igcc: bhel’s experience. bhel – activity locations corp. p&d new delhi vadodara nagpur patna...
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IGCC: BHEL’S EXPERIENCE
BHEL – Activity Locations
Corp. P&D
NEW DELHI
VADODARANAGPUR
PATNA KOLKATAVARANASI
GOINDWAL
HARDWARRUDRAPUR
JAGDISHPURJHANSI
BHOPAL
HYDERABAD
BANGALORERANIPETTIRUCHIRAPALLY
CHENNAI
CHANDIGARH
Registered Office & Corporate HQ : New Delhi15 Manufacturing plants8 Service Centres4 Power Sector Regional HQs•15 Regional Operations offices•Corporate R & D Division : Hyderabad•Over 100 Project construction sites in India & Abroad
BHEL supplied Power Plants in India
Operating Business Areas
Serving core & Infrastructure sectors of the Economy
Power
ThermalBoilers, STG, Auxiliaries, ESP EPC
HydroTurbines, GeneratorsControls
GasOpen Cycle,Combined Cycle
NuclearSTGSG
Power TransmissionSwitchgear, Transformers Insulators, Substations SCADA, HVDC Systems
Industry
Captive Power PlantsBoilers, STGs, Auxiliaries, C&I Systems, DG
TransportationAC/DC Locos Diesel electrics Locos EMUs, Traction Electrics
International Operations
Other ProductsOn-Shore Oil Rigs Compressors, NCES Desalination Plants Valves, Motors
• Products & systems are highly Technology intensive. R&D and Technology Development are of strategic importance
• Judicial mix of in-house developments with import of critical technologies to meet Indian market requirements
• R&D expenditure 2.27 % of Turnover – Highest by any Indian Engineering Company
• Current major development - Coal Gasification for power and other applications and Ultra Super Critical PC plants
Engineering and Technology Focus
Security of Supply
• Coal has a very strong strategic role to play because of•the amount available• its wide distribution• ease and low cost of transport• history of price stability
• It provides• fuel diversity• security of supply• possibility of stable price• reduced dependence on single source
Characteristics of Indian Coals
Ash Content 35 - 45 Percent
Sulphur < 1 Percent
Reactivity Moderately High
Ash fusion temp. > 1500 deg C
Ash Chemistry High in Silica & Alumina
Highly Abrasive
Medium Slagging
Technology options
Coal
Combustion
Pulverised coal Fluidised bed
Gasification/IGCC
Fluidised bedEntrained flowpulverised coal
USC units readyEmission issues
Low grade coalsFuel flexibilityEmission controlMature up to 300MWScale up/USCEmission reduction
Demo/Commercial Plants
Pilot/Demo Plants
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
Research Development Demonstration Deployment Mature Technology
TimeAn
tici
pat
ed C
ost
of
Fu
ll-S
cale
Ap
pli
cati
on
New Technology Deployment Curve for Coal
Not All Technologies at the Same Level of Maturity.
Ox fuel
CO2 Storage
CO2 Capture
IGCC Plants
USCPC Plants
SCPC Plants
620°C+ 600°C
<600°C 565°C
Advanced USCPC Plants620°C+760°C
Expected availability can Increase with time/learning
What is coal gasification ?
It is a process in which coal, air or oxygen and steam react under conditions of certain
temperature and pressure to produce a low or medium calorie fuel gas. Air or oxygen
undergoes combustion reaction with part of the carbon in the coal and releases
exothermic heat. The balance carbon undergoes gasification reaction with steam,
hydrogen and carbon-dioxide, thereby utilizing the exothermic heat released in
combustion reaction.
