Mitsubishi Hitachi Power Systems The Latest Coal … Latest Coal-Fired...Mitsubishi Hitachi Power Systems The Latest Coal-Fired Thermal Power Plant September 11, 2018 Mitsubishi Hitachi

Mitsubishi Hitachi Power Systems

The Latest Coal-Fired Thermal Power Plant

September 11, 2018 Mitsubishi Hitachi Power Systems, Ltd. Executive Vice President Yoshiyuki Wakabayashi

© 2018 Mitsubishi Hitachi Power Systems, Ltd. All Rights Reserved. Proprietary and Confidential Information. This document or information cannot be reproduced, transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems,Ltd. 1

Contents

1. Changes in the Business Environment of the Thermal Power Plant Industry

2. Base Load Power Plants with Flexibility 2-1. Flexible Operation 2-2. Reductions in CO2

3. The MHPS Approach

© 2018 Mitsubishi Hitachi Power Systems, Ltd. All Rights Reserved. Proprietary and Confidential Information. This document or information cannot be reproduced, transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems,Ltd.

2

1. Changes in the Business Environment of the Thermal Power Plant Industry


Energy Trilemma

3

Global Warming

Environment

Economic Efficiency

Energy Security

Energy Trilemma

The challenge of solving the ‘Energy Trilemma’:


The Shift in Worldwide Power Generation

4

Economic development will drive strong growth in power generation. Renewable energy will increase substantially. Total power generation output from coal and gas will be maintained,

with coal share decreasing and gas share will slightly increasing.

28%

0

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

2000 2015 2025 2040

Pow

er g

ener

atio

n,

TWh

再生可能水力原子力石油ガス石炭

15,500

39,300

29,700

24,200

Reference：OECD/IEA 2016 World Energy Outlook

+62%

Renewable Energy

Hydraulic Power

Nuclear Power

Oil

Gas

Coal


Investment in Power Generation: 2016-2040

5

Total investment over the next 25 years forecast to be in excess of $19Tril.（¥2,100Tril. /¥85Tril. per year）

Approx. 80% of total investment to be in renewables and energy transmission/distribution networks.

Japan to follow same trend; $580Bill.(¥64Tril./¥2.6Tril.per year).

World

13%

6%

39%

42% ¥85 Tril. per year

Reference : OECD/ IEA “World Energy Outlook 2017”

Thermal Power

Nuclear Power

Renewable Energy

Energy transmission /distribution networks

11% 6%

41%

42%

Japan

Reference : OECD/ IEA “World Energy Outlook 2016”

¥2.6 Tril. per year

Thermal Power

Nuclear Power

Renewable Energy

Energy transmission /distribution networks


6

日本の２０３０年電源計画

The 5th Strategic Energy Plan of Japan (Cabinet approval on July 3th, 2018) follows “Energy mix” goal.

Renewable energy will increase to 22~24% in 2030. The share of coal and gas thermal power will decrease.

31 26

46.2

27

10.6

3

0 12.2

2014年 2030年

再エネ

原子力

石油

ＬＮＧ

石炭

22~24

20~22

Reference：Agency for Natural and Energy

Renewable Energy

2014

Nuclear Power

Oil

LNG

Coal

2030

Power Source Plan in Japan, 2030

The Shift in Japan’s Power Generation


Factors Driving the Evolution of Thermal Power Technology in Japan

7

Increase of Renewable Energy

Separation of Energy Generation and Transmission

Nuclear Accident in Fukushima

Shale Gas

Paris Agreement

Electric Market Deregulation

The demand for Energy Saving and

High Efficiency

Increased demand for Energy Security, reliable power sources and stable supply

The development of Flexible power sources to compensate for fluctuating renewable energy (Fast startup, Wider operation load range, Higher ramp rate etc.）

Fuel diversity for reduction in CO2 gas emission

Optimization of plant operation and innovation in maintenance technology utilizing ICT

Continuing development of high efficiency thermal power plants (IGCC etc.）

Increasing investment from overseas for the latest coal-fired thermal power technology

Cause Effect


8

2. Base Load Power Plants with Flexibility 2-1. Flexible Operation


Biomass Firing or Co-firing with coal

USC・A-USC (Higher steam temp)

IGCC (New heat cycle)

Utilization as carbon neutral fuel (Including carbon-free hydrogen, carbon-free ammonia etc.)

To capture CO2 emission from flue gas To remove carbon from fuel

Co-firing in PC boiler CFB, BFB, Stoker

CO2 capture (Chemical absorption, amine, physical absorption, etc.)

