global activities for clean coal technology

Global Activities forClean Coal Technology

September 9, 2014

Yozaburo MabuchiSenior Executive Vice PresidentMitsubishi Hitachi Power Systems, LTD

Contents

1

1. Introduction of MHPS

2. Supercritical / Ultra-Supercritical Power Plant

3. Air Quality Control System

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 WorksHitachi Works

Yokohama Head OfficeYokohama Works

Kure Division of Babcock-Hitachi K.K.

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

Global Network of MHPS

5

MHPS has 58 companies in 26 countries.CBC

MHPS Europe(UK)

L&T MHPS JV

MHPS AmericaEnergy and Environment

MHPS DongfangJV 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-SupercriticalPower Plant


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

Aver

age

Gro

ss T

herm

al E

ffici

ency

(LH

V, %

)

620ﾟC

200

300

500

400

600

20

30

Steam Temperature

Ste

am T

emp.

(oC

)

Gro

ss P

lant

Effi

cien

cy (L

HV

%)

538ﾟC

600ﾟC

593ﾟC

10

610ﾟC

40

700

SC(S

uper

criti

cal)

USC

(Ultr

a-Su

perc

ritic

al)

566ﾟC

A-USC

1968 1993

1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 20201910

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 efficiencyIn 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

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℃

Total: 25units


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: 122unitsMHPS: 82 unitsOthers: 40 units(Chinese licensee, Indian JV)

ENEL Torrevaldaliga Nord #2-4

USA: 4units

Midamerican Energy, Walter Scott Jr. Energy

Center #4Malaysia: 1unit

Boxberg R

German: 8units

South Africa: 12units

Mexico: 1uinit

Italy: 3units

China: 40units(by MHPS / Licensee)

Henung Yuhuan #1 to #4And 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 MarketIPP L&T RajpuraSC 700MW x 2

Rajasthan State Power Generation /ChhabraSC 660MW x 2

IPP Jaypee NigrieSC 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 : 866MWMain Steam Flow : 2,695 t/hMain Steam : 538 oC / 24.9 MPagReheat Steam : 566 oCCommercial Operation : 2012/4Fuel : Sub-bituminous coalThermal efficiency : Approx. 2 ~ 3% better*1

Indonesian Project Paiton III


•First coal-fired SC plant in Indonesia•MHPS supplied boiler and steam turbine including construction work



Germany Project Boxberg R

17

Output : 1 x 670MWMain Steam Flow : 1,760 t/hMain Steam : 600 oC/ 29.4 MPagReheat Steam : 610 oCCommercial Operation : 2012/10Fuel : German Lignite coalThermal efficiency : Approx. 5 ~ 6% better*1


•USC steam condition was applied to German lignite-fired boiler•Water content in the coal is approx. 60% and LHV is approx. 2000kcal/kg



3. Air Quality Control System



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 Systemsor Hitachi Plant Construction

ESP*GGHHeat Extractor

GGHRe Heater

FGD

SCR

2次空気2次空気

Low NOx Combustion

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(p

pm)

High Efficiency AQCS development history (PM, SO2)

PM: <20mg/m3N

EP : Electrostatic PrecipitatorGGH ： Gas Gas HeaterRGGH : Rotary GGHH/E : Heat ExtractorR/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 LeakGGH（H/E） FGD

EP（LL temp）FGD

Non LeakGGH（R/H）

EP(Low temp)

Stack StackNon Leak

GGH（H/E）

Non LeakGGH（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

ConventionalBurner

SGRPM

PM+Two-stage combustion

[Coal Firing Boiler] 200ppm (@6%O2)

100

200

300

400

500

600

1980 1985 1990 1995 2000

NO

x (p

pm) 400ppm

300ppmGovernmental

Regulation Local Regulation~50ppm (@6%O2)

NOx Reduction with SCR

NO

x (m

g/m

3 N, 6

%O

2)

00

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.Korea21

Mexico18

Brazil26

Chile11

Saudi Arabia17

Philippines14

Taiwan25

Russia4

China52

Indonesia10Singapore

21

Hong Kong16Thailand

16

Ukraine3Netherlands

1

Austria1

South Africa4

10

17

5

India1 13

Denmark4

12

USA

1

32

25Germany

Italy

Finland4

Czech10

Poland7

14Spain

England12

１

Turkey5

Canada1

Colombia5

Curacao3

Venezuela4

AustraliaMalaysia

1

Myanmar1

Yugoslavia1

Libya3

Zambia2

555

341

17

L

2

2

45

32

L 7

3

2

4

7

3

7

L

3Greece1

Portugal4


MHPS’s AQCS Global Activities

Number ：ReferencesL ：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 138tWelding method: Narrow Gap HSTMaterial: 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 CycleOutline of IGCC System


C～ T

HRSG

～

Gas Turbine

Coal

Gasifier

Cleanup

AirComp.

