The Progress of Osaki CoolGen Project ~ Oxygen-blown Integrated Coal Gasification Fuel Cell Combined Cycle Demonstration Project ~ September, 2017 Osaki Coolgen Corporation
1 Outline 1. Background and Significance of IGCC Development 2. Gasification Technology 3. Osaki Coolgen Project 1 Project Overview 2 Overview and Progress of IGCC Demonstration(STEP1) 3 Demonstration Plan of IGCC with CO 2 Capture(STEP2)
2 Outline 1. Background and Significance of IGCC Development 2. Gasification Technology 3. Osaki Coolgen Project 1 Project Overview 2 Overview and Progress of IGCC Demonstration(STEP1) 3 Demonstration Plan of IGCC with CO 2 Capture(STEP2)
1. Background Characteristics of coal as energy resource Fuel price transition 3 source BP statistics2017 source BP statistics2017
1. Background 4 Percentage of each generation resource
1. Background 5 Coal-fired Power Generation - Current electricity & CO 2 emission and 2040 s prospects - 40 000 35 000 Coal power Oil power Gas power Total CO2 emissions gas Coal CO2 emission[mt-co2] 30 000 25 000 20 000 15 000 10 000 5 000-4 995 9 899 9 598 9 648 9 792 9 911 9 992 1990 2014 2020 2025 2030 2035 2040 Electricity from coal-based power generation 41% (2014) 28% (2040) CO 2 emission from coal-based power generation Source: IEA World Energy Outlook 2015 31% (2014) 27% (2040) Coal-fired power generation in the world : about 30% CO 2 emission from Coal-fired power generation : about 30% Source : IEA World Energy Outlook 2016 New Policies Scenario)
1. Background 6 Coal-fired Power Generation - Current generation capacity and 2040 s prospects - OECD Europe 184GW 91GW Eastern Europe/ Eurasia 111GW 91GW Middle East 0GW 3GW China 855GW 1,137GW OECD America 321GW 208GW Africa 44GW 80GW India 176GW 451GW Other Asia Oceania 184GW 367GW Prospects of the world Coal-fired power generation capacity Source : IEA World Energy Outlook 2016 New Policies Scenario) (2014) (2040) Latin America 7GW 12GW Coal-fired power generation capacity in the world 1,882GW 2,437GW 555GW
1. Background Coal-fired Power Generation Energy self-sufficiency in Japan approx. 6%* Coal-fired generation Essential for the Best Mix energy policy Energy Mix in Japan** Demand of electric power Economic growth Saving energy 196.1TWh - status in Japan - Composition of electrical source 1065TWh Renewable :22-24% Nuclear:22-20% Geothermal :1.0-1.1% Biomass :3.7-4.5% Wind :1.7% PV :7.0 Hydro:8.8-9.2% 966.6TWh 980.8TWh LNG:27% Coal:26% FY2013 FY2030 Oil:3% FY2030 *Source : Japan s Energy White Paper 2016 **Source : METI Long-term energy supply-demand outlook(2015.7)
1. Background 8 Development Road Map of High Efficiency Low Emissions Coal Power Generation Technology in Japan Fuel Cell FC Integrated coal gasification fuel cell combined cycle (IGFC) (MCFC) (SOFC) HRSG Integrated coal gasification combined cycle IGCC) Pulverized coal fired PCF boiler gasifier Steam turbine HRSG Gas turbine Steam turbine Super critical SC 1300 IGCC 1500 IGCC 1700 IGCC Ultra SC USC gasifier Fuel cell Gas turbine 55% CO 2 reduction about 30% 46 ~ 48% CO 2 reduction about 15% Advanced USC A-USC 38% 39 ~ 41% 46 ~ 48% base Steam turbine Efficiency :Net / Higher heating value
1. Significance 9 Significance of Osaki Coolgen Project Global Sustainable Development We must: Efficiently use low cost coal for increased Power Demand Drastically reduce CO 2 emissions against Global Warming In Resources Importing Countries (as Japan) Coal is indispensable to achieve sustainable power supply Development of High Efficient Clean Coal Technology (Step-1) (Step-2) Osaki Coolgen Demonstration Project Oxygen-blown IGCC with high efficiency, high environmenttal performance, reliability, coal variety compatibility and controllability IGCC + CO 2 Capture (Step-3) IGFC + CO 2 Capture
