State-of-the-Art Technologies for Reliable/ Sustainable .... State-of-the-Art Technologies...

State-of-the-Art Technologies for

Reliable/ Sustainable Coal Fired Power Plants

Copyright © 2017 IHI Corporation All Rights Reserved.

September 6th, 2017

Hiroyuki OTANI Board Director Managing Executive Officer President,Resources, Energy&Environment Business Area

1. Introduction of IHI Group Business

2. Overview of IHI Boiler Business

3. State-of-the-Art Technologies for

Reliable/ Sustainable Coal Fired units

4. Summary

Table of Contents

Copyright © 2017 IHI Corporation All Rights Reserved. 2

1. Introduction of IHI Group Business



1-1. Company Profile

4

IHI Head Office, Tokyo

・Founded : A.D.1853

・Head Office : Tokyo, JAPAN

・Capital : JPY 107.165 mil (USD 975 mil)

・Net Sales : JPY 1,486,332 mil (USD 13,512mil)

・Employees : 29,659

・Works in Japan : 7

・Branches / Sales offices in Japan

: 16

・Overseas offices : 13

・URL : www.ihi.co.jp

(IHI Corporation)

Information is on consolidated basis as of March 2017.

The First Steamship Built by Japanese Private Company – “Tsu-un maru”.

http://www.ihi.co.jp/

General-Purpose Machinery

(Compressor, Separator, Turbo charger, etc.)


1-2. Business Areas

5

Industrial Systems

(Steel Manufacturing Furnaces, Heat/Surface Treatment

Equipment, Logistics Systems, Material Handling Equipment, etc.)

Social Infrastructure & Offshore Structure

(Bridge, Transportation System, Security, etc.)

Resources, Energy & Environment

(Boiler, Gas Turbine/Gas Engine, LNG Terminal, Process Plant,etc.)

Aero Engines,

Space

&

Defense

Resources,

Energy

&

Environment

Social Infrastructure

&

Offshore Facilities

Industrial Systems

&

General-Purpose

Machinery

Aero Engines, Space & Defense

(Jet Engine, Rocket)

5

Resources, Energy & Environment

Gas Process/

Storage Plant

• LNG Receiving

Terminal (EPC Service)

• Storage Tank

(LPG, LNG, Helium)

Boiler

AQCS (Air Quality Control System)

• PC Boiler

• Oil / Gas Firing Boiler / HRSG

• DeNOx/DeSOx System

• CCS System

GAS Turbine

• Gas Turbine (for base load & peak cut)

6

IHI Enviro

Corporation

IHI Plant

Engineering

Corporation

Jurong

Engineering

Ltd.

Diesel

United Ltd.

NIIGATA

POWER

SYSTEMS

CO., LTD.

1-3.Overview of Resources, Energy & Environment Business


2. Overview of IHI Boiler Business


Client : Sandy Creek Energy Associates, L.P., USA Unit : Sandy Creek

Turbine Output : 998.5MW(net)

Boiler Capacity : 2,852 t/h

Steam Conditions: 26.9MPa, 585/583 oC

Fuel : Pulverized Coal

100% Sub-bituminous Coal (PRB Coal) Commercial Operation : 2013

References of IHI Sub-Bitu. Coal fired Boilers

2-1 Activity in USA


2-2 Activity in German

9

Client : Trianel Kohlekraftwerk Lünen GmbH & Co. KG

Turbine Output : 1 x 813MW (Gross)

Boiler Capacity : 1 x 2,225 t/h

Steam Conditions(@Boiler outlet): 28.76MPa, 600/610 oC (Ultra Super Critical)

Fuel: Pulverized coal (Bituminous Coal)

Commercial Operation:2013

The Coal Top Plant

Award Winner of

POWER Magazine,2014


10

Photo is provided by J-POWER(EPDC)

Client : Jimah East Power Sdn. Bhd, Malaysia Unit : JEP Unit1 and Unit2

Turbine Output : 2 x 1,064MW (Gross)

Boiler Capacity : 3,025 t/h

Steam Conditions: 27.9MPa, 603/612 oC (USC, Two-pass Type)

Commercial Operation (Scheduled) :

2018 (Unit1), 2019 (Unit2) General Arrangement

2-3 Activity in Malaysia

Site Location for

Jimah East Power Jimah No.1 & 2


2-4 Activity in Morocco

11

Client: Safi Energy Company

Turbine Output: 2 x 693MW (Gross)

