welcome. safety first safety tip for the day big bend station1900 mw 4 coal fired steam units tampa...
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Welcome
SAFETY FIRST
Safety tip for the day
• BIG BEND STATION 1900 MW4 Coal fired steam units
TAMPA ELECTRIC GENERATION
•BAYSIDE POWER STATION 1800 MWRepowered NGCCOne 3 on 1One 4 on 1
•POLK POWER STATION 650 MWOne IGCCTwo Peaking CT’s
•PHILLIPS POWER STATION 36 MWTwo slow speed diesels ________
TOTAL CAPACITY (approx) 4400 MW
• UNIT 1 IGCC, Base load on syngas, intermediate on oil Combined cycle, GE 7F, 7221 192MW
GE D11, steam 120MW Dual fuel, Syngas/Distillate Oil DOE Clean Coal Technology co-funding $120M In service 1996
POLK POWER STATION
•UNIT 2, 3, 4 & 5 Simple Cycle CT, PeakingSimple cycle GE 7FA+E, 7241 165 MW each2 & 3 Dual fuel, Nat gas/Distillate Oil; 4 & 5 Nat Gas onlyUnit 2 in service 2000, Unit 3 2002, Units 4&5 2007
•Total site over 4000 acres (previously mined for phosphate)750 acre cooling pond80 Tampa Electric employees
• Gasification technology originally developed by Texaco, now owned by General Electric• Oxygen blown, slurry fed, entrained flow gasifier• Operating pressure 400 psi nominal• Gasifier vessel refractory lined (largest built)• Radiant plus convective syngas coolers for heat recovery• Single train configuration (one gasifier supplying one CT)• CT is GE 7F w/ MNQC combusters, larger 1st stage nozzle• Diluent N2 plus syngas saturation for NOx control• Modest air extraction rate from CT to ASU• Feedstock is 2200 tons/day coal and petroleum coke blend• ASU by Air Products, 2100 tons/day oxygen production• Sulfuric acid plant by Monsanto, (unique to Florida)• Acid gas removal via MDEA and COS hydrolysis
POLK 1 – Technology Summary
AERIAL PHOTO
ADMINISTRATIONCONTROL
YOU ARE HERE
NOXYGEN PLANT
GASIFIER STRUCTURECOAL SILOS
SLURRY PREPARATION
SULFURIC ACID PLANT
HRSG
UNIT 1 CTSTEAM TURBINEUNIT 2 CTUNIT 3 CT
UNDER CONSTRUCTION
,
Main AirCompressor
32 MW
Dryers
Coal &Pet Coke2300 TPD
Rod Mills
Water &Recycled Char
SlurryTanks
SlurryPump
ProductCompressors
18 MW
Oxygen2100 TPD
ColdBox
LockhopperChar &
Slag
Char & Cl
Compressor Turbine
Combustor
Generator192 MW
CleanStackGas Air
Condenser
CondensatePump
1600 psigSaturated
Steam
7000 KSCFHClean Syngas
Diluent Nitrogen5250 TPD
RadiantSyngasCooler
Gasifier
SyngasCooler
Final Filter
CoolingWater
MDEA Acid Gas RemovalAcid GasH2S + CO2
CoolingWater
55 psigSteam
EconomizedBoiler
Feedwater
BFW Pump
Heat RecoverySteam Generator
(HRSG)
Generator123 MW
Steam Turbine
Raw Syngas
COSHydrolysis
(COS H2S)
Convective
CombustionTurbine
Saturator
WaterScrubbers
400psigSteam
450 gpmSlurry
Backup/StartupDistillate Fuel
To SulfuricAcid Plant
LPSteam
BFW
Overall Flowsheet
LOW EMISSIONS FROM
LOW COST FEEDSTOCKSFOR
LOW COST ELECTRICITY
IGCC DRIVER
POLK 1 PERFORMANCEENVIRONMENTAL
• Polk rated the “Cleanest Coal Fired Power Plant in North America” by the Energy Probe Research Foundation
(total emissions from 2002 TRI data)
LOW EMISSIONS
Typical Emissions (Lb/MMBTU)
Polk Polk Expected (Permit) (Steady State) New IGCC
SO2 0.14 0.12 0.02
NOx 0.055 0.04 0.02 (w/SCR)
Particulate 0.007 <0.004 0.007
Mercury NA NA 90% removal
(New IGCC values are basis 8,800 hhv btu/kwh net)
•Beneficial Reuse of Sulfur – H2SO4 at Polk•Beneficial Reuse of Slag•Low Water Use (2/3 that of PC unit)•Minimal solid waste (no gypsum from FGD)•Zero Process Water Discharge
OTHER ENVIRONMENTAL ADVANTAGES
ENVIRONMENTAL OPPORTUNITIES
Mercury - Cost-Effective Removal on IGCC using small activated carbon bed
( $0.25/MWh vs. $3.10/MWh for PC)
• Testing done at Polk
• Commercially at Eastman to 95+%
Other Volatile Metals – Will also be removed by carbon bed
ENVIRONMENTAL OPPORTUNITIES
CO2 Removal
Solvents used for sulfur removal can also remove CO2 (more cost effective due to <1% volume)
