mitsubishi hitachi power systems -...

Mitsubishi Hitachi Power Systems

Integrated Solutions for flexible operation of fossil fuel power plants

Workshop on the role of the renewable and hydrocarbon nexus in accelerating the energy transitionIEA Gas & Oil Technology collaboration program11&12 October 2018 Venue: The Hotel, Boulevard de Waterloo 38, Brussels

Dr.-Ing. Christian Bergins

Strategic Marketing

Manager

Business Development

[email protected]

© 2018 Mitsubishi Hitachi Power Systems, Ltd.

Proprietary and Confidential Information. This document or information cannot be reproduced, transmitted, or disclosed without prior written consent of Mitsubishi Hitachi Power Systems,Ltd.

Contents

1. Introduction: MHPS & MHI

2. Flexible Generation

3. Fuel Flexibility

2

4. Storage integrated in Power Plants, Developments

5. Summary



3

MHPS Overview


Mitsubishi Hitachi Power Systems Europe

65% 35%

100%

Start of joint venture: 1 February 2014

HQ Location: Yokohama, Japan

Number of MHPS Group companies: 65

Total workforce: approx. 19,500

Capital: ¥100b / $892m (USD/JPY: 112)

Mitsubishi Hitachi Power Systems Europe

HQ Location London

Workforce 1,200

Market Region:

Europe, Middle East, Africa (EMEA)



4

Product Line Up

Geothermal Power Plants

GeneratorsGas Turbines

Peripheral EquipmentCoal Power Plants

Neues Foto Rotterdam

Combined Cycle Gas Turbine Plants Boilers

Steam Turbines

Environmental Plants SCR (DeNOX) Systems / Flue Gas Desulfurization

Integrated Coal Gasification Combined Cycle (IGCC)



Where is MHPS in the MHI World?

5

{Industry & Infrastructure Domain}

{Power Systems Domain} {Aircraft, Defense & Space Domain}



New organisation of MHI, MHPS for Energy Solutions:Extended Portfolio of Power Equipment and Services including ESCO

6

GTCC

★: Renewable Energy

Nuclear PowerBoilerIGCCCentralisedPower Generation

Hydro

DistributedPower Generation

Wind Turbine (Offshore)

Geothermal

Gas Engine

ORC

Biomass

ESS(Battery)

SOFC

EMS

Gas EngineAero-GT HD-GT

0.5 10 5 10 50 100 1000500

Purpose

Utility

IndustryMunicipality

★

★

★

★

★

Diesel Engine

Output [MW]

ESS(LAES,CAES)

★: Large Scale Carbon Capture commercially available

★

★ ESS (PtF)

★: Energy Storage

★

★

★

★

EMS : Energy Management System

ESS : Energy Storage System GTCC : Gas Turbine Combined

System HD-GT : Heavy Duty Gas Turbine

IGCC : Integrated Coal Gasification System

ORC : Organic Rankine Cycle SOFC : Solid Oxide Fuel Cell

LAES : Liquid Air Energy StorageCAES : Compressed Air Energy

StoragePtF : Power to Fuel



© 2018 Mitsubishi Hitachi Power Systems, Ltd. 7

Flexible Power Generation



The future Technology Responses to High RES grid

8



Operational flexibilityExamples for flexible, coal fired power plants

First measure:Utilizing the inherent

flexibility characteristics in old

and new hard coal power plants

60

GW

50

40

30

20

10

Source: VGB PowerTech 11/2012 & own data

0%

20%

40%

60%

80%

100%

Mo Tu We Th Fr Sa Su

150MW Hard Coal,Sept. 2010

0:00 6:00 12:00 18:00 0:00

Time

700 MW Hard Coal,2012

Load

9



10

M501GAC-fAST CC PLANTOver 8OOMW in 30 Minutes

Standard lndustry Design Practices Applied

HRSG: Drum Type design, 3P Reheat with duct firing

30 year design life under cycling duty

Designed to NFPA 85-2011 for avoiding purge at start-up

Stack damper for Heat Retention

SCR and CO catalysts designed for fast response

Single case steam turbine, with welded HP/IP rotor to

enable faster ST ramping

Operational flexibilityFast Start-Up CCGT



11

Operational flexibilityTypical Plant Start-Up Comparison

Hot Start

Reduced Start-up: Time, Fuel & Emissions

Plant Start Up improvements translate to simplified air permits and better overall plant economics



PWPS Gas Turbinesmobile solutions to ensure security of supply

High Efficiency to save Oil & Gas.