Boiler Capacity: 2 x 1,923 t/h

Steam Conditions: 26.5MPa, 603/602oC

(Ultra Super Critical)

Fuel :Pulverized Coal (Bituminous Coal)

Commercial Operation:2018


3. State-of-the-Art Technologies for

Reliable/ Sustainable Coal Fired units


Th

erm

al e

ffic

iency im

pro

ve

me

nt (R

ela

tive

%)

Steam pressure (MPa) 24.1 24.5 29.4 34.3

0

1

2

3

4

5

6

593/593oC

600/600oC

610/610oC

630/630oC

Base:538/566oC

(Conventional Super-Critical Plant)

620/620oC

Isogo new No.1

26.6 MPa

600/610oC

Tachibana-wan No.1

25.0 MPa

600/610oC

Isogo new No.2

26.7 MPa

600/620oC

ST

EA

M T

EM

P. [o

C]

Year of Initial Operation 5

10

15

20

25

600

550

500

450

400

ST

EA

M P

RE

SS

. (

MP

a )

‘55 ‘60 ‘65 ‘70 ‘90 ‘95

30

~

16.6

24.1

31.0

4.1

450

482 485

538

566C 593oC 610oC

620oC

STEAM TEMP.

STEAM PRESS.

2000 ‘14

~

Isogo new No.2

Hekinan No.3

Tachibana-wan No.1

F

u

r

n

a

c

e

F

u

r

n

a

c

e

2

S

H 3

S

H

F

i

n

a

l

S

H

2

R

H

H

R

A

1

R

H

1

S

H

2

E

C

O 1

E

C

O

1

E

C

O

A pioneering and leading company in Ultra Super-Critical (USC) coal-fired boiler,

- The largest capacity- - The highest steam conditions -

Isogo New No.2

Steam Condition: 600/620oC

Tachibana-wan No.1

Capacity： 1,050MW

13

Lünen

27.6 MPa

597/609oC

3-1. IHI USC(Ultra Super Critical) Boiler


630oC

Takehara new No.1


3-2. A-USC

Development of A-USC Technology

A-USC (Advanced USC) technology has been going to develop for improvement of thermal cycle

efficiency from 42% to 46% (net, HHV).

IHI has participated in the Japanese national project from 2008. We has established material

evaluation, manufacturing technology of Ni-based alloy during first 5 years and we has fulfilled

boiler components test with 13000hr exposure under 700deg C steam condition at commercial

coal fired boiler by 2016.

From this fiscal year, IHI is part of new national project to develop maintenance technology for

establishment of more proven condition to the future commercial units.

Boiler component test facility

Heating element

during testing

Mock-up model of SH header


3-3. Woody Biomass Utilization

15

- CO2 reduction according to number of pellet

mill can be achieved

- Achievable of CO2 negative with CO2

capture technologies such as Oxyfuel and

PCC

- Possible utilization of both coal and woody

pellet with minor modification

Verification with 149MW Power Plant in Japan (2015)

Woody Pellet High Ratio Co-firing Features

Kamaishi coal fired power plant : 149MW

(Nippon Steel & Sumitomo Metal Corporation)

One coal mill (total 4 mills) was retrofitted to a pellet mill equipped with a “flow acceleration ring”.


3-4. Solution for Palm Oil Industry

16

- OPT pelletize with IC-reactor can be an

independent system.

- Deashed EFB pellet can be burnt in PC

boilers and CFB with higher combustion

rate/single fuel firing.

- IC-reactor can treated POME and can be

satisfactory in the water quality regulation

and can produce methane for power

generation.

Activities in Malaysia (2015 - )

Palm Oil Industry + IHI’s solutions Features

OPT palletization project is ongoing and toward to the business stage.

POME treatment project is running in demonstration phase.

EFB pellet production is under the early stage of business and they will be utilized in commercial power plant.

EFB pellet production facility POME treatment pilot facility Pilot equipment for OPT pellet


3-5. Oxyfuel Combustion

17

- Lower CO2 capture cost for full capture

- Byproduct reuse such as N2 resulting from

air separation for O2

- Achievable of CO2 capture rate up to 98%

- Applicable to both existing and new power

plants

Air Separation

Unit

Coal

Flue Gas Recirculation H2O

O2

CO2

Air

Non-condensable Gases N2 Boiler

CO2 Processing

Unit

Flue Gas

Treatment

Callide Demonstration Project in Australia (2012 - 2015)

The world’s only-one oxyfuel power plant for CO2 capture from coal fired power plants.

