global activities for clean coal technology
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Global Activities forClean Coal Technology
September 9, 2014
Yozaburo MabuchiSenior Executive Vice PresidentMitsubishi Hitachi Power Systems, LTD
Contents
1
1. Introduction of MHPS
2. Supercritical / Ultra-Supercritical Power Plant
3. Air Quality Control System
4. Advanced Clean Coal Technology
1. Introduction of MHPS
2© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Mitsubishi Hitachi Power Systems, Ltd (MHPS)
Name MITSUBISHI HITACHI POWER SYSTEMS, LTD.
Head Office Yokohama, Kanagawa, JAPAN
Representatives Koji Tanaka (Chairman of the Board)Takato Nishizawa (President and CEO)
Capital 100 Billion JPY
Effective Date February 1, 2014
Employees 23,000 (incl. 7,600 outside Japan)
3© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Integration in the Thermal Power Generation Systems Field
4
Head Office & Main Works in Japan
Nagasaki Works
Takasago WorksHitachi Works
Yokohama Head OfficeYokohama Works
Kure Division of Babcock-Hitachi K.K.
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Global Network of MHPS
5
MHPS has 58 companies in 26 countries.CBC
MHPS Europe(UK)
L&T MHPS JV
MHPS AmericaEnergy and Environment
MHPS DongfangJV MHPS Canada
MHPS Africa(RSA)
DHME(Dalian)
MHPS Americas
MHPS Europe(Germany)
BHPI
MHPS Technical Services
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
MHPS’s Business Field
6© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Gas Turbine Combined Cycle (GTCC) Power Plants
Integrated coal Gasification Combined Cycle (IGCC) Power Plants
Boiler & Turbine Generation Plants
Geothermal Power Plants
Environmental Plants SCR Systems, FGD Systems
Steam Turbines
Gas Turbines
Boilers
Generators
Power Generating Plant Peripheral Equipment
SCR Systems Plant Control System
Fans Fuel Cells (SOFC)
Products & Services
Delivery Records
7
*1; Conversion value corresponding to main steam *2; Over 50MW coal-fired power plant
Product Boilers Steam Turbines Gas Turbines Flue Gas
Desulfurization*2
Selective Catalytic
Reduction*2
Total 936,234t/h(approx. 312GW)*1 341,767MW 106,159MW 121,591MW 91,942MW
Total 4,259 units 2,385 units 787 units 298 units 153 units
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
2. Supercritical/Ultra-SupercriticalPower Plant
8© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
石炭焚火力発電プラントの比較(米国 vs.日本)
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Comparison of Coal Fired Plant Thermal Efficiency by Individual Countries
9
Source:; International comparison of fossil power efficiency and CO2 intensity - Update 2013, Ecofys
Aver
age
Gro
ss T
herm
al E
ffici
ency
(LH
V, %
)
620゚C
200
300
500
400
600
20
30
Steam Temperature
Ste
am T
emp.
(oC
)
Gro
ss P
lant
Effi
cien
cy (L
HV
%)
538゚C
600゚C
593゚C
10
610゚C
40
700
SC(S
uper
criti
cal)
USC
(Ultr
a-Su
perc
ritic
al)
566゚C
A-USC
1968 1993
1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 20201910
Gross Plant Efficiency
Year
History of steam condition and thermal efficiency in Japanese thermal power plant
Efficiency vs Steam Condition for Coal Fired Plant
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 10
Higher steam temperature and pressure improve thermal plant efficiencyIn other words, SC/USC technology provides economical power production, fuel energy saving, lower carbon emission and environment-friendly
11
MHPS Various Coal Experience
Anthracite
Bituminous
Sub-Bituminous
Lignite
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
MHPS can provide various power plants best suited for various kinds of coal based on abundant experiences.
