Global Activities for Clean Coal Technology

Transcription

1 Global Activities for Clean Coal Technology September 9, 2014 Yozaburo Mabuchi Senior Executive Vice President Mitsubishi Hitachi Power Systems, LTD

2 Contents 1. Introduction of MHPS 2. Supercritical / Ultra-Supercritical Power Plant 3. Air Quality Control System 4. Advanced Clean Coal Technology 1

3 1. Introduction of MHPS 2

4 Mitsubishi Hitachi Power Systems, Ltd (MHPS) Name Head Office MITSUBISHI HITACHI POWER SYSTEMS, LTD. Yokohama, Kanagawa, JAPAN Representatives Koji Tanaka (Chairman of the Board) Takato Nishizawa (President and CEO) Capital 100 Billion JPY Effective Date February 1, 2014 Integration in the Thermal Power Generation Systems Field Employees 23,000 (incl. 7,600 outside Japan) 3

5 Head Office & Main Works in Japan Kure Division of Babcock-Hitachi K.K. Takasago Works Hitachi Works Nagasaki Works Yokohama Works Yokohama Head Office 4

6 Global Network of MHPS MHPS Europe (UK) MHPS Europe (Germany) MHPS Dongfang JV DHME (Dalian) MHPS Canada MHPS America Energy and Environment BHPI MHPS Africa (RSA) L&T MHPS JV MHPS Technical Services MHPS Americas MHPS has 58 companies in 26 countries. CBC 5

7 MHPS s Business Field Products & Services Gas Turbine Combined Cycle (GTCC) Power Plants Boilers Integrated coal Gasification Combined Cycle (IGCC) Power Plants Environmental Plants SCR Systems, FGD Systems Gas Turbines Generators Boiler & Turbine Generation Plants Geothermal Power Plants Steam Turbines Power Generating Plant Peripheral Equipment SCR Systems Plant Control System Fans Fuel Cells (SOFC) 6

8 Delivery Records 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 *1; Conversion value corresponding to main steam *2; Over 50MW coal-fired power plant 7

9 2. Supercritical/Ultra-Supercritical Power Plant 8

10 Comparison of Coal Fired Plant Thermal Efficiency by Individual Countries 石炭焚火力発電プラントの比較 ( 米国 vs. 日本 ) Average Gross Thermal Efficiency (LHV, %) Source:; International comparison of fossil power efficiency and CO2 intensity - Update 2013, Ecofys 9

11 Efficiency vs Steam Condition for Coal Fired Plant History of steam condition and thermal efficiency in Japanese thermal power plant Steam Temp. ( o C) Gross Plant Efficiency Steam Temperature 538 C SC(Supercritical) 620 C 600 C 610 C 593 C 566 C USC(Ultra-Supercritical) A-USC Gross Plant Efficiency (LHV%) Year 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 10

12 MHPS Various Coal Experience MHPS can provide various power plants best suited for various kinds of coal based on abundant experiences. Anthracite Bituminous Sub-Bituminous Lignite 11

13 Coal-Fired SC/USC Plant in Japan 中国電力 Misumi#1 ( 98) 1,000MW 24.5MPa x 600/600 関西電力 Maizuru#1 ( 04) 900MW 24.5MPa x 595/595 北陸電力 Tsuruga#1&2( 91/ 00) 500MW 24.1MPa x 566/ MW 24.1MPa x 593/593 東北電力 Haramachi#1&2( 97/ 98) 1,000MW 24.5MPa x 566/593 1,000MW 24.5MPa x 600/600 Total: 25units 九州電力 Matsuura#1 ( 89) 700MW 24.1MPa x 538/566 東京電力 Hirono#5&6( 04/ 13) 600MW 24.5MPa x 600/600 電源開発 Tachibanawan#2( 00) 1,050MW 25.0MPa x 600/610 四国電力 Tachibanawan#1( 00) 700MW 24.1MPa x 566/593 中部電力 Hekinan#1&2( 91/ 92) 700MW 24.1MPa x 538/566 東京電力 Hitachinaka#1&2( 03/ 13) 1,000MW 24.5MPa x 600/600 12

