Perspective on Coal Utilization Technology

Transcription

1 Perspective on Coal Utilization Technology 21st Annual International Pittsburgh Coal Conference on September, 2004 Naokazu Kimura Director, Wakamatsu Research Institute J-Power/EPDC

2 Agenda - About J-Power/EPDC - Example of CCT Application for New P/S - EAGLE Project Progress Report - Potentiality of Coal Gasification Technology

3 about J-Power/EPDCJ - was established in 1952 based on the Electric Power Development Promotion Law. - has deployed its business along the national policy and constructed many large power stations. - Power Generation Capacity (as of September, 2004) Hydro Power : 8,550.5MW (59 stations) Thermal Power : 7,824.5MW ( 8 stations) - was privatized in October, 2003 based on the abolishing the above law. - New Communication name of EPDC is J-Power.

4 J-Power s s Business Domains Under the key words Environment and Energy - Domestic Power Supply as a Wholesaler - Overseas Power Business including Environmental Protection - New Business creation using New Technology

5 Example of J-Power J CCT application The Newest Power Station in J-Power is Shin-Isogo Power station, which is 600MW PCF plant adopting USC(600/610, 25MPa) and Dry Activated coke desulfurization. This Power Station is located at 40km south from Tokyo, it is watched that it is an urban style coal power station.

6 Shin-Isogo Unit. 1 Coal fired Power Station Requirements for Plant Replacement: - Due to meet required capacity from grid, it was constructed the capacity over twice. - In addition, this plant was constructed under the existed plants operation. - The location is in Yokohama city. It is about 40 km south from Tokyo. - Required Flue gas emission is the same level as LNG. Photo of Shin-Isogo Unit. 1

7 Shin-Isogo Unit Boiler SCR AH ESP Dry DeSOx System Flow of Plant Stack Outline of the plant Commissioning April, 2002 Gross Efficiency 43% Capacity 600MW Steam Condition 25MPa 600/610 Emission Flue Gas SOx : 24 ppm NOx : 20 ppm PM : 10 mg/m 3 N

8 EAGLE Project Origin of the Project Name EAGLE Coal Energy Application for Gas, Liquid & Electricity means Multi-Purpose Gasifier

9 Overview of EAGLE Project Project Objectives - Final Target of the EAGLE Project is to toward IGFC, which is combined with Fuel Cell, GT, and ST. It calls triple combined cycle. - Coal must be converted into an ash-free combustible gas with gasification and clean-up to produce a gaseous handling fuel equivalent to LNG. 1. Development of Oxygen-blown entrained-flow gasifier 2. Establishment of Gas cleanup technology for fuel cells Project Support - METI & NEDO

10 Coal Based High Efficiency Power Generation Technologies Steam Condition Sub C. Super C % USC %:Gross Efficiency HHV basis 42 44% 46 48% Fluidized Bed AFBC PFBC A-PFBC Gas Turbine 44% LNG % LNG ~50% LNG1500 >50% Gasification IGCC IGCC1300 IGCC1500 Fuel Cell Present MCFC SOFC >55% IGFC

11 Pulverized Coal O2 G asifier IGFC Technology Flow Diagram Syn gas Cooler Ceramic Filter GGH Scrubber MDEA Absorber CO S Converter MDEA Regenerator Acid Gas Furnac e Lim estone Absorber Gypsum Slag N2 Fuel Cell DC AC HRSG Waste Water Treatment Rectifier AC GT Air Gas Turbine Steam Turbine Stack AC ST Condenser

12 Schedule of the EAGLE Project Feasibility Study Basic & Detail Design Construction Operation & Test Evaluation

13 EAGLE pilot plant system flow Coal Gasification Cold Gas Cleanup Gasifier Syngas Cooler Fine Desulfurizer Coal Limestone Scrubber Char Filter Slag Char GGH Water Scrubber MDEA Absorber MDEA Regenerator Gypsum N2 N2 Air O2 Rectifying Column Comp GT G Incinerator Waste Heat Recovery Boiler Air Feed Compressor Air Air Separation Unit Combustion Turbine Stack

14 EAGLE Gasifier Heat Recovery Section Gasification Section Quench Section Gasifier Type: Oxygen-Blown 1 Chamber 2 Stages Spiral Flow Gasifier Coal Feed Rate: 150 t/d Gasification Pressure: 2.5MPa

