u.s. doe gasification-based ccs projects: status...
TRANSCRIPT
National Energy Technology Laboratory
Gary J. Stiegel Director, Major Projects Division
U.S. DOE Gasification-based CCS Projects: Status Update
U.S. Energy-Related CO2 Emissions, 2012 Million Metric Tons
Source: “U.S. Energy Information Administration, Monthly Energy Review, Tables 12.1 -12.5 (May 2013), preliminary 2012 data, http://www.eia.gov/energy_in_brief/article/greenhouse_gas.cfm
CO2 Emissions by Major Fuel CO2 Emissions by Sector*
Coal, Oil, Gas are all large emitters Electric power is largest, but all
sectors contribute major shares
* Includes small amounts of CO2 from non-biogenic municipal solid waste and geothermal energy
2012 Total: 5299 2012 Total: 5278
Gasification Demonstration Project Summary Southern Co. IGCC
Summit IGCC Polygen Summit Texas Clean Energy CCPI-3 IGCC Polygen; EOR • Penwell, Ector County, TX • 600 MW (syngas); 400 MW (gross) power block; 200 MW (net) to electric grid 0.9 MM tonnes/yr urea • 90% CO2 capture ~2,630,000 tonnes CO2/year (2.0 MMT to EOR, 0.63 MMT to urea) • EOR: Permian basin oil fields • Operations: 2019 • Total Project: $3.85 billion; DOE share: $450 million
Southern Company CCPI-2 IGCC; EOR • Kemper County, MS • 582 MW (net) TRIG™ gasifiers, 2 Siemens combustion turbines, 1 Toshiba steam turbine • 67% CO2 capture (Selexol® process); ~ 3,000,000 tonnes CO2/year • Plant >86% complete. Peak construction labor - 6,121 • Operations: May 2015 • Total Project: $4.685 billion; DOE share: $270 million
HECA IGCC PolyGen Hydrogen Energy California (HECA) CCPI-3 IGCC Polygen; EOR • Kern county, CA • 300 MW (net), 1. MMT/yr Urea/UAN • 90% CO2 capture ~3,020,000 tonnes CO2/year (2.57 MMT to EOR, 0.45 MMT to urea) EOR: Oxy Elk Hills oil field • Operations: June 2020 • Total Project: $5 billion. DOE share: $408 million
Leucadia Leucadia Petccoke to Methanol & Hydrogen; EOR • Lake Charles, LA • 700 MM gal/yr methanol, 110 MMscfd Hydrogen • 89% CO2 capture (Rectisol®); 4,500,000 tonnes CO2/year • EOR: Denbury West Hastings oil field • Operations: December 2017 • Total Project: $436 million; DOE share: $261 million
Southern Company Services, Inc. CCPI-2 Advanced IGCC with CO2 Capture
Status Plant construction >86% complete; Peak
construction labor 6,122 CO2 off-take agreements signed Lignite mine in operation Subsystems commissioning in progress Combustion turbine startup: Sep 2013 Gasifier heat-up: 3Q 2014
Key Dates Project Awarded: Jan 30, 2006 Project moved to MS: Dec 5, 2008 NEPA Record of Decision: Aug 19, 2010 Initiate excavation work: Sep 27, 2010 Operations: May 2015
• Kemper County, MS • 582 MWe (net) with duct firing; 2 TRIGTM
gasifiers, 2 Siemens combustion turbines, 1 Toshiba steam turbine
• Fuel: Mississippi lignite • 67+% CO2 capture (Selexol® process);
3,000,000 tons CO2/year • EOR: Denbury Onshore LLC, Treetop
Midstream Services LLC • Total DOE Project: $2.01 B; DOE Share: $270
MM (13%) • Total estimated plant cost: ~$4.685 B
Kemper IGCC Update • First gasifier heat-up targeted for mid to late summer 2014 • Combined cycle expected in-service in summer 2014 • Current cost estimate assumes in-service date extension to May 31,
2015 Kemper Project Risks
• Labor costs & productivity • Adverse weather conditions • Shortages & inconsistent quality
of equipment & materials • Labor, contractor, or supplier delay • Non-performance under construction or other agreements • Start-up activities
Gasification Area
Liberty Mine
Treated Effluent Reservoir
Lignite Storage Dome Water Treatment Area
Gas Cleanup Area Ash Management Area
Combined Cycle Area
Copyright 2013 Mississippi Power Company
Liberty Belle Dragline
Inside the Boxcut
Copyright 2014 Mississippi Power Company
Combined Cycle Unit Performance Testing
Copyright 2013 Mississippi Power Company
Control Room
Summit Texas Clean Energy CCPI-3: Advanced IGCC-Polygen
• Penwell, Ector County, TX (greenfield) • 600 MWth (syngas); 400 MWe (CC plant); 200 MWe
(net) to grid; 0.82 MMTPY Urea Fertilizer – SFG-500 gasifiers (2 x 50%) – High H2 SGCC6-5000F combined cycle (1 x 1)
• Fuel: PRB sub-bituminous coal • 90% CO2 capture – ~2.63 MMTPY CO2
– 2.0 MMTPY to EOR; 0.63 MMTPY to Urea – 2-stage Water Gas Shift, Linde Rectisol ® AGR
• EOR: Permian Basin oil fields • Total DOE Project: $1.727 B; DOE Share: $450 MM (26%) • Total Plant Cost ~$3.85 B (all in)
Key Dates Project Awarded: Jan 2010 Air Permit; Dec 2010 NEPA Record of Decision: Sep 2011 Financial Close: Mid-Late 2015 Construction Start: Late 2015 Operations Start: 2019
