demonstration of twin ihi gasifier (tigar) for lignite coal · 2015-11-02 · demonstration of twin...

Demonstration of

Twin IHI Gasifier (TIGAR)

for lignite coal

~ IHI Gasification technology~

PT. IHI Gasification Indonesia

IHI Corporation

Gasification Technologies 2015 Conference

Net Sales : JPY 1,456 bil.

(USD 12,120 mil)

Founded ： 1853

Works : 8

Branch Offices : 17(Japan) , 15(Overseas)

Employees : 28,533

The First Steamship Built by Japanese Private

Company – “Tsu-un maru”.

Company Profile (IHI Corporation)

2

Information is on consolidated basis and is corrected as of March 2015

Sales by business segment

(on consolidated basis)

Copyright © 2015 IHI Corporation All Rights Reserved.

Resources,

Energy and

Environment29%

Aero Engines

30%

Industrial

Systems28%

Social Infrastru

cture13%

Overseas Office

Global Subsidiary Company

Global Network

Industrial Systems(Steel Manufacturing Furnaces, Heat/Surface Treatment

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

Social Infrastructure and Offshore Facilities

(Bridge, Transportation System, Security, etc.)

IHI Business Areas

3

General-Purpose Machinery

(Compressor, Separator, Turbo charger, etc.)

Resources, Energy and Environment

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

Aero, Engines

and Space

Development

Resources,

Energy and

Environment

Social Infrastructure

and

Offshore Facilities

Industrial Systems

and

General-Purpose

Machinery

Aero Engines and Space

(Jet Engine, Rocket)


4

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)


・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


6

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


7

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


8

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


9

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


History

Copyright © 2015 IHI Corporation All Rights Reserved. 10

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

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

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


12

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



Copyright © 2015 IHI Corporation All Rights Reserved.13

History

Signing Ceremony, 13 February 2013 First Gasification, 17 January 2015

Inaugulation

Ceremony,

26 February 2015


14

Site Overview



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



16

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



17

Waste Water area

Gasifier structure and Coal crusher area

Gas Purification area

Control Center


Plant photo


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)



Coal delivery

19

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)


RUN3(PKN炭+触媒　1000hr）


RUN4(他炭種/Biomass　1000hr）


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


Another coal, ）

（Another coal, Biomass）

Evaluation, Maintenance





Performance test）



20

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



crush < 10mm

21Copyright © 2015 IHI Corporation All Rights Reserved.

Operation Result


➤ 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


23

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


6. Conclusion

Copyright © 2015 IHI Corporation All Rights Reserved. 24

• 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 !

demonstration of twin ihi gasifier (tigar) for lignite coal · 2015-11-02 · demonstration of twin...

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