10 Outline 1. Background and Significance of IGCC Development 2. Gasification Technology 3. Osaki Coolgen Project 1 Project Overview 2 Overview and Progress of IGCC Demonstration(STEP1) 3 Demonstration Plan of IGCC with CO 2 Capture(STEP2)
2. Gasification Technology Significance of developing Oxygen blown type EAGLE Gasifier 11
2. Gasification Technology Development History and Significance of EAGLE Gasifier of Oxygen Blown Type Coal Energy Application for Gas, Liquid, and Electricity 12 8 OCG Demonstration Plant 1,180t/d FY2016 166MW Osaki EAGLE Pilot Plant 150t/d FY2002 2013 Wakamatsu 3 HYCOL Pilot Plant 50t/d FY1991 1993 Sodegaura Scale Up Process Development Unit 1t/d FY1981 1985 Katsuta
2. Gasification Technology 13 Features of EAGLE Gasifier Oxygen-blown Two-stage Spiral-flow Gasifier
2. Gasification Technology 14 Applicable Coal types for the EAGLE gasifier EAGLE EAGLE Gasifier Coals appropriate for Conventional GasificationGasifier Pulverizing Coal Fired Sub bituminous Coal area EAGLE Pilot Project Achievement Bituminous Coal area Source : JPOWER EAGLE brochure
15 Outline 1. Background and Significance of IGCC Development 2. Gasification Technology 3. Osaki Coolgen Project 1 Project Overview 2 Overview and Progress of IGCC Demonstration(STEP1) 3 Demonstration Plan of IGCC with CO 2 Capture(STEP2)
(1)Project Overview 16 Project Timeline
(1)Project Overview 17 Project Scheme METI (~FY2015) Ministry of Economy, Trade and Industry NEDO (FY2016~): New Energy and Industrial Technology Development Organization Subsidy The Chugoku Electric Power Co., Inc. (Energia) Electric Power Development Co., Ltd. (J-POWER) Joint Investment OSAKI CoolGen Corporation Mitsubishi Hitachi Power Systems, LTD. Coal gasifier unit Combined cycle unit Coordinate all units STEP1 EPC contract STEP1 EPC contract JGC Corporation Gas clean up unit Wastewater treatment Air separation unit STEP1 EPC contract Diamond Engineering Co. Ltd. Coal preparation & supply unit
18 Outline 1. Background and Significance of IGCC Development 2. Gasification Technology 3. Osaki Coolgen Project 1 Project Overview 2 Overview and Progress of IGCC Demonstration(STEP1) 3 Demonstration Plan of IGCC with CO 2 Capture(STEP2)
(2)Overview and Progress(STEP-1) 19 IGCC Process Flow Coal gasification unit Gas clean-up unit Sulfur recovery unit Coal Gasifier Syngas cooler Cyclone Filter Air Limestone absorber Mill Hopper Acid gas furnace Calcium sulfate Air slag Oxygen Air separation unit Compressor Waste water treatment Nitrogen Rectifier Waste water Treat water Sludge Combined cycle unit Air #1 Water scrubber Combustor COS converter Compressor #2 Water scrubber GT Cooling Water DeNOx Acid gas removal ST HRSG Condenser G Flare unit LPG Air Stack
(2)Overview and Progress(STEP-1) 20 Major Specifications Specification Coal Gasification Unit Gas Clean-up Unit Air Separation Unit Combined Cycle Unit Wastewater Treatment Unit Oxygen-Blown Single-Chamber Two-Staged Spiral-Flow Entrained Bed Coal feed 1,180 ton/day Wet Desulfurization Unit Methyl Di-Ethanol Amine (MDEA) Sulfur Recovery Unit Limestone Wet Scrubbing Pressurized Cryogenic Separation GT (MHPS H100 TIT=1300 C class, adopted Multi-Cluster burner Gross Power Output : 166MW (GT+ST) Gas Clean-up Unit Wastewater Treatment
(2)Overview and Progress(STEP-1) 21 STEP1 DemonstrationTargets Item Targets Efficiency Top class Net Efficiency 40.5% (HHV), 42.7%(LHV) Equivalent to Net efficiency 46%(HHV), 48%(LHV),when applied to 1,500 class GT(already developed) in a commercial plant (higher output) Emission Level Coal Variety Compatibility Top class environmental performance SOx : 8ppm NOx : 5ppm Particulate : 3mg/m 3 N (as 16%O 2 equivalent) Applicable to varieties of coal with various ash fusion temperature Plant Reliability Plant Controllability & Operability Economy Aiming at more than 70%/year availability by 5000hrs operation test. Load ramp rate : 1-3%/min. To obtain the prospect that the COE (cost of electricity) of IGCC is the same level as that of USC.