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
関西電力Maizuru#1 (‘04)900MW 24.5MPa x 595/595℃
東北電力 Haramachi#1&2(‘97/’98)1,000MW 24.5MPa x 566/593℃1,000MW 24.5MPa x 600/600℃
東京電力 Hirono#5&6(‘04/’13)600MW 24.5MPa x 600/600℃
中国電力 Misumi#1 (‘98)1,000MW 24.5MPa x 600/600℃
九州電力 Matsuura#1 (‘89)700MW 24.1MPa x 538/566℃
四国電力 Tachibanawan#1(‘00)700MW 24.1MPa x 566/593℃
東京電力 Hitachinaka#1&2(‘03/’13)1,000MW 24.5MPa x 600/600℃
Coal-Fired SC/USC Plant in Japan
12
電源開発 Tachibanawan#2(‘00)1,050MW 25.0MPa x 600/610℃
中部電力 Hekinan#1&2(‘91/’92)700MW 24.1MPa x 538/566℃
北陸電力 Tsuruga#1&2(‘91/’00)500MW 24.1MPa x 566/566℃700MW 24.1MPa x 593/593℃
Total: 25units
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 13
Netherlands: 2units
Poland: 1unit
Greece: 1unit
Jaypee Nigrie #1,2 Mahagenco Koradi#8,9,10 Rajpura #1,2
Korea: 4 units
India: 8units (by L&T-MHPS Boilers Pvt. Ltd. as JV) Indonesia: 1unit
Paiton III Expansion
Taiwan Power Co., Ltd. LIN KOU #1-3
Taiwan: 8units
CFE Pacifico #1
Misumi #1
Japan: 25units
Total: 122unitsMHPS: 82 unitsOthers: 40 units(Chinese licensee, Indian JV)
ENEL Torrevaldaliga Nord #2-4
USA: 4units
Midamerican Energy, Walter Scott Jr. Energy
Center #4Malaysia: 1unit
Boxberg R
German: 8units
South Africa: 12units
Mexico: 1uinit
Italy: 3units
China: 40units(by MHPS / Licensee)
Henung Yuhuan #1 to #4And 37units
Canada: 2units
Australia: 1unit
CS Energy Kogan Creek #1
Enea, Kozienice
Coal-Fired SC/USC Plant in overseas
14
Indian Project Rajpura #1
Global Activity with SC/USC Technology
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
• Rajpura #1 was placed under commercial operation Feb 1st, 2014• This unit was constructed by joint venture established by MHPS and Indian local
company Larsen & Toubro, Ltd.• Fuel is Indian high ash content bituminous coal (ash content is 30%)• Local staff performed engineering/manufacturing/construction/commissioning works
under MHPS’s instruction• High efficiency and reliability of Japanese leading CCT were also proved in India
Output : 700MW
Main Steam Flow : 2,322 t/h
Main Steam : 565 oC / 24.1 MPag
Reheat Steam : 593 oC
Commercial Operation : 2014/2
Fuel : Bituminous coal
NOx (ppm) : 116 (actual) / 365 (limits)
Thermal efficiency : Approx. 4 ~ 5% better*1
*1: Relative value as compared with Sub-critical plant (16.7MPag, 538/538oC)
Activities at Indian MarketIPP L&T RajpuraSC 700MW x 2
Rajasthan State Power Generation /ChhabraSC 660MW x 2
IPP Jaypee NigrieSC 660MW x 2
LMB(L&T-MHPS Boilers Private Ltd.)
MHPS has contributed to Indian power generation with Japan oriented CCT through the JV with Indian company, Larsen & Toubro, Ltd.
LMTG(L&T MHPS Turbine Generators Private Ltd.)
