Overview of the Kemper County IGCC Project Using TRansport Integrated Gasification (TRIGTM)

Randall Rush GM Gasification Technology Southern Company RECS 2012 5 June 2012

Gasification is Not New Technology

n First gasifiers were air-blown First gasifiers were air-blown n
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First chartered gasification companies in England in 1812 and 1816 in the U.S. Primarily product was town gas for street lighting and home heating Primarily product was town gas for street lighting and home heating Gasification produces synthesis gas (syngas) comprised mainly of hydrogen (H2) and carbon Gasification produces synthesis gas (syngas) comprised mainly of hydrogen (H2) monoxide (CO) and carbon monoxide (CO) synthesize any hydrogen/carbon based chemical or burned to This syngas can be used to make syngas can be used to synthesize any hydrogen/carbon based chemical or This power burned to make power was developed by Texaco in the 1940s to produce more Oxygen-based gasification concentrated hydrogen for use in oil refineries Oxygen-based gasification was developed by Texaco in the 1940s to produce more concentrated hydrogenwas Coolwater (110 refineries The first coal-based IGCC for use in oil MW) in the
mid-1980s an EPRI led demonstration of the Texaco (now GE) gasifier Today only five (5) gasifiers world-wide use coal to produce electricity in an IGCC mode of operation
United States (GE & Conoco Phillips) Belguim (Shell) Spain (Shell) Japan (MHI)

First chartered gasification companies in England in 1812 and 1816 in the U.S.

Four (4) new coal-based IGCC units are currently in construction world-wide China (DongGuan and GE-based) US (Ratcliffe and GE-Edwardsport)

Petcoke Gasification to Produce H2 (Kansas)

Kemper County IGCC

Coal Loading Hoppers Water Supply Pond Warehouse Process Air Compressors Gasifier Structure: Gasifiers, Syngas Cooling/Filtration Control/Admin Bldg. Coal Prep

Coal Dome

Water Treatment

Flare

Electrical Switchyard 2 x 1 Combined Cycle Sulfur/CO2 Removal

Sulfuric Acid Production

Cooling Towers

Kemper County IGCC Project Map

~70 miles transmission ~ 60 miles CO2 pipeline (for EOR) ~5 miles natural gas pipeline ~31,000 acre mine site ~2,900 acres plant site ~ 30 miles treated effluent line
New CO2 Pipeline Meridian

Plant Site

Kemper County IGCC Overview

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2x1 Integrated Gasification Combined Cycle (IGCC)

2 TRansport Integrated Gasifiers (TRIG) 2 Siemens SGT6 - 5000F CTs 1 Toshiba Steam Turbine (Tandem Compound Double Flow) 582 MW peak and 524 MW on syngas Heat Rate 11,708 Btu/kWh (29.5% HHV Efficiency w/ CO2 control and 40+% moisture coal) Selexol for H2S and CO2 removal 65+% CO2 capture (~800 lb/mWh emission rate) Mine Mouth Lignite

Plant Site

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Owner & Operator: Mississippi Power Over $2 billion capital investment Commercial Operating Date: May 2014 Use treated effluent from Meridian as makeup water Operate with Zero Liquid Discharge (ZLD) By-Products (TPY)

~3,000,000 - Carbon dioxide used for EOR ~135,000 - Sulfuric acid Kemper Lignite Composition ~20,000 - Ammonia Average Min
Heat Content Moisture Ash Sulfur btu/lb % % % 5,290 45.5 12.0 1.0 4,765 42 8.6 0.35

Max 5,870 50 17 1.7

Development of TRIG for Power and Chemical Production

TRIGTM Leverages Long History of KBR Fluid Catalytic Cracking (FCC) Expertise
First Commercial FCC Unit for Exxon Orthoflow A Design Orthoflow C Design Resid FCCs

