evolution and vision of integrated gasification combined...

1

Evolution and Vision of Integrated Gasification Combined Cycle

and Co-production Systems in China

Xiao, YunhanInstitute of Engineering Thermophysics

Chinese Academy of SciencesJune 16, 2006

Outline

An Effective Solution to the Coal, Electricity, Oil and Transportation in the China’s Development of EnergyPlan for Developing the Co-production in Other CountriesThe Course and Evolution of IGCC and Co-production in ChinaThe Breakthrough for IGCC and Co-production SystemVisionRemarks

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An Effective Solution to the Coal, Electricity, Oil and Transportation in the China’s Development of Energy

National Great Demand－ Electricity, Oil from Coal

coalreserve：coal 92.6% of the gross reserves of the remaining exploitable fossil energy2004：primary energy consumption 1.97 billion tce，coal 2/32020：primary energy demand 2.5～3.3 billion tce，coal 2.1～2.9 billion t

coal power－the base of China power2004：441 million kW， coal-fired 70%2020：900 million kW, coal-fired 580 million kW，64%new coal will be mostly used to generate electricitymajor source of the air pollutant

Soot 70%, SO290%, NOX67%, acid rain 82%, CO270% from coal fired

National Great Demand－Electricity, Oil from Coal(cont.)

Coal based clean fuel－effective pathway to make up lack of oil

Demand: continuous growth of import dependency, exceeds 60% to 2020 , (same as the present US level)clean：low sulfur content，HC, CO, NOX,,PM reduction by 49%, 33%, 27%, 21% respectively

Hydrogen production from coal：8M ton Hydrogen → 66M Cars → 90M ton Coalcoal gasification based co-production

economic, ultra clean, high efficient, power generationeconomic, clean liquid fuelmaximum efficiency and benefitcirculating economy

Corporation Demandenergy production corporations are facing challenges

Yankuang、Huaneng、Luan、Dongguan、Fushan and Shenhua etc. energy corporationsShanxi、Shanxi、Neimeng、Lingdong、West-south、West-north, large scale comprehensive utilization base of coal

advanced core technologies are needed in large scale manufacture industry of energy-power equipment

product upgrade（enhance efficiency, reduce pollutants, new products），enhance market competitionmeet higher and higher domestic market requirementenhance competition in international market

• circulating economy and sustainable development • stricter environmental protection rules• the growth of energy price, possibility of acquirement • enhance competition

• new competitive solution• new comprehensive energy industry• energy-power high technologies cluster

Coal gasification based co-production• integration of coal-based material production and energy

conversion, power, liquid fuel, chemicals and hydrogen

• large scale comprehensive utilization mode

• breakthrough for the limitation of raising efficiency, improving cost-effectiveness and controlling emission in single industry

• solution to the problems of coal, power, oil and transportation

Gasification

Fuels and Chemical Products Production Subsystems

Power Generation System

Coal

Fuels(liquid, H2, etc.)Chemical Products

Electricity

Material and energy exchange

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Plan for Developing the Co-production in Other Countries

Science and Technology Innovation Plan and Progress of Foreign Government

AmericaVision 21 －CCPI－FutureGenCo-production－innovation system of clean coal technology

CCT1986~1993

PPII2001

CCPI2002~2012

FutureGen2003~2012

1.7billion US dollars


a new clean energy demonstration station within ten years based on coal gasification, the co-production of 275MWe/hydrogen production/liquid fuel with CO2 capture and storage

53 million US dollars


4 IGCC demonstration

plants

3 EECP(EarlyEntrance

Coproduction Plant)

Science and Technology Innovation Plan and Progress of Foreign Government (cont.)European Union

2 IGCC demonstration plantsTechnology origin：countries of EUHolland（200MW，efficiency 41％ ), Spain（250MW，efficiency 42－43％）

HYPOGEN project2004 to 2015, the total investment of 1.3 billion Eurobuild a near zero emissions power plant with the gasification as its base, 192MW power and hydrogen and separating and disposing CO2

Germany COORETEC program，fossil fuel based near zero emissions power generation

Japan250MW IGCC demonstration power plant with air-blown, put into operation in 2009CCT-Coproduction，2004Co-production－combination of coal, power, steel, oil chemical engineering is an important pathway to establish circulating-society

Australia Coal 21, coal gasification based power, hydrogen production and synthesis with CO2 capture and storageCanada, CCT roadmap, co-production as the strategic choiceNew Zealand and Britain also take a lot of attention on the development of co-production2004, IEA CCT roadmap, depend on co-production to realize near zero emissions

Science and Technology Innovation Plan and Progress of Foreign Government (cont.)