Maharashtra State Power Generation /Koradi SC 660MW x 3
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 15
16
Output : 866MWMain Steam Flow : 2,695 t/hMain Steam : 538 oC / 24.9 MPagReheat Steam : 566 oCCommercial Operation : 2012/4Fuel : Sub-bituminous coalThermal efficiency : Approx. 2 ~ 3% better*1
Indonesian Project Paiton III
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
•First coal-fired SC plant in Indonesia•MHPS supplied boiler and steam turbine including construction work
Global Activity with SC/USC Technology
*1: Relative value as compared with Sub-critical plant (16.7MPag, 538/538oC)
Germany Project Boxberg R
17
Output : 1 x 670MWMain Steam Flow : 1,760 t/hMain Steam : 600 oC/ 29.4 MPagReheat Steam : 610 oCCommercial Operation : 2012/10Fuel : German Lignite coalThermal efficiency : Approx. 5 ~ 6% better*1
Global Activity with SC/USC Technology
•USC steam condition was applied to German lignite-fired boiler•Water content in the coal is approx. 60% and LHV is approx. 2000kcal/kg
*1: Relative value as compared with Sub-critical plant (16.7MPag, 538/538oC)
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
3. Air Quality Control System
18© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
19© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
One-stop AQCS solution by MHPS
Air Quality Control System for Coal Fired Plant
(GGH: Gas to Gas Heater) * ESP will be supplied by MHI-Mechatronics Systemsor Hitachi Plant Construction
ESP*GGHHeat Extractor
GGHRe Heater
FGD
SCR
2次空気2次空気
Low NOx Combustion
World lowest level emission (SOx, NOx, PM) can be achieved by applying the integrated AQCS system
PM: < 7mg/m3N
1980 1990 1995 2000 2005 2010 2015
SO
2(p
pm)
High Efficiency AQCS development history (PM, SO2)
PM: <20mg/m3N
EP : Electrostatic PrecipitatorGGH : Gas Gas HeaterRGGH : Rotary GGHH/E : Heat ExtractorR/H : Re Heater
AQCS in Japan commercialized from 1970’s High Efficiency AQCS with Low Low temperature EP has been developed
to meet the sever environmental demand Emission level now reaches world lowest level
RGGH FGD Stack EP(Low temp)
Non LeakGGH(H/E) FGD
EP(LL temp)FGD
Non LeakGGH(R/H)
EP(Low temp)
Stack StackNon Leak
GGH(H/E)
Non LeakGGH(R/H)
Non Leak GGH applied to prevent dirty gas leakage.
High Efficiency system with low-low temperature EP applied.
High Efficiency System
SO2:50ppm
SO2:100ppm
SO2:24ppm
20© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Low NOx Combustion Technologies and SCR system
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 21
1,200
800
400
ConventionalBurner
SGRPM
PM+Two-stage combustion
[Coal Firing Boiler] 200ppm (@6%O2)
100
200
300
400
500
600
1980 1985 1990 1995 2000
NO
x (p
pm) 400ppm
300ppmGovernmental
Regulation Local Regulation~50ppm (@6%O2)
NOx Reduction with SCR
NO
x (m
g/m
3 N, 6
%O
2)
00
Combustion technologies without SCR
200
600
1,000
A-PM+Two-stage combustion
M-PM Burner NR3 Burner
Latest Low NOx Burner
Honeycomb Catalyst Plate Catalyst
SCR System
2005 2010
M-PM+Two-stage combustion
• MHPS has reduced boiler outlet NOx emission through continuous development of low NOx combustion technology.
• In combination with SCR system, world lowest level NOx emission is achieved.
22
MHPS Delivered AQCS units all over the world
Japan
MHPS
000 1,258 126
S.Korea21
Mexico18
Brazil26
Chile11
Saudi Arabia17
Philippines14
Taiwan25
Russia4
China52
Indonesia10Singapore
21
Hong Kong16Thailand
16
Ukraine3Netherlands
1
Austria1
South Africa4
10
17
5
India1 13
Denmark4
12
USA
1
32
25Germany
Italy
Finland4
Czech10
Poland7
14Spain
England12
1
Turkey5
Canada1
Colombia5
Curacao3
Venezuela4
AustraliaMalaysia
1
Myanmar1
Yugoslavia1
Libya3
Zambia2
555
341
17
L
2
2
45
32
L 7
3
2
4
7
3
7
L
3Greece1
Portugal4
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
MHPS’s AQCS Global Activities
Number :ReferencesL :License
:SCR 1,027 Units (13 Countries):ESP 1,543 Units (29 Countries):FGD 303 Units (19 Countries)
4. Advanced Clean Coal Technology
23© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Advanced USC (Ultra Super Critical)
The efficiency of the coal fired power plant will be improved by making the steam condition higher temperature and pressure.