Late 30's 1942

1951

Early 1960's 1976 1980's

Design Based on FCC Technology

Orthoflow F Design

1990
Pilot Plant Tech Center

1996
Grand Forks, ND 2,600 Hours Test Run

1996
PSDF-Wilsonville, AL. >15,600 hrs in gasification >2,200 hrs on Mississippi Lignite thru July 11

China 2011 USA 2014

TRIGTM In Kemper County, MS, USA & Dong Guan, China

TRIGTM Attributes/Advantages
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Simple, well established design

Based on technology in use for 70 years Air for power Oxygen for liquid fuels and chemicals Non-slagging design:
l Provides 10-20 year refractory life, l Eliminates black water system l Provides non-fouling syngas cooler operation

Either Air- or Oxygen-blown High Reliability Design

No burners to fail and be replaced Dry dust removal eliminates gray water system Coarse, dry coal feed allows:
l Fewer, lower power pulverizers, and l Less drying than other dry-feed gasifiers

Lower Fuel Costs

Cost-effective using high moisture, high-ash, low rank coals (PRB and lignite). Lower water use compared to pulverized coal (PC) Excellent emissions performance Easier to permit compared to PC Lower cost carbon capture compared to PC

Excellent Environmental Performance

Kemper County IGCC 3-D

Gas Turbines HRSGs Nitrogen Plant CO2 and H2S Removal Steam Turbine Air Compressors HP Coal Feeders

Gasifiers (2) Fluid Bed Dryer System

Sulfuric Acid Production Ammonia Production

Kemper County IGCC 3-D

Flare Derricks Sour Water/NH3 Recovery System H2S Absorbers (2) CO2 Absorbers (6) Dry Ash Filters (4)
Particulate Collection Device (PCD)

AGR Regenerators (2)

Gasifiers (2) Crushed Coal Silos CO2 Compressors

HP Coal Feeders (12)

Main Syngas Coolers (4) Back-pulse Coal Mills (6) Surge Drums Mercury Adsorbers NH3 Removal Admin. Bldg. Syngas Humidifiers

CO2 Flash Drums (8)

To CT s

COS Hydrolysis

WGS Reactors

Steam Turbine

Warehouse

Process Air Compressors (4)

Kemper County IGCC 3-D

Kemper County IGCC 3-D

Kemper County IGCC 3-D

Kemper County IGCC 3-D

(All Process Steps except Selexol and WSA are simple fixed bed reactors or packed columns)
Process Step Humidification / Contaminant Removal Water Gas Shift Process Equipment Packed Bed Column Description Syngas i s contacted with heated water to humidify the gas and to remove halogens (Chlorides, Fluorides, e tc.) Carbon Monoxide (CO) and water (H2O) i n Designer/Supplier KBR

Kemper County Wet Gas Cleanup

Fixed Bed Reactors

COS Hydrolysis

Fixed Bed Reactors

Ammonia Removal CO2 and H2S Removal

Packed Bed Column Packed Bed Columns via UOP's Selexol Process

Catalyst V endor supplies catalyst Syngas are converted to Carbon Dioxide (CO2) and reactor dimensions, KBR designs vessel and Hydrogen (H2)to facilitate carbon capture in subsequent process steps. Carbonyl Sulfide also called Carbon-Oxy- Catalyst V endor supplies catalyst Sulfide (COS) i n Syngas i s converted to and reactor dimensions, KBR Hydrogen Sulfide (H2S) to facilitate sulfur designs vessel removal i n subsequent process steps. Syngas i s contacted with water to remove KBR ammonia (NH3). CO2 and H2S i n Sygnas are removed using UOPs proprietary solvent i n a series of absorbers. UOP supplies process information i ncluding equipment design specifications, KBR designs vessels, piping, e tc. Catalyst V endor supplies bed material and reactor dimensions, KBR designs vessel KBR

Mercury Removal

Packed Bed Adsorber

Mercury (Hg) i s removed on a fixed bed of activated adsorbent. H2S and Ammonia are stripped from sour water collected throughout the facility i n a series of columns. Ammonia i s further purified for sale on commercial market. H2S i s recycled within the process.

