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

2. 2 Index 1.The ELCOGAS company 2.Puertollano IGCC power plant 3.Future of IGCC technology 4.ELCOGAS R&D investment plan 5.Conclusions

3. 3 Index 1.The ELCOGAS company 2.Puertollano IGCC power plant 3.Future of IGCC technology 4.ELCOGAS R&D investment plan 5.Conclusions

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

5. 5 Index 1.The ELCOGAS company 2.Puertollano IGCC power plant 3.Future of IGCC technology 4.ELCOGAS R&D investment plan 5.Conclusions

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

7. General view of the Puertollano IGCC plant Fuel preparation Gasifier Clean-up of gas Combined cycle Laboratory and water treatment CO 2 capture Air separation unit 7

8. 8 Description of the Puertollano IGCC process Fuel design values Syngas composition Fuel design is a mixture 50/50 of coal/coke which now is 45/55. Moreover some tests with biomass were undertaken (meat bone meal, grape seed meal, olive oil waste). Real averageDesignReal averageDesign CO (%)59.2661.25CO (%)59.3060.51 H 2 (%) 21.4422.33 (%) 21.9522.08 CO 2 (%) 2.843.702.413.87 N 2 (%) 13.3210.5014.7612.5 Ar (%)0.901.02Ar (%)1.181.03 H 2 S (%) 0.811.01 H2SH2S (ppmv) 36 COS (%)0.190.17COS (ppmv)96 HCN (ppmv)2338HCN (ppmv) -3 RAW GASCLEAN GAS H2H2 N 2 (%) CO 2 (%) 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

9. 9 1 st 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 WN 2 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) Operational data: Annual energy production

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

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

12. 12 Index 1.The ELCOGAS company 2.Puertollano IGCC power plant 3.Future of IGCC technology 4.ELCOGAS R&D investment plan 5.Conclusions

13. Multi-fuel (coal, biomass, wastes) Multi-product (H 2, electricity, liquid fuels, chemicals) CO 2 capture and storage Potential demonstrating of new process with synthesis gas partial flow. Future of IGCC technology GASIFICATION GAS CLEAN UP COMBINED CYCLE XtL Alternative Fuel & Chemicals COAL + BIOMASS + WASTES CO 2 H2H2 CO + H 2 O CO 2 + H 2 H 2 /CO 2 SEPARATION

14. GASIFICATION CO 2 CAPTURE & H 2 PURIFICATION PROCESS SECONDARY PRODUCTION H 2 : WATER-GAS REACTION PREPARATION CO 2 H2H2 Step 1: Syngas production from Gasification  Fly ash  Char  Cl -  CN -  SH 2  COS  CO 2  N 2 … Step 3: “Shifting” or water-gas reaction Step 4: H 2 and CO 2 separation H2H2 CO 2 & CO + H 2 O CO 2 + H 2 Carbon compound + O 2 + H 2 O CO + H 2 + Impurities 400-1600ºC 10-40 bar Step 2:Conditioning  fly ash removal, particles and sulphur comp. H 2 production from fossil fuels involves CO 2 generation  To talk about “clean” H 2 it is required to consider CCS H 2 Production by coal gasification Future of IGCC technology

15. 15 Index 1.The ELCOGAS company 2.Puertollano IGCC power plant 3.Future of IGCC technology 4.ELCOGAS R&D investment plan 5.Conclusions

16. 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: 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 CO 2 emission reduction in utilization of fossil fuels H 2 production by gasification of fossil fuels Diversification of raw fuels and products Other environment improvements IGCC process optimization Dissemination of results

17. Forum participations. CO 2, H 2, 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. ELCOGAS R&D investment plan Dissemination of results

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

19. Overview of the test rig for mercury and carbonyls analysis 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 Sulphur Recovery 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

20. 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 CO 2 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 / diesel from syngas Availability to undertake tests of gasification of different fuels at large scale to help in design of new IGCC plants Biomass yard ELCOGAS R&D investment plan Diversification of raw fuels and products Pre-selected biomasses

21. Battery of Biomass co-gasification tests Test Month/Year Biomass type Biomass dosage ratio (%wt) Biomass (t) Test Duration (h) 2001 Meat Bone & Meal1%-4,5% 93.3 15 2007- 2009 Oil olive waste (Orujillo) 1 -2 %1,572.8800.3 20084%652.1154 Mar. 20096%395.864.4 Jun. 20098%383.946 Sept. 200910%656.662 Nov - Dec 2011Oil olive waste (Orujillo) 2%218.1106 Oct - Nov 20124%409.3153.5 Oct. 2012Grape Seed Meal 2%179.3127 Nov - Dec 20124%425.7119.5 TOTAL4,986.91,647.7 Critical parameter for biomass selection was the behavior on the ELCOGAS grinding system Load during 8% olive oil waste co-gasification test Biomass selection criteria: Size < 25 mm Humidity < 12 % Price < 150 €/t Availability in large quantities ELCOGAS R&D investment plan Diversification of raw fuels and products