Types of gasification process
• Moving bed gasification process
• Fluidized bed gasification process
• Entrained bed gasification process
Choice of the process
• Fluidized bed gasification process for high ash Indian coals
Coal size <250 microns 5-30 mm Less than 6 mm
Ash % <20 <25 No limitation
Ash fusion C <1350 <1350 No limitation
Effluent Waste water Tar, oils, phenol Waste water
Effluent treatment Relatively less expensive Relatively less
Gasifier area 1.0 3.0 1.6
IGCC maturity Large plants working Large plants working
Demonstrated in 6.2 MW
Coal Gasification Technologies
Entrained Flow Moving Bed Fluidised Bed
ADVANTAGES OF PRESSURISED FLUIDISED BED GASIFIER
• HIGHER UNIT CAPACITY PER UNIT AREA
• IN - BED SULFUR REMOVAL OPTION
• NO TAR OR OIL FORMATION AND EASY GAS CLEANING
• NO LIQUID EFFLUENT FORMATION
• ABILITY TO ACCEPT FINER COALS
• CAPABILITY TO ACCEPT WIDE VARIETY OF COALS
• BETTER RELIABILITY AND CONTROL
• OPERATES IN NON-SLAGGING MODE
• BEST SUITED FOR HIGH ASH INDIAN COALS
• LOWER CAPITAL AND OPERATING COST COMPARED TO ENTRAINED - BED GASIFIER
Fluidised Bed Gasification
Advantages
•Air used as reactant instead of Oxygen• high cost/power consumption of oxygen plant avoided
• Low Temperature Operation• Reliability issues due to high temperature operation eliminated
• In-situ removal of Sulfur, trace elements• Dry granular ash• Large Fluidised Bed Combustion systems in reliable operation
Issues
• Low Calorific Value of Gas (1100 – 1250 Kcal/NM3)• Comparatively high un burnt in ash
Fluidization engineering-ApplicationsFluidized beds are used as a technical process which has the ability to promote high levels of contact between fluid (Liquid/gases) and solids. In addition, it has following advantageous characteristics:
High surface area contact bet fluid and solid per unit bed volume High relative velocities between the fluid and the dispersed solid phase. High levels of intermixing of the particulate phase. Frequent particle-particle and particle-wall collisions Uniform temperature throughout the fluidised bed
GAS CLEAN-UP
GAS
TURBINE H R S G
STEAM
TURBINE
GT POWER STACK ST POWER
2 BLOCKS IN COAL GASIFICATION PLANT
Coal Gas
3 BLOCKS IN COMBINED CYCLE POWER PLANT
STEAMGASEXHAUST
WHAT IS IGCC?
NGOIL
COAL
GASIFICATION
• Reduce adverse impact of fossil fuel combustion on environment
Acid rain Suspended Particulate Matter in atmosphere Green House Effect
WHY IGCC ?
Uses Low Grade fuels
Environment Friendly Power Generation
IGCC Advantages
Conventional IGCC Plant PC fired plant
NOx 350 ppm <25 ppm
SOx 600 ppm 245 ppm
SPM 50 mg/Nm3 2 mg/Nm3
CO2 Emission High 10% Less
Fuel consumption High 5-7% less
Water consumption High 40% Less
Low Emission, High Efficiency
Revised 7/27/0718
Environmental Targets
PollutantIGCC1 PC2 NGCC3
SO20.0128
lb/MMBtu0.085
lb/MMBtu< 0.6 gr S /100
scf
NOx15 ppmv (dry)
@ 15% O2
0.07 lb/MMBtu
2.5 ppmv @ 15% O2
PM0.0071
lb/MMBtu0.017
lb/MMBtuNegligible
Hg > 90% capture1.14 lb/TBtu
Negligible
1 Based on EPRI’s CoalFleet User Design Basis Specification for Coal-Based IGCC Power Plants2 Based on BACT analysis, exceeding new NSPS requirements3 Based on EPA pipeline natural gas specification and 40 CFR Part 60, Subpart KKKK
Power
Fuel gas
Liquid fuels
chemicals
COAL GASIFICATION PLANT
Coal based IGCC plants
New Coal-Based IGCC Plants
S.No. Owner Capacity MW
1 Duke Energy, USA 630
2 GreenGen, China 250
3 ZeroGen, Australia 530
IGCC Technology status - world
• Higher Efficiency• Environment friendly Power• Option to switch to Natural Gas in future, when
available and cost effective• Easy adaptability to meet future environmental norms• Ease of Capture of CO2 • Coal gas from Gasifier can be used for conversion to
oil, chemical and Hydrogen in addition to power generation
