Clean coal technology required for the future and development of IGCC technology.

Transcription

1 Clean coal technology required for the future and development of IGCC technology. November 10, 2009 Tsutomu Watanabe Clean Coal P R&D Co., Ltd. 1 Copyright Clean Coal P R&D Co., Ltd

2 Coal demand growth in the world Forecast of world primary energy demand by fuel million tons oil equivalent 20,000 15,000 10,000 5, , % 10,034 11,730 45% increase 14,121 17, % 26.0% 28.5% 28.8% Other renewables Biomass and waste Hydro Nuclear Natural gas Oil Coal Source:IEA World Energy Outlook 2008 In 2030, total primary energy demand would be 45% higher in the world. The share of coal in global primary energy demand would reach about 30% in 2030 according to the IEA prospect. The coal utilization is expected to be expanded to cope with economic growth in the world. 2 Copyright Clean Coal P R&D Co., Ltd

3 Status of coal fired p in the future TWh Forecast of p generation by fuel Renewables Hydro Nuclear Natural gas Oil Coal World China India USA Germany UK Korea Japan Russian Canada Italy France Brazil Fuel mix in p generation Coal Oil Natural gas Nuclear Hydro Others 0% 20% 40% 60% 80% 100% Source:FEPC Nuclear & Energy 2009 Source:IEA World Energy Outlook 2008 The share of coal fired p in total generation is expected to increase from 41% at present to 44% in Coal fired p would play a major role in electric p section. 3 Copyright Clean Coal P R&D Co., Ltd

4 Why coal fired p? amount and distribution of energy resources Amount of reserves Minable years Coal Natural gas Oil Uranium Amount of coal reserves is relatively large Distribution of reserves North S. & Cent. North S. & Cent. America Asia Middle East America 1.8% S. & Cent. America 4.8% America 4.0% 5.6% Pacific America 6.1% & Africa 4.0% 3.3% Asia S. & Cent. Pacific America 9.8% North Europe 8.3% Asia America North & Eurasia Pacific Middle East 16.6% America 33.0% Middle East 28.4% Europe & Africa 29.8% & Africa & Eurasia 48.9% 69.9% Europe Asia Pacific 34.0% & Eurasia 31.4% Europe 27.8% Middle East & Eurasia & Africa 21.0% 826 billion tons 185 trillion m % 1258 billion barrels 4.74 million tons Coal is evenly distributed Source:BP Statistical Review 2009 URANIUM Copyright Clean Coal P R&D Co., Ltd

5 Main reserves of coal in the world Total World : 826 billion tons Europe & Eurasia 33.0% bil. tons North America 29.8% Middle East &Africa 4.0% 33.4 bil. tons Asia Pacific 31.4% bil. tons S. & Cent. America bil. tons 1.8% 22% 15.0 bil. tons 100 bil. tons 10 bil. tons Source:BP Statistical Review Copyright Clean Coal P R&D Co., Ltd

6 Why coal fired p? Stability of price /1,000kcal Trend of the prices of fossil fuel in Japan (Imported prices: all are imported in Japan) Steam coal LNG Crude oil until August, 2009 Source: Ministry of Finance / Trade Statistics of Japan Coal price is expected to be stable, compared with other fossil fuel prices. 6 Copyright Clean Coal P R&D Co., Ltd

7 Why coal fired p? 3E-concept for energy utilization - Relation between energy mix and coal utilization - Reduction in in SOx, NOx, Particulate and and CO2 emissions. Use of of existent air air pollution control technologies(desulfurization facility, denitrification facility, electric precipitator) CO2 reduction technology is is expected to to advance. Advances of of the the technology in in the the future has has already been incorporated. Environmental Protection The balanced achievement of these 3E-concept is important. Energy Security Economic Growth Increase of of kinds of of usable coal Use of of low low rank coals Use of of CO2 free fuel fuel coal fired p with biomass fuel fuel Highly effective energy utilization Improvement of of existing p station facilities and improvement of of efficiency by optimization of of operation would be expected. Replacement of of existing superannuation facilities with highly effective facilities Development of of highly effective technology for coal utilization. 7 Copyright Clean Coal P R&D Co., Ltd