Water Free to meet requirements in Middle East Area.

Maximum Factory-assembled module to reduce Site Erection Cost and Time.

Fast start to full load within 5 minutes.

Off site maintenance to reduce Shutdown period.

FT4000 SWIFTPAC FT8 MOBILEPAC

World Largest Aero-Derivative

GT of 140MW Twin pack.

Dual fuel capability.

Modular package for easy

installation.

One day installation (Site ready)

None Concrete Foundation

Dual fuel / dual frequency capability.

Two-trailer design for Cost –effective

of transportation and site works.

12



38m

11

m ControlTrailer

GT/GENTrailer

Exhaust StackInlet

Filter

ControlTrailer

GT/GENTrailer

General Arrangement of FT8 MOBILEPAK

13




Fuel Flexibility



Fuel flexibilityBiomass conversion of steam generator

15

Biomass related systems Coal / biomass bunker Coal / biomass feeder Coal / biomass mill Pulverized fuel lines Burners De-asher Air / flue gas systems

References:2002: P.S. Amer 9 in Geertruidenberg, Netherlands, 1 Mill converted2014: P.S. Stustrupvaerket (SSV), Denmark, 930 MWth, 100% conversion (fuel switch coal-biomass-coal possible during operation)2014: P.S. Avedøreværket (AVV1), Denmark, 611 MWth, 100% conversion, burner replacement, mill refurbishment2015: P.S. Atikokan in Ontario, Canada, one burner level, one mil refurbished2010-2014: P.S. Drax Unit 1-3, United Kingdom, 3x660MWel 100% conversion (biomass burners)

Retrofit experience for existing plantssince 2002

Burner

Coal Bunker

Coal Feeder

Boiler

De-Asher PA Fan

FD Fan

Safety Damper

Air Heater

Stack

ID Fan

ESP FGD

Sealing Air Fan

MPS® Mill

Furnace

Biomass /

Biomass /

n x

PAC



“on-the-fly” Fuel Switch from Biomass to Coal

16

Coal & “coarse grained hard pine pellet”

(Grenå)

Mass flow coal 0 → 6.4 kg/s

Mass flow biomass 9.85 → 0 kg/s

Primary Air flow 14.2 Nm3/s

PA Temperature 145 → 309°C

Differential pressure 40 → 48 mbar

Classifier temperature 66 → 95 °C

Mill Motor in 67 → 70 → 60%

Classifier speed 20 → 90 rpm

- Uninterrupted firing

- No supporting fireScreen shot of mill 40 operation charts at

switch from wood pellet to coal operation



“on-the-fly” Fuel Switch from Coal to Biomass

17

Coal & “coarse grained hard pine pellet”

(Grenå)

Mass flow coal 7.34 → 0 kg/s

Mass flow biomass 0 → 9,85 kg/s

Primary Air flow 14,2 Nm3/s

PA Temperature 300 → 140°C

Differential pressure 61 → 54 mbar

Classifier temperature 85 → 62 °C

Mill Motor in 70 → 88 → 75%

Classifier speed 90 → 20 rpm

Screen shot of mill 40 operation charts at switch from coal to wood pellet operation

- Uninterrupted firing

- No supporting fire



Fuel flexibility Conversion of Coal Fired Power Plant to CCGT

18

Owner:HKW-Wuerzburg,

Wuerzburg, Germany

Plant: Combined Cycle Power Plant II

(former coal boiler)

Fuel: Natural gas(GT + duct burner)

GT capacity: 25 MWel

Unit capacity: 55 MWth

Boiler capacity: 95 t/h

SH outlet press: 72 bar

SH outlet temp.: 515 ºC

Fuel switch coal to natural gas, old boiler fully refurbished GT and duct burners added

Heat and Power Plant Wuerzburg, Germany



Fuel flexibility Conversion of Coal Fired Power Plant to CCGT

19

Result of conversion: High operational flexibility, high

efficiency50 000 t/a less CO2 with the same

energy generation

Before Rehabilitation (Plant view in 1987)

After Rehabilitation (2016)



Fuel flexibility Repowering coal power plants with gas turbines

20

330 MWel Coal fired P.S.

GT 60 MWel

Power increase by steam & heat recovery 38MWel

Total el. power Increase: 98 MWel

Fuel utilisation: up to 80 % (CHP)

G

G

Existing Power Plant

Repowering

Gas turbine(s) HP recovery

preheater

LP recovery

preheater

Lignite power plant

Matra, Hungary

(Feedwater pre-heating)

G

G

Existing Power Plant

Repowering

Gas turbine(s) HP recovery

preheater

LP recovery

preheater

IP Superheater

IP Evaporator

IP Economizer

Co-generation power station

„Altbach Deizisau“

(Feedwater pre-heating & IP steam)

2 x 212 MWel Lignite P.S.