Sour Water Treatment / Fixed Tray and Packed Bed Columns Ammonia Recovery

Sulfuric Acid Production H2S burners / Fixed Bed Reactors / Acid Condensers via H2S i s converted i n a series of steps to highly Haldor Topsoe supplies process Haldor Topsoe's Wet Sulfuric Acid (WSA) Process concentrated sulfuric acid (H2SO4) product for information i ncluding equipment design commercial sale. specifications, and some specialized e quipment, KBR designs vessels, piping, e tc.

Kemper CO2 Capture Scheme

Refrig.

Two Stages WGS Selexol Physical Solvent Refrigerated to 40F Carbon Capture: 65+% CO2 Emissions: 800 lb CO2/MWh Yield: >3 MM Tons/yr CO2

Refrig. CO2 Absorbers Product CO2

CO2 Compression And Drying CO2 Flash Tanks To Sulfuric Acid CW

Water Gas Shift Reactors

H2S Absorber

Steam Cond Cond H2S Stripper

Recycle Gas Compressor Acid Gas Concentrator Sour Syngas From Gasifier Steam

Syngas To Turbine

To Gasifier

Selexol: Practicality and Experience

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Stable, well-proved process uses a single physical solvent to remove both CO2 and H2S from syngas. Selexol has a high affinity for CO2 and sulfur compounds. No chemical reactions, only solubility. Solvent was developed over 50 years ago for natural gas treatment. Process was developed for IGCC over 30 years ago. 50 units are in operation worldwide, many for natural gas purification, about 10 worldwide treat syngas or heavy oil.

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Coal-based IGCC Applications

100 MW EPRI Cool Water IGCC Demonstration Plant (Mid1980s)
Removed both CO2 and H2S. Extremely high reliability over 5 year plant life. Also experienced high reliability over 5 year demonstration period. Produced low sulfur syngas and a purified CO2 stream for a urea plant. Removes both CO2 and sulfur from syngas for fertilizer production. Selexol process is reliable, automatic, and low maintenance.

TVA/Muscle Shoals Gasifier Demonstration Plant (Early 1980s)

Coffeyville Resources (2000-present)

WSA Process: Practicality and Experience

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WSA Condenser

The Wet gas Sulfuric Acid process recovers sulfur emissions as high quality, commercial grade H2SO4. Developed by Haldor-Topsoe A/S. Mature technology commercially available since 1980. 75 units operating worldwide (21 more in design/construction). 14 gasification applications treating H2S waste gases. 11 units operating that are similar size or larger than the Kemper design. (Largest is 9x.) Advantages include very low outlet emissions, high reliability, no waste streams, and significant energy recovery as steam.

Lignite Mining
Surface mine Multiple seams Typically 2 - 10 feet thick 30-150 feet deep

Surface Mine: Red Hills Mine

Insert Video Here

Reclamation: Red Hills Mine

Active Mine

Pasture New Timber

Insert Video Here

New Pond

Project Schedule

 Be Aware of Your Surroundings March 2012

Safety

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Goal Zero, No Accidents, No Recordables Target RIR 0.50 Total Project Hours 2,470,754 Recordables 8 RIR Project to Date 0.65 Personnel on Site 1937

Recordable Incidents

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Laborer Carpenter Lead Carpenter Lead Electrician Driller Ironworker Carpenter Driller

Slipped and fell scrapping his leg Fracture - Finger Fracture - Ankle Laceration to Thumb Bee Sting Sutures to Lip Cut Hand Amputated Thumb

 Be Aware of Your Surroundings April 2012

Water Reservoir Lignite Delivery Area

Mass Grading Plant Area Complete 3,400,000 cy Construction Laydown Complete 1,100,000 cy Water Reservoir 380,000 of 380,000 cy Lignite Delivery 191,929 of 320,000 Ash Storage 497,884 of 1,300,000 5,569,814 of 6,500,000 Cubic Yards Total 86%

