evolution and vision of integrated gasification combined...
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Evolution and Vision of Integrated Gasification Combined Cycle
and Co-production Systems in China
Xiao, YunhanInstitute of Engineering Thermophysics
Chinese Academy of SciencesJune 16, 2006
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Outline
An Effective Solution to the Coal, Electricity, Oil and Transportation in the China’s Development of EnergyPlan for Developing the Co-production in Other CountriesThe Course and Evolution of IGCC and Co-production in ChinaThe Breakthrough for IGCC and Co-production SystemVisionRemarks
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An Effective Solution to the Coal, Electricity, Oil and Transportation in the China’s Development of Energy
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National Great Demand- Electricity, Oil from Coal
coalreserve:coal 92.6% of the gross reserves of the remaining exploitable fossil energy2004:primary energy consumption 1.97 billion tce,coal 2/32020:primary energy demand 2.5~3.3 billion tce,coal 2.1~2.9 billion t
coal power-the base of China power2004:441 million kW, coal-fired 70%2020:900 million kW, coal-fired 580 million kW,64%new coal will be mostly used to generate electricitymajor source of the air pollutant
Soot 70%, SO290%, NOX67%, acid rain 82%, CO270% from coal fired
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National Great Demand-Electricity, Oil from Coal(cont.)
Coal based clean fuel-effective pathway to make up lack of oil
Demand: continuous growth of import dependency, exceeds 60% to 2020 , (same as the present US level)clean:low sulfur content,HC, CO, NOX,,PM reduction by 49%, 33%, 27%, 21% respectively
Hydrogen production from coal:8M ton Hydrogen → 66M Cars → 90M ton Coalcoal gasification based co-production
economic, ultra clean, high efficient, power generationeconomic, clean liquid fuelmaximum efficiency and benefitcirculating economy
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Corporation Demandenergy production corporations are facing challenges
Yankuang、Huaneng、Luan、Dongguan、Fushan and Shenhua etc. energy corporationsShanxi、Shanxi、Neimeng、Lingdong、West-south、West-north, large scale comprehensive utilization base of coal
advanced core technologies are needed in large scale manufacture industry of energy-power equipment
product upgrade(enhance efficiency, reduce pollutants, new products),enhance market competitionmeet higher and higher domestic market requirementenhance competition in international market
• circulating economy and sustainable development • stricter environmental protection rules• the growth of energy price, possibility of acquirement • enhance competition
• new competitive solution• new comprehensive energy industry• energy-power high technologies cluster
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Coal gasification based co-production• integration of coal-based material production and energy
conversion, power, liquid fuel, chemicals and hydrogen
• large scale comprehensive utilization mode
• breakthrough for the limitation of raising efficiency, improving cost-effectiveness and controlling emission in single industry
• solution to the problems of coal, power, oil and transportation
Gasification
Fuels and Chemical Products Production Subsystems
Power Generation System
Coal
Fuels(liquid, H2, etc.)Chemical Products
Electricity
Material and energy exchange
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Plan for Developing the Co-production in Other Countries
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Science and Technology Innovation Plan and Progress of Foreign Government
AmericaVision 21 -CCPI-FutureGenCo-production-innovation system of clean coal technology
CCT1986~1993
PPII2001
CCPI2002~2012
FutureGen2003~2012
1.7billion US dollars
2.7billion US dollars
a new clean energy demonstration station within ten years based on coal gasification, the co-production of 275MWe/hydrogen production/liquid fuel with CO2 capture and storage
53 million US dollars
4.7billion US dollars
4 IGCC demonstration
plants
3 EECP(EarlyEntrance
Coproduction Plant)
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Science and Technology Innovation Plan and Progress of Foreign Government (cont.)European Union
2 IGCC demonstration plantsTechnology origin:countries of EUHolland(200MW,efficiency 41% ), Spain(250MW,efficiency 42-43%)
HYPOGEN project2004 to 2015, the total investment of 1.3 billion Eurobuild a near zero emissions power plant with the gasification as its base, 192MW power and hydrogen and separating and disposing CO2
Germany COORETEC program,fossil fuel based near zero emissions power generation
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Japan250MW IGCC demonstration power plant with air-blown, put into operation in 2009CCT-Coproduction,2004Co-production-combination of coal, power, steel, oil chemical engineering is an important pathway to establish circulating-society
Australia Coal 21, coal gasification based power, hydrogen production and synthesis with CO2 capture and storageCanada, CCT roadmap, co-production as the strategic choiceNew Zealand and Britain also take a lot of attention on the development of co-production2004, IEA CCT roadmap, depend on co-production to realize near zero emissions
Science and Technology Innovation Plan and Progress of Foreign Government (cont.)
