MITSUBISHI HEAVY INDUSTRIES, LTD.MITSUBISHI HEAVY INDUSTRIES, LTD.

The Latest Supercritical CoalThe Latest Supercritical Coal--Fired BoilerFired Boilerandand

Integrated Coal Gasification Combined Cycle Integrated Coal Gasification Combined Cycle Technology (IGCC)Technology (IGCC)

APEC Clean Fossil Energy Technical and Policy Seminar

Utility Boiler Market Share in JapanUtility Boiler Market Share in Japan

(Capacity base as of 2004, equal & above 75MW)

Others1.9%

I25.1%

H27.1%

MHI45.9%

Supply Record of Mitsubishi BoilersSupply Record of Mitsubishi Boilers

Number of Supplied Units Capacity

Coal Fired Oil and/or Gas Fired Total

75MW - 149MW 42 64 106 150MW - 299MW 31 82 113 300MW - 499MW 33 72 105 500MW - 999MW 24 45 69 1000MW - 4 3 7 Total 135 266 400

75MW & Larger

Activity and Experience of MHI BoilerActivity and Experience of MHI Boiler(in the World)

Korea 6,291 (44)

Taiwan 21,185 (69)

Germany265 (5)

C.I.S. 1,234 (15)

Poland135 (1)

Yugoslavia490 (5)

Jordan875 (4)

Spain794 (2)Algeria2,036 (8) Tunisia

1,040 (2)

Egypt1,366 (8)

Zambia90 (6)

Liberia30 (1) Nigeria

91 (1)

Kuwait16,399 (17)Saudi Arabia40,380 (90)

Tanzania60 (1)

Turkey 4,968 (17)

Syria 5,131 (13)Iraq 3,883 (16)

Iran 8,240 (22)Pakistan 3,105 (19)

India 5,627 (26)Qatar

149 (1)

U.A.E.2,033 (12)

Bangladesh90 (6)

Thailand21,112 (30)

China18,402 (45)

Japan 294,082 (1,920)

Hong Kong 11,864 (22)Macao 190 (2)

Philippines 7,735 (16)Brunei 380 (2)

Malaysia3,959 (19)

Indonesia7,061 (34)

Australia1,084 (8)

New Zealand825 (1)

Canada 241 (4)

U.S.A. 855 (10)

Bahamas 197 (2)Jamaica 635 (2)

Dominica 900 (3)Venezuela 7,071 (14)

Mexico 26,698 (44)

El Salvador 277 (2)

Colombia 525 (1)Ecuador 884 (5)

Peru 276 (6)

Chile 3,104 (11)

Brazil 4,551 (30)

Total : 572,334t/h (2,824)Unit : t/h( ) : Number of Units

(as of March, 2001)

Singapore 206 (4)

TopicsTopics

1.1. Supercritical CoalSupercritical Coal--Fired BoilerFired Boiler

2.2. Boiler Design FeaturesBoiler Design Features

3.3. Integrated coal Gasification Combined Integrated coal Gasification Combined Cycle (IGCC)Cycle (IGCC)

1.1. Supercritical CoalSupercritical Coal--Fired BoilerFired Boiler

CustomerCustomer’’s Requirements s Requirements for Utility Power Boilersfor Utility Power Boilers

1.1. High Performance High Performance (High Efficiency and Low Emission)(High Efficiency and Low Emission)

2.2. Operability Operability (WSS, DSS and 2 shift operation)(WSS, DSS and 2 shift operation)

3.3. Less and Easy MaintenanceLess and Easy Maintenance

4.4. Wide Fuel Range (Wide Coal Range)Wide Fuel Range (Wide Coal Range)

Trend of Steam ConditionTrend of Steam ConditionTe

mpe

ratu

re (℃

)

200

300

500

400

600

0

20.0

30.0

TemperaturePressure

Pres

sure

(MPa

(g))

1910 1920 1930 1940 1950 1960 1970 1980 1990 2000

538℃ 566℃

600℃

593℃

16.5MPa(g)

24.1MPa(g)

24.5MPa(g)31.0MPa(g)

10.0

History of Steam Pressure and Operation in History of Steam Pressure and Operation in Japanese Utility Power PlantJapanese Utility Power Plant

0

20

40

60

80

100

120

140

1960

1965

1970

1975

1980

1985

1990

1995

2000

C om m erc ia l O peration Year

Uni

t Out

put (

GW

)

V ariab le P ressure O peration Supercritica lC onstant P ressure O peration Supercritica lSubcritica l

Sliding Pressure Supercritical Unit is mainstream.