A-USC Development Outline
Target Steam Temp. : 700oC
Next Generation Development Goal is Net Efficiency 46-48% (HHV)
Development Matter•Material (Ni-base Alloy)•Manufacturing Technique•Design•Lifetime Assessment Methodology
2008 2009 2010 2011 2012 2013 and over
High Temp Corrosion
Steam Oxidization
Fatigue / Creep Rupture
100,000 hr Creep Test
Conceptual Design
Verification of Manufacturing Technique (welding, bending)
Mock-up Test(header, S/H)
A-USC Development Schedule
Test Loop under 700oC Steam Temp.
24© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
Development of Material for Advanced USC
Pipe size: φ558.8 x 138tWelding method: Narrow Gap HSTMaterial: HR6W
Welding test for large-bore piping
(φ350 x 40t, Bend radius 1,400mm, Bend angle 50o)
High frequency induction bending for HR6W
To achieve A-USC technology, new nickel-base alloy material have been developed
MHPS have conducted welding test, bending test, mockup fabrication
100,000 hr creep rupture strengthen including weld joint are continuously being conducted(MHPS have 70,000 hr test data)
Weld Metal
Bond
Base Metal
Macro / Micro structure
Mockup fabrication of HR6W header
Heating temperture : 1050-1150℃
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved. 25
Higher efficiency through coal gasification process coupled with a combined cycle (CC) system.
Reduce CO2 emission by high efficiency and prevent global warming
What is IGCC?
*Integrated coal Gasification Combined CycleOutline of IGCC System
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved.
C~ T
HRSG
~
Gas Turbine
Coal
Gasifier
Cleanup
AirComp.
Air
Steam Turbine
Flue Gas
Combustor
Combined Power Generation(Combination of Brayton & Rankine Cycles)
TEPCO Fukushima IGCC Project (2020~)Nakoso site, Hirono site
Joban Joint Power Co.LTDNakoso #10(Demo. 2007-, Commercial 2013-)
Osaki CoolGen Corp. Osaki CoolGen Project(Demo. 2017-)
Rendering Image
IGCC Projects in Japan(Demonstration and Commercial Plant)
26
Features of IGCC system
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• IGCC plant efficiency is 40-45% relatively higher than coal fired conventional power plant. (base 33%=world average sub-critical plant)⇒ CO2 emission decreases 30-35% lower.
• IGCC discharges coal ash in the form of glassy slag, cutting volumes by more than half.
• IGCC can reduce circulating water for cooling by 40%.
• IGCC technology can also be applied with wider range of coals including LRC (Low Rank Coals).
• MHPS gasification process had been confirmed by using many types of coals form the world
Applicable Coal Range
Symbol shows gasifier experienced coals
Suitable for IGCC
Suitable for Conventional Boiler
Performance of IGCC System
CO2 CirculatingWaterPlant
Efficiency
(%)
EmissionAsh
0
20
40
60
80
100
120
▲65%
▲35%
▲40%
+~45%vs. sub-C
140
160Coal fired conventional
power plant(sub critical plant) =100%
Higher Efficiency and Least Environmental Impact
Approx. 65% decrease in volume
Utilization as a pavement material
are possible.
Utilization as a concrete aggregate
Flyash(Conventional Boiler)
Grassy Molten Slag(IGCC)
Flexibility to “Variety of Coal”
27
Nakoso 250MW IGCC Plant
28© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
Nakoso250MW IGCC
Major Specification
Output 250 MW (gross)
Gasifier Air-blown Dry Feed
Gas Clean-Up MDEA(Methyldiethanol Amine)
Gas Turbine M701DA GT (1 on 1)Plant Efficiency 42% (LHV, net)
Project ScheduleOperation Started Sep. 2007Commercial Operation July. 2013
Nakoso 250MW IGCC Demonstration Plant achieved all the following targets.Excellent Performance (Highest Efficiency, Less Environmental impact)Higher Reliability (World record of continuous operation)Fine Operability (Load change rate >3%/min)Fuel Flexibility (Verified applicability for low-rank coal)
Converted to the First Commercial IGCC Plant in Japan
Targets Achievements Note
Performance
Output (Gross)(Net)
250MW220MW
250MW225MW
Efficiency (Net, LHV) > 42.0% 42.9%
Carbon Conversion > 99.9% > 99.9%
Emission(@dry, 16%O2)
SOx NOx Dust
< 8 ppm< 5 ppm
< 4 mg/m3N
1.0 ppm3.4 ppm
< 0.1 mg/m3N
Operational Flexibility
Coal KindsBituminousSub-
bituminous
Chinese, Canadian2 US (including PRB)3 Indonesian (Adaro,
etc.)Colombian, Russian
9 kinds of coal in total5 Sub-bituminous4 Bituminous
have been used.