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The Course and Evolution of IGCC and Co-production in China
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• Pursuing IGCC since the 70th last century• Plan to build a 10MW IGCC experiment
power station in 1979• Stop without start
• IGCC key technologies and system analysis– Three five-year plans
• USA and PRC Experts Report on IGCC in 1996
• The IGCC engineering project in Yantai,Shandong, initiated in 1999, not start construct yet
• IET pursuing co-production since 1998• The Demonstration Plant in Commercial
Operation since Apr. 2006
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Progress of Science and Technology
973 programhigh-efficient clean energy-power system and study on internal flow during heat-work conversion process(finished)basis research on coal-based pyrolysis, gasification and high temperature clean up(finished)the fundamental research of large-scale and high-efficiency entrained flow coal gasification process, 2004Basic researches on the polygeneration application of the syngasfrom the combination of gasified and pyrolyzed coal gas, 2005
863 programcoal gasification based co-production of power and methanolkey single technologies
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Gasification
new-style coal-water slurry gasification
scale:1150 tons/dayoperation times up to 5130 hours
dry pulverized coal pressurized gasification (1)
scale:24 tons/dayoperation times up to 2100 hours
dry pulverized coal pressurized gasification (2)
scale:45 tons/day
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Synthesis
750 tons per year pilot plant of CTL
7 operation experimentsIn 2004, operation with full load 1500 hourssufficient operation experience and engineering data through 5000 hours run of the plant
5000 tons per year pilot plant of CTL
operation for 6068 hoursfull load operation times up to 4706 hours
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Gas Turbine
heavy duty gas turbine110MWdesign, material development and application parts manufacture ongoing
micro gas turbine100kWdesign, manufactureadjustment ongoing
forge piece of turbine
blade wheel of compressor and turbine
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Gas Turbine (cont.)
heavy-duty gas turbine introduction into Chinagoal: set up the manufacture industry of gas turbine3 times, F class (250MWe), E class(125MWe), gross capacity 16GWe
Dongfang Electric & Mitsubishi: 12, F classHaerbin Power & GE: 20, 9F classShanghai Electric & siemens: 9, F classNanjing Turbine & Electric Machinery Corporation & GE: 4, 9E class
combined manufacturefuel?
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Integrated Design and Dynamical Properties of IGCC
system integration, whole set design and real-time simulation equipmentsoperation optimization method, performance assessment software and maintenance technology of IGCC power station
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The Breakthrough for IGCC and Co-production System
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Yankuang Power and Methanol Co-production System- power : 60MWe , methanol: 240,000 tons /a
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Coal Coal gasifiergasifier : : slurry fed,entrained bed :slurry fed,entrained bed :11501150TPD X 2TPD X 2Power: 60MWePower: 60MWe,,methanol: 240,000 tons/Ymethanol: 240,000 tons/YInvestment: 1Investment: 15.8 5.8 hundred million RMBhundred million RMBCapital payCapital pay--off time: 8.1 yearsoff time: 8.1 years((including including
construction periodconstruction period))Running time: >1000Running time: >1000 hourshours
Yankuang power and methanol co-production demonstration plant
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Progress in System Studyplatform for power and methanol co-production system
System integration and optimization softwareComponent and process simulationSystem analysis
application and test in demonstration plantSystem designComponent and process analysisSimulation and optimization Control,diagnosis, and operation techniqueData acquisition and measurementEvaluation of efficiency and economic performance
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Application and Test in Co-production Demonstration Plant——Component Analysis and Data Acquisition
Component performanceASUSlurry fed gasification
Raw syngas parameters, prediction errors of key components:<1%Gas purification and sulfur recovery
Sulfur content in clean syngas: fit well with design data Mass flow of sulfur and by product steam:fit well with design data
Methanol synthesis and fraction By product steam, power consumption, raw methanol: fit well withrunning data