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The Course and Evolution of IGCC and Co-production in China

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• Pursuing IGCC since the 70th last century• Plan to build a 10MW IGCC experiment

power station in 1979• Stop without start

• IGCC key technologies and system analysis– Three five-year plans

• USA and PRC Experts Report on IGCC in 1996

• The IGCC engineering project in Yantai,Shandong, initiated in 1999, not start construct yet

• IET pursuing co-production since 1998• The Demonstration Plant in Commercial

Operation since Apr. 2006

Progress of Science and Technology

973 programhigh-efficient clean energy-power system and study on internal flow during heat-work conversion process（finished）basis research on coal-based pyrolysis, gasification and high temperature clean up（finished）the fundamental research of large-scale and high-efficiency entrained flow coal gasification process, 2004Basic researches on the polygeneration application of the syngasfrom the combination of gasified and pyrolyzed coal gas, 2005

863 programcoal gasification based co-production of power and methanolkey single technologies

Gasification

new-style coal-water slurry gasification

scale：1150 tons/dayoperation times up to 5130 hours

dry pulverized coal pressurized gasification (1)

scale：24 tons/dayoperation times up to 2100 hours

dry pulverized coal pressurized gasification (2)

scale：45 tons/day

Synthesis

750 tons per year pilot plant of CTL

7 operation experimentsIn 2004, operation with full load 1500 hourssufficient operation experience and engineering data through 5000 hours run of the plant

5000 tons per year pilot plant of CTL

operation for 6068 hoursfull load operation times up to 4706 hours

Gas Turbine

heavy duty gas turbine110MWdesign, material development and application parts manufacture ongoing

micro gas turbine100kWdesign, manufactureadjustment ongoing

forge piece of turbine

blade wheel of compressor and turbine

Gas Turbine (cont.)

heavy-duty gas turbine introduction into Chinagoal: set up the manufacture industry of gas turbine3 times, F class (250MWe), E class(125MWe), gross capacity 16GWe

Dongfang Electric & Mitsubishi: 12, F classHaerbin Power & GE: 20, 9F classShanghai Electric & siemens: 9, F classNanjing Turbine & Electric Machinery Corporation & GE: 4, 9E class

combined manufacturefuel？

Integrated Design and Dynamical Properties of IGCC

system integration, whole set design and real-time simulation equipmentsoperation optimization method, performance assessment software and maintenance technology of IGCC power station

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The Breakthrough for IGCC and Co-production System

Yankuang Power and Methanol Co-production System－ power : 60MWe , methanol: 240,000 tons /a

Coal Coal gasifiergasifier : : slurry fed,entrained bed :slurry fed,entrained bed :11501150TPD X 2TPD X 2Power: 60MWePower: 60MWe，，methanol: 240,000 tons/Ymethanol: 240,000 tons/YInvestment: 1Investment: 15.8 5.8 hundred million RMBhundred million RMBCapital payCapital pay--off time: 8.1 yearsoff time: 8.1 years（（including including

construction periodconstruction period））Running time: >1000Running time: >1000 hourshours

Yankuang power and methanol co-production demonstration plant

Progress in System Studyplatform for power and methanol co-production system

System integration and optimization softwareComponent and process simulationSystem analysis

application and test in demonstration plantSystem designComponent and process analysisSimulation and optimization Control,diagnosis, and operation techniqueData acquisition and measurementEvaluation of efficiency and economic performance

Application and Test in Co-production Demonstration Plant——Component Analysis and Data Acquisition

Component performanceASUSlurry fed gasification

Raw syngas parameters, prediction errors of key components:<1％Gas purification and sulfur recovery

