parameters.

Seaside air intake

Apparently the seaside location of the

plant was not fully taken into account

in specifying the gas turbine inlet air

filter to protect against salt air and

water ingestion. The original filter

lacked any special provisions for water

removal.

Since the face of the gas turbine

intake is only about 50 feet from the

shoreline, and the site is subject to

frequent winter storms and rough sea

conditions, salt water droplet carryover

into the gas turbine compressor

was quite predictable.

In addition, this environment

caused the particulate-capturing ability

of the filter media to deteriorate

over a short time.

Considering the availability target

set for the plant, the owners saw this

problem as serious enough to justify

replacing the original gas turbine inlet

filter with one specifically designed

for the plant site conditions.

Design requirements for the new

filter included inlet flow face velocity

not to exceed 2.7 meters per second,

high droplet removal efficiency using

a stainless steel demister section, a

two-stage coalescer section, a bagtype

pre-filter, and a last stage ÒfineÓ

filter.

The new filter was installed and

commissioned during the scheduled

combined cycle outage at the end of

2003, and its performance has been

reported as being highly satisfactory.

Lessons learned

Results of the three-year availability

improvement project carried out

at the Api plant are impressive and

were mainly implemented during the

first gas turbine major overhaul late in

2003.

After averaging only about 67%

during the first three years of commercial

operation, plant availability (as

measured by percentage of operating

hours relative to 8760 hours per year)

jumped to 94% in 2004.

This performance substantially exceeded

the 87% target and is indicative

of the potential improvement possible

in utilization and profitability.

The longer-term results, factoring

in planned outages and aging of the

new and modified equipment, will

likely be more in line with expectations.

This experience with commercialscale

plants in Europe demonstrates

that IGCC plants can operate at capacity

factors comparable to, if not better

than, conventional coal plants.

GAS TURBINE WORLD: January-February 2006 26

IGCC and Gasification

Financial

Project Sponsors Close Feed Products Financing

Puertollano, Spain . . . . . . . .EDF, Endesa, 1994 coal/coke 300 MW non-recourse Iberdrola ISAB Energy, Italy. . . . . . . . .ISAB, Mission Energy March 1996 asphalt 520 MW non-recourse (refinanced)

Api Energia, Italy . . . . . . . . .Api, ABB May 1996 visbreaker 280 MW non-recourse

(refinanced) tar and steam

Sarlux, Italy. . . . . . . . . . . . . .Saras, Enron Nov 1996 visbreaker 545 MW non-recourse

(refinanced) tar steam + H2

El Dorado. Kansas, US. . . . .Texaco 1996 petroleum 42 MW operating lease

coke and steam

Motiva, Delaware US . . . . . .Star Enterprise August 1997 petroleum 160 MW bonds

coke and steam

Coffeyville, Kansas US. . . . .Farmland, Texaco Dec 1997 petroleum 1,000 tpd bonds

coke ammonia

Singapore Syngas . . . . . . . .Texaco, Messer Dec 2000 heavy oil 54 mmcfd non-recourse

syngas

Select IGCC and Gasification Project Financings. These IGCC and gasification projects were privately project

financed, and in several cases refinanced, with non-recourse arrangements based on project quality and pro forma.

Source: Luke OÕKeefe, Burns & Roe

26 GAS TURBINE WORLD: January-February 2006