Oxy-combustion Chemical looping

9

Flexible Operation

Renewable Energy

Coal-fired Thermal Power Plant

CO2 Scrubbing

To reduce energy loss

Efficiency Improvement

Increase ramping rate Reduce minimum load Reduce startup time

Reductions in CO2 from Coal Fired Power Plants

-Requires-

CO2 Reduction


Power generation with renewable energy such as solar and wind is subject to variable weather conditions.

Increasing output share from renewables increases system instability.

Flexible operation, increased ramping rates and reduced startup times are increasingly being demanded from thermal power plants.

Typical Power Demand Allocation based on “Energy Mix” at 2030 (clear day)

Power Demand

Nuclear Power Hydraulic Power

Solar Power

Coal

Gas, Oil Morning： Thermal power Rapid decrease

Daytime： Solar power increase

Evening： Thermal power Rapid increase

10

The Demand for Thermal Power Plant Flexibility


11

Fuel Coal LNG

Power Plant SC/USC IGCC GT/GTCC

Minimum load

Present 15% (Coal exclusive firing) 35% 30%

Target 10% 35% or less 25%

Ramping rate (Note2)

Present 3～5%/min. 3～10%/min. (Note4)

20%/min.(GT) 15%/min.(GTCC)

Target ～7%/min. 10%/min. (Note1)

5%/min.～ 10%/min. or more

30％/min.（GT) 20％/min.（GTCC）

Startup time (Note3)

Hot: 2hr Cold:10hr (Ignition ~ Full load)

Cold：15hr Hot: 0.2hr(GT)/0.5hr(GTCC) Cold: 0.2hr(GT)/3hr(GTCC)

Gas Turbine (GT)/Gas Turbine Combined Cycle (GTCC) Plant: - High ramping rate and fast startup time - Power supply source for peak demand

Coal-fired Supercritical (SC)/Ultra Supercritical (USC) Plant: - Longer startup time, but lower minimum load - Can provide for both intermediate and base load demand

Note 1) Indirect Firing System Note 2) Coal-fired Thermal Power Plant：Ramping Rate at 50~90% Load Note 3) Hot: Night time shut-down (approx. 8hr), Cold: One week shut-down (more than 150hr) Note 4) The details are covered by next presentation.

The Flexibility of Coal and Gas


12

(B)

(A)

(C)

Challenges for the future are (A) Increase ramping rate, (B) Reduce minimum load, (C) Reduce startup time.

Steam Temp. Control (A)

Pressure Parts Thermal Stress (A)/(C)

Mill Operation (A)/(B)

Flue Gas Emission(B)

Burner Ignition/ Combustion Stability (A)/(B)

Technical Challenges

Turbine Thermal Stress (A)/(C)

Mill Boiler

Turbine Gen.

Gov

Improving Coal Fired Power Plant Flexibility


13

Technical Challenges Measures (*Challenges for the future ) Burner ignition/ combustion stability(A)/(B)

Burner Modification

Mill operation (A)/(B) VVVF modification of mill motor Mill capacity increase Indirect firing system (Bin System)

Steam temperature control (A)

Improvement of control method Parameter tuning utilizing ICT

Pressure parts thermal stress (A)/(C)

Reinforcement of pressure part Structure modification Replacement to high-grade material

Turbine thermal stress (A)/(C)

Lifetime evaluation/optimization of operation utilizing ICT

Flue gas emission(B) Installation of gas bypass for prevention of SCR catalyst degradation

Measures to Improve Coal Fired Power Plant Flexibility

(A) Increase ramping rate (B) Reduce minimum load (C) Reduce startup time

③

②

④

①


Ignition condition

Burner Load 100% 50% 20% Boiler Load 100% 30% 8%

14

Detailed Improvement Idea -Wider Burner Turn-down- ① Burner Modification

The latest burner design is capable of stable ignition at low load, allowing for lower minimum boiler load operation.

2ry Air

M-PM Burner (Circular Firing) NR3 Burner (Opposed Firing)

2ry Air 2ry Air Burner ignition stability is improved by enhancing mixture of fuel and 2ry air.

Stable ignition can be maintained at 20% burner load with the latest burner.


② VVVF modification of mill motor

15

30

50

75

100

Bo

iler

Lo

ad[%

]

Mill table rotation speed is decreased by VVVF and mill minimum load is lowered.