IGCC - Technology for present and future
Gasification and IGCC developments in BHEL
Objectives:
Efficient utilization of high ash Indian coals in utility of power generation employing advance IGCC technology
Development of appropriate process technology and equipment for gasification and associated subsystems
Development of simulation model and optimal system integration
Development of process technology for gas clean-up
14/11/2011 Indo-Japan Workshop on Clean Coal Technology 25
Gasification characteristics of Indian Coal & IGCC
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
IGCC Development - BHEL
LearningGasifier & Wet gas Clean up Design & OperationSystem Integration
PFBG Pilot Plant Studies(18TPD PEDU)200 mm test facility
PFBG Retrofit to 6.2 MW CCDP
182 MW IGCC Demonstration Plant
6.2 MW IGCC Pilot Plant (CCDP) with Moving Bed Gasifier
LearningPFB Gasification Technology for Indian coals established.Design parameters met/exceeded
6.2 MW IGCC Plant at BHEL, Tiruchi
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
Parameters of 6.2MWe IGCC with moving - bed gasifier
Parameter
Type of coal
Ash content
Coal capacity
Gas pressure
Gas temperatureGross Calorific Value
Specific gas yield
Carbon conversion
Unit Design Actual
Percent
tpd
Kg/cm2(g)
Deg C
Kcal/Nm3
Nm3/kg coal
Percent
Singareni Singareni
39140
10
540 - 590
1100 - 1490
1.90 - 2.38
91
37
150
10
590
1200
2.0
86
Objective: To gain experience on system integration and operation of
gasifier in IGCC mode
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
~
~
TARSEPARATOR
SETTLERDRUM
COAL
1
3
6 7
9
10
12
141315
16
540oC
2.2Mwe
4Mwe
FLARELEAN LIQUORTAR OIL4
5
8
11
1 COAL LOCK2 GASIFIER3 ASH LOCK4 DRUM5 AIR STEAM MIXER6 GAS COOLER7 TAR QUENCH8 VENTURI SCRUBBERS9 COMBUSTION CHAMBER10 COMPRESSOR11 GAS TURBINE12 HRSG13 DEAERATOR14 STEAM TURBINE15 BOOSTER COMPRESSOR16 SYSTEM PRESSURE CONTROL
COAL AIR STEAM GAS WATER ASH
FIG. 4 SCHEMATIC OF 6.2 MWe IGCC WITH MOVING BED GASIFIER
ASH
AIR
2
BFW FROM 14
TO 4
M
M
Schematic of 6.2MWe IGCC with moving bed gasifier
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
Summary of operation Moving - bed gasifier
Parameters
Longest continuous operation, hours 635
Total number of gasification runs
5500Cumulative operation, hours
20
Total number of operations in IGCC mode 7
Power generation, MWe
Gas turbine :
Steam turbine :
Carbon conversion efficiency, percent 79 - 91
Cold gas efficiency, percent 68 - 79
3.8
1.5
Hot box-up and restart established in gasification mode
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
Different Views of APFBG Pilot Plant
200mm APFBG PLANTObjective:
To create a research facility with maximum flexibility for carrying out fundamental development work
Design Parameters:• Coal throughput : 1.2 TPD• Coal size range : - 4mm• Gasifier inside dia. : 200mm• Free Board dia : 200/250mm• Pressure : 3 ata• Temperature : 1050oC• Velocity : 1.8m/sAdditional facilities• Candle filter for medium temperature gas cleaning• PC based control and data acquisition system• Bottom ash carbon burn up system- optional• Inbed gas sampling facility• Provision for Radio tracer studies • Recycle of cyclone fines • Bed pressure drop measurement
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
1
LEGEND
COAL HOPPER
19
OUT
INWATER
16
WATER
17
43
2A1A
4A78
3A
COAL LOCK 2
AIR HEADER
COAL ROTARY VALVESORBENT HOPPERSORBENT LOCK 1SORBENT LOCK 2SORBENT ROTARY VALVE
ELECTRODE BOILER
1110
1312
1516
191817
14
COMBUSTOR
PRIMARY CYCLONE
BOTTOM ASH LOCK
ASH LOCK 2 (PC)ASH LOCK 1 (PC)
GASIFIER ASSEMBLYCATALYTIC COMBUSTOR
CONNECTING PIECE 2
CONNECTING PIECE 1
ELECTRIC HEATER9
BOTTOM ASH ROTARY VALVE
SECONDARY CYCLONE20
18
CY.1 ASH
N2/ AIR
AIR
ASHP
S
H2
COAL LOCK 12
COAL
15
11
1
S
CL
V
2
CL
01
S
3
4
CL
02
BED MATL.