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.LTDNakoso #10(Demo. 2007-, Commercial 2013-)

Osaki CoolGen Corp. Osaki CoolGen Project(Demo. 2017-)

Rendering Image

IGCC Projects in Japan(Demonstration and Commercial Plant)

26

Features of IGCC system

© 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 CirculatingWaterPlant

Efficiency

(%)

EmissionAsh

0

20

40

60

80

100

120

▲65%

▲35%

▲40%

＋~45%vs. sub-C

140

160Coal 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”

27

Nakoso 250MW IGCC Plant

28© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved

Nakoso250MW 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 ScheduleOperation Started Sep. 2007Commercial 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

Targets Achievements Note

Performance

Output (Gross)(Net)

250MW220MW

250MW225MW

Efficiency (Net, LHV) > 42.0% 42.9%

Carbon Conversion > 99.9% > 99.9%

Emission(@dry, 16%O2)

SOx NOx Dust

< 8 ppm< 5 ppm

< 4 mg/m3N

1.0 ppm3.4 ppm

< 0.1 mg/m3N

Operational Flexibility

Coal KindsBituminousSub-

bituminous

Chinese, Canadian2 US (including PRB)3 Indonesian (Adaro,

etc.)Colombian, Russian

9 kinds of coal in total5 Sub-bituminous4 Bituminous

have been used.

Start-up Time < 18 hr 15 hr

Minimum Load 50% 36%

Ramping Rate 3%/min 3%/min

ReliabilityLong-term Continuous Operation

2,000 hr 3,917 hr Cumulative operating hours :> 25,000 hrs.

Achievements of Nakoso 250MW IGCC Plant


0

20

40

60

80

100

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

Load

Factor [%]

Achievements of Nakoso 250MW IGCC PlantOperability (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

85 41 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 92013 2014

Commercial Operation

Operation history and schedule after starting commercial operation (June 30, 2013).

Maintenance*


DesignTest Results

Osaki CoolGen Project


Major SpecificationOutput 166 MW (gross)Gasifier Oxygen-blown Dry Feed

Gas Clean-Up MDEA(Methyldiethanol Amine)

Gas Turbine 1300oC classPlant Efficiency 40.5% (HHV, net)

Project ScheduleConstruction Started March 2013Demo. Operation Start March 2017Rendering Image

Commercial-scale IGCC Project


High Efficiency by using state of the art Gas TurbineLower CO2 emission intensity than the latest USC coal fired power plant.Fuel Flexibility for high moisture Low Rank CoalHighly Reliable system verified in Nakoso 250MW IGCC plant

Major Specification

Output 540 MW (gross)480 MW (net)

Gasifier Air-blown Dry FeedGas Clean-Up MDEAGas Turbine M701F GT (1 on 1)Plant Efficiency 48% (LHV, net)

33

• In July 2014, MHI Received Order for World's Largest Post Combustion CO2 Capture System for a Coal-fired Power Generation Plant,for Japan-U.S. Joint Enhanced Oil Recovery (EOR) Project

• Project : CO2 Capture + EOR

• Developed by NRG Energy and JX Japan

• Supported by U.S. DOE and JBIC

• Client: Petra Nova CCS • Plant: NRG Parish Station• Location: Texas • Capacity: 4,776 MT/Day• CO2 Capture Technology:

MHI’s KM CDR Process • Solvent: KS-1• Operation Start: 2016

CO2 Scrubbing + EOR


Clean Coal Technology Showcase Project in U.S.

34

Showcase Project:‐ Coal Upgrading (Hg Removal)‐ CO2 Capture + EOR‐ AQCS + Zero Liquid Discharge

MHPS/MHI can provide one‐stop solution to Existing Coal Power Plant


35

Conclusion

MHPS shall be continuously developing clean coal technology to improve plant efficiency and reduce carbon emission

MHPS shall contribute to environmental conservation and carbon emission reductionto provide Japanese clean coal technology worldwide


global activities for clean coal technology

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