Sulfur content in clean syngas: fit well with design data Mass flow of sulfur and by product steam:fit well with design data

Methanol synthesis and fraction By product steam, power consumption, raw methanol: fit well withrunning data

Combined cycle( Gas turbine, HRSG)Can simulate design condition and off design conditionPart load, full load: errors with measurements(pressure ratio, exhaust temperature, compressor outlet temperature) <2%

ComparisonSimulation results with design dataSimulation results with operation data

Database Various operation condition（full load, part load）

Application and Test in Co-production Demonstration Plant——System Simulation and Test

Operation modeOnly methanolOnly electricity(IGCC)Part load parallel co-production systemFull load parallel co-production systemPart load serial-parallel co-production systemFull load serial-parallel co-production system

Comparison of simulation results with design data and measurement results

Node parameters (flowrate, composition): fit wellProducts fit well(power and methanol)

Application and Test in Co-production Demonstration Plant——Efficiency Evaluation and Comparison (Operation Data)

Methanol production Energy consumption=product methanol energy /total input thermal heat Net electric efficiency=net power output/(total input thermal heat-methanol energy consumption)Total energy utilization ratio=(net power output + methanol exergy + by product LP steam exergy)/(coal exergy+ auxiliary input exergy)

Part load: total energy utilization ratio

serial-parallel> parallel: 7.03 points percentagesNet electric efficiency

serial-parallel> parallel: 3.73 points percentagesFull load：

total energy utilization ratioserial-parallel> parallel: 3.41 points percentages

Net electric efficiencyserial-parallel> parallel:3.41 points percentages

Application and Test in Co-production Demonstration Plant——Performance Evaluation

total energy utilization ratio —— avoid part load operationParallel system(full load > part load : 3～4 points)；serial-parallel(full load > part load : 3～4 points);Methanol synthesis efficiency: part load ↓ (50% load, methanol energy consumption ↑ 87%）Gas turbine efficiency: part load ↓ (62% load, efficiency ↓ 3.5 points）

Potential for performance improvement by system synthesisHeat recovery(purification, synthesis,….)

Fuel heating, humidificationComponent load match at the design stageASU lower bound condition（70% load，gasifier: O2 evacuation,>10000 Nm3/h）Coordination of gasifier and purification（at full load, if 75% gasifier load, operation pressure decrease → purification process deviates from design point → performance worsening）Deviation of gas turbine exhaust temperature and compositions → HRSG steam generation rate < design data, 68.5t/h vs. 74t/h

Application and Test in Co-production Demonstration Plant

Conclusion 1一Database development(multi components and various operation conditions): gasification, shift, heat recovery, sulfur recovery, methanol synthesis,fraction, gas turbine, ASUAnalysis of mass streams, heat streams, power streams: based on components and system

Components and processes models can be used in performance prediction and analysis, to be improved: part load

Part load, methanol production(error: 10%）——operation pressure deviate from design value:30%Steam production prediction, deviation increase at part load

Simulation results fit with plant operation data

Application and Test in Co-production Demonstration Plant (cont.)

Conclusion 2一Evaluation of part load, full load; parallel co-production, serial-parallel co-production

Total energy utilization ratio: Co-production > single production, 3 points; net electric efficiency : Co-production > single production, 3 points

Technical and economic evaluation Avoid part load operationImprovement potential: by system synthesisOperation results show: high efficiency, economic

• test and improve components and system simulation

• certify efficiency increase

• database and experience

Methanol, Power Co-production Analysis and Integration Platform——System Integration and Optimization Software

Independent development: part work, apply for software copyright——“co-production analysis and synthesis software”

AdvantagesWide range——electricity, chemical engineering, co-production system,..Advanced research technique——simulation, synthesis and optimizationPowerful ability for optimization——certainty and uncertaintyOpen——user model and algorithm

iSIGHT(experiment design, optimization, approach, monte carlosimulation, reliability analysis/optimization, multi objectivesoptimization

Aspen plus(Chemical engineering)

Gate cycle(power engineering)

gPROMS(user models)

Other softwares(Matlab, excel,.)

