The Progress of Osaki CoolGen Project - JCOAL 一般 …. The Progress of Osaki...September, 2017...

September, 2017Osaki Coolgen Corporation

The Progress of Osaki CoolGen Project~ Oxygen-blown Integrated Coal Gasification Fuel Cell

Combined Cycle Demonstration Project ~

Outline

1. Background and Significance of IGCC Development

2. Gasification Technology

3. Osaki Coolgen Project （1）Project Overview（2）Overview and Progress of IGCC

Demonstration(STEP1)（3） Demonstration Plan of IGCC with

CO2 Capture(STEP2)

1

Outline





CO2 Capture(STEP2)

2

Fuel price transitionCharacteristics of coal as energy resourceLow cost and stable supply compared to other fossil fuels

Distributed widely all over

the world

Abundance of reserves

Distribution of Coal resourcesProves reserves

1. Background

source：BP statistics2017 source：BP statistics2017

Oil

Gas

Coal

3

Percentage of each generation resource

Source：Energy balances of OECD countries 2016(IEA)／Energy balances of non-OECD countries 2016(IEA)

Coal ‒fired power generation accounts for about 40% of the world electricity generationThe coal-fired power generation is widely used in high energy-consuming countries

such as China, India and the US.

The proportion of coal-fired power generation is about 30% in Japan.

1. Background 4

Coal-fired power generation in the world : about 30% CO2 emission from Coal-fired power generation : about 30%

Coal-fired Power Generation- Current electricity & CO2 emission and 2040’s prospects -

Source: IEA World Energy Outlook 2015

Coal

gas

Source : IEA World Energy Outlook 2016（New Policies Scenario)

Electricity from coal-based power generation

41% (2014)

28% (2040)

CO2 emission from coal-based power generation

31% (2014)

27% (2040)

4 995 9 899 9 598 9 648 9 792 9 911 9 992

-

5 000

10 000

15 000

20 000

25 000

30 000

35 000

40 000

1990 2014 2020 2025 2030 2035 2040

CO

2 em

issi

on[M

t-CO

2]

Coal power Oil power Gas power Total CO2 emissions

1. Background 5

OECD America321GW→208GW

Latin America7GW→12GW

Other Asia Oceania184GW→367GW

China855GW→1,137GW

India176GW→451GW

Africa44GW→80GW

Middle East0GW→3GW

OECD Europe184GW→91GW

Eastern Europe/ Eurasia111GW→91GW

Source : IEA World Energy Outlook 2016（New Policies Scenario)

: 2014 : 2040

Prospects of the world Coal-fired power generation capacity

Coal-fired Power Generation- Current generation capacity and 2040’s prospects -

(2014) (2040)

Coal-fired power generation capacity in the world⇒ 1,882GW → 2,437GW （555GW）

1. Background 6

8

Coal-fired generation ⇒ Essential for the “Best Mix” energy policy Energy self-sufficiency in Japan＝ approx. 6%*

Coal-fired Power Generation

Demand of electric power Composition of electrical source

966.6TWh 980.8TWh

Coal:26%

LNG:27%

Nuclear:22-20%

Renewable :22-24%

Geothermal :1.0-1.1%

Wind :1.7%

PV :7.0

Hydro:8.8-9.2%

Biomass :3.7-4.5%

1065TWh

Oil:3%FY2030 FY2030FY2013

Economic growth

Energy Mix in Japan**Saving energy196.1TWh

1. Background

- status in Japan -

**Source : METI Long-term energy supply-demand outlook(2015.7)*Source : Japan’s Energy White Paper 2016

Efficiency :Net / Higher heating value

Ultra SC（USC）

Super critical（SC）

Advanced USC（A-USC）

46 ~ 48%CO2 reduction about ▲15%

1300℃ IGCC 1500℃ IGCC 1700℃ IGCC

(MCFC)(SOFC)

Fuel Cell（FC）Integrated coal gasification fuel

cell combined cycle (IGFC)

Integrated coal gasification combined cycle（IGCC)

Pulverized coal fired（PCF）

55%～CO2 reduction about ▲30%）

Gas turbinegasifier

HRSG

Steam turbine

boiler

Steam turbine

gasifier Gas turbineFuel cell

HRSG

Steam turbine

Development Road Map of High Efficiency Low Emissions Coal Power Generation Technology in Japan

39 ~ 41%base

38% 46 ~ 48%

1. Background 8

We must:

Efficiently use low cost coal for increased Power Demand Drastically reduce CO2 emissions against Global Warming

(Step-1)

Significance of Osaki Coolgen Project

IGCC + CO2 Capture(Step-2)

Oxygen-blown IGCC with high efficiency, high environment-tal performance, reliability, coal variety compatibility and controllability

IGFC + CO2 Capture

Osaki Coolgen Demonstration Project

Development of High Efficient Clean Coal Technology

(Step-3)

Coal is indispensable to achieve sustainable power supply

Global Sustainable Development

In Resources Importing Countries (as Japan)

1. Significance 9

Outline





CO2 Capture(STEP2)

10


Significance of developing Oxygen blown type “EAGLE” Gasifier

High efficiency and low carbonization of coal-fired power generation and effective utilization of coal and its byproduct

Drastically to improve power generation efficiency and significantly to reduce carbon dioxide emission.

