global activities for clean coal technology - 133.163.205.27133.163.205.27/content/100580309.pdf ·...

Global Activities for

Clean Coal Technology

September 10, 2014

Yasuo Fujitani

Senior Executive Vice President

Mitsubishi Hitachi Power Systems, LTD

Contents

1

1. Introduction of MHPS

2. Supercritical / Ultra-Supercritical Boiler Technology

3. Air Quality Control System Technology

4. Advanced Clean Coal Technology

1. Introduction of MHPS

2 © 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.

Mitsubishi Hitachi Power Systems, Ltd (MHPS)

Name MITSUBISHI HITACHI

POWER SYSTEMS, LTD.

Head Office Yokohama, Kanagawa,

JAPAN

Representatives Koji Tanaka (Chairman of the Board)

Takato Nishizawa (President and CEO)

Capital 100 Billion JPY

Effective Date February 1, 2014

Employees 23,000

(incl. 7,600 outside Japan)


Integration in the Thermal Power

Generation Systems Field

4

Head Office & Main Works in Japan

Nagasaki Works

Takasago Works

Hitachi Works

Yokohama

Head Office Yokohama Works

Kure Division of

Babcock-Hitachi K.K.

© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.

//upload.wikimedia.org/wikipedia/commons/e/e2/Mitsubishi_heavy_industries_Yokohama_building_2012.JPG

Global Network of MHPS

5

MHPS has 58 companies in 26 countries.

CBC

MHPS Europe (UK)

L&T MHPS JV

MHPS America Energy and Environment

MHPS Dongfang

JV MHPS Canada

MHPS Africa (RSA)

DHME (Dalian)

MHPS Americas

MHPS Europe (Germany)

BHPI

MHPS Technical Services


MHPS’s Business Field


Gas Turbine Combined Cycle (GTCC) Power Plants

Integrated coal Gasification Combined Cycle (IGCC) Power Plants

Boiler & Turbine Generation Plants

Geothermal Power Plants

Environmental Plants SCR Systems, FGD Systems

Steam Turbines

Gas Turbines

Boilers

Generators

Power Generating Plant Peripheral Equipment

SCR Systems Plant Control System

Fans Fuel Cells (SOFC)

Products & Services

Delivery Records

7

*1; Conversion value corresponding to main steam

*2; Over 50MW coal-fired power plant

Product Boilers Steam

Turbines Gas Turbines

Flue Gas

Desulfurization*2

Selective

Catalytic

Reduction*2

Total 936,234t/h

(approx. 312GW)*1 341,767MW 106,159MW 121,591MW 91,942MW

Total 4,259 units 2,385 units 787 units 298 units 153 units


2. Supercritical/Ultra-Supercritical

Boiler Technology


石炭焚火力発電プラントの比較（米国 vs.日本）


Comparison of Coal Fired Plant Thermal Efficiency by Individual Countries

9

Source:； International comparison of fossil power efficiency and CO2 intensity - Update 2013, Ecofys

Ave

rag

e G

ross T

he

rma

l E

ffic

ien

cy (

LH

V, %

)

620ﾟC

200

300

500

400

600

20

30

Steam Temperature S

tea

m T

em

p.

(oC

)

Gro

ss P

lan

t E

ffic

ien

cy (

LH

V%

)

538ﾟC

600ﾟC

593ﾟC

10

610ﾟC

40

700

SC

(Su

pe

rcri

tica

l)

US

C(U

ltra

-Su

pe

rcri

tic

al)

566ﾟC

A-USC

1968 1993

1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 1910

Gross Plant Efficiency

Year

History of steam condition and thermal efficiency in Japanese thermal power plant

Efficiency vs Steam Condition for Coal Fired Plant

© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 10

Higher steam temperature and pressure improve thermal plant efficiency

In other words, SC/USC technology provides economical power production, fuel energy

saving, lower carbon emission and environment-friendly

11

MHPS Various Coal Experience

Anthracite

Bituminous

Sub-Bituminous

Lignite


MHPS can provide

various power plants

best suited for various

kinds of coal based on

abundant experiences.