Methanol, Power Co-production Analysis and Integration Platform——System Integration and Optimization Software（IGCC）

syngas

steam

Makeup water

synthesis

Gasifier and GCU models GT and HRSG models

Steam

airboiler

ST

gasifier methanolsynthesis

CH4O

power

O2水

2.5MPa Steam

Heat recoveryand GCU

purge gas

2.5MPaSTEAM

syngas

exhaust

0.5MPa steam

coal energy

BFW

BFW

Methanol only system

powerrpoduciton

gasifier

O2

heat recoveryand GCU

0.5MPa steamcoal

water

exhaustpower

power

power only system

gasifier CH4Osynthesis

methanolO2

shift, syngas purifyand heat revovery

purge gas合成新鲜气

syngas purify andheat recovery

syngas forpower

GT combinedcycle

feedwater

power

feedwater

feedwater

saturate steamat 2.5MPa




steam turbine

power

power

coal water

power

boiler

Air

exhaust gas

exhaust gas

steam for self use

Parallel system

steam for self use

GT combinedcycle


methanol

coal

O2water

shift, syngass purifyand heat recovery

syngas for power

purge gas

saturated steam at 2.5MPa

exhaust gas

power

feedwater

syngass purifyand heat recovery

feedwater feedwater

power

power



saturated steam at 05MPa

purify syngas for power

Serial-parallel system

steam for self use

GT combinedcycle


methanol

coal

O2water

(shift) syngass purifyand heat recovery

purge gas


exhaust gas

power

feedwater feedwater

power

power




Serial system

Methanol, Power Co-production Analysis and Integration Platform——System Comparison

power:60MW，methanol:2,40,000 tonsGPMSSlurry fed, Quench gasifierparallel+GPMS， one dimension，RPLUG，kinetics controlled modelSerial-parallel+GPMS， one dimension，RPLUG，kinetics controlled modelserial+LPMS ，CO rich gas, one through

Methanol=constant,CH4O production energy consumption：

serial-parallel< methanol only:4.6%Gas turbine=constant, Methanol=constant,total energy utilization ratio:serial-parallel >parallel: 2 pointsGas turbine=constant :net electricity efficiency serial-parallel 38%> power only: 5 points

Relative M

ethanol production E

nergy consumption

（%

）

Methanol production Energy consumption

Comparison of Net electric efficiency

Net electric efficiency

Comparison of total energy utilization ratio

Total energy utilization ratio

s-m c-p c-s-p c-s40

50

60

70

80

90

100

s-m c-p c-s-p c-s s-p0.0

0.1

0.2

0.3

0.4

0.5

0.6

c-p c-s-p c-s s-p0.000.050.100.150.200.250.300.350.400.450.500.55

：methanol only：parallel co-production：power only：serial-parallel co-production：serial co-production

Methanol, Power Co-production Analysis and Integration Platform

ConclusionPlatform designed for methanol, power co-production, a tool for system integration, analysis, progress in system research toolComponent model:relationship of input and output under various operation condition, fit well with reference and operation data,suitable for system analysis, integration and optimizationSystem comparisons; sensitive studySerial-parallel co-production system; ways to improve system performance：purge gas, by product steam,expander, syngashumidification

• disclosure the inherence relationship of different components of co-production system

• improve the capability of platform

Combustor Designing Program

The results of numerical simulation of a LM1600 gas turbine combustor, laminar flamelet model, gri3.0 chemical mechanism

The results of numerical simulation of a F101 gas turbine combustor, PDF transport model, D0 radiation model

1D designing code for combustors (flow and A/F ratio distribution, thermo dynamical calculation)3D CFD software of verification

The first pressurized, full-size test rig for heavy-duty gas turbine combustors in China

