Development status of the EAGLE Gasification Pilot Plant

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1 Development status of the EAGLE Gasification Pilot Plant Gasification Technologies 2002 San Francisco, California, USA October 27-30, 2002 Masaki Tajima Energy and Environment Technology Development Dept. New Energy and Industrial Technology Development Organization JAPAN Jun-ichi Tsunoda ( junichi_tsunoda@jpower.co.jp ) EAGLE Technology Development Group Wakamatsu Research Institute Technology Development Center Electric Power Development Co., Ltd. JAPAN Electric Power Development Co., Ltd. 1

2 1. Introduction In the energy policy of Japan, the coal has been held an important position as alternative energy resource to oil because coal is a fossil fuel abundant and widespread all over the world. In Japan, it is a vital resource for energy security because the supply is stable. In the long-term energy supply-demand outlook, the proportion of coal fired power generation occupied for installed generating capacity is being estimated that it is t increase from 11.1% ( 25 million kw, in 1999 ) to 16.5% ( 44 million kw, in 2010 ). And in the future, the diversification of electric power sources has also been required continuously in order to deal with the long-term electric power demand, so it will keep shouldering the important role. Meanwhile, it is heighten the consciousness for the global environmental problem, for example, the very severe target for CO2 reduction was set at the COP3 held in Therefore, it is necessary to develop technologies for efficient use of coal to expand the coal utilization that meets the social demand for better environment. And then, fuel cells and other new technologies are being developed for high efficient power generation. In order to apply coal to fuel cells, it must be gasified and cleaned by removing impurities such as ash, sulfur compound and halogens. IGFC ( Integrated Coal Gasification Fuel Cell Combined Cycle ) is a combination of the coal gasifier, fuel cell, gas turbine and steam turbine. This system is expected to show much higher efficiency compared with conventional pulverized coal fired thermal power generation. Also, it is expected to be an ultimate power generation system using coal. EAGLE ( coal Energy Application for Gas, Liquid and Electricity ) pilot plant is the test facility which aimed at realization of IGFC system. This project is supported directly by the Japanese government ( Ministry of Economy, Trade and Industry ; METI ) and implemented under the commission from the New Energy and Industrial Technology Development Organization ( NEDO ). Electric Power Development Co., Ltd. 2

3 2. Outline of the EAGLE pilot plant 2.1 Overview of the pilot plant Figure-1 shows the appearance photograph of the EAGLE pilot plant. Figure-1 The View of the EAGLE Pilot Plant It has an oxygen blown, entrained flow type gasifier. The gasifier has a single chamber with a two-stage spiral flow, and the facility processes 150 tons per day of coal. Under operation pressure 2.5 MPa, it produces medium calorific synthesis gas ( syngas ) with a heat content of about 10,000 kj/m3n. Oxygen is produced by the air separation unit ( ASU ) and is supplied to the gasifier. The high temperature raw gas is cooled in the syngas cooler. Impurities in the raw gas are removed at water scrubbers and MDEA ( methyldiethanol amine ) absorber. Part of the cleaned syngas is further desulfurized by the precise desulfurizer for fuel cells. IGFC is made up of gasifier and three kinds of power generation systems, the Fuel Cells, Gas turbine and Steam turbine. But, the purposes of this project are to establish the technologies of coal gasification and syngas clean up for fuel cell, so the EAGLE pilot plant does not have any steam turbine or fuel cell. Figure-2 shows the system flow diagram, and the specifications of the EAGLE pilot plant is shown in table-1, the development objectives are pointed out in table-2. Electric Power Development Co., Ltd. 3

4 Coal Gasification Facilities Gas Clean-up Facilities Gasifier Syngas Cooler Precise Desulfurizer Pulverized Coal COS Converter MDEA Regenerator Limestone Absorber Filter Slag Char GGH Primary Water Scrubber Secondary Water Scrubber MDEA Absorber Acid Gas Furnace Oxygen Nitrogen Air Comp. GT G Incinerator HRSG Stack Air Compressor Rectifier Air Separation Unit Gas Turbine Unit Figure-2 System flow diagram of the EAGLE Pilot Plant Item Coal Gasifier Coal input Operation pressure Coal feed system Gas clean-up facilities Gas processing capacity Sulfur compound recovery facility Air separation facility Oxygen production Oxygen concentration Raw air feed rate Raw air pressure Gas turbine output Table-1 Specifications of the EAGLE Pilot Plant Spec. Oxygen-blown, entrained-flow ( two-stage tangential flow type ) 150 tons per day 2.5 MPa Rock hopper + nitrogen transport (dry feed ) Wet gas clean-up using MDEA 14,600 m3n/h ( at MDEA absorber outlet ) Limestone-Gypsum process Pressurized cryogenic separation 4,600 m3n/h 95 vol % 27,500 m3n/h 1.09 MPa 8,000 kw Electric Power Development Co., Ltd. 4

