Demonstration of Twin IHI Gasifier (TIGAR) for lignite coal · Easy familiarization by operator ......
Transcript of Demonstration of Twin IHI Gasifier (TIGAR) for lignite coal · Easy familiarization by operator ......
Demonstration of
Twin IHI Gasifier (TIGAR)
for lignite coal
~ IHI Gasification technology~
PT. IHI Gasification Indonesia
IHI Corporation
Gasification Technologies 2015 Conference
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Company – “Tsu-un maru”.
Company Profile (IHI Corporation)
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cture13%
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Unreacted char is burned with air
High temperature bed materials are circulated
Circulation
Steam gasification
Combustor
Gasifier
Fuel
SteamAir
(heat emission)
・Atmosphericpressure
・Low temperature
1. Characteristics of TIGAR
(heat absorption)
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・Components of TIGAR are based on mature Fluidized Bed technology・The low grade material (lignite, biomass) can be gasified, and applied to chemical raw material, fuel
Applicable Fuel
Coal (lignite)
Biomass
Application
CTLDME
Methanol
Fuel cell
NH3
SNG
Chemical feedstock
Auto fuel
Shift
Synthesis
Hydrogen
MethaneReforming
Syngas(CO,H2)
GT, GE Fuel Direct
reduction iron making
Syngas
H2
51%
CO
18%
CO219%
CH4
9%
Other HC
3%
Syngas
component
・Hydrogen rich gas
5
Combustor
Cyclone
Gasifier
Heat
Recovery
Area
(HRA)
Bag Filter
Exhaust Pipe
(HRA)
Cyclone
Syngas
TreatmentProcess
TIGAR Process
OperationIHI’s CFB experience
・ Steam Flow Rate : ~310 ton/ hr(Max. 1500ton/day as Lignite feed rate)
・ Since 1992
・ Delivery Record : Japan, China, Thailand
Operation philosophy of TIGAR is similar to CFB
Easy familiarization by operator
TIGAR has been developed based on CFB as mature technology, so TIGAR has same
features such as good fuel flexibility and environmental adaptation.
Furnace Cyclone
External
Heat
Exchanger
Heat
Recovery
Area
(HRA)
Bag Filter
Stack
CFB process
Similarity
Similarity between CFB and TIGAR
Maintenance Conventional equipment can be adopted
Familiar maintenance know-how
2. Feature of TIGAR
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CFB structure TIGAR structure
Cyclone
Furnace
HRA
Hopper
EVA
PSH
SSH
ECO
GAH
EHE
Height
55m
Combustor
Gasifier
Cyclone
HRA
Cyclone
Height
55m
Actual CFB Boiler
(1000 tons/day)
Commercial Plant
(1000 tons/day)
Key components of TIGAR and equipment such as coal feeder and fans are similar to CFB.
In addition, size of the commercial plant of TIGAR is within IHI’s experienced CFB.
Similarity of Key Components between CFB and TIGAR
2. Feature of TIGAR
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Palm Waste
WoodTIGAR
Easy utilization of Lignite and
Biomass
because of operation under
atmospheric pressure
Applying simple feeding system
to gasifier by gravity.
(Now Using little amount of seal
Nitrogen)
No special preparation !
Only rough crushed (Bulk) !