2.2. Boiler Design FeaturesBoiler Design Features

Furnace Water Wall ConfigurationFurnace Water Wall Configuration&&

Operation ResultsOperation Results

What is required to the Latest boiler design? What is required to the Latest boiler design?

(4)Middle Load Operation

(5)Partial Load Efficiency(2)Easy maintenance

(3)Easy Construction

Supercritical Pressure with high steam temperature

(1) Higher Plant Efficiency

Sliding Pressure OperationSimple Structure

Less Welding point

TARGET

Furnace Waterwall DesignFurnace Waterwall DesignSpiral Water WallVertical Water Wall

(with Rifled Tube)

Velocity: HigherVelocity: BASE

Tube: LessTube: BASE

(1)Simple Structure- Easy Manufacturing and Construction- Shorter Installation Period- Less Thermal Stress

(2)Low Pressure Drop of Water Wall- Low Auxiliary Power Consumption- Low Temperature Imbalance

(3)Easy Removal of Slag- Less Slag Accumulation- No Local Concentration of Slag

Merits of Vertical WW to Spiral WWMerits of Vertical WW to Spiral WW

Mitsubishi Super Critical and Supercritical Coal Fired Boiler wiMitsubishi Super Critical and Supercritical Coal Fired Boiler with Vertical th Vertical Water WallWater Wall

Soma Joint EPCO.Soma Joint EPCO. Shinchi P/SShinchi P/S

1,000MW 24.1MPa×538/566℃ (1995)

Tohoku EPCO.Tohoku EPCO. Haramachi P/SHaramachi P/S

1,000MW 24.5MPa×566/593℃ (1997)

Tokyo EPCO.Tokyo EPCO. Hirono P/SHirono P/S

600MW 24.5MPa×600/600℃ (2004)Kobe steel IPPKobe steel IPP Kobe P/SKobe P/S

700MW 24.1MPa×538/566℃ (2002)

Kyushu EPCO.Kyushu EPCO. Matsuura P/SMatsuura P/S

700MW 24.1MPa×538/566℃ (1989)

Chugoku EPCO.Chugoku EPCO. Misumi P/SMisumi P/S

1,000MW 24.5MPa×600/600℃ (1998) Kansai EPCO.Kansai EPCO. Maizuru P/SMaizuru P/S

900MW 24.5MPa×595/595℃ (2004)

Chubu EPCO.Chubu EPCO. Hekinan P/SHekinan P/S

700MW 24.1MPa×538/566℃ (1991)

Tokyo EPCO. Hirono #5 Unit 600MWTokyo EPCO. Hirono #5 Unit 600MWCoalCoal--Fired Supercritical PlantFired Supercritical Plant

Steam Pressure (MPa(g)) 25.4

Steam Temp. (deg-C) 604 / 602

Evaporation (kg/h) 1,770,000

Fuel Coal

Fuel-Oil (30%)

Commercial Operation Jul.2004

2003/8/22撮影

BTG and AQCS supplied by Mitsubishi

Single Responsibility by MHISingle Responsibility by MHIfor Hirono #5for Hirono #5

Boiler(incl. fan, AH,mill)

dry ESP FGD(wet scrubber)

StackSCR

G

S/T

Turn key contract of Boiler, S/T and AQCS

Steam Turbine & Steam Turbine & GeneratorGenerator

StackStack

ESPESP

FGDFGD

Boiler & SCRBoiler & SCR

Kansai EPCO. Maizuru #1 Unit 900MWKansai EPCO. Maizuru #1 Unit 900MWCoalCoal--Fired Supercritical PlantFired Supercritical Plant

