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PRENFLO PSG and PDQ Latest Developments based on

Decades of Gasification Experience

Fourth International Conference on Clean Coal Technologies CCT 2009 3rd International Freiberg Conference on IGCC & XtL Technologies

Dresden, Germany 18-21 May 2009

Dr. Stefan Hamel, Uhde GmbH, Germany

http://www.cct2009.org/

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Does Gasification make any sense @ ~50 US$/bbl?

Yes, because

• Gasification feedstock is unrelated to short-term oil price volatility

• Gasification is a poly-generation technology

• Gasification enables power generation with CCS

• Gasification is clean, efficient, and well-proven

• and...

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Energy Reserves (billion tons, oil equivalent)

• ...Gasification applies sustainable resources

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Uhde‘s Gasification Highlights – SUMMARY:

Development, Design and Construction of

first Koppers-Totzek Coal Gasification Plant

first Texaco Coal Gasification Plant

first HTW Coal Gasification Plant

first Shell-Koppers Coal Gasification Plant

first PRENFLO Coal Gasification Plant

Over 100 Gasifiers designed, built and put into successful operation by Uhde

Invention of Entrained-Flow Gasification:

Koppers-Totzek: dry-fed, membrane wall, multiple burners (1941)

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Uhde‘s proprietary Koppers-Totzek Gasification Process First Entrained-Flow Gasification Technology

Koppers-Totzek gasification plant Modderfontein, South Africa

1,000 t/d of ammonia

Koppers-Totzek gasification plant Ramagundam, India 900 t/d of ammonia

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HTW coal gasification plant Berrenrath, Germany

1,000 t/d of ammonia

GE (Texaco) coal gasification plant Oberhausen, Germany hydrogen, oxochemicals

First GE (Texaco) Coal Gasification Plant with radiant cooler First HTW Coal Gasification Plant in commercial-scale

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First PRENFLO Demonstration Plant – 1980‘s

PRENFLO plant in Fürstenhausen / Germany

8World‘s largest single-train IGCC: PRENFLO Gasification Elcogas, Puertollano, Spain

Feedstock: petcoke / coal with addition of biomass

PRENFLO Gasifier

Gas Treatment

Coal PreparationASU

Combined Cycle

New CO2 capture Pilot Plant under implementation

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PRENFLO gasifier and waste heat boiler (PSG)

• dry coal/petcoke powder feed• 4 horizontal co-annular burners• membrane wall• waste heat boiler (PSG)

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PRENFLO Membrane Wall protected by the slag layer

BFW, 40-70 bar

Water Tube(membrane wall)

Gasification Reactor

> 1500 °C

molten slag flows downwards

solidified slagmolten slag

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PRENFLO Gasifier Membrane Wall

View to gasifier membrane wall after operation (PRENFLO burner)

View to gasifier membrane wall before 1st operation (PRENFLO burner)

Perfect slag layer protecting membrane wall

12PRENFLO Gasifier - erection of internals (Puertollano)

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Lifting of PRENFLO Gasifier / HP-Boiler (Puertollano)

14Puertollano IGCC: Operating Experience

General

Gasification is flexible with broad range of solid fuelshigh-ash hard coal and petroleum coke

addition of biomass successully demonstrated

Flexible load change behaviourNearly constant gas heating value irrespective of fuelNo formation of higher hydrocarbons, methane < 0.1 vol. %Non-leachable slag productionFly ash sold to cement industryElcogas statistics show that the vast majority of down-times was caused by non-gasifier related issues

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PRENFLOwith Direct Quench

PDQ

16The PRENFLO process with Direct Quench (PDQ)

TargetsIntegrate Lessons Learned from >10 years operation of Puertollano IGCC

Optimize PRENFLO technology for chemical and hydrogen applications

Identify areas of significant Capital Cost Reduction

Water Quench instead of Gas Quench and Waste Heat Boiler

Keep commercially proven elements of PRENFLO technology

Design of a robust system

17The PRENFLO process with Direct Quench (PDQ)

Process characteristicsPressurized entrained-flow gasification

Dry coal dust feeding

Multiple co-annular burners (horizontal, tangential arrangement)

Membrane Wall, no refractory

Operation pressure flexible to requirementsapprox. 25 - 40 bar

Raw gas temperature outlet of quenchapprox. 200 - 250 °C

Slag lock-hopper system

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Slag

Feed,oxygen

Waste heat boilers

Raw gas(incl. fly ash)

