IGCC: Towards zero emissions power plants

1. Conference on Clean Coal and Carbon Capture and Storage Technologies 2nd and 3rd December, 2013 at Trichy (India) IGCC: Towards zero emissions power plants Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain

2. Index • The ELCOGAS company • Puertollano IGCC power plant • Future of IGCC technology • ELCOGAS R&D investment plan • Conclusions

3. Index • The ELCOGAS company • Puertollano IGCC power plant • Future of IGCC technology • ELCOGAS R&D investment plan • Conclusions 3

4. The ELCOGAS company ELCOGAS is an Spanish company established in April 1992 to undertake the planning, construction, management and operation of a 335 MWeISO IGCC plant located in Puertollano (Spain) Shareholders Puertollano Puertollano IGCC Plant REPSOL refinery ENCASUR (open cast coal mine)

5. Index • The ELCOGAS company • Puertollano IGCC power plant • Future of IGCC technology • ELCOGAS R&D investment plan • Conclusions

6. Combined cycle Gasification ASU Description of the Puertollano IGCC process

7. General view of the Puertollano IGCC plant Air separation unit Gasifier Fuel preparation Combined cycle Laboratory and water treatment Clean-up of gas CO2 capture 7

8. RAW GAS CLEAN GAS Real average Design Real average Design CO (%) 59.26 61.25 CO (%) 59.30 60.51 H2 (%) (%) H2 21.44 22.33 21.95 22.08 CO2 (%) CO2 (%) 2.84 3.70 2.41 3.87 N2 (%) N2 (%) 13.32 10.50 14.76 12.5 Ar (%) 0.90 1.02 Ar (%) 1.18 1.03 H2S (%) H2S (ppmv) 0.81 1.01 3 6 COS (%) 0.19 0.17 COS (ppmv) 9 6 HCN (ppmv) 23 38 HCN (ppmv) - 3 Description of the Puertollano IGCC process Fuel design values Fuel design is a mixture 50/50 of coal/coke which now is 45/55. Moreover some tests with biomass wereundertaken (meat bone meal, grape seed meal, olive oil waste). With those fuels at 50:50, the whole plant demonstrated a gross efficiency of 47.2% and a net efficiency of 42%, under acceptance tests in 2000 year Syngas composition

9. Operational data:Annual energyproduction 1st 5 years: Learning curve 2003: Major overhaul Gas Turbine findings 2004 & 2005: Gas turbine main generation transformer isolation fault 2006: Gas turbine major overhaul & candle fly ash filters crisis 2007 & 2008: ASU WN2 compressor coupling fault and repair MAN TURBO 2010: No operation due to non-profitable electricity price (30-40 days). 2011: 100,000 EOH Major Overhaul 2012: 1,498 hours in stand-by due to regulatory restrictions. (3,969 in 2013)

10. Operational data: Emissions 2012 Natural gas (NGCC) Coal gas (IGCC) ELCOGAS power plant emissions in NGCC & IGCC modes

11. Operational data: Variable costs 2012 Note: Net energy variable costs (average 2012)

12. Index • The ELCOGAS company • Puertollano IGCC power plant • Future of IGCC technology • ELCOGAS R&D investment plan • Conclusions 12

13. CO + H2O CO2 + H2 H2/CO2 SEPARATION Future of IGCC technology • Multi-fuel (coal, biomass, wastes) • Multi-product (H2, electricity, liquid fuels, chemicals) • CO2capture and storage COAL + BIOMASS + WASTES COMBINED CYCLE GAS CLEAN UP XtL Alternative Fuel & Chemicals GASIFICATION Potential demonstrating of new process with synthesis gas partial flow. H2 CO2

14. SECONDARY PRODUCTION H2: WATER-GAS REACTION CO2 CO2 CAPTURE & H2PURIFICATION PROCESS GASIFICATION PREPARATION H2 H2 Production by coal gasification Future of IGCC technology Step 1: Syngas production from Gasification Carbon compound + O2 + H2O CO + H2 + Impurities 400-1600ºC 10-40 bar Step 2:Conditioningfly ash removal, particles and sulphur comp. • Fly ash • Char • Cl- • CN- • SH2 • COS • CO2 • N2 … Step 3: “Shifting”orwater-gas reaction CO + H2O CO2 + H2 Step 4: H2 and CO2 separation H2 CO2 & H2 production from fossil fuels involves CO2 generation  To talk about “clean” H2 it is required to consider CCS