Steam Pressure (MPa(g)) 25.4

Steam Temp. (deg-C 598/598

Evaporation (kg/h) 2,570,000

Fuel Coal

Fuel-Oil (30%)

Commercial Operation Aug.2004

2003/8/22撮影

BTG supplied by Mitsubishi

Design Coal for Maizuru #1Design Coal for Maizuru #1-- 107 kinds of coal from all over the world 107 kinds of coal from all over the world --

40

50

60

70

80

90

100

600070008000900010000110001200013000140001500016000

Gross Calorific Value (Moist,Mineral-Matter-Free Basis,btu/lb)

Fixe

d C

arbo

n (D

ry/M

iner

al-M

atte

r-Fr

eeB

asis

, %)

Meta-anthracite

Anthracite

Semianthracite

Low VolatileBituminous

Medium VolatileBituminous

High VolatileA Bituminous

High VolatileB Bituminous

High VolatileC BituminousorSubbituminous A

LigniteSub-BituminousB,C

Various Sources of CoalVarious Sources of CoalAustralia Australia USAUSACanadaCanadaIndonesiaIndonesiaSouth AfricaSouth AfricaChinaChinaColumbiaColumbiaRussiaRussiaNew ZealandNew Zealand

Operation Results of Maizuru #1 BoilerOperation Results of Maizuru #1 Boiler-- Boiler Efficiency Boiler Efficiency --

85

90

95

150 300 450 600 750 900Boiler Load (MW)

Boi

ler E

ffici

ency

(%)

Guarantee

Test Result

Boi

ler e

ffici

ency

as

HH

V b

asis

(%)

Operation Results of Maizuru #1 BoilerOperation Results of Maizuru #1 Boiler-- NOx Emission NOx Emission --

0

10

20

30

40

50

150 300 450 600 750 900Boiler Load (MW)

NO

x (p

pm ;

6%O

2)

Test result #1 (base)

Test result #2 (high molar ratio)

NO

x (lb

/mm

Btu

)

0.075

0.050

0.025

0 NO

x at

SC

R o

utle

t (pp

mas

6%

O2)

Test Result #1 (SCR operation: Base)

Test Result #2

(SCR operation: Low NOx Mode)

3. Integrated coal Gasification 3. Integrated coal Gasification Combined Cycle (IGCC)Combined Cycle (IGCC)

Why IGCCWhy IGCC？？

1990 1995 2000 2005 2010 2015 202035

40

45

50

Conventional Coal Fired Unit

+5%(abs.)

IGCC 1500°C GT

Higher plant efficiency with Less emissionN

et P

lant

Effi

cien

cy(%

,LH

V)

600

550

500 Mai

n st

eam

tem

p.(℃

)

566℃600℃

Why IGCCWhy IGCC？？

0

20

40

60

80

100

120

140

CO2 Waste WaterAshPlantEfficiency

%

Coal fired USC Plant =100%

Emission

Higher plant efficiency with Less emission

Principle of MHI AirPrinciple of MHI Air--blown Gasifierblown Gasifier

Water

(Combustion)

Slag

AirAir

Coal

Ruductor

Combustor

(Gasification)

Char

Syn gas CO:30%,H2:10%HHV 1,100kcal/m3N

Appearance of Slag

Coal

200t/d gasifier

Schematic Diagram of IGCC

High Temp.Filter

Gasifier

Air Booster

Gas Turbine Steam Turbine

Coal

M

HRSGHRSG

WashingGypsumrecovery

Wet Desul-furization

Air

MHI supplies all the key components of gasifier, clean-up system and C/C.

Comparison of Gasifier SystemComparison of Gasifier System

O2

-1

base

+1

+2

+3

+4

+5%

Air-blown⇒ Lower auxiliary power

needed than O2 blown

Dry coal feed⇒ Lower heat loss

than slurry feed

GasificationAgent

Coal FeedHighest efficiencyD

iffer

ence

in N

et P

lant

Effi

cien

cy(a

bs.)

