CoalCoal- gas gas based based Combined Combined Cycle Cycle Power Power Generation Generation : :

BHELs BHELs Experience Experience

Panoramic view of BHELs IGCC Plant at Tiruchi

Indian Power Scenario

Current capacity - 115 GW 50 times increase in last 50 years since Independence

Forms of Power
Hydro 25% Wind Power 2%

Nuclear 1%

Thermal 72%
Nuclear
Hydro
Wind Power

Thermal

BHELs Supply 70%

Clean Coal Technologies in Power Generation

Pulverised coal combustion with super critical steam parameters Atmospheric pressure fluidised bed combustion in both bubbling and circulating beds together with sorbent injection for SOx reduction Pressurised fluidised bed combustion in combined cycle mode of operation Integrated Gasification Combined Cycle ( IGCC ) using different types of gasifier and in combined cycle Coal washing

Need for IGCC

h COAL IS THE MAINSTAY PRIMARY FUEL IN INDIA FOR POWER GENERATION h HIGHER OVERALL THERMAL EFFICIENCY

REDUCTION IN ENVIRONMENTAL POLLUTION DUE TO CO2, SOX, NOX. AND PARTICULATES

Comparison of efficiencies of super critical Vs IGCC power plants

60 Net Thermal Efficiency% 55 50 45 566 oC 600 oC 40 35 30 1990 1995 2000 2005 Year of commercial use 2010 623oC Super Critical PC Power Plant (15 oC Amb.) IGCC (15 oC Amb) 1500 oC 1300 oC

Comparison of cycle efficiencies of PC-fired Vs IGCC power plants

( Indian conditions )
45.4 42.2 42.5

Cycle efficiency, percent

39.9 34.2 36.2 36.8

SUPER CRITICAL 660 MW

HGCU 98 MW

HGCU 401 MW

SUB CRITICAL 500 MW SUB CRITICAL 100 MW

CGCU 409 MW CGCU 104 MW

PC FIRED

100 MW IGCC
With FR 6FA GT

400 MW IGCC
With FR 9FA GT

(Ambient temperature : 27 OC, CGCU: Cold gas clean up

Cooling water temperature: 32 OC)

HGCU: Hot gas clean up at 540 deg C

Vision - 21 Program of USDoE aims at



near Zero emission of SOx, NOx and particulate matter

 reduction in CO2 release to half of the current level

In India, CO2 emission has nearly doubled during1989-99 and is expected to grow at an annual rate of 3.2% during the period upto 2020

BHELs Gasification & IGCC Development Programme

6.2 Mwe IGCC with moving bed gasifier Process & Equipment Development (PEDU)pilot plant based on PFBG 6.2 Mwe IGCC retrofitted with PFBG
StartJ uly, 1983 Commg Mar 1988 Compln Sep, 1992

To gain experience in gasification and IGCC plant operation

Compln Jan, 1997

StartM ay, 1986

CommgM ay, 1988

Design and fabrication of major equipment and development of PFBG technology

StartS ep, 1993

Commg Jan, 1996

Data generation for scaled-up gasifier and its integration with CC

Schematic of 6.2MWe IGCC with moving bed gasifier

COAL 1
B FW F R O M 1 4

T A R O IL

LE A N LIQ U O R

F LA R E

54 0 o C 6
2

16

TAR SEPARATOR
5

SET T LER DRUM 9

M
10

4M w e 11

A IR

12
ASH

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

CO AL LO CK G A S IF IE R ASH LO CK DRUM A IR S T E A M M IX E R G A S C O O LE R TAR QUENCH VENTURI SCRUBBERS C O M B U S T IO N C H A M B E R CO M PRESSO R G A S T U R B IN E HRSG DEAE RATO R S T E A M T U R B IN E BO O S T E R C O M P R E S SO R SYSTEM PRESSUR E CO N TRO L CO AL A IR STE AM GAS W AT E R AS H

15

14

~
2 .2 M w e

13

TO 4

F IG . 4 S C H E M A T IC O F 6 .2 M W e IG C C W IT H M O V IN G B E D G A S IF IE R

Parameters of 6.2MWe IGCC with moving - bed gasifier

Parameter
Type of coal Ash content Coal capacity Gas pressure Gas temperature Gross Calorific Value Specific gas yield Carbon conversion Percent tpd Kg/cm2(g) Deg C Kcal/Nm3 Nm3/kg coal Percent

Unit

Design
Singareni 37 150 10 590 1200 2.0 86

Actual
Singareni 39 140 10 540 - 590 1100 - 1490 1.90 - 2.38 87-91

Objective: To gain experience on system integration and operation of gasifier in IGCC mode

Summary of operation Moving - bed gasifier

Parameters
Longest continuous operation, hours Cumulative operation, hours Total number of gasification runs Total number of operations in IGCC mode Cumulative operation in IGCC mode, hours Longest continuous operation in IGCC mode, hours Carbon conversion efficiency, percent Cold gas efficiency, percent 635 5500 20 7 1100 257 79 - 91 68 - 79