5 Item Coal gasifier Gas clean-up facilities Various coal correspondence for Scale up Table-2 Major objectives of this project Target Calorific value of gas: > 10,000kJ/m3N Carbon conversion : > 98 % Cold gas efficiency : > 78 % Sulfur compound : < 1 ppm Halogens : < 1 ppm Ammonia : < 1 ppm Dust : 1 mg/m3n ( at precise desulfurizer outlet ) Obtaining gasification data for more than 5 kinds of coal Verify the scale up factors for commercial plant 2.2 Details of the EAGLE Gasifier Figure-3 shows the vertical section drawing of the EAGLE gasifier. The gasifier has two stages of coal burner, and each stage has four burners. Two char burners are also placed in lower stage. The pulverized coal is supplied to the gasifier by nitrogen transport system. In the gasifier, swirl flow is formed because coal and char are fed from tangential direction by nitrogen, it makes residence time longer for high gasification efficiency. The pulverized coal is equally fed into upper and lower burners, the gasification reaction is controlled by adjusting the oxygen flow rate. On the lower burner stage, the gas temperature is kept high enough for stable slag discharge because oxygen is supplied relatively much. And then, at the upper burner stage, the oxygen flow Pressure Vessel Membrane Wall Upper Burner Lower Burner Char Burner Slag Raw gas Heat Recovery section Membrane Wall with Refractory Gasification section Slag Quench section Figure-3 The EAGLE Gasifier Electric Power Development Co., Ltd. 5

6 rate is optimized so that the cold gas efficiency of whole gasifier may become a maximum. Thus, the design achieves both high gasification efficiency and stable operation. Further, the throat section of gasifier is furnished with recycled synthesis gas from the outlet of the primary water scrubber to prevent slagging. The raw gas, which made by gasification reaction, is cooled by passing through the syngas cooler. And then, the raw gas passes through a cyclone and a char filter to remove the char contained therein, and is sent to the gas clean-up facilities. The captured char is recycled to the gasifier through the char burners by nitrogen transportation system. The ash component is melted in the high temperature region caused by gasification reaction, and is discharged as melting slag from the slag tap located at bottom of the gasifier. Figure -4 shows a simplified diagram of the EAGLE gasifier. Upper Burner H 2 CO Oxygen Upper Stage : Lean Oxygen Coal Char Char + CO 2 + H 2 O CO + H 2 Coal CO 2 H 2 O Lower Stage : Rich Oxygen Coal + O 2 CO 2 + H 2 O Lower Burner Slag 1,200 1,600 Temperature ( C) High-Efficiency Gasification Stable Slag Discharge Figure-4 Features of the EAGLE gasifier Electric Power Development Co., Ltd. 6

7 2.3 Details of Gas Clean-up Facilities The raw gas, which is 400 degrees centigrade at outlet of the filter, passes through the gas-gas heat exchanger, and then goes in the primary water scrubber. Impurities, such as dust which could not be caught by the filter, halogens and ammonia are removed in the scrubber. The gas passes into the absorption tower, where methyl diethanolamine ( MDEA ) liquid is used to chemically absorb hydrogen sulfide ( H2S ) from the raw gas. MDEA is not effective for absorbing carbonyl sulfide ( COS ), so the COS converter which uses a catalyst to convert COS to H2S is installed before the MDEA absorber. H2S is absorbed by MDEA, and is later removed from MDEA liquid by steam stripping at the MDEA regenerator. The stripped gas is fed to the acid gas furnace, where it is completely combusted to form sulfur dioxide. This is then sent to the limestone absorber, which uses the limestone-gypsum method to recover it as gypsum. The cleaned syngas that comes out of the MDEA absorber is heated again to 200 degrees centigrade in the gas-gas heat exchanger and supplied to the gas turbine. Part of clean syngas is sent to the precise desulfurizer, where it is further purified until sulfur content of syngas is low enough for the fuel cells. 2.4 Air Separation Facilities and Gas Turbine The air separation facilities use a cryogenic separation process, where pressurized air is liquefied and separated, making use of the different boiling points of oxygen and nitrogen. This system provides oxygen of 95% purity for gasifier operation. And produced nitrogen is used in the pulverized coal transport system and is injected to gas turbine combustor to reduce NOx, as well as for other uses such as in seals for the various towers and tanks, and for purging system. The cleaned syngas is sent to the gas turbine, which generates electricity for the EAGLE pilot plant. The systems are also set up so that extracted air from the gas turbine compressor can be supplied to the air separation facilities for use as source air. Electric Power Development Co., Ltd. 7