Achieved over 10,000 hours oxyfuel operation without serious technical barrier

Ready for large scale commercial plant

Oxyfuel Combustion Features

Callide A Power Station

Owned by CS Energy

4 x 30 MWe

Steam : 136 t/h at 4.1MPa, 465oC

Commissioned : 1965 – 69

Refurbished : 1997/98

Placed in storage in 2002


3-6. PCC Technologies

18

- Flexible design for both full capture and partial capture

- Sequential scale up by increasing the number of PCC

module

- Applicable to not only Coal fired boiler but also the

other use such as NG-GTCC and Biomass power plant.

- Applicable to both existing and new power plants

PICA Project (PCC-IHI-CSIRO-AGL Project) in Australia (2014 - )

Post Combustion Capture (PCC) Features

CO2

Coal

N2, H2O, O2

CO2 Capture

Boiler

Air

Flue Gas

Treatment

(Chemical Absorption System)

Demonstration for Post-combustion capture of CO2 (PCC) technology at AGL Loy Yang A brown coal fuelled power station in Victoria of Australia.

Achieved 5,000 hours operation with IHI’s original sorbent developed by 20t/day pilot plant in Aioi, Japan

To realize large scale commercial plant

PICA plant: 0.5t/day in Loy Yang A Power Station

◆Business Model Example


3-7. Twin IHI Gasifier (TIGAR®)

19

～2010 2011 2012 2013 2014 2015 2016 2017 2018 2019

6 ton/day pilot plant

50 ton/day prototype plant

TIGAR is being developed with the support of METI and NEDO

TIGAR is ready to commercialize TIGAR leads to Hydrogen Society in Japan

◆What is TIGAR?

Steam

Syngas

Air

Flue Gas

Hot Bed Circulation TIGAR®

Urea, Fertilizer

FCV

Coal

Fuel for Power Station

Household Fuel Cell CO2

TIGAR is a gasifier suitable for low rank feedstock

like lignite and biomass.

TIGAR has been developed

based on the fluidized bed

technologies of which we

have extensive experience

and knowledge.

Using steam as gasifying

agent, H2 rich syngas can

be obtained.

Currently we are in the final stage of development

Biomass

Commercial Stage

◆CO2-Free Hydrogen Supply Chain

Business Model A Business Model B

Feedstock Biomass Lignite with CCS

TIGAR

Capacity

200 ton/day

as feedstock

1000 ton/day

as feedstock

Product CO2-free-H2

5,000 ton/year as H2

CO2-free-NH3 200,000 ton/year as NH3

End use FCV, Fuel Cell Power plant, Urea

CO2 Free/

Negative

H2

CO2 Free/

Negative

NH3

as H2 carrier

http://www.google.co.jp/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjAvO7p77nUAhVGW7wKHdNIDCwQjRwIBw&url=http://www.chemistryexplained.com/Ce-Co/Coal.html&psig=AFQjCNET3uqxVvaXyOsIp6f1_1tygXlgXg&ust=1497410684526631

http://www.google.co.jp/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwifo-WC8LnUAhUMa7wKHVTCDtoQjRwIBw&url=http://www.thompsondryers.com/biomass/&psig=AFQjCNHNs-RqOdFBDHVvJ6Mk0_hl9Lxtjg&ust=1497410774585018

Boiler capacity : 1000MW

NH3 co-combustion rate : 20% (HHV basis)

Boiler capacity : 1000MW

NH3 co-combustion rate : 20% (HHV basis)

2017: Co-combustion test at combustion test facility

Feasibility study for Ammonia storage system

2018 : Feasibility study for co-combustion system of

boiler plant


3-8. NH3 utilization and co-combustion technology

20

IHI focuses on ammonia (NH3) as hydrogen carrier and CO2 free fuel to utilize on coal

firing boiler in the hydrogen energy based society.

IHI participated in SIP (Strategic Innovation Promotion Program) which is a Japanese

national project from this fiscal year to develop NH3 co-combustion technology in the

coal firing boiler.

Global Ammonia Network Combustion test facility

Development plan of NH3 co-combustion in SIP

Reduction of CO2 emission

1.26 million ton CO2 per year

4. Summary



4. Summary

22

Large Scale Power Plant Technology

Application of Renewable material resources

Improvement High Press./Temp. Steam Technology

We are Confident that IHI’s Coal fired power

Plant technologies will fit to Best-mix for

world wide energy requirements.

Thank you for your attention!


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