Dry

Air

Dry

MHI

Wet

O2

Development of IGCC in JapanDevelopment of IGCC in Japan

1980 1990 2000 20101985 1995 20051

10

100

1000

5

50

500

5000

Fuel

Cap

acity

( t/d

)

1700t/dDemo. Plant(250MW-class )

2t/d PDU(Yokosuka)

200t/dPilot Plant(Nakoso)

Commercial Plant(600MW-class )

250MW IGCC Demonstration Plant250MW IGCC Demonstration Plant

HRSG,Stack

Desulfurization

Gasifier

GT / ST

Key Dates2002.4 Project Start2004.9 Erection Start2007.9 - 2010.3

Demonstration Run

Project SchemeMETI

Clean Coal PowerR&D Co., Ltd.

30% subsidy

Hokkaido EPCo.Tohoku EPCo.Tokyo EPCo.Chubu EPCo.Hokuriku EPCo.Kansai EPCo.Chugoku EPCo.Shikoku EPCo.Kyushu EPCo.J-PowerCRIEPI

70%contribution

researchers

METI : Ministry of Economy, Trade and Industry EPCo. : Electric Power CompanyCRIEPI : Central Research Institute of Electric Power Industry

MHI

Joint Project Agreement

Single Point ResponsibilitySingle Point Responsibility

250MW IGCC Demonstration PlantSpecificationGasifier Dry feed,Air blown,Entrained flow typeDesulfurization Wet clean-upGas turbine 1,250°C Class

Coal feed 1,700 t/dayPlant Efficiency 48%(Gross)(LHV) 42%(Net)Emission SOx : 8ppmV(16%O2,dry) NOx : 5ppmV

Dust : 3.3mg/m3N

250MW

140140

330330230230

40

42

44

46

48

50

D-Series G/T(1,200°C)

52

400

500

600

300

% MWP

lant

Effi

cien

cy (N

et,L

HV

)

Demo.Plant

F-Series G/T(1,350°C)

G-Series G/T(1,500°C)

200

470MW

650MW

Gro

ss O

utpu

t

Performance of Commercial PlantPerformance of Commercial Plant

42

45

48

ConclusionConclusion1.1. We can supply and construct We can supply and construct whole coal whole coal

fired plantfired plant and and IGCC plantIGCC plant with single with single responsibility.responsibility.

2.2. Reliability and high performance of MHIReliability and high performance of MHI’’s s latest design for supercritical boiler latest design for supercritical boiler (600/600C) with vertical water wall have been (600/600C) with vertical water wall have been confirmed. confirmed.

3.3. Air blown IGCC achieves higher plant Air blown IGCC achieves higher plant efficiency.efficiency.MHI will be ready for the design of MHI will be ready for the design of commercial plant immediately after 250MW commercial plant immediately after 250MW demonstration run in 2007.demonstration run in 2007.

ENDEND

WeakConc

Conc

WeakConc

Conc

Low NOx ALow NOx A--PM Burner forPM Burner forMaizuru#1 & Hirono#5 BoilerMaizuru#1 & Hirono#5 Boiler

Weak:Fuel Lean

Conc:Fuel Rich

Oil

Maizuru #1 Boiler

Operational ResultsOperational Results-- NOx vs. Unburned CarbonNOx vs. Unburned Carbon --

A-PM Burner

Low NOx Burner

Low Volatile Matter Coal

High Volatile Matter Coal

4

3

2

1

050 100 150 200

NOx at boiler outlet (6% O2) (ppm)

Unb

urne

d C

arbo

n in

Fly

Ash

(%)

5

（（1000MW Utility Boiler1000MW Utility Boiler））

MRS (MRS (MMitsubishi itsubishi RRotary otary SSeparator) eparator) PulverizerPulverizer

RawCoalPulverized

Coal

GrindingTable

Roller

Recirculation ofCoarse Particles

Driving Deviceof Separator

HydraulicLoadingDevice

Rotary Separator (MRS)