Sensors

• 250 channels

• Flue gas composition, exit temperature, dynamical pressure, flame video

980

10201020

1020

1020

1046.24

1046

.24

1046.24

1046.24

1046.24

1046.241060

1060

1060

1060

Compressor•Air flow rate 3.2kg/s at 5 atm

Test section•Power of the combustor: 2MW

Fuel supply•Syn-gas, distillated oil, propane

Recorders and analyzers

•256-chennel high-speed dynamical signal recorder and analyzer

•Flue gas analyzer

Control system

Experimental Platform

Pressurized full-size combustor test rig

In-situ Measurement Platform

The capability of in-situ measurement and adjustment being established

•Liner sleeve temperature measurement

•Dynamical pressure monitoring

•Flue gas composition/combustion efficiency analysis

•HMI engineer station-monitoring and recording the parameters of the engine control unit

Signal transformation and data processing/parameter monitoring and recording of engine control system

In-situ pressure and temperature transformation unit

Agilent VXI data acquisition

system

Interface of HMI engineer station

•Pressure and temperature transformation

•Agilent VXI data acquisition system

•HMI engineer station: monitoring and recording data of the engine control unit

Experimental Study of Diluted CombustionFundamental Study of Humid CombustionHumid Air Combustion-Full Size Combustor TestingIn-situ Combustion Experiment-Testing of Fuel Humidification

Laboratory Study of Humid Combustion

Numerical and experimental results of a combustion field

Flame appearance v.s. air humidity

•Flame geometry•Pollutant formation•Flame stability

Study of Humid Air Combustion on the Full Size Combustor Test Rig

Dry air

Air humidity: 5%

Air humidity: 7%

Temperature field NO field

350

400

450

500

550

600

650

0 200 400 600 800

距喷嘴端面的轴向距离mm

周向

平均

壁面

温度

40MW，加湿质量比17.2%



40MW，加湿质量比0%

In-situ Combustion Test－Fuel Humidification

•At base load, dry fuel: NOx425mg/Nm3; fuel humidity 17.2%:NOx 119mg/Nm3

•Other performances not apparently influenced0

50

100

150

200

250

300

350

400

450

0 0.05 0.1 0.15 0.2 0.25

相对加湿量

NOx(mg/Nm3)@16O2

0

1

2

3

4

5

6

CO(ppm)

NO(mg/Nm3)@16O2

CO(ppm)

Experiments and Tests of Fuel Gases of Variable Heating Value

In-situ Experiment—Tail Gas, SyngasMixing Combustion

In-situ Test of Mixed Fuel Combustion

4443CO ppm0.990.990.990.99Combustion efficiency42.042.042.042.0Power (MW)

11338.411229.611542.210730.5Heating value (kJ/kg)Syn+TailSyn+TailSyn+TailSyn.

350

400

450

500

550

600

650

0 200 400 600 800

距喷嘴端面的轴向距离mm

周向

平均

壁面温

度

驰放气=0Nm3/h，H2%=36.3%，42.0KW

驰放气=2684Nm3/h，H2%=38.6%，42.0KW

驰放气=2797Nm3/h，H2%=38.8%，42.0KW

驰放气=3327Nm3/h，H2%=39.8%，42.0KW

Liner sleeve temperatureAmplitude and frequency of dynamical pressure

Stable working condition

Summary of R&D Process of Co-production by IET

Completing the first cycle of fundamental－test－demonstrationPursuing IGCC since the 70th last century（Sino-US IGCC specialist report, 1996）1998 began the explore of co-production 1999－2004, focused study of co-production in the 973 project “Optimization, integration and innovation of general power systems”At the end of 2000, the collaborative project “Co-production of electric power and methanol from coal gasification” with Yankuang startedIn 2002, the construction of Huairou experimental base of energy and environmental laboratory was supported by a major project of knowledge innovation of the Chinese Academy of SciencesIn 2002, a 863 project supported R&D of syngas combustors of gas turbines and system demonstrationIn April of 2006, an early co-production system came into operationRoadmap for Developing Coal Gasification Based Co-production in ChinaAdvantages of Coal Gasification Based Co-production and the Barriers to and Options for Its Development in China

Established the experimental platform of the key processes of co-production, made breakthrough of key technologies, and the results were applied in the first demonstration system of co-production in Chinaprogressive execution of co-production, verification of high efficiency and low emissions of co-production

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Vision

Advantages of Coal Gasification Based Co-production and the Barriers to and Options for Its Development in China

high technologies clustergasification and syngasconditioningCoal-derived gas fired gas turbineSynthesis for liquids and chemicalsHydrogen production, carbon capture and sequestration…

mergingCoal Power generation industry and coal chemistry industryCoal based chemical engineeringTechnology suppliers, engineering designers and manufacturer

collaboration among Gov., Ind., Ins., Uni.