15. Index • The ELCOGAS company • Puertollano IGCC power plant • Future of IGCC technology • ELCOGAS R&D investment plan • Conclusions 15

16. ELCOGAS R&D investment plan • PUERTOLLANO IGCC ACTIVITIES: • Based on the opportunity that an IGCC plant represents • Can be relevant in: • climate change mitigation • energy supply reliability In 2007 a R&D investment plan was elaborated and results are yearly reported to Spanish authorities for evaluation. Its 6 master research lines are: Diversification of raw fuels and products CO2 emission reduction in utilization of fossil fuels H2 production by gasification of fossil fuels IGCC process optimization Other environment improvements Dissemination of results

17. ELCOGAS R&D investment plan Dissemination of results • Forum participations. CO2, H2, and sustainability associations and Technological Platforms. European and Spanish.Coordinating working groups in Technological Spanish Platforms. • Participation in conferences, seminars, congresses. • Consulting services.Germany, China, Chile • Attending and promoting technical visits.Generally international visits.

18. ELCOGAS R&D investment plan Optimization of IGCC process Oriented to improve availability & costs Elimination of membrane water leakages at reaction chamber Test materials Ceramic filters Gasifier materials/Syngas corrosion processes

19. ELCOGAS R&D investment plan Other environmental improvements • Liquid wastes reduction (Zero Liquid Discharges).Installation of a new liquid waste treatment plant (evaporation – crystallization). • Improvements in the dry dedusting system. • Improvements in SulphurRecovery plant. • In progress several modifications to improve availability and to reduce S emissions. • Optimization of additives parameters. • Internal research for improve the quality of subproducts • Emissions reduction during start up and other transitory situations. Overview of the new ZLD plant Overview of the test rig for mercury and carbonyls analysis

20. ELCOGAS R&D investment plan Diversification of raw fuels and products • Project FECUNDUS (RFCS-CT-2010-00009, 2010-2013) • Selection of biomass and undertake real co-gasification test (2 and 4 % in weight of biomass) for asset its influence in CO2 capture process. • Project PIIBE (ESP-CENIT). • To impulse biofuels technologies in Spain. ELCOGAS has coordinated the subproject about biodiesel from gasification by real co-gasification 10% of biomass and syngas characterization (F-T process in laboratory). • Meat and Bone Meal (MBM) co-gasification test (2001) • Possibility to install a pilot plant in IGCC of Puertollano to develop process to obtain gasoline / dieselfrom syngas • Availability to undertake tests of gasification of different fuels at large scale to help in design of new IGCC plants Pre-selected biomasses Biomass yard

21. ELCOGAS R&D investment plan Diversification of raw fuels and products Biomass selection criteria: Size < 25 mm Humidity < 12 % Price < 150 €/t Availability in large quantities Critical parameter for biomass selection was the behavior on the ELCOGAS grinding system Load during 8% olive oil waste co-gasification test

22. ELCOGAS R&D investment plan H2 production and CO2 emission reduction • Clean H2 production by gasification of fuels • Collaboration in several projects (HYDROSEP (UE-RFCS) and SPHERA (ESP-CENIT) • H2 production optimization using the CO2-H2 Pilot Plant • Possibility to collaborate with The National Center for Hydrogen “CNH2” (SPAIN) • CO2 Emission reduction • IGCC Efficiency Optimization • Analysis of viability to improve efficiency based on Critical Assessment of Puertollano IGCC design. • Auxiliary consumption optimization. New revision • Development of tools to improve efficiency. Supervision on line of main (120) equipment efficiency. Installed and in tests • Integration optimization. Improvement of controls to adjust heat & mass balances in real operation • And • CO2 capture for CCS with IGCC

23. ELCOGAS R&D investment plan – Line CO2 PSE-CO2 project TARGETS To demonstrate the feasibility of capture of CO2 and production of H2 in an IGCC that uses solid fossil fuels and wastes as main feedstock. To obtain economic data enough to scale it to the full Puertollano IGCC capacity in synthetic gas production. PARTICIPANTS & BUDGET ELCOGAS – UCLM – Ciemat – INCAR CSIC 14.5 M€ (initially 18.5 M€) COORDINATED Project of pilot plant in an existing IGCC of Puertollano (pre-combustion technology) is part of a Spanish national initiative, “Advanced technologies of CO2 conversion, capture and storage” and it is coordinated with other related projects: Project # 2 is to explore oxyfuel combustion to be applied in the construction of a pilot plant (20-30 MW) to be built in El Bierzo, NW of Spain. CIUDEN Project # 3 is to study and regulate geological storage in Spain. IGME Project # 4 is to study public awareness of CCS technologies. CIEMAT

