Perspective on Coal Utilization Technology
Perspective on Perspective on Coal Utilization TechnologyCoal Utilization Technology
Naokazu KimuraDirector, Wakamatsu Research Institute
J-Power/EPDC
Naokazu KimuraNaokazu KimuraDirector, Wakamatsu Research InstituteDirector, Wakamatsu Research Institute
JJ--Power/EPDCPower/EPDC
21st Annual International Pittsburgh Coal Conferenceon 14 - 16 September, 2004
AgendaAgendaAgenda
- About J-Power/EPDC
- Example of CCT Application for New P/S
- EAGLE Project Progress Report
- Potentiality of Coal Gasification Technology
about J-Power/EPDCabout Jabout J--Power/EPDCPower/EPDC
- was established in 1952 based on the Electric Power Development Promotion Law.
- has deployed its business along the national policyand constructed many large power stations.
- Power Generation Capacity (as of September, 2004)Hydro Power : 8,550.5MW (59 stations) Thermal Power : 7,824.5MW ( 8 stations)
- was privatized in October, 2003 based on the abolishing the above law.
- New Communication name of EPDC is J-Power.
J-Power’s Business DomainsJJ--PowerPower’’s Business Domainss Business Domains
Under the key words ““Environment and EnergyEnvironment and Energy””
- Domestic Power Supply as a Wholesaler
- Overseas Power Business includingEnvironmental Protection
- New Business creation using New Technology
Example of JExample of J--Power CCT applicationPower CCT application
• The Newest Power Station in J-Power is Shin-Isogo Power station, which is 600MW PCF plant adopting USC(600/610℃, 25MPa) and Dry Activated coke desulfurization.
• This Power Station is located at 40km south from Tokyo, it is watched that it is an urban style coal power station.
Shin-Isogo Unit. 1 Coal fired Power StationShin-Isogo Unit. 1 Coal fired Power Station
Photo of Shin-Isogo Unit. 1
Requirements Requirements for Plant Replacement:for Plant Replacement:
- Due to meet required capacity fromgrid, it was constructed the capacityover twice.
- In addition, this plant was constructed under the existed plants operation.
- The location is in Yokohama city.It is about 40 km south from Tokyo.
- Required Flue gas emission is thesame level as LNG.
ShinShin--Isogo Unit. 1Isogo Unit. 1
AH
Stack
Boiler
SCR ESP
360 ℃ 150 ℃ 125℃
Outline of the plant
Commissioning April, 2002Gross Efficiency 43%Capacity 600MWSteam Condition 25MPa
600/610℃
Emission
Flue Gas SOx : 24 ppmNOx : 20 ppmPM : 10 mg/m3N
System Flow of Plant
DryDeSOx
EAGLE ProjectEAGLE Project
Origin of the Project Name “EAGLE”Coal Energy Application for Gas, Liquid & Electricity
means
MultiMulti--Purpose GasifierPurpose Gasifier
Overview of EAGLE ProjectOverview of EAGLE ProjectOverview of EAGLE ProjectProject Objectives
Project Support- METI & NEDO
- Final Target of the EAGLE Project is to toward IGFC, which is combined with Fuel Cell, GT, and ST.It calls triple combined cycle.
- Coal must be converted into an ash-free combustible gas with gasification and clean-up to produce a gaseous handling fuel equivalent to LNG.1. Development of Oxygen-blown entrained-flow gasifier2. Establishment of Gas cleanup technology for fuel cells
Coal Based High Efficiency Power Generation Technologies
Coal Based High Efficiency Coal Based High Efficiency Power Generation TechnologiesPower Generation Technologies
Steam Condition
Gasification
Fuel Cell
Gas Turbine
Fluidized Bed
%:Gross Efficiency HHV basis
LNG1500℃LNG1100℃
Super C.Sub C.
IGCC
AFBC
IGFCMCFC
IGCC1300℃ IGCC1500℃
A-PFBC
SOFC
USC
PFBC
LNG1300℃
Present
42~44%
42~44% 46~48%
48~50%
>55%
48%44%
>50%
IGFC Technology Flow DiagramIGFC Technology Flow DiagramIGFC Technology Flow Diagram
D CACFuel Cell
G asifier
PulverizedCo al
SyngasCoo ler
Ceram icFilter
G G H
Slag
Scrubber
CO S Converter
M D EAAb so rb er
H RSG
Rectifier
A irG asTurb ine
SteamTurb ine
Co ndenser
Stack
ST
G T
AC
AC
W aste W aterTreatm entN 2
O 2
Lim estoneAb so rb er
Acid G asFurnace
M D EARegenerato r
G ypsum
D CACFuel Cell
G asifier
PulverizedCo al
SyngasCoo ler
Ceram icFilter
G G H
Slag
Scrubber
CO S Converter
M D EAAb so rb er
H RSG
Rectifier
A irG asTurb ine
SteamTurb ine
Co ndenser
Stack
ST
G T
AC
AC
W aste W aterTreatm entN 2
O 2
Lim estoneAb so rb er
Acid G asFurnace
M D EARegenerato r
G ypsum
Schedule of the EAGLE ProjectSchedule of the EAGLE Project95 96 97 98 99 00 01 02 03 04 05 06
Feasibility Study
Basic & Detail Design
Construction
Operation & Test
Evaluation
EAGLE pilot plant system flowEAGLE pilot plant system flowEAGLE pilot plant system flow
Coal
Gasifier Syngas Cooler
Char Filter
CharSlag
N2
O2
Air
Air FeedCompressor
Rectifying Column
Air
Combustion Turbine
GComp GT
Incinerator
Air Separation Unit
Waste HeatRecovery Boiler
WaterScrubber
MDEAAbsorber
GGH
Fine Desulfurizer
MDEARegenerator
LimestoneScrubber
Gypsum
Stack