S
S
CLPAIR
VENT
2A
1A
4A
3A
AIR
VENT
12
13
14
ASH
1
S
AS
HV
S
9
PCV 02
8
FCV 03
S
ASH
2
BOTTOM ASH
FC
V 0
2
7
PR
V
AIR
FR
OM
CO
MP
RE
SS
OR
PC
V 0
1
FCV 01
Ø 200 mm APFBG TEST FACILITY (WITH CANDLE FILTER) -PFD
10
415V
, 3Ø
415V
, 3Ø
(Located in control panel)
25NB
V48
V50
V49
V19
V17
S
FROM OVERHEAD TANK
SAMPLINGFOR GAS
15N
B
V37
DRAIN
VENT
V3
V18
V34
15NB
CF8
CF7
CF6
V10V4
15 N
B
25NB
PRV
V27
V33
CA7
DRAIN
CA6
CF4
DRAIN
DRAIN
25N
B
DRAIN
65NB
VENT
V41
SV-2
V40
N2 HEADER
V42
V44 V46V45V43
TO CONTROL VALVE PCV-51
V29
V22
V23
AR-2
AR-1AIR SUPPLYFROM V-29
ON AIR HDR
V21
HG
V55
V47
65NB
V12
65N
B
SP-2
15NB
B.F
FM-5
5
V13
V11
25N
B
HGV53
HG
V52
V2
65N
B
SP-1
V7 15N
B
15NB
B.F
FM-5
4
V5 V6
15 N
B
15 NB
COPPER TUBE
Closed whensolenoid is notenergised
AIR RECEIVERFROM INSTRUMENTATION
27
27 AIR HEADER
22 HOT GAS CANDLE FILTER
V20
51I/P
V39
V36V35
V38
SPV
40NB
15NB
V30
V28
V31
V32
CY.2 ASH
25NB
HCP
SV-1
V26
25
H1 H2
BPV
25N
B
A24
Q21
H28H27 S25
BPCU
230V, 1Ø
230V, 1Ø
26
2
FM-53
H
40NB
FM-52
CW OUT
PCV51
VE
NT
(T
O P
ED
U S
TA
CK
)
24
V9
V15
FE-5140NB
V14
FM
-51
CW IN
CYLINDER BANK
V16
2324
2625
21
15N
B
ASH VESSEL FOR HOT GAS CANDLE FILTER
ASH VESSEL FOR CYCLONE-2
BACK PULSE GAS RESERVOIRHOT GAS GENERATOR (Catalytic Combustor)
GAS COOLER
CF5
22V8
25NB65N
B
CF-1
VENT
CA-4
CA5
HG
V54
V1
20
HGV51
CA-1
50N
B
15NB
50N
B
CA-3CA-2
2125NB
CF-3
23
50NB
CF-2
CF ASH
VENT
NITROGEN
R&D Studies conducted on AFBG
Optimization of reactant ratios for different coals
Effect of blast temperature
Fines re-cycle using loop seal
Performance of ceramic candle filters
Tracer studies for estimation of particle residence time &
solid flow pattern
Estimation of trace contaminants in different streams
Bed ignition using Hydrogen fired catalytic combustor
Testing of different solid fuels
Gasifier performance with oxygen enriched air and steam
Coal throughput 18 T / DAY
Gasifier diameter 450 mm
Gasification media AIR / Steam mix
Gasification temp. 1000º C
Gasification pr. 11 kg / cm2
Gas calorific value 1050 Kcal / Nm3
Process evaluation and Demonstration Unit (PEDU) at R&D, Hyderabad
18 TPD Pressurised Fluidized Bed
Gasification Pilot Plant (PEDU)
Phased Developmental Studies
Phase - I
Phase - II
Phase - III
PERFORMANCE TESTING AND PROCESSRELIABILITY
SYSTEM OPTIMISATION
PERFORMANCE OPTIMISATION AND RELIABILITYOF GASIFICATION PROCESS UNDER ELEVATED SYSTEM PRESSURE
PEDU - Summary of operations
Phase I Phase IIIPhase II
Development of distributor design
Start up with charcoal
Testing with coals of 35-40 %ash
Operating pressure : 2 - 10 ata
Operation Methodology
Test duration: 48 hrs
Cumulative operation: 1200 hrs
Parametric studies
Testing with coals of 28-52 % ash
Carbon conversion upto 90 %
Specific gas yield: 2.1-2.7 Nm3/ kg
Gas calorific value: 900-1000kcal/Nm3
Cumulative operation: 800 hrs
Hot gas start up implemented
Recycle of cyclone ash tested
Improvement in gas calorific
value upto 1020 kcal/ Nm3
Long duration operation: 204 hrs
Cumulative operation: 500 hrs
Learnings
Equipment performance at design pressure proved
Process tested
Start up to be modified
Refractory lining changed
Modification of start up and establishing operation methodology
Bench marking of parameters to suit coal types
Hot gas start up improves ignition and change over
Recycling improved carbon conversion and gas yield
PEDU - Performance Summary
Parameter
Type of coal
Ash content
Cold gas efficiency
Gas pressure
Gas temperature
High Calorific Value
Specific gas yield
Carbon conversion
Unit Design Actual
Percent
Percent
Kg/cm2(g)
Deg C
Kcal/Nm3
Nm3/kg coal
Percent
Singareni Singareni
28 - 5262
9
950 - 1000
950 - 1097
1.96 - 2.70
75 - 90
37
70
10
1050
1150
3.0
90
Hot gas efficiency Percent 90 75 - 83
Total operation : 2500 hours Longest single run : 204 hours