Raw gas

Slag

Feed,oxygen

PRENFLO gasifier with Direct Quench (PDQ)

PRENFLO gasifier with Steam Generation (PSG)

Direct Quench

Feed,oxygen

Raw gas

Samegasifier design

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PRENFLO with Direct Quench

1000 MWth , 40 bar

PRENFLOTMwith

Direct Quench

PDQ

© Uhde 2008

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Raw Gas

S/G=1.3

PSG Gasifier Gas Quench

Waste H. Boiler

FAFilter

Scrubber

CO-Shift

Saturator H2 Gas

Steam

Raw gas

S/G=1.3

PDQ Gasifier Direct Quench

Scrubber CO-Shift

H2 Gas

Steam

PSG:

PDQ:

PRENFLO PSG vs. PRENFLO PDQ Impact on Cost: Process Configuration (e.g. H2 plant)

substituted by Direct Quench

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PRENFLO PSG vs. PRENFLO PDQ Impact on Cost: Plant Layout

PRENFLO (PDQ)

PRENFLO (PSG)

EPC cost savings: ~30 %

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-4,0%

-3,5%

-3,0%

-2,5%

-2,0%

-1,5%

-1,0%

-0,5%

0,0%

0% 20% 40% 60% 80% 100%

shifted gas fraction

Δ o

f ele

ctric

effi

cien

cy [%

-poi

nts]

• CTC• CTL • IGCC-CCS

PRENFLO PSG vs. PRENFLO PDQ Impact on Efficiency

IGCC H2

In the targeted applications, PDQ is -1.0 to -1.8 %-points lower than PSGthis low impact does notjustify the higher capital costof a waste heat boiler design

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February 2009:New Co-operation Agreement Elcogas ~ Uhde

• Extensive integration of Operating Experience with technology and engineering know-how

• Joint implementation of R&D projects• Platform for plant reliability, operator training,

operating and maintenance services• Regular exchange and presence on site

24One of the latest projects: TransGas Coal-to-Liquids Complex (18,000 bpd)

2 x PRENFLO Gasification with MTG based on Coal

Mingo County, West Virginia

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Summary

Gasification will play an increasingly important role in our future. Oil and gas supply and demand do not match any longer.

February 2009: Co-operation Agreement signed between Elcogas and Uhde: Operating experience and engineering fully integrated into PRENFLO

Lessons Learned from >10 years operation of the Puertollano plant and decades of experience in coal gasification and all related down-stream processes provide full benefit to successful future projects

As a technology-driven engineering company, Uhde can act as integrated Licensor, E, EP or EPCM contractor – PRENFLO is a product

Depending on the application, PRENFLO is available with conventional steam generation (PSG) or direct quench mode (PDQ) with significant cost savings

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Thank you for your attention.

PRENFLO IGCC, Puertollano, SpainMay 2009 www.prenflo.com

Slide Number 1Does Gasification make any sense �@ ~50 US$/bbl?Slide Number 3Uhde‘s Gasification Highlights – SUMMARY:Uhde‘s proprietary Koppers-Totzek Gasification Process�First Entrained-Flow Gasification TechnologyFirst GE (Texaco) Coal Gasification Plant with radiant cooler�First HTW Coal Gasification Plant in commercial-scaleFirst PRENFLO Demonstration Plant – 1980‘s World‘s largest single-train IGCC: PRENFLO Gasification Elcogas, Puertollano, Spain�Feedstock: petcoke / coal with addition of biomassPRENFLO gasifier and waste heat boiler (PSG)PRENFLO Membrane Wall protected by the slag layerPRENFLO Gasifier Membrane WallPRENFLO Gasifier - erection of internals (Puertollano)Lifting of PRENFLO Gasifier / HP-Boiler (Puertollano)Puertollano IGCC: Operating ExperienceSlide Number 15The PRENFLO process with Direct Quench (PDQ)The PRENFLO process with Direct Quench (PDQ)PRENFLO gasifier �with Steam Generation (PSG)PRENFLO �with Direct Quench��1000 MWth, 40 bar �Slide Number 20Slide Number 21Slide Number 22Slide Number 23One of the latest projects:�TransGas Coal-to-Liquids Complex (18,000 bpd) �2 x PRENFLO Gasification with MTG based on CoalSummarySlide Number 26