・ Particle size : 10mm under
・ Total moisture : < 35~45 %*
Lignite
*As received base
is acceptable
2. Feature of TIGAR
Fuel variety
and simple fuel supply system
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① Lower CAPEX and simple Operation & Maintenance
- Lower pressure and lower temperature in operating condition
② Simple Fuel preparation
- Coarse size and higher moisture are acceptable
③ No N2 contamination in Syn-gas, No ASU for gasification,
because of Steam gasification
IHI
-TIGAR-Entrained bed Moving bed
Gasifier type Fluidized bed
Pressure Atmospheric >3MPa >3MPa 1-3MPa
Temperature 800-1,000℃ >1,400℃ >1,400℃ >1,200℃
Gasification agent Steam Oxygen Oxygen Oxygen
Fuel particle size <10mm <0.1mm <0.1mm 4~5mm
Fuel configuration Bulk, powder Powder Slurry Bulk
Residue Dry Ash Slag Slag Dry Ash
2. Feature of TIGAR
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6t/d@Yokohama, JAPAN Commercial plant image
TIGAR×4units (1reserve)
Coal feed : 3000 t/d
( Substantially NH3 : 1000 t/d)
2004
~2009 2010 2011 2012 2013 2014 2015 2016 2017
Basic Test 6TPD Pilot Plant
50TPD Prototype Plant EPCDemonstrati
on Test
Commerci
al
Plant
at present
Japanese Government (METI*) Support
*Ministry of Economy, Trade and Industry
50t/d@Kujang, INDONESIA
3. Development of TIGAR
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History
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TIGAR design method has been constructed by several fundamental experiments
and simulations, and confirmed at Pilot Plant. Using this method, 50t/d
demonstration plant was designed.
0
0.2
0.4
0.6
0.8
1
1.2
0 0.5 1 1.5 2 2.5dimensionless time t/τ [-]
E [-]
Exp.(L=1m)
Cal.(L=1m)
0.0
0.2
0.4
0.6
0.8
1.0
0 10 20 30Time [min]
Carb
on
con
ver
sion
rati
o
lignite Sub-Bituminous
Bituminous
0.0
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0.6
0.8
1.0
0 10 20 30Time [min]
Carb
on
con
ver
sion
rati
o
lignite Sub-Bituminous
Bituminous
Gasification behavior6t/d pilot plant @ Yokohama
Prediction [%]
Exp
erim
enta
l [%
]
Prediction of
gasification efficiency
3. Development of TIGAR
Design method of gasifier
Prediction of coal residence time
in the gasifier
Target fuel
Design
Condition
•Capacity
•Temperature
•S/C
•Combustion Air
>>
>
11
<Plant site>
<50t/d 3D bird’s view>
4. 50t/d Demonstration at Indonesia
Purpose
<50t/d plant spec>
①Check the maintenance durability in long
operation (Total 4,000 hr operation)using Indonesia lignite.
②Confirmation of TIGAR performance and reliability, and reflect in commercial plant engineering.
③Demonstration of TIGAR gasification technology for future clients.
Coal feed rate50 t/d (as received,
43% moisture)
Syngas output 1,800 m3N/h-dry
Steam
generation
4.5 t/h (2.0MPaG,
513deg.C)
Site area 100m × 80m
Jakarta
IHI Cilegon factory
PT Pupuk Kujang(About 75km from Jakarta)
Java, INDONESIA
Easy access
for site visit
Easy access
for maintenance
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Organization chart
METIMinistry of Economy,
Trade and Industry
MEMRMinistry of Energy and
Mineral Resources
Ministry of
Industry
Ministry of
state-owned
enterprises
ARDEMRAgency of Research and
Development of Energy and
Mineral Resource
PT. Pupuk
Indonesia
(PIHC)
tekMIRAPT. Pupuk
Kujang
Cooperation
Government Talk
IHI Corporation
PT. IHI Gasification
Indonesia
Support
4. 50t/d Demonstration at Indonesia
Copyright © 2015 IHI Corporation All Rights Reserved.