14 Coal-Fired SC/USC Plant in overseas German: 8units China: 40units (by MHPS / Licensee) Japan: 25units Total: 122units MHPS: 82 units Others: 40 units (Chinese licensee, Indian JV) Boxberg R Henung Yuhuan #1 to #4 And 37units Misumi #1 Netherlands: 2units Italy: 3units Korea: 4 units USA: 4units Poland: 1unit Canada: 2units ENEL Torrevaldaliga Nord #2-4 Greece: 1unit Enea, Kozienice Taiwan: 8units Taiwan Power Co., Ltd. LIN KOU #1-3 Malaysia: 1unit Midamerican Energy, Walter Scott Jr. Energy Center #4 South Africa: 12units India: 8units (by L&T-MHPS Boilers Pvt. Ltd. as JV) Indonesia: 1unit Australia: 1unit Mexico: 1uinit Jaypee Nigrie #1,2 Mahagenco Koradi #8,9,10 Rajpura #1,2 Paiton III Expansion CS Energy Kogan Creek #1 CFE Pacifico #1 13

15 Global Activity with SC/USC Technology Indian Project Rajpura #1 Rajpura #1 was placed under commercial operation Feb 1 st, 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 : Main Steam Flow : Main Steam : Reheat Steam : 700MW 2,322 t/h 565 o C / 24.1 MPag 593 o C Commercial Operation : 2014/2 Fuel : NOx (ppm) : Bituminous coal 116 (actual) / 365 (limits) Thermal efficiency : Approx. 4 ~ 5% better *1 *1: Relative value as compared with Sub-critical plant (16.7MPag, 538/538 o C) 14

16 Activities at Indian Market IPP L&T Rajpura SC 700MW x 2 LMB(L&T-MHPS Boilers Private Ltd.) Rajasthan State Power Generation /Chhabra SC 660MW x 2 IPP Jaypee Nigrie SC 660MW x 2 LMTG(L&T MHPS Turbine Generators Private Ltd.) Maharashtra State Power Generation /Koradi SC 660MW x 3 MHPS has contributed to Indian power generation with Japan oriented CCT through the JV with Indian company, Larsen & Toubro, Ltd. 15

17 Global Activity with SC/USC Technology Indonesian Project Paiton III First coal-fired SC plant in Indonesia MHPS supplied boiler and steam turbine including construction work Output : Main Steam Flow : Main Steam : Reheat Steam : 866MW 2,695 t/h 538 o C / 24.9 MPag 566 o C Commercial Operation : 2012/4 Fuel : Sub-bituminous coal Thermal efficiency : Approx. 2 ~ 3% better *1 *1: Relative value as compared with Sub-critical plant (16.7MPag, 538/538 o C) 16

18 Global Activity with SC/USC Technology Germany Project Boxberg R USC steam condition was applied to German lignite-fired boiler Water content in the coal is approx. 60% and LHV is approx. 2000kcal/kg Output : Main Steam Flow : Main Steam : Reheat Steam : 1 x 670MW 1,760 t/h 600 o C/ 29.4 MPag 610 o C Commercial Operation : 2012/10 Fuel : German Lignite coal Thermal efficiency : Approx. 5 ~ 6% better *1 *1: Relative value as compared with Sub-critical plant (16.7MPag, 538/538 o C) 17

19 3. Air Quality Control System 18

20 Air Quality Control System for Coal Fired Plant FGD 2 次空気 Low NOx Combustion SCR GGH Heat Extractor (GGH: Gas to Gas Heater) ESP* * ESP will be supplied by MHI-Mechatronics Systems or Hitachi Plant Construction GGH Re Heater One-stop AQCS solution by MHPS World lowest level emission (SOx, NOx, PM) can be achieved by applying the integrated AQCS system 19