PROCESS AND EQUIPMENT DEVELOPMENT UNIT (PEDU)
The pilot plant was designed with in-house expertise
Established for assessment of performance of gasifier and
subsystems
Concurrent cold model studies for refinement in the performance
of gasifier and subsystems
Resulted in the development of air-steam distributor, fines recycle
system, operation methodology, process control philosophy
Capability for design and fabrication of process equipment and
scale up to commercial size plant established
Optimum operating parameters and reliable gasifier performance
established
40
Panoramic view of the CCDP at BHEL, TiruchyPanoramic view of the CCDP at BHEL, Tiruchy
Schematic of 6.2 MWe IGCC plant with PFBG
Parameters of 6.2MWe IGCC with pressurised fluidized- bed gasifier
Parameter
Type of coal
Ash content
Coal capacity
Gas pressure
Gas temperature
High Calorific ValueSpecific gas yield
Carbon conversion( *without recycle of cyclone fines )
Unit Design Actual
Percent
tpd
Kg/cm2(g)
Deg C
Kcal/Nm3
Nm3/kg coal
Percent
Singareni Singareni
32132
11.5
975
1170
2.50
42
168
12.5
1000
1050
2.57
Objective: To demonstrate the PFBG technology and its
integration with IGCC
85*85
Gasifier Operation
Continuous operation of the demo plant is carried out to
confirm the reliability & performance of the gasifier.
Gasifier was operated for more than 4100 hrs or
200days.
Gas produced from gasifier is given to HPBP furnaces.
More than 30000 tons of gas supplied to HPBP.
Gained experience in continuous operation & the
performance of gasifier is as per expectations.
Plant has logged about 10,000 hours of operation so far.
Gasifier Operation-Operating parameters
The Gasifier was operated at variable load condition
to meet the demand and to check the reliability
Gas Flow rate : 5000-10500 kg/hr
Gasifier pressure: 3-7 kg/Sq. cm
Temperature: 950-1050 deg C
Calorific Value of Syngas: 950-1050 Kcal/Nm3
Fly Ash Recycle Studies
• BHEL has experience of fly ash recycle with non mechanical valves in CFBC boiler
• To improve carbon conversion, the system was adopted in Gasifier
• System incorporated in CCDP . Unburnt carbon was reduced from about 17 -18% to 12 % • Cold Model Studies in Corporate R&D
• Tests in 200 mm rig after incorporating Loop seal
Cold Model
Fly Ash Recycle System with loop seal
CFBC Facility CCDP Gasifier
6
8
10
12
14
16
18
20
-15 -10 -5 0 5 10 15 20 25
time hours
Lo
ss O
n I
gn
itio
n (
LO
I)%
Dec 05
May 06
without recycle with recycle
Effect of Recycle on Fly Ash Un-burnt Carbon
PICTORIAL VIEW OF HPTGA FACILITY
PARAMETERS OF KINETIC EXPERIMENTS
Gasification Reactions
)3(2
)2(2
)1(
)(4)(2)(
)()(2)(
)(2)()(2)(
ggs
ggs
gggs
CHHC
COCOC
HCOOHC
Parameters 1 2 3
Total system pressure Bar 1.5 10 30
Sample temperature oC 900 1000 1050
Reactants Steam Carbon dioxide Hydrogen
Reactant concentration(Nitrogen diluent)
Mole % 15 40 100
DEVELOPMENT OF GASIFICATION RATE EQUATION
• Empirical nth order kinetics
(4)β
x1n
ApvKdt
dx
(3)RTE
EoAvK
(2)n
ApvKr
(1)1
1r
xdt
dx
PFBG PHENOMENOLOGICAL MODEL
• It is an one dimensional steady state model• It incorporates fluid bed hydrodynamics. Two phase theory of fluidisation has been assumed• Reaction kinetic models for three gasification reactions are considered• Combustion reactions and coal devolatilisation rections are assumed to be instantaneous• The model provides specific gas yield and gas composition as well as heat and mass balance for each stream as well as each component
Freeboard common product gas
Bubble phase Emulsion phase
T = Constant T = Constant
Mass
Exchange
H
Ub Umf
Product gas
TWO – PHASE MODEL REPRESENTATION
Freeboard
Bubble phase Emulsion phase
Gaseous products from ith cell Gaseous products from ith cell
Water gas shift reaction
Water gas shift reaction Gasification reactions