Major Events Start of Civil work Power receiving for commissioning Gasifier start-up by coal Start of demonstration (2)Overview and Progress(STEP-1) 22 IGCC Construction Progress FY 2012 2013 2014 2015 2016 2017 2018 Mar HRSG SGC Gas ASU Gas on Gasifier on on on cleanup Pressurization turbine unit test on start-up of May Nov DecDec Jan Jul Nov Apr Design, Manufacturing, Construction, site site site site site piping Jul Operation Mar
(2)Overview and Progress(STEP-1) 23 Mechanical completion (13 th April 2016)
(2)Overview and Progress(STEP-1) 24 Gas Clean Up Unit
(2)Overview and Progress(STEP-1) 25 Combined cycle Unit
(2)Overview and Progress(STEP-1) 26 Air separation Unit
(2)Overview and Progress(STEP-1) STEP1 Commissioning results and demonstration plan FY 2015 2016 2017 2018 Individual machinery and system test Integrated Commissioning Demonstration GT no load test Coal gasification test load dump test load dump test Relief valve test Gasifier/GT characteristic test Automatic plant control adjustment Test of heat run and performance Test of automatic plant start-up/shut down Verification of basic performance and reliability Verification of compatibility of coal variety Verification of controllability results plan 27 Operating data (AS of July,2017) Power generation Gross output Gasifier Operating hours Continuous Operating hours 300,638 MWh 2,415 h 514 h
3. Osaki Coolgen Project (2)Overview and Progress(STEP-1) Commissioning 28 April-2016 Gas turbine start up June Parallel in power grid July Gasifier start up by coal August Start of power generation by coal
3. Osaki Coolgen Project (2)Overview and Progress(STEP-1) Commissioning November Achievement Gasifier load : 100% Power generation : 166MW (100%) 29 March-2017 Start of Demonstration August-2017 Completion Ceremony
30 Outline 1. Background and Significance of IGCC Development 2. Gasification Technology 3. Osaki Coolgen Project 1 Project Overview 2 Overview and Progress of IGCC Demonstration(STEP1) 3 Demonstration Plan of IGCC with CO 2 Capture(STEP2)
3 Demonstration Plan of IGCC with CO 2 Capture (STEP-2) 31 STEP2 / CO 2 Capture test (FY 2016-2020) steam CO2 capture unit CO 2 Capture unit Steam (17% s lipstream test) Sweet Sweet Shift shift Reactors reactors CO H2O CO2 H2 CO + H 2 O CO 2 + H 2 H2 H 2 CO CO2, 2, H H2 2 Absorber CO CO2 2 Feed Gas CO2 Capture test 17% slipstream syngas equivalent to 15% of total CO 2 volume CO, CO, H 2 H2 COCO2 2 Flash Flash Drums drums CO 2 Capture method Physical absorption IGCC Gasifier Physical Absorption absorption CO shift section Sweet Shift (Downstream of desulfurization) Scrubber MDEA Coal Sour Shift Catalyst pilot test N 2 N2 O 2 O2 Air separation Separation unit Steam steam Sour Shift Catalyst Pilot Test unit Sour Shift Reactor (Low temperature) Sour Shift Reactor (low temprature catalyst) Feed Gas Sour Shift (Upstream of desulfurization) gas Gas clean Clean-up unit unit
3 Demonstration Plan of IGCC with CO 2 Capture (STEP-2) 32 STEP2 Demonstration Targets Item Basic Performance (CO 2 capture) CO 2 Capture rate : more than90% CO 2 Purity : more than 99% Targets Generating Plant Efficiency To obtain a prospect of 40%(net, HHV) power generation efficiency while 90% of CO 2 volume is captured in newly-installed commercial IGCC with 1,500 C class GT. Operability & Reliability To establish operation procedures with load change and verify the reliability for IGCC system combined with CO 2 Capture
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