Combined cycle( Gas turbine, HRSG)Can simulate design condition and off design conditionPart load, full load: errors with measurements(pressure ratio, exhaust temperature, compressor outlet temperature) <2%
ComparisonSimulation results with design dataSimulation results with operation data
Database Various operation condition(full load, part load)
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Application and Test in Co-production Demonstration Plant——System Simulation and Test
Operation modeOnly methanolOnly electricity(IGCC)Part load parallel co-production systemFull load parallel co-production systemPart load serial-parallel co-production systemFull load serial-parallel co-production system
Comparison of simulation results with design data and measurement results
Node parameters (flowrate, composition): fit wellProducts fit well(power and methanol)
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Application and Test in Co-production Demonstration Plant——Efficiency Evaluation and Comparison (Operation Data)
Methanol production Energy consumption=product methanol energy /total input thermal heat Net electric efficiency=net power output/(total input thermal heat-methanol energy consumption)Total energy utilization ratio=(net power output + methanol exergy + by product LP steam exergy)/(coal exergy+ auxiliary input exergy)
Part load: total energy utilization ratio
serial-parallel> parallel: 7.03 points percentagesNet electric efficiency
serial-parallel> parallel: 3.73 points percentagesFull load:
total energy utilization ratioserial-parallel> parallel: 3.41 points percentages
Net electric efficiencyserial-parallel> parallel:3.41 points percentages
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Application and Test in Co-production Demonstration Plant——Performance Evaluation
total energy utilization ratio —— avoid part load operationParallel system(full load > part load : 3~4 points);serial-parallel(full load > part load : 3~4 points);Methanol synthesis efficiency: part load ↓ (50% load, methanol energy consumption ↑ 87%)Gas turbine efficiency: part load ↓ (62% load, efficiency ↓ 3.5 points)
Potential for performance improvement by system synthesisHeat recovery(purification, synthesis,….)
Fuel heating, humidificationComponent load match at the design stageASU lower bound condition(70% load,gasifier: O2 evacuation,>10000 Nm3/h)Coordination of gasifier and purification(at full load, if 75% gasifier load, operation pressure decrease → purification process deviates from design point → performance worsening)Deviation of gas turbine exhaust temperature and compositions → HRSG steam generation rate < design data, 68.5t/h vs. 74t/h
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Application and Test in Co-production Demonstration Plant
Conclusion 1一Database development(multi components and various operation conditions): gasification, shift, heat recovery, sulfur recovery, methanol synthesis,fraction, gas turbine, ASUAnalysis of mass streams, heat streams, power streams: based on components and system
Components and processes models can be used in performance prediction and analysis, to be improved: part load
Part load, methanol production(error: 10%)——operation pressure deviate from design value:30%Steam production prediction, deviation increase at part load
Simulation results fit with plant operation data
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Application and Test in Co-production Demonstration Plant (cont.)
Conclusion 2一Evaluation of part load, full load; parallel co-production, serial-parallel co-production
Total energy utilization ratio: Co-production > single production, 3 points; net electric efficiency : Co-production > single production, 3 points
Technical and economic evaluation Avoid part load operationImprovement potential: by system synthesisOperation results show: high efficiency, economic
• test and improve components and system simulation
• certify efficiency increase
• database and experience
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Methanol, Power Co-production Analysis and Integration Platform——System Integration and Optimization Software
Independent development: part work, apply for software copyright——“co-production analysis and synthesis software”
AdvantagesWide range——electricity, chemical engineering, co-production system,..Advanced research technique——simulation, synthesis and optimizationPowerful ability for optimization——certainty and uncertaintyOpen——user model and algorithm
iSIGHT(experiment design, optimization, approach, monte carlosimulation, reliability analysis/optimization, multi objectivesoptimization
Aspen plus(Chemical engineering)
Gate cycle(power engineering)
gPROMS(user models)
Other softwares(Matlab, excel,.)