24. PRENFLO Gasifier Coal preparation ASU Combined Cycle New CO2 capture pilot plant Sulphur Recovery ELCOGAS R&D investment plan – Line CO2 Puertollano IGCC power plant and pilot plant location

25. CO2 capture & H2 productionPilot plant Recycle compressor COAL + COKE Syngas Raw gas COMBINED CYCLE FILTRATION SYSTEM PURIFICATION & DESULPHURATION GASIFICATION 2% 2% H2 rich gas 37.5 % CO2 50.0 % H2 3.0 % CO +H2S (1.44%) CO2 100 t/d Raw H2 (80% of purity) IP STEAM 40% CO2 & H2 separation (Chemical, aMDEA) Tail gas 1.3 bar SHIFTING REACTORS SWEET /SOUR HYDROGEN PURIFICATION (PSA) CO + H2O → CO2 + H2 Pure H2 (2 t/d) 99.99% H2 @ 15 bar

26. Consejería de Educación, Ciencia y Cultura CO2 capture & H2 productionPilot plant • Installation unique in the world: 14 MWt pre-combustion technology integrated in an existing IGCC. • 3 step process: shifting unit, CO2/H2 separation by chemical absorption, and H2 purification by PSA. All technology used is commercial. • 100 t/d of CO2 are captured and 2 t/d of pure H2 are produced • In service since October 2010. Operation is intermittent, linked to official Research projects, collaborations and internal research campaigns. • 1,017 hours of operation accumulated. • Cost of construction (equipment & services): 13.5 Million € • No storage is foreseen PSA adsorbers CO2 absorber Control room CO2 stripper WGS reactors 26

27. CO2 capture & H2 production Conclusions The carbon capture pilot Project has been a success: first of its kind in the world, >90% capture rate achieved and CO2 capture cost can be <30 €/t Commercial technologyat any scale is available: the singularity comes from “integration in a existing IGCC plant” Tests carried out show room for improvement in operating conditions and optimization of energy balance. Carbon capture cost estimations come from figures of a real project. From now on, the pilot is being used for internal research But it is also open for international research projects and for other kinds of collaboration

28. Fuel preparation Combined cycle Gasification Filtration and wet scrubbing Unit ofCO2 capture Desulphurization and sulphur recovery S CO2 Combined cycle Fuel preparation Unit of CO2 capture Gasification Filtration and wet scrubbing CO2 + H2S CO2 capture & H2 production Results and learning CO2 capture in IGCC plants • With SWEET catalyst • With SOUR catalyst (1.5%) Based on our CO2 capture pilot plant, we have scaled the cost of a CO2 capture unit at scale 1:1 about 350 M€. Approximately, it represents the cost of the desulphurization and sulphur recovery units in an IGCC w/o CO2 capture. By installing an IGCC with CO2 acid capture to store or use CO2 together with ~1.5% H2S, the investment costs are similar to those w/o CO2 capture. And the only penalty is the decreasing efficiency: From 42 33%currently and from 50 44% near future 28

29. Index • The ELCOGAS company • Puertollano IGCC power plant • Future of IGCC technology • ELCOGAS R&D investment plan • Conclusions

30. Conclusions IPCC Unless greenhouse gas emissions are cut by 50-80% by 2050 (especially CO2), the impact of global warming can be disastrous. World energy demand Expect to be doubled by 2050. We must act fast using a portfolio of solutions (energy efficiency improvement, renewables & CCS) to reduce CO2 emissions in the required massive scale • IGCC technology can contribute to this aim because: • Existing IGCC plants are an opportunity to develop cleaner electricity with fossil fuels, so next IGCC generation must learn from them • IGCC is a promising technology with the minimum variable costs and the best environmental performance and it can be adapted to multifuel and polygeneration • Main burden for IGCC technology deployment is high investment requires a long term regulatory frame 30

31. Conference on Clean Coal and Carbon Capture and Storage Technologies 2nd and 3rd December, 2013 at Trichy (India) IGCC: Towards zero emissions power plants Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain THANK YOU FOR YOUR ATTENTION 31