22. Clean H 2 production by gasification of fuels  Collaboration in several projects (HYDROSEP (UE-RFCS) and SPHERA (ESP- CENIT)  H 2 production optimization using the CO 2 -H 2 Pilot Plant  Possibility to collaborate with The National Center for Hydrogen “CNH2” (SPAIN) CO 2 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 CO 2 capture for CCS with IGCC ELCOGAS R&D investment plan H 2 production and CO 2 emission reduction

23. 23 To demonstrate the feasibility of capture of CO 2 and production of H 2 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. TARGETS Project of pilot plant in an existing IGCC of Puertollano (pre-combustion technology) is part of a Spanish national initiative, “Advanced technologies of CO 2 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 PARTICIPANTS & BUDGET ELCOGAS – UCLM – Ciemat – INCAR CSIC 14.5 M€ (initially 18.5 M€) COORDINATED PSE-CO 2 project ELCOGAS R&D investment plan – Line CO 2

24. Puertollano IGCC power plant and pilot plant location PRENFLO Gasifier Coal preparation Sulphur Recovery Combined Cycle New CO 2 capture pilot plant ASU ELCOGAS R&D investment plan – Line CO 2

25. 25 COMBINED CYCLE COAL + COKE GASIFICATION Raw gas FILTRATION SYSTEM Syngas PURIFICATION & DESULPHURATION Tail gas 1.3 bar IP STEAM SHIFTING REACTORS CO 2 CO 2 & H 2 separation (Chemical, aMDEA) 100 t/d CO + H 2 O → CO 2 + H 2 Raw H 2 (80% of purity) 40% H 2 rich gas 37.5 % CO 2 50.0 % H 2 3.0 % CO HYDROGEN PURIFICATION (PSA) Recycle compressor Pure H 2 (2 t/d) 99.99% H 2 @ 15 bar SWEET /SOUR +H 2 S (1.44%) 2% SWEETSOUR Flow (Nm 3 /h) 3,6104,006 P (bar) 19.823.6 T (ºC)126138 % CO 2 60.4553.72 % H 2 21.9519.57 % H 2 O0.2910.40 % H 2 S00.70 % COS00.11 CO 2 capture & H 2 production Pilot plant

26. Installation unique in the world Installation unique in the world: 14 MW t pre- combustion technology integrated in an existing IGCC. technology used is commercial 3 step process: shifting unit, CO 2 /H 2 separation by chemical absorption, and H 2 purification by PSA. All technology used is commercial. 100 t/d of CO 2 2 t/d of pure H 2 100 t/d of CO 2 are captured and 2 t/d of pure H 2 are produced Operation is intermittent, 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 Consejería de Educación, Ciencia y Cultura CO 2 stripper CO 2 absorber PSA adsorbers WGS reactors Control room 26 CO 2 capture & H 2 production Pilot plant

27. 1)The carbon capture pilot Project has been a success: first of its kind in the world, >90% capture rate achieved and CO 2 capture cost can be <30 €/t 2)Commercial technology at any scale is available: the singularity comes from “integration in a existing IGCC plant” 3)Tests carried out show room for improvement in operating conditions and optimization of energy balance. 4)Carbon capture cost estimations come from figures of a real project. 5)From now on, the pilot is being used for internal research 6)But it is also open for international research projects and for other kinds of collaboration CO 2 capture & H 2 production Conclusions

28. 28  With SWEET catalyst  With SOUR catalyst CO 2 capture in IGCC plants Fuel preparation Gasification Filtration and wet scrubbing Desulphurization and sulphur recovery Unit of CO 2 capture Combined cycle S CO 2 Fuel preparation Gasification Filtration and wet scrubbing Unit of CO 2 capture Combined cycle CO 2 + H 2 S Based on our CO 2 capture pilot plant, we have scaled the cost of a CO 2 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 CO 2 capture. By installing an IGCC with CO 2 acid capture to store or use CO 2 together with ~1.5% H 2 S, the investment costs are similar to those w/o CO 2 capture. And the only penalty is the decreasing efficiency: From 42 33% currently and from 50 44% near future (1.5%) CO 2 capture & H 2 production Results and learning

29. 29 Index 1.The ELCOGAS company 2.Puertollano IGCC power plant 3.Future of IGCC technology 4.ELCOGAS R&D investment plan 5.Conclusions

30. Conclusions IPCC  Unless greenhouse gas emissions are cut by 50-80% by 2050 (especially CO 2 ), 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 CO 2 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. 31 IGCC: Towards zero emissions power plants Francisco García Peña – Engineering R&D Director, ELCOGAS, Spain Conference on Clean Coal and Carbon Capture and Storage Technologies 2nd and 3rd December, 2013 at Trichy (India) THANK YOU FOR YOUR ATTENTION