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Methanol, Power Co-production Analysis and Integration Platform——System Integration and Optimization Software(IGCC)
syngas
steam
Makeup water
synthesis
Gasifier and GCU models GT and HRSG models
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Steam
airboiler
ST
gasifier methanolsynthesis
CH4O
power
O2水
2.5MPa Steam
Heat recoveryand GCU
purge gas
2.5MPaSTEAM
syngas
exhaust
0.5MPa steam
coal energy
BFW
BFW
Methanol only system
powerrpoduciton
gasifier
O2
heat recoveryand GCU
0.5MPa steamcoal
water
exhaustpower
power
power only system
gasifier CH4Osynthesis
methanolO2
shift, syngas purifyand heat revovery
purge gas合 成 新 鲜 气
syngas purify andheat recovery
syngas forpower
GT combinedcycle
feedwater
power
feedwater
feedwater
saturate steamat 2.5MPa
saturate steamat 2.5MPa
saturate steamat 0.5MPa
saturate steamat 0.5MPa
steam turbine
power
power
coal water
power
boiler
Air
exhaust gas
exhaust gas
steam for self use
Parallel system
steam for self use
GT combinedcycle
gasifier CH4Osynthesis
methanol
coal
O2water
shift, syngass purifyand heat recovery
syngas for power
purge gas
saturated steam at 2.5MPa
exhaust gas
power
feedwater
syngass purifyand heat recovery
feedwater feedwater
power
power
saturated steam at 2.5MPa
saturated steam at 2.5MPa
saturated steam at 05MPa
purify syngas for power
Serial-parallel system
steam for self use
GT combinedcycle
gasifier CH4Osynthesis
methanol
coal
O2water
(shift) syngass purifyand heat recovery
purge gas
saturated steam at 2.5MPa
exhaust gas
power
feedwater feedwater
power
power
saturated steam at 2.5MPa
saturated steam at 2.5MPa
saturated steam at 0.5MPa
Serial system
Methanol, Power Co-production Analysis and Integration Platform——System Comparison
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power:60MW,methanol:2,40,000 tonsGPMSSlurry fed, Quench gasifierparallel+GPMS, one dimension,RPLUG,kinetics controlled modelSerial-parallel+GPMS, one dimension,RPLUG,kinetics controlled modelserial+LPMS ,CO rich gas, one through
Methanol=constant,CH4O production energy consumption:
serial-parallel< methanol only:4.6%Gas turbine=constant, Methanol=constant,total energy utilization ratio:serial-parallel >parallel: 2 pointsGas turbine=constant :net electricity efficiency serial-parallel 38%> power only: 5 points
Relative M
ethanol production E
nergy consumption
(%
)
Methanol production Energy consumption
Comparison of Net electric efficiency
Net electric efficiency
Comparison of total energy utilization ratio
Total energy utilization ratio
s-m c-p c-s-p c-s40
50
60
70
80
90
100
s-m c-p c-s-p c-s s-p0.0
0.1
0.2
0.3
0.4
0.5
0.6
c-p c-s-p c-s s-p0.000.050.100.150.200.250.300.350.400.450.500.55
:methanol only:parallel co-production:power only:serial-parallel co-production:serial co-production
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Methanol, Power Co-production Analysis and Integration Platform
ConclusionPlatform designed for methanol, power co-production, a tool for system integration, analysis, progress in system research toolComponent model:relationship of input and output under various operation condition, fit well with reference and operation data,suitable for system analysis, integration and optimizationSystem comparisons; sensitive studySerial-parallel co-production system; ways to improve system performance:purge gas, by product steam,expander, syngashumidification
• disclosure the inherence relationship of different components of co-production system
• improve the capability of platform
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Combustor Designing Program
The results of numerical simulation of a LM1600 gas turbine combustor, laminar flamelet model, gri3.0 chemical mechanism
The results of numerical simulation of a F101 gas turbine combustor, PDF transport model, D0 radiation model
1D designing code for combustors (flow and A/F ratio distribution, thermo dynamical calculation)3D CFD software of verification
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The first pressurized, full-size test rig for heavy-duty gas turbine combustors in China
Sensors
• 250 channels
• Flue gas composition, exit temperature, dynamical pressure, flame video
980
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1046.24
1046
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1046.24
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1046.241060
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1060
Compressor•Air flow rate 3.2kg/s at 5 atm
Test section•Power of the combustor: 2MW
Fuel supply•Syn-gas, distillated oil, propane
Recorders and analyzers
•256-chennel high-speed dynamical signal recorder and analyzer
•Flue gas analyzer
Control system
Experimental Platform