Hot Air

Fineness of Pulverized CoalFineness of Pulverized Coal

0

2

4

6

8

60 70 80 90 100200 mesh through (wt%)

100

mes

h / 5

0 m

esh

resi

due

(wt%

)

100 mesh residue50 mesh residue

-- Maizuru #1 Boiler Maizuru #1 Boiler --

ITEM 2005 2006 2007 2008 2009 2010 2011 2012 2013250MW Demo. Plant In Japan

Commercial Plant

Output : 480MWGT : M501GGasifier : 3,000t/dayStructure : 1 on 1

(Ref.) AEP600MW Class IGCC

Development Schedule of IGCCDevelopment Schedule of IGCCCommercial Plant in US on 2013

FEED：FRONT END ENGINIEERING DESIGN

US coal test(scheduled)

FEED Operation StartReceive PO

Design / Manufacture / Construction

Manufacture/ Construction

PreliminaryDesign

Design

Operation

Reflect for the FEED

Operation

FEED start

Manufacture/Construction

MHI Air-blown Oxygen-blown type

Coal Feed Dry SlurryGasification Agent Air Oxygen

Reactor Durability >2 years (expected/water wall furnace) <2 years(Refractory)Total Reliability Single Gasifier Spare Gasifier needed

Burner Durability >1 year (expected/lower heat flux) 60-90 Days(erosion by Slurry)

Feature of MHI AirFeature of MHI Air--blown Gasifierblown Gasifier

MembraneWaterwall

Syngas, Char

Slag

Combustor

Reductor

Coal

CharCoal

Coal Slurry

Gasifier

Radiant Cooler

SyngasChar

More reliable than oxygen-blown type

RefractoryLining

Refractory

Insulation

Coal Range for gasificationCoal Range for gasification

FC : Fixed Carbon, VM : Volatile Matter

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700

Fuel

Rat

io (=

FC/V

M)

Ash Melting Temperature［℃］

Suitable for PC Boiler

Australian CoalAmerican CoalChinese CoalSouth African CoalIndonesian CoalJapanese Coal

easy to gasify

Difficult to gasify

17 kinds of imported coal were successfully gasified.MHI air blown gasifier can adopt wider range of coals.

Suitable forIGCC

US PRBcoal

US Easterncoal

Demo.Plantdesign coal

Demo. Plant Under Constructionin Joban EPCo. Nakoso P/S

Gasifier manufacturing in Nagasaki WorksMHI can supply pressure vessels from our in-house factory.

Examples of MHI's Experience

(by ASTM Coal Rank)

Reliable and Proven Boiler Design to burn Wide

Range of Coal

ASTMASTM’’s Coal Classifications Coal Classification

PhilippineIndiaSpainMexicoPetacalcoChina

Item Unit Tampa（U.S.A）

Wabash River

（U.S.A）

Nakoso Demo. Plant

(Japan)

IGCCCommercial

PlantRemark

Output (Gross) MW 322 296 250 500

(Net) MW 250 262 220 450

Gasifier －O2 blown

Slurry feedO2 blown

Slurry feed

MHIAir blownDry feed

MHIAir blownDry feed

Clean up － Wet C/U(MDEA)

Wet C/U(MDEA)

Wet C/U(MDEA)

Wet C/U(MDEA)

G/T － F class F classMHI

M701DMHI

M501G Plant Efficiency(Gross) %, HHV 46.3

(measured)42.7

(design) 46.0 51.0 Higher plant Efficiency

(Net) % , HHV 36.5 (measured)

39.7(design) 40.5 46.0 Higher plant

Efficiency

Emission SOx lbs./mmBtu 0.21 0.31 0.06 0.06 Lower SOx emission

NOx lbs./mmBtu 0.27* 0.22 * 0.03 0.03 Lower NOx emission

Particulate Matter lbs./mmBtu 0.01 0.03 0.01 0.01

Start of Operation － 1996 1995 2007 2013～

Summary of IGCC Demonstration PlantSummary of IGCC Demonstration Plant

*：without SCR