Hot box-up and restart established in gasification mode

Comparison of process characteristics of moving - bed Vs Pressurised fludised - bed gasifier

Parameter
Coal feed size limitations

Moving bed
5 - 30 mm#

PFBG
- 6 mm

Remarks
# Loss of 20-30% under size coal (<5 mm) reduces raw coal utilisation

Gasification medium Raw gas heat recovery for HP steam generation Med.temp./ hot gas clean-up In-bed desulphurisation

Air-Steam O2 - Steam Not possible due to presence of tar * Not possible Not possible

Air-Steam O2 - Steam Possible * Loss of efficiency due to sensible heat loss @ Improved overall efficiency In-bed desulphurisation is less expensive $ Effluent treatment is complex and expensive

Possible@ Easy Dry ash ( waste water if wet gas clean-up is used )

Effluents

Tar,oils,phenols and liquors $

Schematic of PEDU pilot plant with PFBG

COAL WATER AIR 1 9 8 3 2 TO ETP 10 11

12

AIR AIR 7 4

13 6 5 STEAM 6

1 2 3 4 5 6 7 8 9 10 11 12 13

COAL FEED LOCKS COAL ROTARY FEEDER GASIFIER AIR PLENUM SCREW ASH EXTRACTOR ASH LOCK AIR STEAM MIXER CYCLONE QUENCH PIPE GAS QUENCH VESSEL VENTURI SCRUBBER FLARE STACK CLEAN GAS COMPRESSOR PROVISION FOR RECYCLE COAL AIR STEAM WATER ASH COAL GAS SLURRY

ASH

ASH

FIG. 5 SCHEMATIC OF PEDU PILOT PLANT

Process evaluation and Demonstration Unit (PEDU)

Coal throughput Gasifier diameter Gasification media Gasification temp. Gasification pr. Gas calorific value (HCV) Coal size 18 T / DAY 450 mm AIR / Steam mix 1000 C 11 kg / cm2 1050 Kcal / M3 1 to 4 mm

Developmental Studies in PFBG

Phase - I Phase - II PERFORMANCE TESTING AND RELIABILITY SYSTEM OPTIMISATION PERFORMANCE OPTIMISATION AND RELIABILITY OF GASIFICATION PROCESS UNDER ELEVATED SYSTEM PRESSURE

Phase - III

PEDU - Summary of operations

Phase I
Development of distributor design Start up with charcoal Testing with coals of 35-40 %ash Operating pressure : 2 - 10 ata Test duration: 48 hrs Cumulative operation: 1200 hrs

Phase II
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

Phase III
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 Hot gas start up improves ignition and change over Recycling improved carbon conversion and gas yield

Modification of start up Bench marking of parameters to suit coal types

PEDU - Performance Summary

Parameter
Type of coal Ash content Cold gas efficiency Gas pressure Gas temperature High Calorific Value Specific gas yield Carbon conversion Hot gas efficiency Percent Percent Kg/cm2(g) Deg C Kcal/Nm3 Nm3/kg coal Percent Percent

Unit

Design
Singareni 37 70 10 1050 1150 3.0 90 90

Actual
Singareni 28 - 52 62 9 950 - 1000 950 - 1097 1.96 - 2.70 75 - 90 75 - 83

Total operation : 2500 hours

Longest single run : 204 hours

PEDU - Transient response on bed slumping

SYSTEM PRESSURE

BED DP AT DIFF. LEVELS GAS

REFRACTORY RADIATION EFFECT

TIME, HOURS

PEDU - Restart after power failure

4 2

BED DP AT DIFF. LEVELS

GAS AIR COAL STEAM

TIME, HOURS

Panoramic view of BHELs IGCC Plant at Tiruchi

View of the Power House at CCDP , BHEL, Trichy

Schematic of 6.2 MWe IGCC plant with PFBG

Parameters of 168 tpd pressurised fluidized- bed gasifier

Parameter
Type of coal Ash content Coal capacity Gas pressure Gas temperature High Calorific Value Specific gas yield Carbon conversion
( *without recycle of cyclone fines )

Unit
Percent tpd Kg/cm2(g) Deg C Kcal/Nm3 Nm3/kg coal Percent

Design
Singareni 42 168 12.5 1000 1050 2.57 85

Actual
Singareni 32 132 11.5 975 1170 2.50 85*

Objective: To demonstrate the PFBG technology

Summary of operation Pressurised fluidised - bed gasifier (168 tpd )

Parameters
Longest continuous operation, hours Cumulative operation, hours Total number of gasification runs Total number of operations in IGCC mode Carbon conversion efficiency, percent Cold gas efficiency, percent
Hot box-up and restart established in gasification mode The scaled up PFBG (1:3.3 in size and 1:9.33 in capacity) was successfully operated and data generated for further gasifier technology/ process development. IGCC mode operation was carried out to establish system integration of PFBG with CC module. Earlier, adequate IGCC operational experience had already been gained with moving-bed gasifier.