Gas phase mass exchange Gas phase mass exchange
Gaseous products from (i-1)th cell Gaseous products from (i-1)th cell
product gas
CO2, N2, steam Ub
CO2, N2, steam, Umf
i = 0
ith cell
(i+1)th cell
i = final cell
PHENOMENA IN THE REACTION ZONEProduct gas
Model flow chart
Yes No
(InHeat – Out Heat)*100/Inheat < 0.1
No
Output
Yes solid
s
Tbe
d
Rbed Yes
No
Compute Bubble frction (b), , Other hydrodynamic parameters
Distribute the initial moles in the bubble and emulsion phases
Start
Read the input data bed particle size, bed particle ash density temperature, coal feed rate, coal analysis, steam flow rate, temperature, air flow rate
Read reactor dimensions, distributor details, Insulation details
Guess residence time and Carbon Conversion
Calculate the viscosity, density of the mixture
Calculate the weight of the bed from guess conversion
Calculate the moles of the products of drying, combustion and devolatilization.
Devolatilization products are distributed equally in each cell.
Calculate the overall carbon conversion from gas moles from the last cell
cell.
Calculate the carbon conversion in each cell (solving the differential equations for reaction rate, diffusion rate, and water gas shift reaction rate both in bubble and
emulsion phases) and update the gas moles for each cell.
Ccal- Cguess < 1.0
Cguess = Ccal
Yes
Calculate Heat input, Heat out, Heat loss from the bed
No
COMPARISON OF GAS COMPOSITION (CCDP PLANT)
14/11/2011 Indo-Japan Workshop on Clean Coal Technology
57
Gasification characteristics of Indian Coal & IGCC
COMPARISON OF GAS COMPOSITION (APFBG PLANT)
14/11/2011 Indo-Japan Workshop on Clean Coal Technology
58
Gasification characteristics of Indian Coal & IGCC
125 MW IGCC Demonstration Plant Initiative by Principal Scientific Advisor to GOI
• The PSA’s office set up R&D Committee under the chairmanship of
the Scientific Secretary to oversee the development of IGCC and
setting up the first ~100 MW demonstration plant in India
• Members from the PSA’s office, NTPC, DST, CSIR, DAE & BHEL
• The Committee noted that
• IGCC with Pressurised Fluidised Bed Gasification(PFBG) is
ideally suited for Indian coals
• There is not much international experience with PFBG
• Experience in BHEL’s three R&D plants and new experiments
as required shall form the basis to validate the design of
~ 100 MW plant
Performance parameters selected by R&D Committee
Carbon Conversion Efficiency 85 % Cold Gas efficiency 71 % Gross Efficiency 39% Gas Calorific Value 1000-1100 Kcal/NM3
• Broad Operating range with good availability factor, long term operating experience
• A working group was constituted to validate the 100 MW design of BHEL• The group was headed by DAE with representatives from NTPC and BHEL
• A national level committee chaired by Scientific Secretary to the PSA to GOI and members from NCL, IICT, BARC, NTPC, BHEL reviewed the status and set performance targets for installating commercial scale IGCC
• The committee participated in the tests in the facilities, analysed the data and concluded that
• the targeted performance have been met• the feasibility of scaling up the pilot plant is established
• The committee recommended that a commercial scale IGCC plant be installed
• The committee also suggested that the tests in the pilot plant continue to improve performance further
Gasification & IGCC Developmentin BHEL
Tests at Corporate R&D
Working group participated in the following tests in the 200 mm facility at BHEL’s Corporate R&D • X-Ray Radiography studies • Radio Tracer Study• Gasification Tests with various
• mean particle size• fluidisation velocity• steam to coal ratio• air to coal ratio• bed temperature
• X-ray radiography studies in cold model ( 100 mm dia) fluidizer at BARC to study the bubble hydrodynamics.