関西電力Maizuru#1 (‘04)

900MW 24.5MPa x 595/595℃

東北電力 Haramachi#1&2(‘97/’98)

1,000MW 24.5MPa x 566/593℃

1,000MW 24.5MPa x 600/600℃

東京電力 Hirono#5&6(‘04/’13)

600MW 24.5MPa x 600/600℃

中国電力 Misumi#1 (‘98)

1,000MW 24.5MPa x 600/600℃

九州電力 Matsuura#1 (‘89)

700MW 24.1MPa x 538/566℃

四国電力 Tachibanawan#1(‘00)

700MW 24.1MPa x 566/593℃

東京電力 Hitachinaka#1&2(‘03/’13)

1,000MW 24.5MPa x 600/600℃

Coal-Fired SC/USC Plant in Japan

Total: 25units

12

電源開発 Tachibanawan#2(‘00)

1,050MW 25.0MPa x 600/610℃

中部電力 Hekinan#1&2(‘91/’92)

700MW 24.1MPa x 538/566℃

北陸電力 Tsuruga#1&2(‘91/’00)

500MW 24.1MPa x 566/566℃

700MW 24.1MPa x 593/593℃


Netherlands: 2units

Poland: 1unit

Greece: 1unit

Jaypee Nigrie #1,2 Mahagenco Koradi #8,9,10

Rajpura #1,2

Korea: 4 units

India: 8units (by L&T-MHPS Boilers Pvt. Ltd. as JV) Indonesia: 1unit

Paiton III Expansion

Taiwan Power Co., Ltd. LIN KOU #1-3

Taiwan: 8units

CFE Pacifico #1

Misumi #1

Japan: 25units

Total: 122units MHPS : 82 units

Others: 40 units (Chinese licensee, Indian JV)

ENEL Torrevaldaliga Nord #2-4

USA: 4units

Midamerican Energy,

Walter Scott Jr. Energy

Center #4 Malaysia: 1unit

Boxberg R

German: 8units

South Africa: 12units

Mexico: 1uinit

Italy: 3units

China: 40units (by MHPS / Licensee)

Henung Yuhuan #1 to #4 And 37units

Canada: 2units

Australia: 1unit

CS Energy Kogan Creek #1

Enea, Kozienice

Coal-Fired SC/USC Plant in overseas

14

Indian Project Rajpura #1

Global Activity with SC/USC Technology


• Rajpura #1 was placed under commercial operation Feb 1st, 2014

• This unit was constructed by joint venture established by MHPS and Indian local

company Larsen & Toubro, Ltd.

• Fuel is Indian high ash content bituminous coal (ash content is 30%)

• Local staff performed engineering/manufacturing/construction/commissioning works

under MHPS’s instruction

• High efficiency and reliability of Japanese leading CCT were also proved in India

Output : 700MW

Main Steam Flow : 2,322 t/h

Main Steam : 565 oC / 24.1 MPag

Reheat Steam : 593 oC

Commercial Operation : 2014/2

Fuel : Bituminous coal

NOx (ppm) : 116 (actual) / 365 (limits)

Thermal efficiency : Approx. 4 ~ 5% better*1

*1: Relative value as compared with Sub-critical plant

(16.7MPag, 538/538oC)

Activities at Indian Market

IPP L&T Rajpura SC 700MW x 2

Rajasthan State Power Generation /Chhabra SC 660MW x 2

IPP Jaypee Nigrie SC 660MW x 2

LMB(L&T-MHPS Boilers Private Ltd.)

MHPS has contributed to Indian power generation with Japan oriented CCT through the JV with Indian company, Larsen & Toubro, Ltd.

LMTG(L&T MHPS Turbine Generators Private Ltd.)