21 High Efficiency AQCS development history (PM, SO 2 ) 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 EP (Low temp) Non Leak Non Leak RGGH FGD Stack EP GGH GGH Stack (Low temp) (H/E) FGD (R/H) Non Leak Non Leak GGH EP GGH Stack (H/E) (LL temp) FGD (R/H) SO2 (ppm) SO2:100ppm SO2:50ppm PM: <20mg/m 3 N Non Leak GGH applied to prevent dirty gas leakage. SO2:24ppm PM: < 7mg/m 3 N High Efficiency System High Efficiency system with low-low temperature EP applied EP : Electrostatic Precipitator GGH : Gas Gas Heater RGGH : Rotary GGH H/E : Heat Extractor R/H : Re Heater 20

22 Low NOx Combustion Technologies and SCR system Latest Low NOx Burner SCR System M-PM Burner NR3 Burner Honeycomb Catalyst Plate Catalyst NOx (ppm) Conventional Burner 400ppm SGR 300ppm PM Governmental Regulation [Coal Firing Boiler] 200ppm (@6%O2) Combustion technologies without SCR PM+Two-stage combustion NOx Reduction with SCR 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. Local Regulation ~50ppm (@6%O 2 ) A-PM+Two-stage combustion 1,200 1, NOx (mg/m 3 N, 6%O 2 ) M-PM 200 +Two-stage combustion

23 MHPS s AQCS Global Activities MHPS Delivered AQCS units all over the world Denmark Finland Poland Germany 4 Czech Austria England Ukraine Netherlands Yugoslavia 1 Portugal Greece Turkey 4 1 L Spain Italy 5 Libya Saudi Arabia India L Zambia 2 South Africa 4 Myanmar 1 Thailand 16 5 Malaysia 1 Singapore 21 Russia 4 S.Korea China Australia 3 Japan MHPS , Taiwan Hong Kong 16 Philippines Indonesia 10 1 :SCR 1,027 Units (13 Countries) :ESP 1,543 Units (29 Countries) :FGD 303 Units (19 Countries) Canada 1 L USA 341 Mexico Colombia 5 2 Chile 11 1 Curacao 3 Brazil 2 26 Venezuela 4 Number :References L :License 22

24 4. Advanced Clean Coal Technology 23

25 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 Schedule A-USC Development Outline and over Target Steam Temp. : 700 o C Next Generation Development Goal is Net Efficiency 46-48% (HHV) Development Matter Material (Ni-base Alloy) Manufacturing Technique Design Lifetime Assessment Methodology High Temp Corrosion Steam Oxidization Fatigue / Creep Rupture Conceptual Design 100,000 hr Creep Test Verification of Manufacturing Technique (welding, bending) Mock-up Test (header, S/H) Test Loop under 700 o C Steam Temp. 24

26 Development of Material for Advanced USC Welding test for large-bore piping 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 Pipe size: φ558.8 x 138t Macro / Micro structure Welding method: Narrow Gap HST Material: HR6W High frequency induction bending for HR6W Mockup fabrication of HR6W header Heating temperture : (φ350 x 40t, Bend radius 1,400mm, Bend angle 50o) 25

27 Outline of IGCC System *Integrated coal Gasification Combined Cycle What is IGCC? Higher efficiency through coal gasification process coupled with a combined cycle (CC) system. Reduce CO2 emission by high efficiency and prevent global warming IGCC Projects in Japan (Demonstration and Commercial Plant) Combined Power Generation (Combination of Brayton & Rankine Cycles) Coal Gasifier Steam Turbine ~ TEPCO Fukushima IGCC Project (2020~) Nakoso site, Hirono site Clean up Air Comp. Combustor ~ Air C T Gas Turbine HRSG Flue Gas Osaki CoolGen Corp. Osaki CoolGen Project (Demo ) Rendering Image Joban Joint Power Co.LTD Nakoso #10 (Demo , Commercial 2013-) 26