8 Technical issues to respond to expectation of coal utilization Development of clean coal p technology The expectation for coal use for the future is great. Technological development to respond to the expectation is to be achieved Environmental Protection technology compatible with Economic Growth Reduction in CO2 emission 0.10 Method1: Improvement of thermal efficiency 0.05 Combustion technology (USC, A-USC) Coal gasification technology 0.00 (IGCC,( IGFC * )) *IGCC with fuel cell Method2: CO2 capture and storage CO2 capture technology (pre-combustion + conventional plant or IGCC) and (post-combustion + conventional plant), etc. CO2 storage technology could be applied to all the fossil fuel Energy Security IGCC is an effective option to solve the technical issues realize 3E concept. Copyright Clean Coal P R&D Co., Ltd Comparison of CO2 emission kg-co2/mj : : Thermal coal Crude oil LNG Use of low rank coals that is hardly used in conventional coal fired plants. Coal gasification technology (IGCC) others? 8

9 IGCC technology : Thermal efficiency Improvement Net Plant Efficiency (%LHV) Prospected IGCC applied for 1700 GT In the near future IGCC by 1600 GT Target is equal to or over 50% IGCC(48~50%) by 1500 GT IGCC(45~46%) by 1300 GT IGCC Demo Plant(42%) by 1200 GT USC PC Units(41~43%) Conventional PC Units(40~41%) Thermal efficiency improves in cope with high temperature gas turbine combined cycle technology. 9 Copyright Clean Coal P R&D Co., Ltd

10 IGCC technology : Effect of thermal efficiency Improvement Thermal efficiency of coal fired p stations in the world(2006) LHV% 60% 50% Thermal efficiency 50% is expected by IGCC 40% potential 30% 20% Japan Germany USA Austraila China India Source: ECOFYS, INTERNATIONAL COMPARISON OF FOSSIL POWER EFFICIENCY (2008) Large potential of improvement in coal fired p efficiency by IGCC though upper assumption would not be practical at present. 10 Copyright Clean Coal P R&D Co., Ltd

11 IGCC technology : Increase in kinds of coal Billion tons North America Amount of coal that can be used For IGCC For PCF China India Australia South Africa (example in Japan) PCF : Pulverized Coal Firing Indonesia Low rank coal use could be increased because IGCC utilizes different type of coals. Biomass fuel can be also used for IGCC. 11 Copyright Clean Coal P R&D Co., Ltd

12 Relation between CO2 capture technology and IGCC CO2 capture technology pre-combustion type and post-combustion type, etc. IGCC applying pre-combustion technology could compensate the thermal efficiency decrease caused by CO2 capture, because of the high efficiency p generation. Although effectiveness should be studied, application of post-combustion type might be possible. It would depend on technological development in the future what type of CO2 capture technology is the best for IGCC. Moreover, highly effective and zero emission p generation would be achieved by combining IGFC (IGCC with fuel cell) with CCS by application of pre-combustion technology. It would be matter for long-term technological development 12 Copyright Clean Coal P R&D Co., Ltd

13 Introduction : Fundamental concept of IGCC System IGCC: Integrated Coal Gasification Combined Cycle IGCC is a new p generation system aiming at higher efficiency than conventional coal-fired systems by integrated coal gasification with combined cycle p generation technology. Coal Technology breakthrough part Gas purification technology improvement of environmental performance Gasifier Gas Turbine Conventional part Boiler (HRSG) Exhaust Gas Treatment (NOx) Gasification technology Increase of kinds of usable coal CO2 capture technology Expectation of CO2 free Steam Turbine Various clean coal p technologies are applied to IGCC. 13 Copyright Clean Coal P R&D Co., Ltd

14 Introduction : Gasification technology Coal with low ash melting temperature hardly used in conventional stations, could be used in IGCC. Low rank coal and biomass fuel could be also usable. Volume of waste is reduced by half in IGCC, compared with conventional stations becasue coal ash is discharged from the gasifier as glassy slag. Solid fuel + Air Gasifier Reaction for Gasification C + CO2 = 2CO C + H2O = CO + H2 CO + H2O = CO2 + H2 CO,H2 rich gas CO H2 NH H 2 S 3 HCl Slag Copyright Clean Coal P R&D Co., Ltd N 2 14

15 Introduction : Gas purification technology Gas purification facility of IGCC removes sulfur compound and nitrogen compounds, etc. Exhaust of SOx, NOx and particulate to the atmosphere is decreased. Before gas purification Water Amine solution After gas purification CO H2 CO H2 H 2 S N 2 HCl NH 3 Removing nitrogen compound, etc. Removing sulfur compound. N 2 particulate HCl NH 3 H 2 S gypsum 15 Copyright Clean Coal P R&D Co., Ltd

