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
MORE INFO
Practical
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Gained in the
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the Great
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Gasification
Plant, April
2006
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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