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Pressurized full-size combustor test rig
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In-situ Measurement Platform
The capability of in-situ measurement and adjustment being established
•Liner sleeve temperature measurement
•Dynamical pressure monitoring
•Flue gas composition/combustion efficiency analysis
•HMI engineer station-monitoring and recording the parameters of the engine control unit
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Signal transformation and data processing/parameter monitoring and recording of engine control system
In-situ pressure and temperature transformation unit
Agilent VXI data acquisition
system
Interface of HMI engineer station
•Pressure and temperature transformation
•Agilent VXI data acquisition system
•HMI engineer station: monitoring and recording data of the engine control unit
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Experimental Study of Diluted CombustionFundamental Study of Humid CombustionHumid Air Combustion-Full Size Combustor TestingIn-situ Combustion Experiment-Testing of Fuel Humidification
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Laboratory Study of Humid Combustion
Numerical and experimental results of a combustion field
Flame appearance v.s. air humidity
•Flame geometry•Pollutant formation•Flame stability
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Study of Humid Air Combustion on the Full Size Combustor Test Rig
Dry air
Air humidity: 5%
Air humidity: 7%
Temperature field NO field
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0 200 400 600 800
距喷嘴端面的轴向距离mm
周向
平均
壁面
温度
40MW,加湿质量比17.2%
40MW,加湿质量比11.0%
40MW,加湿质量比8.9%
40MW,加湿质量比0%
In-situ Combustion Test-Fuel Humidification
•At base load, dry fuel: NOx425mg/Nm3; fuel humidity 17.2%:NOx 119mg/Nm3
•Other performances not apparently influenced0
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0 0.05 0.1 0.15 0.2 0.25
相对加湿量
NOx(mg/Nm3)@16O2
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CO(ppm)
NO(mg/Nm3)@16O2
CO(ppm)
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Experiments and Tests of Fuel Gases of Variable Heating Value
In-situ Experiment—Tail Gas, SyngasMixing Combustion
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In-situ Test of Mixed Fuel Combustion
4443CO ppm0.990.990.990.99Combustion efficiency42.042.042.042.0Power (MW)
11338.411229.611542.210730.5Heating value (kJ/kg)Syn+TailSyn+TailSyn+TailSyn.
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0 200 400 600 800
距喷嘴端面的轴向距离mm
周向
平均
壁面温
度
驰放气=0Nm3/h,H2%=36.3%,42.0KW
驰放气=2684Nm3/h,H2%=38.6%,42.0KW
驰放气=2797Nm3/h,H2%=38.8%,42.0KW
驰放气=3327Nm3/h,H2%=39.8%,42.0KW
Liner sleeve temperatureAmplitude and frequency of dynamical pressure
Stable working condition
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Summary of R&D Process of Co-production by IET
Completing the first cycle of fundamental-test-demonstrationPursuing IGCC since the 70th last century(Sino-US IGCC specialist report, 1996)1998 began the explore of co-production 1999-2004, focused study of co-production in the 973 project “Optimization, integration and innovation of general power systems”At the end of 2000, the collaborative project “Co-production of electric power and methanol from coal gasification” with Yankuang startedIn 2002, the construction of Huairou experimental base of energy and environmental laboratory was supported by a major project of knowledge innovation of the Chinese Academy of SciencesIn 2002, a 863 project supported R&D of syngas combustors of gas turbines and system demonstrationIn April of 2006, an early co-production system came into operationRoadmap for Developing Coal Gasification Based Co-production in ChinaAdvantages of Coal Gasification Based Co-production and the Barriers to and Options for Its Development in China
Established the experimental platform of the key processes of co-production, made breakthrough of key technologies, and the results were applied in the first demonstration system of co-production in Chinaprogressive execution of co-production, verification of high efficiency and low emissions of co-production
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47
Vision
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Advantages of Coal Gasification Based Co-production and the Barriers to and Options for Its Development in China
high technologies clustergasification and syngasconditioningCoal-derived gas fired gas turbineSynthesis for liquids and chemicalsHydrogen production, carbon capture and sequestration…
mergingCoal Power generation industry and coal chemistry industryCoal based chemical engineeringTechnology suppliers, engineering designers and manufacturer
collaboration among Gov., Ind., Ins., Uni.