16 IGCC + CO2 capture by pre-combustion technology IGCC + CO2Capture (pre-combustion Type) CO is converted into CO2 by injecting steam(h2o) into the fuel gas before combusting in the gas turbine CO2 is collected through CO2 separation and capture facility. CO CO2 Coal Gasifier Gas purification H2 CO conversion facility H2 CO2 separation and capture facility H2 Gas Turbine H2O CO2 16 Copyright Clean Coal P R&D Co., Ltd

17 IGCC project in Japan : Location of demonstration plant Fukushima Prefecture IWAKI City IWAKI city Nakoso area TOKYO Demonstration Plant Located within the NAKOSO P Station of JOBAN JOINT POWER CO.,LTD. Copyright Clean Coal P R&D Co., Ltd 17

18 IGCC project in Japan : Schematic diagram of the IGCC Coal Gasifier HRSG Porous Filter Gas Turbine Wet Gas Clean-Up Combustor Gypsum recovery Air Steam Turbine Char G Slag N 2 Air O 2 Air is utilized for burning coal ASU M Gasifier Boost-up Compressor ASU of Air-blown IGCC is very small. HRSG Stack Mainly N2 is utilized for coal and char transport 18 Copyright Clean Coal P R&D Co., Ltd

19 Comparison among IGCC Projects IGCC projects with O2-blown type have been executed all over the world while air-blown type IGCC is adopted in Nakoso. Projects Site Buggenum Netherland Puertollano Spain Wabash River USA Tampa USA Nakoso Japan Gasifier type O 2 -blown Dry-feed (Shell) O 2 -blown Dry-feed (Plenflo) O 2 -blown Slurryfeed (E-Gas TM ) O 2 -blown Slurryfeed (GE) Air-blown Dry-feed (MHI) Coal consumption 2,000 t/d 2,600 t/d 2,500 t/d 2,500 t/d 1,700 t/d Gross output (GT) 284 MW (1100 class) 335 MW (1300 class) 297 MW (1300 class) 315 MW (1300 class) 250MW (1200 class) Demonstratio n test start Jan Dec Oct Sep Sep Copyright Clean Coal P R&D Co., Ltd

20 Advantage of Air-blown IGCC Air-blown IGCC applied in Nakoso is expected to realize high thermal efficiency compared with oxygen-blown IGCC Thermal efficiency Auxiliary P Gross efficiency Net efficiency Oxygen-blown IGCC Air-blown IGCC Copyright Clean Coal P R&D Co., Ltd 20

21 Specification of Nakoso IGCC Capacity Coal Consumption System Efficiency (Target Values) Flue Gas Properties (Target Values) Gasifier Gas Treatment Gas Turbine Gross 250 MW gross approx. 1,700 metric t/day Air-blown & Dry Feed Wet (MDEA) + Gypsum Recovery class (50Hz) 48% (LHV) 46% (HHV) Net 42% (LHV) * 40.5% (HHV) SOx NOx Particulate 8 ppm 5 ppm 4 mg/m 3 N (16%O 2 basis) *While target net thermal efficiency is 48~50% in commercial IGCC plant applying 1500 class gas turbine, class gas turbine was adopted to reduce the capacity of plant for economy 21 Copyright Clean Coal P R&D Co., Ltd

22 Status of operating test on Nakoso IGCC Construction of demonstration plant was completed in September, 2007 Operating test started after the completion. Operating test is still going on and will end in March, The main results of operating test at present Result value of net thermal efficiency is 42.9%LHV (target value is 42%) Highly efficient operation was achieved. The amount of SOx, NOx and particulate emission is less than designed value. Environmental performance was satisfied with the design. 2,000hours continuous operation was achieved in the first year. Reliability was confirmed. Stable operation with bituminous coal (China) and subbituminous coal (USA, Indonesia) was confirmed. Several kinds of coal were tested to increase the flexibility. 22 Copyright Clean Coal P R&D Co., Ltd

23 Status of operating test on Nakoso IGCC Remaining items in the test 5,000 hour durability test is continuing until March Additional kinds of coal flexibility test Operational optimization tests Subject after the operation test Japanese government is now conducting feasibility study of CCS application utilizing the Nakoso IGCC plant. 23 Copyright Clean Coal P R&D Co., Ltd