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History
Signing Ceremony, 13 February 2013 First Gasification, 17 January 2015
Inaugulation
Ceremony,
26 February 2015
4. 50t/d Demonstration at Indonesia
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Site Overview
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4. 50t/d Demonstration at Indonesia
15
Material
Handling
TIGAR
Waste water
treatment
HRA
HRA
Bag Filter
Exhaust Pipe
Incinerator
Gas purification
(low pressure)
Gas purification
(high pressure)
1/4
3/4
Utility System
O2 Supply
System
N2 Supply
System
LPG System Instrumentation
Air System
Cooling Water
System Amine Supply
System
Emergency Generator
Steam Drum
Process flow
O2 supply
Tar Cracker
4. 50t/d Demonstration at Indonesia
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Waste Water area
Gasifier structure area
Gas Purification area
TIGAR Control Center
KIKC
Gate
KIK
C M
ain
Ro
ad
Kujang
Plant
TIGAR Site
Layout
Coal yard
Coal handling
system
LPG area
Machinery
house
Utility area
100m
80m
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4. 50t/d Demonstration at Indonesia
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Waste Water area
Gasifier structure and Coal crusher area
Gas Purification area
Control Center
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Plant photo
4. 50t/d Demonstration at Indonesia
Coal yard
18
Loading at coal jetty4000 ton coal on 230 ft Barge
Unloading at port (near Jakarta)
Design Coal : “East Kalimantan coal” 3400kcal/kg GAR at 43% moisture
From East Kalimantan to JawaTruck transports coal from stockyard near portto the TIGAR site.TIGAR site have 10 days stockyard (500ton)
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4. 50t/d Demonstration at Indonesia
Coal delivery
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4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
RUN1(PKN炭 1000hr)
評価、分析、メンテナンス
RUN2(パラメータ試験)
評価、分析、メンテナンス
RUN3(PKN炭+触媒 1000hr)
評価、分析、メンテナンス
RUN4(他炭種/Biomass 1000hr)
評価、分析、メンテナンス
Plant Demolition
2015 2016 2017
RUN1
RUN2
RUN3
RUN4
Plan
(East Kalimantan coal,
Adjustment)
(PKN炭、他炭種)
(他炭種、バイオマス)
Test schedule
(East Kalimantan coal,
Another coal, )
(Another coal, Biomass)
Evaluation, Maintenance
Evaluation, Maintenance
Evaluation, Maintenance
Evaluation, Maintenance
(East Kalimantan coal,
Performance test)
4. 50t/d Demonstration at Indonesia
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Operation Result
➤ Total 700hr gasification operation
➤ Without drying, roughly crushed lignite
were accepted
Example of operation
East Kalimantan Coal
TM (ar) 42 %
Ash (adb) 8 %
VM (adb) 38 %
FC (adb) 37 %
Total Sulphur (adb) 0 %
Gross Calorific Value
(ar)3380 kcal/kg
4. 50t/d Demonstration at Indonesia
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crush < 10mm
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Operation Result
4. 50t/d Demonstration at Indonesia
➤ With Indonesian operators we succeeded to ensure the stable operation
➤ Optimization of operation are still needed
Composition of Gasifieroutlet syngas
Seal N2 for Coal feedingline are detected.
*
*
5. Marketability of lignite gasification- Why Indonesia?
Natural GasCoal
Policy of Indonesia energy supply
Export
Indonesia Coal Resources Natural gas Utilization in Indonesia
WEC, Survey of Energy Resources 2010 The 1st JAPAN-INDONESIA ENERGY FORUM, 2013
The 1st JAPAN-INDONESIA ENERGY FORUM, 2013
22
: Important source of foreign exchange
acquisition by LNG export : Energy security
Energy situation in Indonesia
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Natural Gas ReformerAmmonia
Process
Urea Process
Gasifier
TIGARLignite
Change !
NH3 manufacturing capacity of Pupuk Indonesia holdings (PIHC) Group
Pusri
1350 t/d
790 t/d
1200 t/d
1200 t/d
Kujang
1160 t/d
1000 t/d
Petrokimia Gresik
1350 t/d
Kaltim
1800 t/d
1800 t/d
1000 t/d
1000 t/d
Iskandar Muda
1100 t/d
1200 t/d
5. Marketability of lignite gasification- Indonesian Fertilizer Industry
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6. Conclusion
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• TIGAR is based on CFB technology, and steam
gasification. It has the feature of easy O&M, fuel flexibility
(Lignite, Biomass), H2 rich syngas.
• From the 50t/d Demonstration operation in Indonesia, we
are getting data for commercial plant. And we will prove
and appeal above TIGAR’s merit through 4000hr
demonstration operation.
• We would like to contribute for effective use of resources
by TIGAR technology.
Thank you for your attention !