National Science and Technology Development Plan of Medium and Long Term

strategic high-technology, Fundamental ScienceEnergy resource & ocean

economic, efficient, clean utilization of coal－coal gasification based co-production was a strategic choice

Roadmap for Developing Coal Gasification Based Co-production in China

pathway to the goal, advice on what, who, how, when, what conditions

clear, consensus goalcommon development frameharmonious stepoptimized share of work and collaboration

supportDepartment of High and New Technology Development and Industrialization, MOSTBureau of High-Technology Research and Development , CASNRDC

implementationInstitute of Engineering ThermophysicsThe expert committee of clean coal technology, high technology R&D program

Co-production－integration energy system innovationStep by step development

Integration of mature single technology, acquirement of practice knowledge and experiencebreakthrough in all ways of special key technologyfinally realization zero emissions

Plan as a wholenation leading and corporation self-determinationindustry development and science and technology innovationinternational collaboration and self-innovation

Roadmap for Developing Coal Gasification Based Co-production in China (cont.)

Industries

Yankuang Group Corporation Limited, Shandonga new co-production plant of power and 800 thousand tons liquid fuel per year

Lu’an Group, Shanxipower and 160 thousand tons liquid fuel per year co-production demonstration project, laid a foundation

China Shenhua Group800 MW power and 400 thousand tons methanol per year co-production project, pre-flexibility report of the project finished

China Huaneng Group120MWe, GreenGen project, flexibility report of the project finishedjoined American FutureGen coalition

Industries－Region

The Changjiang River Deltathe driver to develop IGCC

The Pearl River Deltauncertainty of LNG supply uncertainty of oil pricestricter environmental requirementpower plants choose IGCCplanning to newly build IGCC power plants from the range of 100MW to 800MW，future co-production

Final goalform competitive clean coal technologies with proprietary intellectual property rights and to support the development of energy equipment industry and to realize fast development of efficient, clean utilization of coal

Goal in 2010finish research, development and demonstration of key technologies break through special problems of co-productionCommercial demonstration of IGCC Demonstration of typical co-production of F-T fuel and electricity

Goal for IGCC and Co-production

Goal in 2015Demonstration co-production plants each with400MWe IGCC and one million F-T liquid fuelPilot plant of co-production of hydrogen and electricity with CO2 capture

Goal in 2020installed IGCC capacity with 15000MWeF-T Liquid for oil capacity 40 million tons per yearDemonstration of co-production of hydrogen and electricityready for CO2 capture

Goal for IGCC and Co-production (cont.)

Development in the Eleventh Five-Year Plan Period

enlarge and deepen key technologies, realize the validation, integration and application of key technologies guidelines－“science and technology R&D, engineering demonstration, industrial harmony, policy encourage, moderate development”Insist on five combinations：“self-R&D and introduction & improvement, technology innovation and engineering demonstration, near demand and future development, government propose and corporation effort (including institutes ), industry harmony and policy encourage”promote IGCC and co-production rational development

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Remarks

Coal-based co-production technology is very important to China. It is the direction of the development of clean coal technology and an option to resolve energy problems of coal, power, oiland transportationGreat progresses were made on single technologies of co-production and system integrationThe first co-production industrial demonstration of power and methanol were constructed, the breakthrough of IGCC and co-production were realizedGovernmental support and right decision, combination of industry, university and institute, effective international collaboration are neededCo-production will realize irreplaceable contribution to the development of energy, industrialization and heavy chemical engineering

Remarks

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Thank you for your attention！

Xiao, [email protected]

Acknowledgement

National Basic Research (973) Program High Technology Research and Development (863) Program Knowledge Innovation Project of the Chinese Academy of SciencesThe team of Energy & Power System RDD in IET

evolution and vision of integrated gasification combined...

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