• ANN model for data analysis.
• Solid tracer studies in 200 mm PFBG for residence time distribution.
• Gasification experiments for Dadri coal in 200 mm PFBG.
• Basic phenomenological model of PFBG.
• Basic scale up criteria evolved.
• Interim report submitted to R&D Committee.
CompletedWorking Group Activities
Conclusions & Recommendations of R&D Committee
• Results of the experiments at the 6.2 MWe IGCC at BHEL are close to the values set by the R&D Committee.
• Technical Feasibility of upgrading 6.2 MW CCDP/BHEL to ~100 MW established
• The DPR may be prepared by ED/BHEL, Tiruchy Complex and ED/Energy Technologies/NTPC within three months (Jan 06)
• Notwithstanding the DPR preparation work, all further experimental work, required to be done on the 6.2 MWe IGCC for addressing the remaining technical issues, should be continued by the Working Group • specifically, chairman/ R&D Committee opined that Loop Seal method to be tried in CCDP to reduce un burnt carbon in fly ash
Parameters Unit APFBG PEDU CCDP 125 MW NTPC
182 MW APGENCO
Gasifier Internal dia
m 0.20 0.45 1.10 3.20 3.65
Coal Throughput
tons / day 1.2 18 168 1860 2259
Gasification temperature
o C 1000 1000 1025 1025 1025
Gasification Pressure
Kg/cm2(a) 2.00 10.0 10.0 30 28
Scale-up ( Successive plants)
Diameter Ratio 1 : 1 1 : 2.25 1 : 3.3 1 : 2.91 1 : 1.14
Coal Throughput
Ratio 1 : 1 1 : 15 1 : 9.33 1 : 11.1 1 : 1.21
Pressure Ratio 1 : 1 1 : 5 1 : 1.3 1 : 2.31 1 : 0.9
Scale up of Gasifier
Pilot Plants1.2 – 4 ata200 – 450 mm DiaCCDP (6.2 MW) 8 – 10 ata 1.1 m Dia
30 ata testing
Design of 28 ata 3.65 m dia182 MW IGCCSimulation
model for sizeScale up
Gasification reactivity data1.2, 10, 30 ataUsing HP TGA
Validation with pilot plant & CCDP data using reactivity, hydrodynamics at corresponding pressure & temp.
Validated simulation model updation with 30 ata reactivity data and hydrodynamics, corrected for pressure & temp.
Phenomenological model of PFBG
APPROACH FOR GASIFIER SCALE-UP DESIGN
Design of 30 ata 3.20 m dia
125 MW IGCC *
* Gasifier Design was reviewed by Team of experts from IIT-Chennai, NIT-Trichy & Prof Bo leckner, Chalmers University, Sweden
Back up experience and data from BHEL’s gasifier pilot plants and CCDP cold Model support studies.
Both geometrical and pressure scale adopted in designing the gasifier for 182 MW IGCC from 6.2 MW CCDP.
Modeling techniques used for scale up adopting all parameters at the corresponding pressure and temperatures
Simulation modeling is widely applied for scale up of fluidized bed reactors from pilot plant data (HTW gasifier scaled up from 1.5 – 10 ata, 10 – 25 ata higher capacity gasifier and subsequently to gasifier for 440 MW IGCC)
Power block is well proven and is backed up by GE (vendor)
System integration made using the operational experience of CCDP which has most of the integration features of 182 MW IGCC.
Steady state integration checked through simulation using ASPEN plus software.
GASIFIER SCALE-UP DESIGNCont..