8 3.The Status of the EAGLE Project 3.1 Development schedule This project was started from a feasibility study in The design works were carried out from 1996 to 1997, and the construction works were started in The pilot plant started receiving electric power from the grid in July 2001, and then, the trial operation of equipment were begun in earnest. Now, we are proceeding the test run of the whole plant. In this year, 9 Runs have been scheduled. 3 Runs were done by September, and what is more, 2 Runs will be carried out by the time when this conference is held. It will be able to report include those results in the conference. In future, the test run is planned to continue until June 2006, after that, the evaluation work of this project will be carried out. The project development schedule is shown in figure-5. ( Fiscal Year ) Feasibility Study Design Ope ration & Test Construction Figure-5 Development schedule Evaluation 3.2 Operation experience The EAGLE gasifier has operated total 430 hours by October since the first gasification operation in March Until now, it has been confirmed that the gasifier load of 100%, and each equipment has been verified and adjusted. Though some troubles arose, most of the problems are being solved, and we have acquired much knowledge. At Run02, the 100% load operation was carried out and the gasifier was continuously operated during 290 hours. Gas turbine had been only operated by light oil as trial operation, but the first run by syngas was also carried out as the fuel switching test at Run02. Electric Power Development Co., Ltd. 8

9 Footsteps Table-3 shows the summary of gasification operations at the present time. At the beginnings of test run, the plant was caused forced outages by troubles, but it ran for 290 hours at latest test run ( Run02 ). Though we once experienced the slag tap plugging in start-up period ( Run00-2 ), this problem was solved by the improvement on the starting procedure and it has not recurred. It is suspected that some of troubles were caused by the beginning condition of the plant, like the strainer plugging, they are gradually going to be settled in which the test run goes on with the progress of the adjustment. Run No. Date Table-3 Summary of Test Runs ( in 2002 ) Operation Coal hours consumption Substance Run00-1 Mar. 14 0: ton The first operation by coal Run00-2 Mar. 17 3: ton Run01 Apr. 24 1: ton Run01-1 June 28 8: ton Run01-2 July : ton Run02 Oct :53 1,207.9 ton Total 428:09 1,731.7 ton Adjustment of facilities Verification at 20% load Modify the start-up procedure Verification at 40% load Verification at 60% load Check the countermeasures Verification at 80% load Operation with char recycle Verification at 100% load GT operation by syngas The plant behavior at full load is shown as a trend, figure-6. It is the data on October 9th, 2002 ( Run02 ). The lower stage is supplied oxygen more than the upper stage, so it keeps higher temperature about 1,500. Upper temperature of the gasifier is about 1,000. Figure-7 shows the composition of syngas sampled at the outlet of the primary water scrubber. It is taken into account the fact that the plant is in the adjustment phase, it can be evaluated that the data is equivalent to the expected value. The nitrogen content is relatively high, it will be adjusted and reduced in future test operation. Electric Power Development Co., Ltd. 9

10 Coal, Char (t/h) Coal flow (Upper) Coal flow (Lower) Char flow Gasifier temp. (Upper) Gasifier temp. (Lower) O2 for Coal (Upper) O2 for Coal (Lower) 3,500 3,000 2,500 2,000 1,500 1,000 Temp.(C), O2 flow (m3n/h) :00 3:00 6:00 9:00 12:00 15:00 18:00 21:00 0:00 Time Figure-6 Trend at full load on October 9th, CO Outlet of the primary water scrubber N2, CO, H2, CO2 (%) H2 CO2 N2 CH4 N2 CO 10 CO2 H Gasifier Load (%) Figure-7 The composition of the syngas ( Run02 ) Electric Power Development Co., Ltd. 10

11 4.about EPDC EPDC ( Electric Power Development Co. Ltd.,) is the largest electric wholesaler in Japan. We have 58 hydro power stations ( total 8,261MW ) and 8 thermal power stations ( 7 coal fired and 1 geothermal, total 7,825MW ) and transmission lines, etc. Especially, we make continuous efforts for the development of the clean coal technology, and it has been developed the technologies such as USC ( Ultra Super Critical ), PFBC ( Pressurized Fluidized Bed Combustion ) and A-PFBC ( Advanced PFBC gasification ). In 1952, EPDC was established as a special public corporation under the Power Development Promotion Low. Originally, the Japanese government ( Ministry of Finance, MOF ) owned 100 percent of its stock, but currently about one-third of ownership is held by nine electric power companies. EPDC is to be completely privatized by 2003 under the Japanese Cabinet decision adopted June In accordance with these government policies, we are preparing ourselves for a new start as a private organization. 5.Acknowledgement The EAGLE project is proceeded by EPDC with assistance of the Ministry of Economy, Trade and Industry ( METI ), and the New Energy Industrial Technology Development Organization ( NEDO ). We would like to express gratitude for collaboration and guidance of all concerned associates, especially the Agency of Natural Resources and Energy of METI. Electric Power Development Co., Ltd. 11

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