5 mills operation load range is expanded to 30% load and rapid load change at 30%~100% load is achieved. VVVF : Variable Voltage Variable Frequency

0 10 20 30 40 50 60 70 80 90 100 110

5 Mills

3 Mills

4 Mills

5 Mills

2 Mills

Boiler Load[%]

VVVF modification

30

50

75

100

5 Mills

2 → 5 Mills

Rapid load change without Mill on/off

Waiting for Mill Start

Expand 5 Mills Operation Load Range

Time Time


16

③ Indirect Firing System (Bin System)

Direct Firing System Indirect Firing System

Higher ramping rate and lower minimum load can be developed by utilizing indirect firing system technology.

Boiler

Coal Feeder

Mill

Bunker

Pulverized Coal+1ry Air

Boiler

Mill

Bunker

Pulverized Coal+1ry Air

Bin

Exhaust Fan Increase

Fuel Flow

Long Response

Time

Short Response

Time

Coal Feeder

Mill

Ou

tlet

Fu

el F

low

Time

Load Increase

Signal

Direct Firing Indirect Firing


Geothermal IGCC Coal-fired GTCC

1. Efficiency improvement by centralized monitoring

2. Unplanned outage reduction by predictive analytics

3. Maintenance optimization 4. Operation improvement by utilizing expert

know-how 5. Startup reliability improvement

6. Grid support and Frequency response 7. Turndown improvement 8. Peak power response 9. Faster startup 10. Fuel Diversity

11. Thermal performance improvement 12. Part load efficiency improvement 13. Reduction of auxiliary power

Customer Benefits ICT Service Categories Service Example

Flexible Operation

Performance Improvement

O&M Optimization

• MHPS ICT solution provides value-added services to our customers. • Customer benefits are delivered through our three service categories.

MHPS-TOMONI Solution Samples / ICT Solutions

Remote Monitoring Service＋Predictive analytics AI Technology for Coal-fired Power Plant Plant Optimization System (POPS)

17


Boiler Digital Twin

Real Boiler Boiler Digital Twin (Digital space)

High accuracy algorithm

with Machine Learning

Boiler Digital Twin; a model based simulation program that utilizes AI machine learning technology to optimize operational performance and efficiency.

MHPS applies its OEM knowledge to provide customized solutions based on customer needs.

An economic benefit of approx. $1.0Mil. is being realized at Taiwan’s Rinkou thermal power plant due to AI Combustion Tuning.

18

Optimal Solution

Operation Data OEM Knowledge

+ Machine Learning


④ Parameter tuning utilizing ICT

Machine Learning

Model

Various Coal

Operation Data

Boiler Combustion Tuning with AI technology

Optimum Setting

Simulation

The AI machine learning model is equipped with a range of coal and combustion operational data .

Highly accurate settings for boiler combustion are tuned automatically to optimize economic, environmental and flexibility performance.

Fuel Diversity Secure control margin

Fuel consumption Auxiliary power Ammonia consumption etc.

Flue gas property (NOx, CO, Unburnt carbon)

Training

Economy

Environment

Flexibility

19


20

2. Base Load Power Plants with Flexibility 2-2. Reductions in CO2


21

Roadmap of next-generation Thermal Power Technology

Photos by Mitsubishi Heavy Industries, Ltd., Joban Joint Power Co., Ltd., Mitsubishi Hitachi Power Systems, Ltd., and Osaki CoolGen Corporation

65％ 60％ 55％

50％ 45％ 40％

Gas Turbine Combined Cycle (GTCC) Efficiency: 52% CO2 emissions: 340 g/kWh

Power generation efficiency

GTFC

IGCC (Verification by blowing air)

A-USC

Ultra Super Critical (USC) Efficiency : 40% CO2 emissions: 820 g/kWh

1700 deg. C-class IGCC

1700 deg. C-class GTCC

IGFC

LNG thermal power

Coal-fired thermal power

2030 Present

Integrated coal Gasification Combined Cycle (IGCC)

Efficiency: 46 to 50% CO2 emissions: 650 g/kWh (1700 deg. C class) Target: Around 2020

Efficiency: 46% CO2 emissions: 710 g/kWh Target: Around 2016

Advanced Ultra Super Critical (A-USC)

Integrated Coal Gasification Fuel Cell Combined Cycle (IGFC)


Gas Turbine Fuel Cell Combined Cycle (GTFC)

Ultrahigh Temperature Gas Turbine Combined Cycle


Advanced Humid Air Gas Turbine (AHAT)

Around 2020

Reduction of CO2 by 20%



* The prospect of power generation efficiencies and discharge rates in the above Figure were estimated based on various assumptions at this moment.