Start-up Time < 18 hr 15 hr
Minimum Load 50% 36%
Ramping Rate 3%/min 3%/min
ReliabilityLong-term Continuous Operation
2,000 hr 3,917 hr Cumulative operating hours :> 25,000 hrs.
Achievements of Nakoso 250MW IGCC Plant
29© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
0
20
40
60
80
100
28‐Jun 26‐Jul 23‐Aug 20‐Sep 18‐Oct 15‐Nov
Load
Factor [%]
Achievements of Nakoso 250MW IGCC PlantOperability (Load Change) Reliability
Verified at 3%/min load change operation which is required as middle range operation
Environmental Performance
0
10
20
30
40
50
Net Efficiency(%-LHV)
SOx(ppm)
NOx(ppm)
Dust(mg/kg)
42.0 42.9
85 41 3.4 <0.1
Cumulative operation exceeded 25,000 hrs. The continuous operation last year achieved
no forced outage - Ave. load factor > 99% The continuous operation 3,917hr renewed the
world record.
Continuous Operation 3,917 hrs.Average Load Factor > 99%
*: Maintenance for changing from demonstration to commercial plant and intermittent inspection
7 8 9 10 11 12 1 2 3 4 5 6 7 8 92013 2014
Commercial Operation
Operation history and schedule after starting commercial operation (June 30, 2013).
Maintenance*
30© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
DesignTest Results
Osaki CoolGen Project
31© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
Major SpecificationOutput 166 MW (gross)Gasifier Oxygen-blown Dry Feed
Gas Clean-Up MDEA(Methyldiethanol Amine)
Gas Turbine 1300oC classPlant Efficiency 40.5% (HHV, net)
Project ScheduleConstruction Started March 2013Demo. Operation Start March 2017Rendering Image
Commercial-scale IGCC Project
32© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
High Efficiency by using state of the art Gas TurbineLower CO2 emission intensity than the latest USC coal fired power plant.Fuel Flexibility for high moisture Low Rank CoalHighly Reliable system verified in Nakoso 250MW IGCC plant
Major Specification
Output 540 MW (gross)480 MW (net)
Gasifier Air-blown Dry FeedGas Clean-Up MDEAGas Turbine M701F GT (1 on 1)Plant Efficiency 48% (LHV, net)
33
• In July 2014, MHI Received Order for World's Largest Post Combustion CO2 Capture System for a Coal-fired Power Generation Plant,for Japan-U.S. Joint Enhanced Oil Recovery (EOR) Project
• Project : CO2 Capture + EOR
• Developed by NRG Energy and JX Japan
• Supported by U.S. DOE and JBIC
• Client: Petra Nova CCS • Plant: NRG Parish Station• Location: Texas • Capacity: 4,776 MT/Day• CO2 Capture Technology:
MHI’s KM CDR Process • Solvent: KS-1• Operation Start: 2016
CO2 Scrubbing + EOR
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
Clean Coal Technology Showcase Project in U.S.
34
Showcase Project:‐ Coal Upgrading (Hg Removal)‐ CO2 Capture + EOR‐ AQCS + Zero Liquid Discharge
MHPS/MHI can provide one‐stop solution to Existing Coal Power Plant
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
35
Conclusion
MHPS shall be continuously developing clean coal technology to improve plant efficiency and reduce carbon emission
MHPS shall contribute to environmental conservation and carbon emission reductionto provide Japanese clean coal technology worldwide
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD. All Rights Reserved
36
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