LDF Area Stacker Re-Claimer Foundation

Deep Foundations Auger Cast Piling 158,121 LF of 175,730 LF Installed 90%

Underground Utilities Storm Drains 100% 18,500 of 18,500 LF Fire Protection 84% 20,920 of 24,911 LF Potable Water 64% 12,652 of 19,244 LF Other Pipe 64% 48,828 of 75,718 LF Total U/G Pipe 68% 100,900 of 148,462 LF

LDF Area Concrete Foundations Concrete Foundations 66,618 CY of 103,537* CY Installed 64%

Structural Steel Gasifier 30% 7,224 of 23,874 Tons Gas Clean Up 15% 1,852 of 12,084 Tons Combined Cycle - 25% 356 of 1,421 Tons LDF 0% 0 of 527 Tons BOP 0% 0 of 200 Tons Totals 25% 9,432 of 38,079 Tons

Gasifier Structural Steel

Gas Clean Up and By Products Structural Steel

Combined Cycle Structural Steel

Process Piping Above Ground Gasifier 3% 4,932 of 155,631* LF Gas Clean Up 1% 4,182 of 315,321* LF Combined Cycle 2% 1,102 of 76,237* LF LDF 0% 0 of 21,882 LF BOP 0% 0 of 7,047* LF Totals 2% 20,218 of 576,118 LF

Combined Cycle Structural Steel Combined Cycle

HRSGs

HRSG Erection 42%

Combined Cycle Steam Turbine Erection 25%

Concrete Tanks Fire Protection - 98% Waste Water - 98% Condensate - 85%

Architectural Buildings Warehouse 100% Main Electrical Bldg Admin/Control Bldg Maintenance Shop 100% Main Electrical Bldg 94% Gasifier Elect Bldgs 94% Combined Cycle Elect Bldg 88% Admin/Control Bldg 74% Warehouse

Maintenance Shop

Coal & Ash Silos Fabrication Coal Silos Ash Silos Crushed Ash Total 58% 63% 40% 58%

Treated Effluent Water Line Horizontal Directional Drill

Off Site Pipe Lines Treated Effluent Water Line 65% 111,391 of 170,578 LF Natural Gas Line 0% 0 of 33,125* LF Mobilization June 2012 CO2 Line 0% 0 of 342,202* LF Mobilization June 2012 Total 21% 110,875 of 525,707LF

Hwy 493 Modifications

88% Complete Turn Lanes

June 21, 2010 Day 1

April 30, 2012 - 22 Months Later

Kemper County IGCC 6,287,567 CY

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Earthwork

Dirt Sidewalk 6,287,567 CY 8038.1 Miles

Kemper will have enough cubic yards of earthwork to construct a 4 foot wide by 1 foot deep sidewalk around the US starting in Jacksonville, FL and heading to Los Angeles, CA to Seattle, WA to Augusta, ME and back to Jacksonville, FL.

Deep Foundations Total (Caisson & ACP)

Kemper County IGCC 201,800 LF 38.2 miles

Birmingham to Plant Miller 20 miles

Kemper will have enough linear feet of caissons and auger cast piles to stretch from APCO Headquarters in Birmingham to Plant Miller in Quinton, AL and back!

Kemper County IGCC 93,260 CY

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Concrete

St. Louis Gateway Arch 38,107 CY

Kemper will have enough cubic yards of concrete to construct the foundations and inner structure of the St. Louis Arch twice and still have 17,000 CY left over!
630

630

Kemper County IGCC 34,643 tons

Structural Steel

Golden Gate Bridge Main Towers 44,400 tons (Both)

Kemper will have enough tonnage of steel to build 80% of the main towers of the Golden Gate Bridge in San Francisco.

746

Kemper County IGCC 536,113 SF

Grating

Football Field 57,600 SF

Kemper will have enough square feet of grating to cover more than 9 football fields!

x9

Kemper County IGCC 75,752 LF

Guardrail & Handrail

Talladega Superspeedway 1 Lap = 2.66 Miles 14,045 LF

Kemper will have enough linear feet of guardrail & handrail to wrap around the track at Talladega Superspeedway nearly 5 times!