Status Urea contract: 2011; CO2 contracts: 2011 PPA: Dec 2011; expired Dec 2013 & being renegotiated China Exim signed for debt financing MOU: Sep 2012 Currently negotiating with a number of firms for
engineering, procurement, and construction services; anticipating multiple contracts
Summit Texas Clean Energy
Permitted Air Emissions, metric tons/year
CO 1,064.000
Pb 0.018
NOx 204.300
PM 377.500
PM10 349.300
PM2.5 338.700
SO2 233.200
VOCs 35.900
Carbonyl sulfide 2.380
Formaldehyde 2.690
Hydrochloric acid 1.260
Hydrofluoric acid 0.750
Hg 0.009
NH3 329.300
H2S 2.900
H2SO4 13.200
ParticulateRemoval
SyngasCleanup
ShiftReactor
Gasifier
Generator
ElectricPower
ElectricPower
Heat RecoverySteam Generator
Air
Steam
Steam Turbine
StackSteam
Air
GasTurbine
Oxygen
SlagBy-product
Syngas
Solids
Generator
Nitrogen
HydrogenSeparation
Clean Syngas
Ammonia/UreaProduction
MercuryRemoval
Moisture
ASUPRB Coal ~5,252 TPD
Inert Slag ~410 TPD
CO2 (EOR) ~6,609 TPD CO2 (Urea)
~1,814 TPD
H2SO4 ~53 TPD
Granulated Urea ~2,483 TPD
Syngas Composition, %
Hydrogen, H2 91
Nitrogen, N2 6
Carbon Monoxide, CO < 3
Other < 1
Electricity Generation/Use, MWe
Faceplate (comb. cycle) 400
Site Conditions* -84
Auxilary Loads -120
Products -75
Duct Burner (on NG) +75
Net to Grid 196
*Factors: shaft limit, average 82o day and site elevation
Argon ~119 TPD
Quantities are in metric tons per day (TPD) except as otherwise indicated.
Summit Texas Clean Energy Annual Revenues (30-yr avg)
59.85% 18.81%
18.81%
1.72% 0.69%
0.43% 0.21% 0.18%
Revenues
UreaCarbon DioxidePowerArgonBrine WaterSlagNitrogenSulfuric Acid
Summit Texas Clean Energy, LLC Plant Site
Kinder Morgan CO2Interconnect Northwest Border of Pennwell Site (Facing East)
Hydrogen Energy California Advanced IGCC-Polygen
• Kern County, CA (greenfield) • Up to 300 MWe (net) with load following; 1.0 MMT/yr urea/UAN
– MHI oxygen-blown gasifier (1 x 100%) – MHI G-class air cooled combustion turbine (1)
• Fuel: Sub-bituminous coal/petcoke • 90% CO2 capture – 3,020,000 tonnes CO2/year
– 2.57 MM tonnes EOR; 0.45 MM Urea production – 2-stage Water Gas Shift, Linde Rectisol ® AGR
• EOR: Elk Hills oil field • Use of brackish water for power production; ZLD • Total DOE Project: $4.028 B; DOE - $408 MM (10%) • Total Plant Cost: ~$5 B
Key Dates Project Awarded: Sep 2009 New Owner, SCS Energy: Sep 2011 Financial Close: Jun 2015 Construction: Jul 2015 Start of Operation: Jun 2020
Status Power/Fertilizer/CO2/EPC discussions in
progress FEED completion: Apr 2013 Draft PSA/EIS: Jun 2013 Final Determination of Compliance (air permit):
Jul 2013
IGCC Poly-generation with Integrated Carbon Capture & Sequestration
HECA Plant Layout
HECA Site Location
Project Site
Power Line CO2 Pipeline
Elk Hills Oil Field
Bakersfield 20 miles northeast
Water Wells
Process Water Line
Leucadia Energy, LLC ICCS Area 1 Petcoke Gasification to Methanol
• Lake Charles, LA • GE Energy Gasification (4 gasifiers: 3 hot/1 spare) • 700 MMgal/yr methanol; 110 MMSCFD H2
• Fuel: Petcoke • 89% CO2 capture (Rectisol® process);
4,500,000 tonnes CO2/year • CO2 to Denbury pipeline for EOR in Texas
at West Hastings oil field • Total Project: $436 MM; DOE Share: $261
MM (60%) Key Dates Phase 2 awarded: Jun 17, 2010 Complete CCS FEED: Jul 2011 NEPA ROD: Dec 2013 Financial close: Jul 2014 Construction: Jul 2014 Operation: Dec 2017
Status Product off-take contracts finalized (BP,
APCI) Record of Decision – Issued Dec 2013 FEED in progress for gasification plant
Leucadia Site
Site preparation and drainage - Completed
Current Site Cleared
Site to be raised to 10 Ft above Sea Level (Post Rita Flood Level)
Panoramic View of Current Site Cleared Looking South
• Carbon mandates/monetization would be beneficial • Government financial incentives not a panacea • Initial estimates of project costs are overly optimistic
– Costs increase as project develops through FEED and construction; Labor markets are critical
– Do more value and detailed engineering during FEED • Fixed price EPC contracts are difficult
– Volatile labor market requires Large contingencies – Availability of cranes and other heavy equipment
• Construction schedules need to be realistic • Reaching financial close for debt and equity financing takes
longer than expected. • Permitting of CO2 storage for geologic sequestration or EOR
is potentially problematic
Observations/Lessons Learned
Be Conservative!!!!
For Additional Information
Office of Fossil Energy www.fe.doe.gov
NETL www.netl.doe.gov
Gary J. Stiegel 412-386-4499