Maharashtra State Power Generation /Koradi SC 660MW x 3


16

Output : 866MW


Main Steam : 538 oC / 24.9 MPag



Fuel : Sub-bituminous coal


Indonesian Project Paiton III


•First coal-fired SC plant in Indonesia

•MHPS supplied boiler and steam turbine including construction work



(16.7MPag, 538/538oC)

Germany Project Boxberg R

17

Output : 1 x 670MW


Main Steam : 600 oC/ 29.4 MPag



Fuel : German Lignite coal



•USC steam condition was applied to German lignite-fired boiler

•Water content in the coal is approx. 60% and LHV is approx. 2000kcal/kg


(16.7MPag, 538/538oC)


3. Air Quality Control System Technology



One-stop AQCS solution by MHPS

Air Quality Control System for Coal Fired Plant

(GGH: Gas to Gas Heater) * ESP will be supplied by MHI-Mechatronics Systems

or Hitachi Plant Construction

ESP*

GGH

Heat Extractor GGH

Re Heater

FGD

SCR

2 次空気 2 次空気

Low NOx Burner

World lowest level emission (SOx, NOx, PM) can be achieved by applying the integrated AQCS system

PM: < 7mg/m3N

1980 1990 1995 2000 2005 2010 2015

SO

2 (

pp

m)

- 20 - © 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.

High Efficiency AQCS development history (PM, SO2)

PM: <20mg/m3N

EP : Electrostatic Precipitator

GGH ： Gas Gas Heater

RGGH : Rotary GGH

H/E : Heat Extractor

R/H : Re Heater

AQCS in Japan commercialized from 1970’s

High Efficiency AQCS with Low Low temperature EP has been developed

to meet the sever environmental demand

Emission level now reaches world lowest level

RGGH FGD Stack EP

(Low temp)

Non Leak

GGH

（H/E） FGD

EP

（LL temp） FGD

Non Leak

GGH

（R/H）

EP

(Low temp) Stack Stack

Non Leak

GGH

（H/E）

Non Leak

GGH

（R/H）

Non Leak GGH applied to

prevent dirty gas leakage. High Efficiency system with

low-low temperature EP

applied.

High Efficiency System

SO2:50ppm

SO2:100ppm

SO2:24ppm

Low NOx Combustion Technologies and SCR system


1,200

800

400

Conventional

Burner

SGR

PM

PM+Two-stage combustion

[Coal Firing Boiler]

200ppm (@6%O2)

100

200

300

400

500

600

1980 1985 1990 1995 2000

NO

x (

pp

m)

400ppm

300ppm Governmental

Regulation Local Regulation

~50ppm (@6%O2)

NOx Reduction with SCR

NO

x (

mg

/m3N

, 6

%O

2)

0 0

Combustion technologies without SCR

200

600

1,000

A-PM+Two-stage combustion

M-PM Burner NR3 Burner

Latest Low NOx Burner

Honeycomb Catalyst Plate Catalyst

SCR System

2005 2010

M-PM +Two-stage combustion

• MHPS has reduced boiler outlet NOx emission

through continuous development of low NOx

combustion technology.

• In combination with SCR system, world lowest

level NOx emission is achieved.

22

MHPS Delivered AQCS units all over the world

Japan

MHPS

000 1,258 126

S.Korea

21

Mexico

18

Brazil

26

Chile

11

Saudi Arabia

17

Philippines

14

Taiwan

25

Russia

4

China

52

Indonesia

10 Singapore

21

Hong Kong

16 Thailand

16

Ukraine

3 Netherlands

1

Austria

1

South Africa

4

10

17

5

India

1 1 3

Denmark

4

12

USA

1

32

25

Germany

Italy

Finland

4

Czech

10

Poland

7

14

Spain

England

12

１

Turkey

5

Canada 1

Colombia

5

Curacao

3

Venezuela

4

Australia Malaysia

1

Myanmar

1

Yugoslavia

1

Libya

3

Zambia

2

555

341

17

L

2

2

45

32

L 7

3

2

4

7

3

7

L

3

Greece

1

Portugal

4


MHPS’s AQCS Global Activities

Number ：References

L ：License

：SCR 1,027 Units (13 Countries)