For New Solid Fuel Power Plants (EPRI estimates)
25% Higher COE with IGCC
50% + Higher COE with PC
CO2 Sequestration
Saline aquifer injection – USF feasibility study
FUEL FLEXIBILITY• Polk has operated on over 20 different fuels including: Coals
Coal BlendsCoal/Pet Coke BlendsCoal/Coke/Biomass Blends
• Slagging gasifier requires somewhat higher fusion temps (Polk targets 2350 – 2700 F T-250 temps)
• Low rank fuels can be used in slurry fed gasifiers, but hurt efficiency
• Power block can operate on syngas or distillate oil
RELATIVE FUEL PRICES AT POLK
• 40% Coal/60% Pet Coke Blend 1.0
• Pet Coke 0.7
• Coal 1.5
• Natural Gas 3.6
• Low Sulfur Oil 6.0
LOW COST FEEDSTOCKS
RENEWABLE FUELS
BIOMASS CO-UTILIZATION TESTS
• Eucalyptus Biomass Test - December, 2001
• Bahiagrass Biomass Test - April, 2004 (Bahiagrass Harvest and Storage Test started approximately one year prior)
• No impact on syngas quality or emissions
• Minor issues with material handling
REPRESENTATIVE COSTS
Fuel processing costs per mmbtu fuel input(Excludes combined cycle costs)
Fuel $1.62O&M $0.96“Controllable Expense” $2.58A&G, Depreciation, Taxes, etc $1.06Solid Fuel Processing Cost $3.64
For Natural Gas Comparison, Multiply by heat rate ratio: $3.64 X 9,500 / 7,000 = $4.93
Current Natural Gas Price: $8.00 +/-
KEY AVAILABILITY STATISTICS
Polk Unit 1 IGCC Factors
0
10
20
30
40
50
60
70
80
90
100
96 97 98 99 00 01 02 03 04 05 06
Year
Ho
urs
/ P
eri
od
Ho
urs
x 1
00
CT On Syngas Early CT Fleet Issues CT Availability Early CT Fleet Issues
TEC’s ADVANCMENTS of IGCC
• Refractory life extension to 3 years
• Successful integration of fines recycle
• NOx below 15ppm with diluent N2 and saturation
• Successful zero process water discharge system
• Air extraction/integration with GE 7F turbine
• IGCC use with sulfuric acid plant with variable %
• Leader in clean coal power production > 13M gwhrs
• IGCC ambassadors, 4000+ visitors
• HIGHER INSTALLED COST – TRUE Current estimates are 10 – 20% higher than SCPC unit with scrubber and
SCR. This is offset by lower fuel cost and reduced emissions.
• NO SINGLE SUPPLIER OR OVERALL PERFORMANCE
GUARANTEE – NO LONGER TRUE Alliances GE/Bechtel and Conoco/Phillips-Fluor are offering comprehensive
EPC contracts with performance guarantees.
• NO FINANCIAL REWARD FOR SUPERIOR
ENVIRONMENTAL PERFORMANCE – SOMEWHAT TRUE IGCC is capable of lower emissions than other coal based technologies and
will be the most cost effective at mercury and CO2 removal. Anticipated
environmental regulations will define financial value.
PERCEPTIONS AND MISPERCEPTIONSREGARDING IGCC
PERCEPTIONS AND MISPERCEPTIONSREGARDING IGCC (cont’d)
• IGCC HAS LOW AVAILABILITY – NOT TRUE Overall reliability of the power block is higher than other “coal-fired” units
(95%). The dual fuel capability of IGCC adds significant value. Gasifier
reliability (currently low 80%), will be higher for next generation, dual train
plants.
• IGCC IS EXPERIMENTAL AND REQUIRES UNIQUE SKILLS
– NOT TRUE Gasification has been used since the 1800’s and there are hundreds of gasifiers
operating worldwide. The first generation IGCC plants have now been in
service for 10 years.
Tampa Electric (a modest size electric utility) has successfully operated and
maintained the Polk Unit 1 IGCC since 1996.
POLK UNIT 6• TEC is planning for the addition of a 630 MW IGCC unit in 2013.
• Preliminary engineering and preparations for permitting and regulatory approval are in progress.
• TEC has been awarded a $133.5M tax credit under the Energy Policy Act of 2005 for Polk 6.
• Expected configuration is two gasifiers feeding two CT’s with one ST. Minimum scale up (same size gasifiers as Polk 1).
• Allowances made in design for addition of CO2
capture and sequestration equipment.
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