Efficiency: 63% CO2 emissions: 280 g/kW Target: 2025

Efficiency : 57% CO2 emissions: 310 g/kWh Target: Around 2020

Source: METI News Release, Jun 30, 2016 http://www.meti.go.jp/press/2016/06/20160630003/20160630003.html


Japan boasts the highest efficiencies in the world thanks to the widespread use of Supercritical/Ultra Supercritical thermal power plants.

Worldwide CO2 emissions can be reduced by more than 10% if efficiencies in other countries are improved to similar levels as those found in Japan.

22

Efficiencies of Coal-fired Power Plants Around the World

20%

25%

30%

35%

40%

45%

1990 1994 1998 2002 2006 2010 2014

Australia

China

Germany

India

Japan

Korea

UK+Ireland

United States

Ave

rag

ed G

ross

Pla

nt

Effi

cien

cy (

LHV

, %

)

Source: International comparison of fossil power efficiency and CO2 intensity - Update 2016, Ecofys

Japan Japan Australia

China

Germany

India

Korea

England＋Ireland

USA

Japan


The Contribution of SC/USC/IGCC to Reductions in CO2

CO2 Emission Intensity (approx. value)

23

Sub-C SC USC IGCC/A-USC 0.9 0.85 0.8 0.7

Indonesia Sub-bituminous Coal-fired 3 projects （1,000MW×5units/USC under construction by MHPS） Approx. 4 million ton reduction in CO2 per year Equivalent to approx. 0.3% reduction in total CO2 emissions from Japan*

Fukushima Revitalization Power IGCC Project （540MW×2units/IGCC） Approx. 1.8 million ton reduction in CO2 per year Equivalent to approx. 0.1% reduction in total CO2 emissions from Japan*

Total number of SC/USC Plants supplied by MHPS (170units total / Japan:26units / Overseas:144units） Approx. 100mil. ton reduction in CO2 per year Equivalent to approx. 8%** reduction in total CO2 emissions from Japan*

unit：kg/kWh Reference：Agency for Natural Resources and Energy (March, 2015)

CO2 emission reduction (When Compared to Sub-C plant)

* 1.3 billion ton at FY2015(Environment ministry 2nd review meeting（July 10,2017) ** Assume all plants as USC/800MW (averaged output of SC/USC plants in Japan)

• IGCC: Integrated Gasification Combined Cycle • A-USC: Advanced Ultra Super Critical pressure

• Sub-C: Sub-Critical pressure • SC: Super Critical pressure • USC: Ultra Super Critical pressure


24

What is IGCC?

C ～ T

HRSG

～

Gas Turbine

Coal

Gasifier

Clean up

Air Comp.

Air

Steam Turbine

Flue Gas

Combustor

Combined Power Generation (Combination of Brayton & Rankine Cycles)

Joban Joint Power Co. LTD Nakoso #10 (Demo. 2007-, Commercial 2013-)

Osaki CoolGen Corp. Osaki CoolGen Project (Demo. 2017-)

IGCC Projects in Japan

543MW Hirono (COD : 2021)

543MW Nakoso (COD : 2020)

Fukushima Revitalization Power

Higher efficiencies and reduced CO₂ emissions through a coal gasification process coupled with a combined cycle (CC) system

Integrated coal Gasification Combined Cycle

IGCC Technology


Benefits of IGCC: Environmental Performance / Fuel Diversity

25

CO2 Circulating

Water Plant Efficiency Emission

Ash Volume

0

(%)

20

40

60

80

100

120

140

▲60%

▲10~15%

▲30%

Coal-fired USC power plant Benchmark (steam 600°C)

＋10~15%

Higher Efficiency and Least Environmental Impact “Diversity of Coal”

Australia76.4 Bil.ton

U.S.237.3 Bil.ton

China 114.5 Bil.ton

India60.6 Bil.ton

North America7.8 Bil.ton

Europe116.7 Bil.ton

Russia157.0 Bil.ton

Africa32.9 Bil.ton

Asia73.7 Bil.ton

South America14.6 Bil.ton

Anthracite, Bituminous：403.2 Bil.ton

Sub-Bituminous：287.4 Bil.ton

Lignite：201.0 Bil.ton

Merits of IGCC

(1) The gasifier unit turns coal into Syngas and molten ash, which collects on the inside wall by way of centrifugal force