150 3000 37 5 75 - 85 55 - 62

Profile of bed temperature in 168 tpd PFBG

1100 1050

1000

temp.-Deg.C

IN-BED LOWER LEVEL

950

900
IN-BED UPPER LEVEL

850

800 15.00 16.00 17.00 18.00

Time-hrs

Profile of flow rates in 168 tpd PFBG

12000 AIR FLOW 10000 40 35 30 8000 25 COALFLOW (AROUND 6000 KG/H) 6000 20 15 10 2000 STEAM FLOW 5 0 15 15.5 16 16.5 17 17.5 18

4000

Time-hrs

Coalflow-rpm

flow-kg/hr

Profile of gasifier and system pressures in 168 tpd PFBG

12 11 10

Gasifier pressure

PRESSURE- KG/SQ.CM

9 8 7 6 5 4 3 2 1 0 15 16 17 18

Pressure at gas cleaning exit

ressure

Press.Diff. Across system = 1.4-1.5 Kg / sq.cm

TIME-HRS

168 tpd PFBG - Profile of gasifier bed pressure drop

5000

4500

4000

3500

3000 DP mmWC

2500

2000

1500

1000

FIRST LEVEL

(0.8 m )

500

SECOND LEVEL (2.35 m ) THIRD LEVEL (4.95 m )

16 TIME / HOURS 17 18

0 15

168 tpd PFBG - Hot restart after box-up

1000 12
10000 9000

900

TEMP

10

AIR

8000 7000 6000 5000 4000 3000 2000

700

PRESSURE, Kg/cm sq.

TEMP. IN DEG. C

FLOW RATE, Kg/hr.

800

600

COAL

500

PRESSURE

STEAM
400 0
1000 0

300 REAL TIME, HOURS

-2

11:00

12:00

13:00

14:00

15:00

16:00

11:00 12:00 13:00 14:00 15:00 16:00

REAL TIME, HOURS

Representative gas compositions

Parameters Gasifier capacity Gasification temperature Gas composition
volume (dry gas)) (%

Unit tpd Deg C

Bench scale 1.2 1050

PEDU 18 950

PFBG 168 950

H2 CO CH4 CO2 O2 N2 Gross calorific value Heat loss ( percent of coal heat )

percent percent percent percent percent percent Kcal/Nm3 percent

16.00 16.70 1.00 9.80 0.00 56.20 1086 4.6

15.12 18.23 0.87 12.00 0.00 53.78 1095 3.2

16.80 15.80 1.70 10.00 0.20 55.50 1150 0.2

Gasification Technology for Indian Coals

IGCC development abroad is based on entrained flow gasifiers. This technology is suitable for low ash coals available in those countries. Indian coals are characterised by their high ash content as well as high ash melting temperatures which lead to high heat loss in the form of molten slag. Hence not suitable . Moving - bed technology generates tar which results in problems of handling and disposal of tar and limitations for scale up of size of gasifier . Hence not suitable . Syngas generated by this process is being used for production of chemicals only. This process is not being employed for IGCC application anywhere.

high ash, high fusion temperature Indian Coals .

Pressurized Fluidized - Bed Gasifier ( PFBG ) is the most suited for

Type - wise Coal Reserves

( Million Tonnes )

Type of coal Prime Coking Medium Coking Blendable / Semi Coking Non - coking

Proven 4614 11267 482 66032

Indicated 699 11133 904 76765

Inferred -1106 222 38369

Total 5313 23506 1608 181166

Total

82395

89501

39697

211593

Deterioration of Coal Quality available for power generation over the period

1970s
PROXIMATE ANALYSIS FIXED CARBON VOLATILE MATTER MOISTURE ASH HHV % % % % 36.5 25.5 10.0 28.0

1980s
32.4 21.6 16.0 30.0

1990s
25.0 18.0 12.0 45.0

kcal/kg 4750.0 4050.0 3000.0

Characteristics of Indian Coals

Ash Content Sulphur Reactivity Ash Chemistry 35 - 45 Percent < 1 Percent Moderately High High in Silica & Alumina Highly Abrasive Medium Slagging

Ash fusion temp. > 1500 deg C

International Studies
IEA-CR published report CCC39 Advanced Clean Coal Technologies & Low Value Coals during Nov.2000 by Katherina Rousaki & Gordon Couch Report covers status of IGCC plants throughout the World Important Conclusions, inter alia, are :

Air blown Fluidised Bed is preferable for Low rank coals with high reactivity Commercial scale Demo Plants are the need of the hour

100 MWe IGCC demonstration plant

Proposed 100 MWe

1500 TPD
(PFBG)
Scale up: Geometrical - 1: 2 Capacity - 1: 8.63

CCDP,Tiruchy ( 6.2 Mwe )

168 TPD
(PFBG) 18 TPD (PFBG)

Scale up: Geometrical - 1: 3.3 Capacity - 1: 9.33

PEDU, Corp. R&D, Hyderabad