Coal Gasification Cold Gas Cleanup
N2
EAGLE GasifierEAGLE GasifierEAGLE Gasifier
Heat Recovery Section
Gasification Section
Quench Section
Gasifier Type:Oxygen-Blown 1 Chamber2 Stages Spiral Flow Gasifier
Coal Feed Rate: 150 t/dGasification Pressure: 2.5MPa
Coal Gasification of the EAGLE Pilot PlantCoal Gasification of the EAGLE Pilot PlantCoal Gasification of the EAGLE Pilot Plant
Coal
Pulverizer
CoalBunker
FluxBunker
LockHoppers
O2
N2Air Separation
Unit
Slag
Steam Steam
FiltersCyclone
LockHoppers
Cold GasCleanup
Cold GasCleanup
Recycled Gas/N2
Char N2
Gasifier Syngas Cooler RecycledGas
Cold Gas Cleanup of the EAGLE Pilot PlantCold Gas Cleanup of the EAGLE Pilot PlantCold Gas Cleanup of the EAGLE Pilot Plant
No.1 WaterScrubber
No.2 WaterScrubber
MDEAAbsorber
MDEARegenerator
SulfurRecoveryUnit
Incinerator
Acid Gas
RawSyngas
Fine Desulfurizer
HalideAdsorber
COSConverterGasifier
GGH
Clean Syngas
Sulfur Recovery Unit of the EAGLE Pilot PlantSulfur Recovery Unit of the EAGLE Pilot PlantSulfur Recovery Unit of the EAGLE Pilot Plant
Acid GasFurnace
Acid Gas
Light OilGas Cooler
Vessel
SO3 MistSeparator
LimestoneSlurry
Air
Stack
Dehydrator
Gypsum
LimestoneScrubber
ASU & GT of the EAGLE PlantASU & GT of the EAGLE PlantASU & GT of the EAGLE Plant
Air FeedCompressor Heat
ExchangerRectifyingColumn
Air
Air
MS Adsorber
HP-N2
MP-N2
O2
LP-N2
CoalGasification
Waste HeatRecovery Boiler
Stack
Incinerator
Clean Syngas
GCOMP GT
Major Test Items during the Operation periodMajor Test Items during the Operation period
2002 2003 2004 2005 2006
◎ Coal In (March)
Gasifier trial operationFull Plant trial operation
GT Integration operationPerformance Test (Coal A)
Coal Flexibility Test (Coal B,C,D,E)
Long Run Test for 1,000hrs
EAGLE Plant Modification
ASU-GT Integration Test
After the construction of EAGLE pilot plant, we confirmed as follows;- Settled on Basic Operation Manual. - Confirmed that load change rate 8%of ASU was achieved
in the dynamic operation test.- Confirmed that we could operate the full plant integration
with 100 % plant capacity. - Confirmed high efficient dust removal without filter
breaking.- The volume of quench gas was reduced from initial 50%
to 30%. - GT was satisfactorily operated with Syngas. - 291 hrs continuous operation was achieved.
Highlights in 2002 & 2003Highlights in 2002 & 2003Highlights in 2002 & 2003
Project Targets and ResultsProject Targets and ResultsProject Targets and Results
Total Operation Time : 2,073 hrsTotal Coal Consumption: 9,547 ton
1,000 hrs Long Run test will be started soon !
Item Targets Results
Carbon Conversion Efficiency >98 % ≧99 %
Cold Gas Efficiency >78 % ≧78 %
Calorific Value (HHV) 10,000 kJ/m3N ≧10,100 kJ/m3N
Continuous Operation Time 1,000 hrs 291 hrs
Kinds of Coal 5 kinds 2 kinds
Sulfide Compounds 1 ppm <0.1 ppm #1
Halogenated Compounds 1 ppm 1 ppm
Ammonia 1 ppm 1 ppm
Particulate Matter 1 mg/m3N 1 mg/m3N
#1: Outlet of Fine Desulfurizer
Test Schedule of the EAGLE ProjectTest Schedule of the EAGLE ProjectTest Schedule of the EAGLE Project
(1)The Long Run Test is the most important test item in this year to confirm reliability.We will start the Long Run for 1,000 hrs. soon.
(2)Coal flexibility test is also important test item for the design of the next large scale plant. We will test at least 5 kinds of coals including 2 kinds we have already tested.
(3)We are planning to examine the possibility of EAGLE gasifier for scale up. One of the tests is that operation condition such as coal injection velocity, etc. will be changed to obtain the design data.
Potentiality of coal gasification technologyPotentiality of coal gasification technology
• CO2 issue is increasingly getting hot topics, requirement of High Efficiency Technology such as IGCC or IGFC, will be increased in future.
• It is necessary to proceed CCT program included outlook of CO2 recovery and sequestration as a final target.
• In this case, Coal Gasification will be Key Technology considering of coal utilization potentiality in future.
• Coal Gasification is also possible to apply for NH3, GTL, and H2 production, it can be said that the technology expandability is so wide range.
Under the SeaUndergroundCoal Mine
CO2
Hydrogen
Coal
Gasifier
Gas Clean Up
Oxygen
Air Separation Unit
Sift Reactor
CO2 Separator
AC GT
HRSG
ST
CO2 Disposal
Synthetic Fuel GTL, DME
Electricity IGCC, IGFC
Fertilizer Synthetic Chemical Fertilizer Reactor
Synthetic Chemical Fuel Reactor
Potentiality of coal gasification technologyPotentiality of coal gasification technology
SummarySummarySummary
- Coal Gasification will be Key TechnologyKey Technology in future.
- J-Power will complete the EAGLE project and create New business internationally using this technology.
- J-Power will proceed the management persisted in coal.