Perspective on Coal Utilization Technology

Perspective on Perspective on Coal Utilization TechnologyCoal Utilization Technology

Naokazu KimuraDirector, Wakamatsu Research Institute

J-Power/EPDC

Naokazu KimuraNaokazu KimuraDirector, Wakamatsu Research InstituteDirector, Wakamatsu Research Institute

JJ--Power/EPDCPower/EPDC

21st Annual International Pittsburgh Coal Conferenceon 14 - 16 September, 2004

AgendaAgendaAgenda

- About J-Power/EPDC

- Example of CCT Application for New P/S

- EAGLE Project Progress Report

- Potentiality of Coal Gasification Technology

about J-Power/EPDCabout Jabout J--Power/EPDCPower/EPDC

- was established in 1952 based on the Electric Power Development Promotion Law.

- has deployed its business along the national policyand 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.

J-Power’s Business DomainsJJ--PowerPower’’s Business Domainss Business Domains

Under the key words ““Environment and EnergyEnvironment and Energy””

- Domestic Power Supply as a Wholesaler

- Overseas Power Business includingEnvironmental Protection

- New Business creation using New Technology

Example of JExample of J--Power CCT applicationPower 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.

Shin-Isogo Unit. 1 Coal fired Power StationShin-Isogo Unit. 1 Coal fired Power Station

Photo of Shin-Isogo Unit. 1

Requirements Requirements for Plant Replacement:for Plant Replacement:

- Due to meet required capacity fromgrid, it was constructed the capacityover 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 thesame level as LNG.

ShinShin--Isogo Unit. 1Isogo Unit. 1

AH

Stack

Boiler

SCR ESP

360 ℃ 150 ℃ 125℃

Outline of the plant

Commissioning April, 2002Gross Efficiency 43%Capacity 600MWSteam Condition 25MPa

600/610℃

Emission

Flue Gas SOx : 24 ppmNOx : 20 ppmPM : 10 mg/m3N

System Flow of Plant

DryDeSOx

EAGLE ProjectEAGLE Project

Origin of the Project Name “EAGLE”Coal Energy Application for Gas, Liquid & Electricity

means

MultiMulti--Purpose GasifierPurpose Gasifier

Overview of EAGLE ProjectOverview of EAGLE ProjectOverview of EAGLE ProjectProject Objectives

Project Support- METI & NEDO

- 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 gasifier2. Establishment of Gas cleanup technology for fuel cells

Coal Based High Efficiency Power Generation Technologies

Coal Based High Efficiency Coal Based High Efficiency Power Generation TechnologiesPower Generation Technologies

Steam Condition

Gasification

Fuel Cell

Gas Turbine

Fluidized Bed

%:Gross Efficiency HHV basis

LNG1500℃LNG1100℃

Super C.Sub C.

IGCC

AFBC

IGFCMCFC

IGCC1300℃ IGCC1500℃

A-PFBC

SOFC

USC

PFBC

LNG1300℃

Present

42～44%

42～44% 46～48%

48~50%

>55%

48%44%

>50%

IGFC Technology Flow DiagramIGFC Technology Flow DiagramIGFC Technology Flow Diagram

D CACFuel Cell

G asifier

PulverizedCo al

SyngasCoo ler

Ceram icFilter

G G H

Slag

Scrubber

CO S Converter

M D EAAb so rb er

H RSG

Rectifier

A irG asTurb ine

SteamTurb ine

Co ndenser

Stack

ST

G T

AC

AC

W aste W aterTreatm entN 2

O 2

Lim estoneAb so rb er

Acid G asFurnace

M D EARegenerato r

G ypsum

D CACFuel Cell

G asifier

PulverizedCo al

SyngasCoo ler

Ceram icFilter

G G H

Slag

Scrubber

CO S Converter

M D EAAb so rb er

H RSG

Rectifier

A irG asTurb ine

SteamTurb ine

Co ndenser

Stack

ST

G T

AC

AC

W aste W aterTreatm entN 2

O 2

Lim estoneAb so rb er

Acid G asFurnace

M D EARegenerato r

G ypsum

Schedule of the EAGLE ProjectSchedule of the EAGLE Project95 96 97 98 99 00 01 02 03 04 05 06

Feasibility Study

Basic & Detail Design

Construction

Operation & Test

Evaluation

EAGLE pilot plant system flowEAGLE pilot plant system flowEAGLE pilot plant system flow