Efficiently to capture CO2 by pre-combustion method.

To use low-grade coal(sub-bituminous coal and brown coal) and high-grade coal(bituminous coal) for gasification.

To re-use coal ash and reduce in volume as slug of glass type

Multi-purpose uses of coal gasification gasFor the gasification gas to be widely used as synthetic fuels and chemical raw materials.

11

Process Development Unit（1t/d／FY1981～1985／Katsuta）

HYCOL Pilot Plant（50t/d／FY1991～1993／Sodegaura）

EAGLE Pilot Plant（150t/d／FY2002～2013／Wakamatsu）

OCG Demonstration Plant（1,180t/d／FY2016～

166MW／Osaki）

Coal Energy Application for Gas, Liquid, and Electricity

× 3

× 8

Scale Up

2. Gasification TechnologyDevelopment History and Significance of “EAGLE” Gasifier of Oxygen Blown Type

12

Features of EAGLE GasifierOxygen-blown Two-stage Spiral-flow Gasifier

2. Gasification Technology 13

0.50

1.00

1.50

2.00

2.50

1150 1200 1250 1300 1350 1400 1450 1500 1550 1600 1650 1700

Ash Melting Temperature [℃]

Fixed carbon/Volatile matter [－]

Conventional Gasifier

Pulverizing Coal FiredEAGLE Gasifier

◆、◆：EAGLE AchievementPilot Project

Applicable Coal types for the “EAGLE ” gasifierEAGLE

Source : JPOWER EAGLE brochure

Coals appropriate for Gasification

Pulverizing Coal Fired

Sub bituminous Coal area Bituminous Coal area：EAGLE Pilot Project Achievement

2. Gasification Technology 14

Outline





CO2 Capture(STEP2)

15

Project Timeline

Coal

GTCompressorN2

O2

Fuel Cell

ASU

CO2

Gasifier Gas Clean up

H2

Step-2

CO, H2

このイメージは、現在表示できません。このイメージは、現在表示できません。

Step-1

Step-3GeneratorST

(1)Project Overview 16

METI (~FY2015)： Ministry of Economy, Trade and IndustryNEDO (FY2016~):New Energy and Industrial Technology Development Organization

OSAKI CoolGen Corporation

The Chugoku Electric Power Co., Inc. (Energia)Electric Power Development Co., Ltd. (J-POWER)

Subsidy

Mitsubishi Hitachi Power Systems, LTD.Coal gasifier unitCombined cycle unitCoordinate all units

STEP1 EPC contract

JGC Corporation

Gas clean up unitWastewater treatmentAir separation unit

DiamondEngineering Co . Ltd.Coal preparation & supply unit

Project Scheme

Joint Investment

STEP1 EPC contract STEP1 EPC contract

(1)Project Overview 17

Outline





CO2 Capture(STEP2)

18

IGCC Process Flow

Air

Combined cycle unit

Cooling Water

ST

Condenser

HRSG

GGT

Combustor

CycloneFilter

Coal gasification unit

Nitrogen

Air

Compressor

Gas clean-up unit

Coal

Mill

Hopper

slag

#1Water

scrubber

Stack

Oxygen

Rectifier

Air separation unit

GasifierSyngascooler

COSconverter

Acid gasremoval

Limestoneabsorber

Acid gasfurnace

Air

Calciumsulfate

Waste water treatment

Sludge

Treat waterWaste water

Sulfur recovery unit

LPGAir

Flare unit#2

Waterscrubber

DeNOx

Compressor

(2)Overview and Progress(STEP-1) 19

Specification

Coal Gasification UnitOxygen-Blown Single-Chamber Two-Staged Spiral-Flow Entrained Bed Coal feed ：1,180 ton/day

Gas Clean-up Unit Wet Desulfurization Unit ： Methyl Di-Ethanol

Amine (MDEA)Sulfur Recovery Unit ： Limestone Wet Scrubbing

Air Separation Unit Pressurized Cryogenic Separation

Combined Cycle Unit GT (MHPS ： H100 TIT=1300°C class,

adopted Multi-Cluster burner）Gross Power Output : 166MW (GT+ST)

Wastewater Treatment Unit Gas Clean-up Unit Wastewater Treatment

Major Specifications(2)Overview and Progress(STEP-1) 20

STEP1 DemonstrationTargetsItem Targets

EfficiencyTop class Net Efficiency 40.5% (HHV), 42.7%(LHV)Equivalent to Net efficiency 46%(HHV), 48%(LHV) ,when applied to1,500℃ class GT(already developed) in a commercial plant (higher output)

Emission Level

Top class environmental performanceSOx : 8ppmNOx : 5ppmParticulate : 3mg/m3N (as 16%O2 equivalent)

Coal Variety Compatibility Applicable to varieties of coal with various ash fusion temperature

Plant Reliability Aiming at more than 70%/year availability by 5000hrs operation test.