15 Coal Gasification of the EAGLE Pilot Plant Coal Coal Bunker Flux Bunker Lock Hoppers Gasifier Syngas Cooler Recycled Gas Steam Steam Recycled Gas/N2 Cold Gas Cleanup Pulverizer Air Separation Unit N2 O2 Cyclone Filters Cold Gas Cleanup Slag Char Lock Hoppers N2

16 Cold Gas Cleanup of the EAGLE Pilot Plant Fine Desulfurizer Incinerator Gasifier COS Converter Acid Gas Sulfur Recovery Unit Raw Syngas GGH No.1 Water Scrubber Halide Adsorber No.2 Water Scrubber MDEA Absorber MDEA Regenerator Clean Syngas

17 Sulfur Recovery Unit of the EAGLE Pilot Plant Limestone Scrubber Acid Gas Furnace SO3 Mist Separator Stack Acid Gas Light Oil Gas Cooler Air Dehydrator Limestone Slurry Gypsum Vessel

18 ASU & GT of the EAGLE Plant HP-N2 MP-N2 O2 Clean Syngas Coal Gasification Incinerator MS Adsorber LP-N2 Waste Heat Recovery Boiler Air Air Feed Compressor Heat Exchanger Rectifying Column Air COMP GT G Stack

19 Major Test Items during the Operation period Coal In (March) Gasifier trial operation Full Plant trial operation GT Integration operation Performance Test (Coal A) Coal Flexibility Test (Coal B,C,D,E) Long Run Test for 1,000hrs EAGLE Plant Modification ASU-GT Integration Test

20 Highlights in 2002 & 2003 After the construction of EAGLE pilot plant, we confirmed as follows; - Settled on Basic Operation Manual. - Confirmed that load change rate 8%of ASU was achieved in the dynamic operation test. - Confirmed that we could operate the full plant integration with 100 % plant capacity. - Confirmed high efficient dust removal without filter breaking. - The volume of quench gas was reduced from initial 50% to 30%. - GT was satisfactorily operated with Syngas hrs continuous operation was achieved.

21 Project Targets and Results Item Targets Results Carbon Conversion Efficiency >98 % 99 % Cold Gas Efficiency >78 % 78 % Calorific Value (HHV) 10,000 kj/m 3 N 10,100 kj/m 3 N Continuous Operation Time 1,000 hrs 291 hrs Kinds of Coal 5 kinds 2 kinds Sulfide Compounds 1 ppm <0.1 ppm #1 Halogenated Compounds 1 ppm 1 ppm Ammonia 1 ppm 1 ppm Particulate Matter 1 mg/m 3 N 1 mg/m 3 N Total Operation Time : 2,073 hrs Total Coal Consumption: 9,547 ton #1: Outlet of Fine Desulfurizer 1,000 hrs Long Run test will be started soon!

22 Test Schedule of the EAGLE Project (1)The Long Run Test is the most important test item in this year to confirm reliability. We will start the Long Run for 1,000 hrs. soon. (2)Coal flexibility test is also important test item for the design of the next large scale plant. We will test at least 5 kinds of coals including 2 kinds we have already tested. (3)We are planning to examine the possibility of EAGLE gasifier for scale up. One of the tests is that operation condition such as coal injection velocity, etc. will be changed to obtain the design data.

23 Potentiality of coal gasification technology CO2 issue is increasingly getting hot topics, requirement of High Efficiency Technology such as IGCC or IGFC, will be increased in future. It is necessary to proceed CCT program included outlook of CO2 recovery and sequestration as a final target. In this case, Coal Gasification will be Key Technology considering of coal utilization potentiality in future. Coal Gasification is also possible to apply for NH3, GTL, and H2 production, it can be said that the technology expandability is so wide range.

24 Potentiality of coal gasification technology Coal Gas Clean Up AC GT HRSG ST Electricity IGCC, IGFC Gasifier Oxygen Air Separation Unit Synthetic Chemical Fuel Reactor Synthetic Chemical Fertilizer Reactor Synthetic Fuel GTL, DME Fertilizer Sift Reactor CO2 Separator CO2 Hydrogen CO2 Disposal Under the Sea Underground Coal Mine

25 Summary - Coal Gasification will be Key Technology in future. - J-Power will complete the EAGLE project and create New business internationally using this technology. - J-Power will proceed the management persisted in coal.