2 x Hitachi H-25AX – 30 MWel

Power increase by preheaters 20 MWel

Total el. power Increase: 100 MWel

Fuel utilisation: 90.3 % (CHP)

More Efficiency, More Power, High load flexibility, Lower specific EmissionsQuicker reserve power than CCGT (ST already in operation)

Cheaper than separate, new CCGT and similar efficiency regarding NG



Conversion from coal to highly efficient CHP CCGT

Oeresundsverket, Malmö, Sweden

447 MW Combined Cycle Power Plant

Build in existing building, replacing coal boiler

Gas Turbine:

1 x GE 9FB – 293 MW

Heat Recovery Steam Generator:

1 x Triple Pressure Boiler

HP: 309 t/h, 140 bar, 567 ºC

Steam Turbine:

1 x Extraction/Condensing Type

161 MWel

Up to 250 MWth heat supply

Up to 90% fuel efficiency

Fuel:

Natural Gas

Year of Commissioning : 2009

Even when all other conversion ideas are uneconomic:

Existing assets and infrastructure still can be used for modern heat and/or

power generation

21




Power Plant Integrated Storage



Liquid Air Energy Storage (LAES) Time-shift of electric power / energy storage

GLiquid

air storage

M

Coldstorage

LAES storage (liquid air production & waste heat recovery in LP PH)

LAES energy release (liquid air evaporation and heating by bleed steam, air expansion)

HP pre-heating LP pre-

heating

0,5

0,4

0,3

0,2

0,10 200 400 600 800 900

PNet [MW]

𝛈𝐍𝐞𝐭[−]

reduced

minimnum

load by

process

integrated

storage

High

additional

power by

small fuel

demand

increase

time shift of

electric power

combined operation

(with LAES)

steam cycle only

Effective reduction of minimum load by- Energy storage (increased self

consumption)- Reduction of LP bleed steam (avoiding

ventilation)

Increase of maximum power- by utilizing stored energy- with minimum OPEX compared to GT

topping cycle

Efficient combination possible with CHP plants and heat storage

23



CCU/PtF integrated in Biomass CHP Plants or Industry

24

Transmission

systemHeat

consumers

Heat storage

Electric Power Pel

Thermal Power Qth

Industry

(heat consumer)

H2

water electrolysis

CO2

Fuel

synthesis

water

gas

(CO2 lean)

gas

(CO2

rich)

“low carbon” O2

Post combustion

CO2 capture

815MWth

344MWel 158MWth200kt/year

Significant amounts of

synthetic biofuels are

produced for additional CO2

reduction in the transport

sector

CCU can be sized larger to

absorb excess intermittent

RES electricity and re-use

more CO2

Fuel

CCU: Carbon Capture and UtilisationPtF: Power to Fuel



Developments towards zero carbon energy

25

Solid Oxide Fuel Cells (SOFC)

Effectively utilizing high exhaust temperature at 1,000°C

High durability, solid-state material

Fuel flexibility using natural gas, oil or coal

First demonstrators in operation

Power-to-Fuel (PtF) & Carbon Capture and Utilisation

(CCU)

Methanol synthesis from CO2 and hydrogen

The processing of methanol into various (drop-in) fuels

Small demonstrators under construction

Today, small scale gas turbines (e.g. H25) are ready for

deployment to operate on hydrogen or hydrogen rich gases, COG

and refinery gas references exist

MHPS is involved in Hydrogen Conversion Project at Natural Gas

GTCC Power Plant in the Netherlands (for 440MW GTCC by 2023)

Hydrogen Combustion in Gas Turbines



Summary

26

Today many power plants need to operate in a wide load

range with fast ramping and frequent starts while maintaining

equipment durability, environmental compliance, and low cost of

electricity.

Operational Flexibility and Fuel Flexibility is key to ensure

security of supply, economic operation as well as CO2 emission

reduction using existing assets or designing new equipment.

MHPS has proven fuel switches for existing plants to natural

gas and biomass. Hydrogen as a fuel in gas turbines is possible

already today.

MHPS is working on different technologies for integrated

energy storage to serve the future requirements of energy

markets.




27

mitsubishi hitachi power systems -...

Documents