Coal

Gasifier Syngas Cooler

Char Filter

CharSlag

N2

O2

Air

Air FeedCompressor

Rectifying Column

Air

Combustion Turbine

GComp GT

Incinerator

Air Separation Unit

Waste HeatRecovery Boiler

WaterScrubber

MDEAAbsorber

GGH

Fine Desulfurizer

MDEARegenerator

LimestoneScrubber

Gypsum

Stack

Coal Gasification Cold Gas Cleanup

N2

EAGLE GasifierEAGLE GasifierEAGLE Gasifier

Heat Recovery Section

Gasification Section

Quench Section

Gasifier Type:Oxygen-Blown 1 Chamber2 Stages Spiral Flow Gasifier

Coal Feed Rate: 150 t/dGasification Pressure: 2.5MPa

Coal Gasification of the EAGLE Pilot PlantCoal Gasification of the EAGLE Pilot PlantCoal Gasification of the EAGLE Pilot Plant

Coal

Pulverizer

CoalBunker

FluxBunker

LockHoppers

O2

N2Air Separation

Unit

Slag

Steam Steam

FiltersCyclone

LockHoppers

Cold GasCleanup

Cold GasCleanup

Recycled Gas/N2

Char N2

Gasifier Syngas Cooler RecycledGas

Cold Gas Cleanup of the EAGLE Pilot PlantCold Gas Cleanup of the EAGLE Pilot PlantCold Gas Cleanup of the EAGLE Pilot Plant

No.1 WaterScrubber

No.2 WaterScrubber

MDEAAbsorber

MDEARegenerator

SulfurRecoveryUnit

Incinerator

Acid Gas

RawSyngas

Fine Desulfurizer

HalideAdsorber

COSConverterGasifier

GGH

Clean Syngas

Sulfur Recovery Unit of the EAGLE Pilot PlantSulfur Recovery Unit of the EAGLE Pilot PlantSulfur Recovery Unit of the EAGLE Pilot Plant

Acid GasFurnace

Acid Gas

Light OilGas Cooler

Vessel

SO3 MistSeparator

LimestoneSlurry

Air

Stack

Dehydrator

Gypsum

LimestoneScrubber

ASU & GT of the EAGLE PlantASU & GT of the EAGLE PlantASU & GT of the EAGLE Plant

Air FeedCompressor Heat

ExchangerRectifyingColumn

Air

Air

MS Adsorber

HP-N2

MP-N2

O2

LP-N2

CoalGasification

Waste HeatRecovery Boiler

Stack

Incinerator

Clean Syngas

GCOMP GT

Major Test Items during the Operation periodMajor Test Items during the Operation period

2002 2003 2004 2005 2006

◎ Coal In (March)

Gasifier trial operationFull Plant trial operation

GT Integration operationPerformance Test (Coal A)

Coal Flexibility Test (Coal B,C,D,E)

Long Run Test for 1,000hrs

EAGLE Plant Modification

ASU-GT Integration Test

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. - 291 hrs continuous operation was achieved.

Highlights in 2002 & 2003Highlights in 2002 & 2003Highlights in 2002 & 2003

Project Targets and ResultsProject Targets and ResultsProject Targets and Results

Total Operation Time : 2,073 hrsTotal Coal Consumption: 9,547 ton

1,000 hrs Long Run test will be started soon !

Item Targets Results

Carbon Conversion Efficiency >98 % ≧99 %

Cold Gas Efficiency >78 % ≧78 %

Calorific Value (HHV) 10,000 kJ/m3N ≧10,100 kJ/m3N

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/m3N 1 mg/m3N

#1: Outlet of Fine Desulfurizer

Test Schedule of the EAGLE ProjectTest Schedule of the EAGLE ProjectTest 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.

Potentiality of coal gasification technologyPotentiality 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.

Under the SeaUndergroundCoal Mine

CO2

Hydrogen

Coal

Gasifier

Gas Clean Up

Oxygen

Air Separation Unit

Sift Reactor

CO2 Separator

AC GT

HRSG

ST

CO2 Disposal

Synthetic Fuel GTL, DME

Electricity IGCC, IGFC

Fertilizer Synthetic Chemical Fertilizer Reactor

Synthetic Chemical Fuel Reactor

Potentiality of coal gasification technologyPotentiality of coal gasification technology

SummarySummarySummary

- Coal Gasification will be Key TechnologyKey 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.