Corp. R&D, Hyderabad
18TPD
(PEDU)
6.2MWCCDP
182MWIGCC
Tiruchy
Scale up:Geometrical - 1:1.14 Capacity - 1: 1.21Pressure - 1:0.9
Scale up of Gasifier for IGCC – BHEL’s approach
Scale up:Geometrical - 1: 3.3 Capacity - 1: 9.33Pressure - 1:1.2
1.2TPD
(APFBG)
Corp R&D
Hyderabad
Dia 0.2 mPress 2.0 ata
Scale up:Geometrical - 1: 2.25Capacity - 1: 15Pressure - 1:5
125MWIGCC
NTPC Auraiya
Scale up:Geometrical - 1: 2.91Capacity - 1: 11.1Pressure - 1:3
APGENCO
Vijayawada
* VETTED BY A DESIGN REVIEW TEAM (Prof. Bo Leckner, Sweden; 3 members from IIT,Chennai; 1 member from NIT, Trichy)
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
External Support
IIT M - Chennai
• CFD Modeling and investigation of gasification to optimize methodology for scaling up
• CFD Study of Gasifier along with fly Ash Recycle loop
• Analysis of Heat Recovery System
• Finite Element Analysis of the System – for stress levels
Chalmers University - Sweden
• Design Review of Large scale Gasification System by Prof. BoLeckner
SHORT TERM / MID TERM PLANS FOR IGCC GROUP
Medium temperature gas clean up for IGCC
Performance evaluation for Dynamic Classifier
Hydrogen production from coal gas
Reactivity studies for different candidate coals
Development if Integrated Gasification Fuel Cell System for power generation
Participation in 182 MW IGCC testing and data analysis
Basic engineering of 450 MW IGCC power plant
MEDIUM TEMPERATURE MULTI-CONTAMINANT GAS CLEANUP FOR COAL GAS AND IGCC APPLICATIONS Phase 1
OBJECTIVE
Develop a Medium Temperature Gas Cleanup System for IGCC for removal of Ammonia, Alkalis and Sulphur
Work to be carried out at an existing Test facility available at IICT Using expertise of IICT in the area of Sorbent development. Sorbent developed to be coated on a Ceramic Honeycomb made by CTI, Bangalore with coating methodology to be developed by CPRI Bangalore
STATUS
MoU s’ signed with IICT Hyderabad and CPRI Bangalore
Bench-scale as well as Lab-Scale setups ready for experimentation at IICT
Preliminary identification of Sorbents for all the three contaminants (Ammonia, Sulphur and Alkalis ) through literature carried out and a report made
Experiments for Ammonia Cleanup being carried out in the Lab-scale
Sorbents tested for Ammonia sorption are :-
Zinc Oxide on Activated Carbon and Alumina, Nickel Oxide on Titania at 500OC and 1 to 5 Kg/cm2 System Pressure
The first phase of the project has been completed.
Lab Scale Test Setup
Bench Scale Test Facility
CORE STRENGTH OF IGCC GROUP
Pilot scale process development of fluidized bed gasification and combustion of coal, lignite and other low grade fuels
Modeling and simulation of fluidized bed gassifier for design and performance prediction
Scale-up methodology for commercial size PFBG plants
Reactivity studies and derivation of kinetic parameters for gasification and other reactions
Development of Hot Gas Clean-up Systems including circulating granular bed filter, candle filter for IGCC and related applications
Software development capabilities for real time Data Acquisition System, process and performance evaluations
Expertise in handling gasification and combustion related analytical instruments
PRODUCTS AND SYSTEMS DEVELOPED / COMMERCIALESED IN BHEL
Process and engineering document for coal gasification and
combustion for setting up pilot plant test facility for ESKOM,
South Africa
Detailed technical report for 125/182 MW IGCC for NTPC/APGENCO
Bharat Heavy Electricals Limited, Tiruchirapalli
Coal Research
Objective Characterization of Coals, Biomass for predicting combustion, slagging, blending, emission and gasification Creating coal sample bank
Outlay 17.43 crores
Status All equipment ordered; 14 received; commissioning to begin in Sep 10 Drop Tube Furnace to be developed in house with support from experts Building nearing completion Specialist Engineers undergoing training Lateral Induction being expedited
Other Activities Identify expertise within the country and outside for networking, collaborative / joint working, short/long term availability (sabbatical) Identify additional equipment required and initiate action Membership in EPRI “Coal Fleet for tomorrow” program
Coal Research Center
In India, coal will be the dominating fuel feed
stock for IGCC
BHEL has hands - on experience in
design, engineering, fabrication, erection
and testing of both moving - bed and
pressurised - fluidized-bed gasifier ( PFBG )
systems and their integration to IGCC
To sum up . . . .
COAL RESEARCH FACILITY
View of the Gasifiers at BHEL, Tiruchy
Coal Research Facilities at Moula-Ali, Hyderabad
PFBC & HGCS Facilities
18 TPD PFBG Pilot Plant
PEDU
6 TPD Coal PFBC Test Facility
Overall View of AFBC Test Rig
Sorbent Reactivity Test Apparatus
Different Views of APFBG Pilot Plant
200 mm Dia Fluidizer Perspex
Model
880 mm Dia Fluidizer