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National Science and Technology Development Plan of Medium and Long Term
strategic high-technology, Fundamental ScienceEnergy resource & ocean
economic, efficient, clean utilization of coal-coal gasification based co-production was a strategic choice
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Roadmap for Developing Coal Gasification Based Co-production in China
pathway to the goal, advice on what, who, how, when, what conditions
clear, consensus goalcommon development frameharmonious stepoptimized share of work and collaboration
supportDepartment of High and New Technology Development and Industrialization, MOSTBureau of High-Technology Research and Development , CASNRDC
implementationInstitute of Engineering ThermophysicsThe expert committee of clean coal technology, high technology R&D program
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Co-production-integration energy system innovationStep by step development
Integration of mature single technology, acquirement of practice knowledge and experiencebreakthrough in all ways of special key technologyfinally realization zero emissions
Plan as a wholenation leading and corporation self-determinationindustry development and science and technology innovationinternational collaboration and self-innovation
Roadmap for Developing Coal Gasification Based Co-production in China (cont.)
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Industries
Yankuang Group Corporation Limited, Shandonga new co-production plant of power and 800 thousand tons liquid fuel per year
Lu’an Group, Shanxipower and 160 thousand tons liquid fuel per year co-production demonstration project, laid a foundation
China Shenhua Group800 MW power and 400 thousand tons methanol per year co-production project, pre-flexibility report of the project finished
China Huaneng Group120MWe, GreenGen project, flexibility report of the project finishedjoined American FutureGen coalition
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Industries-Region
The Changjiang River Deltathe driver to develop IGCC
The Pearl River Deltauncertainty of LNG supply uncertainty of oil pricestricter environmental requirementpower plants choose IGCCplanning to newly build IGCC power plants from the range of 100MW to 800MW,future co-production
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Final goalform competitive clean coal technologies with proprietary intellectual property rights and to support the development of energy equipment industry and to realize fast development of efficient, clean utilization of coal
Goal in 2010finish research, development and demonstration of key technologies break through special problems of co-productionCommercial demonstration of IGCC Demonstration of typical co-production of F-T fuel and electricity
Goal for IGCC and Co-production
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Goal in 2015Demonstration co-production plants each with400MWe IGCC and one million F-T liquid fuelPilot plant of co-production of hydrogen and electricity with CO2 capture
Goal in 2020installed IGCC capacity with 15000MWeF-T Liquid for oil capacity 40 million tons per yearDemonstration of co-production of hydrogen and electricityready for CO2 capture
Goal for IGCC and Co-production (cont.)
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Development in the Eleventh Five-Year Plan Period
enlarge and deepen key technologies, realize the validation, integration and application of key technologies guidelines-“science and technology R&D, engineering demonstration, industrial harmony, policy encourage, moderate development”Insist on five combinations:“self-R&D and introduction & improvement, technology innovation and engineering demonstration, near demand and future development, government propose and corporation effort (including institutes ), industry harmony and policy encourage”promote IGCC and co-production rational development
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57
Remarks
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Coal-based co-production technology is very important to China. It is the direction of the development of clean coal technology and an option to resolve energy problems of coal, power, oiland transportationGreat progresses were made on single technologies of co-production and system integrationThe first co-production industrial demonstration of power and methanol were constructed, the breakthrough of IGCC and co-production were realizedGovernmental support and right decision, combination of industry, university and institute, effective international collaboration are neededCo-production will realize irreplaceable contribution to the development of energy, industrialization and heavy chemical engineering
Remarks
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59
Thank you for your attention!
Xiao, [email protected]
Acknowledgement
National Basic Research (973) Program High Technology Research and Development (863) Program Knowledge Innovation Project of the Chinese Academy of SciencesThe team of Energy & Power System RDD in IET