：ESP 1,543 Units (29 Countries)

：FGD 303 Units (19 Countries)

4. Advanced Clean Coal Technology


Advanced USC (Ultra Super Critical)

The efficiency of the coal fired power plant will be improved by making the

steam condition higher temperature and pressure.

A-USC Development Outline

Target Steam Temp. : 700oC

Next Generation Development

Goal is Net Efficiency 46-48%

(HHV)

Development Matter

•Material (Ni-base Alloy)

•Manufacturing Technique

•Design

•Lifetime Assessment

Methodology

2008 2009 2010 2011 2012 2013 and over

High Temp Corrosion

Steam Oxidization

Fatigue / Creep Rupture

100,000 hr Creep Test

Conceptual Design

Verification of Manufacturing

Technique (welding, bending)

Mock-up Test

(header, S/H)

A-USC Development Schedule

Test Loop under

700oC Steam Temp.


Development of Material for Advanced USC

Pipe size: φ558.8 x 138t

Welding method: Narrow Gap HST

Material: HR6W

Welding test for large-bore piping

(φ350 x 40t, Bend radius 1,400mm, Bend angle 50o)

High frequency induction bending for HR6W

To achieve A-USC technology, new nickel-base

alloy material have been developed

MHPS have conducted welding test, bending test,

mockup fabrication

100,000 hr creep rupture strengthen including

weld joint are continuously being conducted

(MHPS have 70,000 hr test data)

Weld Metal

Bond

Base Metal

Macro / Micro structure

Mockup fabrication of HR6W header

Heating temperture : 1050-1150℃


Higher efficiency through coal

gasification process coupled with a

combined cycle (CC) system.

Reduce CO2 emission by high

efficiency and prevent global

warming

What is IGCC?

*Integrated coal Gasification Combined Cycle

Outline of IGCC System


C ～ T

HRSG

～

Gas Turbine

Coal

Gasifier

Clean up

Air Comp.

Air

Steam Turbine

Flue Gas

Combustor

Combined Power Generation (Combination of Brayton & Rankine Cycles)

TEPCO Fukushima IGCC Project (2020～)

Nakoso site, Hirono site

Joban Joint Power Co.LTD

Nakoso #10

(Demo. 2007-, Commercial 2013-)

Osaki CoolGen Corp.

Osaki CoolGen Project

(Demo. 2017-)

Rendering Image

IGCC Projects in Japan

Features of IGCC system

27 © 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved

• IGCC plant efficiency is 40-45% relatively higher than

coal fired conventional power plant.

(base 33%=world average sub-critical plant)

⇒ CO2 emission decreases 30-35% lower.

• IGCC discharges coal ash in the form of glassy slag,

cutting volumes by more than half.

• IGCC can reduce circulating water for cooling by 40%.

• IGCC technology can also be

applied with wider range of coals

including LRC (Low Rank Coals).

• MHPS gasification process had

been confirmed by using many

types of coals form the world

Applicable Coal Range

Symbol shows gasifier experienced coals

Suitable for IGCC

Suitable for Conventional Boiler

Performance of IGCC System

CO2 Circulating

Water Plant Efficiency

(%)

Emission

Ash

0

20

40

60

80

100

120

▲65%

▲35%

▲40%

＋~45%

vs. sub-C

140

160 Coal fired conventional

power plant

(sub critical plant) =100%

Higher Efficiency and Least Environmental Impact

Approx. 65% decrease in volume

Utilization as a pavement material

are possible.