24 CONCLUDING REMARKS: Regarding IGCC Development of clean coal p technology is a key factor to solve the global warming issue while pursuing 3E concept. Therefore, in Japan, entire electric p utilities are involved in the IGCC technology development.. Wide market expansion regarding the technology is expected in the developing country and the advanced country including BRICS. It seems that international technological competition would advance. Each country would hopefully work positively regarding IGCC technology to achieve worldwide economic growth and 3E simultaneously. CCP R&D would like to join the effort and contribute to the technological progress. 24 Copyright Clean Coal P R&D Co., Ltd

25 CONCLUDING REMARKS: In General It will be necessary for the electric p industry to develop the technology of the combination with ready-made technologies, new technologies and other industry (Regarding IGCC; Chemical industry) technologies in the future. For realizing good combination, Integrated technological control and measures with such as the cost reduction of individual elements while achieving reliability improvement IGCC is the typical example, and the integrated system consists of considerably complex elements. IGCC would hopefully become a good example for such efforts on the technological development of overall system and each element. 25 Copyright Clean Coal P R&D Co., Ltd

26 Thank you! 26 Copyright Clean Coal P R&D Co., Ltd

27 Attachment 1: Demonstration Project Scheme 30% subsidy METI METI: Ministry of Economy, Trade and Industry CCP Joint project agreement 70% contribution Personnel Hokkaido EPCo. Tohoku EPCo. Tokyo EPCo. Chubu EPCo. Hokuriku EPCo. Kansai EPCo. Chugoku EPCo. Shikoku EPCo. Kyushu EPCo. J-POWER CRIEPI EPC Contract Mitsubishi Heavy Industries, Ltd. Operator, etc. Joban Joint P Co., Ltd. 27 Copyright Clean Coal P R&D Co., Ltd

28 Attachment 2:View of IGCC Demonstration Plant HRSG Gasifier GT, ST & Generator Gas Clean-up 28 Copyright Clean Coal P R&D Co., Ltd

29 Attachment 3: Demonstration Project Schedule FY Preparatory verification test Design of demo plant Environmental Impact assessment Construction of demo plant CCP established Operating test The construction work finished in September 2007, and the test operation has been executing now. 29 Copyright Clean Coal P R&D Co., Ltd

30 Attachment 4: Status of Targets & Accomplishments Target First year Second year Third year Safe and Stable Operation Long Term Continuous Operation 250MW >2000hr Net Thermal Efficiency >42.5% (LHV basis) 250MW 2039hr ( hr) Carbon Conversion Rate >99.9% >99.9% Environmental Performance Coals SOx <8ppm NOx <5ppm Dust <4mg/m3N Bituminous Sub-bituminous 42.4% 42.9% 1.0ppm 3.4ppm <0.1mg/m3N Chinese Start-up Time <18hr 20hr 15hr Minimum Load 50% 50% Chinese, PRB & Indonesian expand coal flexibility Load Change Rate 3%/min 1.2%/min (no try) 3%/min Durability & Maintainability Evaluate during 5000hr test (in progress now) 5000hr evaluation 30 Copyright Clean Coal P R&D Co., Ltd

31 Attachment 5: Optimization Test Results Design values Results Atmospheric Temperature Gross Output Gas Turbine Output Steam Turbine Output Net Efficiency (LHV) 15 C (59 degf) 250 MW MW MW 42.5 % 9.9 C (50 degf) MW MW MW 42.9 % Cold Gas Efficiency of Gasifier Carbon Conversion Efficiency 73 % >99.9 % 77 % >99.9 % Syngas LHV Composition CO CO2 H2 CH4 N2 & Others 4.8 MJ/m3N 28.0 % 3.8 % 10.4 % 0.3 % 57.5 % 5.6 MJ/m3N 31.9 % 2.7 % 10.0 % 1.4 % 54.0 % Environmental Performance (16% O2 Corrected) SOx NOx Particulate <Target values> 8 ppm 5 ppm 4 mg/m3n 0.5 ppm 3.9 ppm <0.1 mg/m3n Correction value at Copyright Clean Coal P R&D Co., Ltd

32 Attachment 6: Operating Results (As of October 31,, 2009) Operating Time GT Operation by Syngas Gasifier Operation 4,911 hrs 5,008 hrs P Generation Fuel Consumption Cumulative gross output Cumulative coal consumption 1,010 GWh 332 kton (metric) 32 Copyright Clean Coal P R&D Co., Ltd