PlantControllability &

OperabilityLoad ramp rate : 1-3%/min.

Economy To obtain the prospect that the COE (cost of electricity) of IGCC is thesame level as that of USC.


IGCC Construction Progress

FY 2012 2013 2014 2015 2016 2017 2018

MajorEvents

▼Start of Civil w

ork

▼Power receiving for com

missioning

▼Gasifierstart-up by coal

▼Start of demonstration

OperationDesign, Manufacturing, Construction,

▼HR

SG on site

▼Gasifier on site

▼SGC

on site

▼Gas cleanup unit on site

▼ASU

on site

▼Pressurization test of piping

▼Gas turbine

start-up

MarJulAprNovJulJanDecDecNovMayMar


Mechanical completion

Existing PlantChugoku electric power co.

Osaki PS 1-1

Gasification

Gas Clean up

Air Separation

Combined Cycle

Waste Water Treatment

Sulfur Recovery

(13th April 2016)


Gas Clean Up Unit(2)Overview and Progress(STEP-1) 24

Combined cycle Unit(2)Overview and Progress(STEP-1) 25

Air separation Unit(2)Overview and Progress(STEP-1) 26

STEP1：Commissioning results and demonstration planFY 2015 2016 2017 2018

Individual machinery and system test

Integrated C

omm

issioning

GT no load testCoal gasification testload dump testload dump test，Relief valve testGasifier/GT characteristic test Automatic plant control adjustmentTest of heat run and performanceTest of automatic plant start-up/shut down D

emonstration

・Verification of basic performanceand reliability・Verification of compatibility of coal variety・Verification of controllability

resultsplanresultsplan

Power generation Gross output

GasifierOperating hours

Continuous Operating hours

Operating data(AS of July ,2017) 300,638 MWh 2,415 h 514 h

27(2)Overview and Progress(STEP-1)

CommissioningApril-2016Gas turbine start upJuneParallel in power grid

JulyGasifier start up by coal

AugustStart of power generation by coal

283. Osaki Coolgen Project (2)Overview and Progress(STEP-1)

CommissioningNovemberAchievementGasifier load : 100%Power generation : 166MW (100%)

March-2017Start of Demonstration

293. Osaki Coolgen Project (2)Overview and Progress(STEP-1)

August-2017Completion Ceremony

Outline





CO2 Capture(STEP2)

30

STEP2 / CO2 Capture test (FY 2016-2020)

Coal

N2

O2steam Sour Shift Reactor

(low temprature catalyst)

gas clean up unit

steam

CO2Sweet shift reactorsCO＋H2O ⇒ CO2＋H2

CO, H2

CO2, H2

H2Absorber

CO2 Flash drums

CO2 capture unit(17% s lipstream test)

Sour Shift Catalyst Pilot Test unit

IGCC

Air separation unit

Gasifier

Scrubber MDEA

Physical absorption

Sour Shift Catalyst pilot testFeed Gas Sour Shift

(Upstream of desulfurization)

CO2 Capture testFeed Gas 17% slipstream

syngas equivalent to 15% of total CO2 volume

CO2Capturemethod

Physical absorption

CO shift section

Sweet Shift (Downstream of desulfurization)

Air Separation unit

CO2 Capture unit

Sweet Shift ReactorsCO + H2O → CO2 + H2

Steam

Steam

CO2 Flash Drums

Physical Absorption

Gas Clean-up unit

N2

O2

CO, H2

CO2, H2

H2

CO2

Sour Shift Reactor(Low temperature)

（3） Demonstration Plan of IGCC with CO2 Capture (STEP-2) 31

Item Targets

Basic Performance(CO2 capture)

CO2 Capture rate : more than90%CO2 Purity : more than 99%

GeneratingPlant

Efficiency

To obtain a prospect of 40%(net, HHV) power generation efficiencywhile 90% of CO2 volume is captured in newly-installed commercialIGCC with 1,500°C class GT.

Operability & Reliability

To establish operation procedures with load change and verify thereliability for IGCC system combined with CO2 Capture

STEP2 Demonstration Targets（3） Demonstration Plan of IGCC with CO2 Capture (STEP-2) 32

The Progress of Osaki CoolGen Project - JCOAL 一般 …. The Progress of Osaki...September, 2017...

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