Utilization as a concrete aggregate

Flyash (Conventional Boiler)

Grassy Molten Slag (IGCC)

Flexibility to “Variety of Coal”

Nakoso 250MW IGCC Plant


Nakoso 250MW IGCC

Major Specification

Output 250 MW (gross)

Gasifier Air-blown Dry Feed

Gas Clean-Up MDEA (Methyldiethanol Amine)

Gas Turbine M701DA GT (1 on 1)

Plant Efficiency 42% (LHV, net)

Project Schedule

Operation Started Sep. 2007

Commercial Operation July. 2013

Nakoso 250MW IGCC Demonstration Plant achieved all the following targets.

Excellent Performance (Highest Efficiency, Less Environmental impact)

Higher Reliability (World record of continuous operation)

Fine Operability (Load change rate >3%/min)

Fuel Flexibility (Verified applicability for low-rank coal)

Converted to the First Commercial IGCC Plant in Japan

0

20

40

60

80

100

28-Jun 26-Jul 23-Aug 20-Sep 18-Oct 15-Nov

Load

Fac

tor

[%]

Achievements of Nakoso 250MW IGCC Plant

Operability (Load Change) Reliability

Verified at 3%/min load change operation which

is required as middle range operation

Environmental Performance

0

10

20

30

40

50

Net Efficiency

(%-LHV)

SOx

(ppm)

NOx

(ppm)

Dust

(mg/kg)

42.0 42.9

8 5 4 1 3.4

<0.1

Cumulative operation exceeded 25,000 hrs. The continuous operation last year achieved

no forced outage - Ave. load factor > 99% The continuous operation 3,917hr renewed the

world record.

Continuous Operation 3,917 hrs.

Average Load Factor > 99%

*: Maintenance for changing from demonstration to commercial plant and intermittent inspection

7 8 9 10 11 12 1 2 3 4 5 6 7 8 9

2013 2014

Commercial Operation

Operation history and schedule after starting

commercial operation (June 30, 2013).

Maintenance*


Design

Test Results

Commercial-scale IGCC Project


High Efficiency by using state of the art Gas

Turbine

Lower CO2 emission intensity than the

latest USC coal fired power plant.

Fuel Flexibility for high moisture Low Rank

Coal

Highly Reliable system verified in Nakoso

250MW IGCC plant

Major Specification


480 MW (net)

Gasifier Air-blown Dry Feed

Gas Clean-Up MDEA

Gas Turbine M701F GT (1 on 1)

Plant Efficiency 48% (LHV, net)

Process Development Unit

（1t/d／1981～1985／Katsuta）

HYCOL Pilot Plant

（50t/d／1990～1993／Sodegaura）

EAGLE Pilot Plant

（150t/d／2002～2013／Wakamatsu）

OCG demonstration Plant

（1,180t/d／2016～／Osaki）

Coal Energy Application for Gas, Liquid, and Electricity

× 3

× 8

Development history of the “EAGLE ” gasifier

31



Major Specification


Gasifier Oxygen-blown Dry Feed

Gas Clean-Up MDEA (Methyldiethanol Amine)

Gas Turbine 1300oC class

Plant Efficiency 40.5% (HHV, net)

Project Schedule

Construction Started March 2013

Demo. Operation Start March 2017 Rendering Image


First step: Oxygen-blown IGCC

Second step: IGCC with CO2-capture Third step: IGFC with CO2-capture

To transportation/storage

Shift reactor

CO2 capture

CO2

H2-rich gas

Air separation

unit

Air Oxygen

Coal

Gasifier Syngas cooler

CO, H2

Steam

Air Gas

turbine Steam turbine

Steam

Generator

Stack Combustor

Fuel Cell

Compressor

HRSG

33

Conclusion

MHPS shall be continuously improving

thermal plant efficiency and developing

clean coal technology

MHPS shall contribute to environmental

conservation and carbon emission reduction

to provide Japanese clean coal technology

worldwide


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