I probably don't need it so I don't know what it is. But, what is the express card used for? (Why might I need it?)
Expresscard is a type of expansion slot meant for laptop computers. You can buy a bunch of modules for it that expand your laptop's capability, like additional USB ports, additional Firewire ports (or both USB/Firewire), eSATA, 3G wireless data cards, a whole bunch of things (
here's a good listing of currently-available expresscards).
The possibilities for expansion are nice, but the problem is, fewer and fewer laptops are supporting it now, opting instead to have the standard USB ports (and firewire on the high end). This is because the anecdotal evidence seems to point to very few people actually
using the expresscard slot. I have to admit, my last MBP had it, but I never once plugged anything into it although I kept telling myself I would, someday. So, I didn't really miss it when it went away on my new 2010 MBP.
Part of the problem is that nearly every expresscard out there has some module that juts out quite a ways from the side of the laptop, so it's not something you can just keep plugged in all the time without risking some kind of damage during travel.
Is the removable battery a big plus? Does it make it easier to fix when broken?
Obviously yes, a removable battery is easy to replace when it breaks because you just pop it right out and slide in a new one. Whereas the "sealed" battery is not considered user replaceable by Apple, even though the only thing standing in the way is the outer casing, and some tri-wing screws that require a screwdriver that's a little harder to obtain than the ones you might already have laying around the house.
On the other hand, Apple really touts the long life of these batteries. On the removeable batteries, I was lucky to get 3 hours of battery life on my 2007 MBP, and things started to go downhill with battery life between 300 and 500 charge cycles, where now Apple claims you're supposed to be good to go for 8 hours on the current batteries, and still supposed to be mostly good even after 1,000 charge cycles.
I'd use it for content consumption, programming, and some graphic design (photoshop stuff). I would NOT use it for any gaming, and not so much video watching. So, do you think I need the 2.66ghz one?
Depends on how much photoshop you're doing. If it's a lot and you can easily, afford the 2.66, it might be worth the extra kick especially if you intend to keep it for a few years.
Then again, I should point out that I did a lot of Photoshopping with a 2.33GHz C2D MBP and it served me fine for 3 years.
What kind of physical condition are Apple refurbs in?
Could there be scratches or other damage on the screen or body of the MBP? What about stuck/dead pixels?
Apple is well known for being VERY meticulous about their refurbs. You might even argue that they get
more attention to quality control than the brand new models rolling out of the factory. In most cases, you wouldn't be able to tell the laptop was a refurb without being told. And this is probably because Apple knows most people would reject their refurbs if there were obvious physical blemishes, even if the refurbs cost less.
I don't know for sure about dead pixels, but seeing as some of those laptops probably got returned
because of dead pixels, I would bet Apple makes sure the refurbs don't have any.