28 Features of IGCC system Higher Efficiency and Least Environmental Impact 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%. Flexibility to Variety of Coal 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 (%) ~45% vs. sub-c Coal fired conventional power plant (sub critical plant) =100% 35% 65% 40% 0 Circulating Plant CO2 Ash Water Efficiency Emission Performance of IGCC System Flyash (Conventional Boiler) Approx. 65% decrease in volume Grassy Molten Slag (IGCC) Utilization as a Utilization as a pavement material concrete aggregate are possible. Suitable for IGCC Symbol shows gasifier experienced coals Suitable for Conventional Boiler Applicable Coal Range 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 27

29 Nakoso 250MW IGCC Plant Nakoso 250MW IGCC Major Specification Output 250 MW (gross) Gasifier Gas Clean-Up Air-blown Dry Feed MDEA (Methyldiethanol Amine) Gas Turbine M701DA GT (1 on 1) Plant Efficiency 42% (LHV, net) Project Schedule Operation Started Sep Commercial Operation July 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 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 28

30 Achievements of Nakoso 250MW IGCC Plant Targets Achievements Note Performance Output (Gross) (Net) 250MW 220MW 250MW 225MW Efficiency (Net, LHV) > 42.0% 42.9% Carbon Conversion > 99.9% > 99.9% Emission 16%O2) SOx NOx Dust < 8 ppm < 5 ppm < 4 mg/m 3 N 1.0 ppm 3.4 ppm < 0.1 mg/m 3 N Operational Flexibility Reliability Coal Kinds Bituminous Subbituminous Chinese, Canadian 2 US (including PRB) 3 Indonesian (Adaro, etc.) Colombian, Russian Start-up Time < 18 hr 15 hr Minimum Load 50% 36% Ramping Rate 3%/min 3%/min Long-term Continuous Operation 2,000 hr 3,917 hr 9 kinds of coal in total 5 Sub-bituminous 4 Bituminous have been used. Cumulative operating hours : > 25,000 hrs MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 29

31 Achievements of Nakoso 250MW IGCC Plant Operability (Load Change) Verified at 3%/min load change operation which is required as middle range operation 100 Reliability 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. Load Factor [%] Continuous Operation 3,917 hrs. Average Load Factor > 99% Environmental Performance Design Test Results 0 28 Jun 26 Jul 23 Aug 20 Sep 18 Oct 15 Nov Operation history and schedule after starting commercial operation (June 30, 2013). 20 Commercial Operation 10 0 Net Efficiency (%-LHV) 8 SOx (ppm) <0.1 NOx (ppm) Dust (mg/kg) Maintenance* *: Maintenance for changing from demonstration to commercial plant and intermittent inspection 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 30

32 Osaki CoolGen Project Rendering Image Major Specification Output Gasifier Gas Clean-Up 166 MW (gross) Oxygen-blown Dry Feed MDEA (Methyldiethanol Amine) Gas Turbine 1300 o C class Plant Efficiency 40.5% (HHV, net) Project Schedule Construction Started March 2013 Demo. Operation Start March MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 31

33 Commercial-scale IGCC Project Major Specification Output 540 MW (gross) 480 MW (net) Gasifier Air-blown Dry Feed Gas Clean-Up MDEA Gas Turbine M701F GT (1 on 1) Plant Efficiency 48% (LHV, net) 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 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 32

34 CO 2 Scrubbing + EOR 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: MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 33

35 Clean Coal Technology Showcase Project in U.S. MHPS/MHI can provide one stop solution to Existing Coal Power Plant Showcase Project: Coal Upgrading (Hg Removal) CO2 Capture + EOR AQCS + Zero Liquid Discharge 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 34

36 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 reduction to provide Japanese clean coal technology worldwide 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved 35

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