Session 2_Mr. Ishii (Japan)
Transcript of Session 2_Mr. Ishii (Japan)
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