(2) The molten ash is then drained from the gasifier into a water bath

⇒ This process allows IGCC to minimize gasifier size while utilizing a wide range of coal types


26

Fukushima Revitalization Power IGCC Project

Major Specification

Output 543 MW (gross)

Gasifier Air-blown Dry Feed

Gas Clean-Up MDEA (Methyl diethanol Amine)

Gas Turbine M701F GT (1 on 1)

Operation Start 2020 (Nakoso site) 2021 (Hirono site)

Construction status of Nakoso 543MW IGCC (As of July, 2018)

Source : HP of Nakoso IGCC Power GK

Source : HP of Nakoso IGCC Power GK

Schedule 2016.10 Site Mobilization Started 2016.12 EPC FTK Contracts Awarded 2017.4 Construction Started Fabrication of Main Equipment Started

The project is continuing to proceed on schedule


Osaki CoolGen Project

27

Major Specification Output 166 MW (gross)

Gasifier Oxygen-blown Single-chamber Two-stage Entrained-flow

Gas Clean-Up MDEA (Methyldiethanol Amine)

Gas Turbine H-100 GT (1 on 1) Plant Efficiency 42.7% (LHV, net) Project Schedule Construction Started March 2013 Demo. Ope. Started March 2017 (First step)

：Osaki CoolGen Project Demonstration Test Area (First step)

Inside grounds of Chugoku Electric’s Osaki Power Station

Photos courtesy of Osaki CoolGen Corp.

Sponsored by METI and NEDO

Rendering Image

Air

Coal

Syngas(H2,CO)

Heat recovery steam generator

Air Stack

Gasifier

CO shift reactor CO2 Capture

Unit

H2

CO2,H2

ガス化

Air separation unit

Steam turbine

Gas turbine

Generator

First step： Oxygen-blown IGCC

Second step： IGCC with CO2 Capture

IGCC:166MW(Coal feed rate:1180t/d) Gasifier : Single Chamber with Two Stages Spiral Flow Gasifier

Third step: IGFC with CO2 Capture

ＦＣ

Oxygen

CO2 Transport and Storage (*3)

Add installing CO shift reactor and CO2 capture unit

(*1)

(*1) Demo. Operation of Second step will start in FY 2019

(*2) Demo. Operation of Third

step will start in FY 2021 (*3) CO2 Transportation and

Storage are outside of the Osaki CoolGen Project. (*2)


28

Carbon Capture Process for Low Carbon Society

Co-developed technology by MHI Engineering and Kansai Electric since 1990

Save energy through proprietary KS-1TM high performance solvent Reliable & proven technology with 14 operating plants worldwide

Commercial Carbon Capture plant in Texas for EOR*1 • Client：Petra Nova, 50/50 joint

venture of NRG Energy and JX Nippon Oil & Gas Exploration

• Plant : NRG WA Parish power plant • Flue gas：from coal fired power

plant • CO2 capture capacity：

4,776ton/day*2 • Capture efficiency：90％ • Commercial operation：Dec., 2016

l*1 EOR: Enhanced Oil Recovery

l*2 World largest in capacity


The MHPS Approach

29

The challenge of solving the energy trilemma…

Global Warming

Environment

Economic Efficiency

Energy Security

MHPS continues to develop and refine power system technology to meet the evolving challenges of today’s world.

The MHPS approach Environment：

Biomass Firing or Co-firing, Bio-jet Fuel, High Efficiency CCS, Utilization/Combustion of Carbon-free Hydrogen & Ammonia, AQCS etc.

Economic Efficiency： High efficiency GT, USC/A-USC, IGCC, SOFC etc. which utilize economical and limited fossil fuels effectively in the developing countries

Energy Security： Effective use of Lignite/Sub-bituminous Coal, Biomass Fuel Fabrication, Geothermal Power Generation, Higher Efficiency and Ramping Rate of PC Plant for Power System Stability etc.

Energy Trilemma


The MHPS Approach

30

Power generation with renewable energy will increase in order to reduce CO2 emissions.

Thermal power is essential to balance the

power fluctuations brought about by increases in renewable energy.

MHPS continues to contribute to power system stability through highly efficient and flexible next generation thermal power technologies.


Mitsubishi Hitachi Power Systems

31

Documents

Mitsubishi Hitachi Power Systems The Latest Coal … Latest Coal-Fired...Mitsubishi Hitachi Power Systems The Latest Coal-Fired Thermal Power Plant September 11, 2018 Mitsubishi Hitachi