Industrial Size Gasification Applications Industrial Size Gasification Applications Using the BGL 1000 Gasifier ModuleUsing the BGL 1000 Gasifier Module

2006 Gasification Technologies Conference2006 Gasification Technologies Conference

October 1-4, 2006Washington, DC

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Study Sponsored by Department of Energy Study Sponsored by Department of Energy -- National National Energy Energy Technology Laboratory Technology Laboratory

This study was performed under US DOE Contract NO. DE-AC26-04NT41817

Jeffrey Hoffmann, DOE Project ManagerPhone Number: 412-386-5134

Gary Stiegel, DOE Technical Manager GasificationPhone Number: 412-386-4499

US DOE has an Industrial Gasification Assessment currently in the Stakeholder Discussions under the direction of Don Bonk, Industrial Gasification

AgendaAgenda

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• Industrial Energy Markets– Natural Gas– Electricity

• BGL 1000 Gasifier Module

• Applications Evaluated– Syngas– Syngas with hydrogen extraction– Substitute Natural Gas (“SNG”)– Small power

• Conclusions

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Industrial Energy Markets

Projected 2006 U.S. Natural Gas Consumption by SectorProjected 2006 U.S. Natural Gas Consumption by Sector

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Based on DOE/EIA AEO2006 Reference Case Data

~21,000 Trillion Btu Total

ResidentialElectric Power

CommercialIndustrial

5,160 (25%)5,290 (25)%

7,500 (36%)

3,010 (14%)

U.S. Industry Natural Gas Consumption as Fuel by Region U.S. Industry Natural Gas Consumption as Fuel by Region -- 20012001

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U.S. Industry Natural Gas Consumption as Fuel by Sector U.S. Industry Natural Gas Consumption as Fuel by Sector -- 20012001

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Projected 2006 U.S. Electricity Consumption by SectorProjected 2006 U.S. Electricity Consumption by Sector

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Based on DOE/EIA AEO2006 Reference Case Data

~3.72 Million GW-hrs Total

Residential

Other 0.04 (0.01)

Commercial

Industrial1.35 (36%)1.04 (28)%

1.29 (35%)

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U.S. Industry Annual Net Electric Energy Consumption by U.S. Industry Annual Net Electric Energy Consumption by Region Region -- 20012001

~110,000 MW (15,300 MW On-site)

U.S. Annual Net Electric Energy Consumption by Industry U.S. Annual Net Electric Energy Consumption by Industry -- 20012001

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BGL 1000 Gasifer Module

Allied Syngas Corporation (ASC) BGL 1000 Gasifer ModuleAllied Syngas Corporation (ASC) BGL 1000 Gasifer Module

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• ASC’s standard gasification module is the “BGL 1000”

– Producing a nominal 1,000 MMBtu/hr gasifier of clean syngas

– Syngas • ~ 337 Btu/SCF HHV

• ~ 60% CO; 30% H2; 6% CH4; 4% CO2

– Consuming a nominal 1,000 tons per day of coal

BGL Fuel FlexibilityBGL Fuel Flexibility

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• Washed or unwashed bituminous coals• Non caking to strongly caking coals• Ash: 0.5 to 21% wt; silica ratio 45 to 85• Moisture: 3 to 28% wt• Sulfur: 0.5 to 5.6% wt• Chlorine: up to 0.6% wt• Size: 2.0 x 0.25 inch• Coals can be changed while operating

Essentially all US coals can be used.

BGL 1000 Gasifier at SVZ in Schwarze PumpeBGL 1000 Gasifier at SVZ in Schwarze Pumpe

1420 m(66 ft)

Gasifier Overall Dimensions

• Inside diameter 12.0 ft

• Outside diameter 16.0 ft

• Height approx. 40.0 ft

58 m(190 ft)

0 m

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Applications Evaluated

Major Systems Comprising the Major Systems Comprising the Syngas ProductionSyngas Production Reference Plant Reference Plant

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Major Systems Comprising the Major Systems Comprising the Syngas and HSyngas and H22 CoCo--ProductionProduction Plant Plant

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Major Systems Comprising Major Systems Comprising SNG ProductionSNG Production Plant Plant

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Major Systems Comprising the Syngas to Power Plant

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BGL 1000 Estimated Performance (IL #6 Coal)BGL 1000 Estimated Performance (IL #6 Coal)

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Key Inputs:

Coal 1,145 t/d 1,118 MMBtu/hr

Oxygen 583 t/d 99.5 % purity

Steam 29.2 KPPH 510 psia 680 F

Outputs (MMBtu/hr):

Syngas Syngas/ SNG Syngas/Hydrogen Electric

Syngas 952 769 - -

Hydrogen* - 184 - -

SNG - - 791 -

Electric** - - - 400

Total 952 953 791 400

* Without water shift ~573 MSCFH, 13.75 MMSCFD** 117 MW net based on GE 6 FA combined cycle (35.8%, 9545 Btu/kWhr) with O 2 over the fence

ConclusionsConclusions

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• Industry natural gas demand of over 7,500 BCF annually

• Industry electric demand:• Over 110,000 MW annually• Including over 15, 300 MW existing on-site generation

• Over 100 industry plants were identified that had natural gas demand in excess of 1000 MMBtu/hr.

• Co-production involving syngas, hydrogen, SNG and power provide additional opportunities in certain markets

• Existing infrastructure can reduce capital costs and facilitate environmental permitting

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Allied Syngas Corporation400 Building435 Devon Park DriveWayne, PA 19087

WorleyParsons Group, Inc2675 Morgantown roadReading, PA 19607

U.S. Department of EnergyNational Energy Technology Laboratory626 Cochrans Mill RoadPittsburgh, PA 15236