APEC Clean Fossil Energy Technical and Policy Seminar

The Latest Supercritical Coal-Fired Boiler and Integrated Coal Gasification Combined Cycle Technology (IGCC)

MITSUBISHI HEAVY INDUSTRIES, LTD.

Utility Boiler Market Share in Japan

Others 1.9%

MHI 45.9%

I 25.1%

H 27.1%

(Capacity base as of 2004, equal & above 75MW)

Supply Record of Mitsubishi Boilers

75MW & Larger
Capacity 75MW - 149MW 150MW - 299MW 300MW - 499MW 500MW - 999MW 1000MW Total Number of Supplied Units Oil and/or Total Coal Fired Gas Fired 42 64 106 31 33 24 4 135 82 72 45 3 266 113 105 69 7 400

Activity and Experience of MHI Boiler

(in the World)
Unit : t/h ( ) : Number of Units

Total : 572,334t/h (2,824)

(as of March, 2001)

Germany 265 (5) C.I.S. 1,234 (15) Poland 135 (1) Jordan 875 (4) Spain 794 (2) Algeria 2,036 (8) Zambia 90 (6) Egypt Tunisia 1,366 (8) 1,040 (2) Kuwait 16,399 (17) Saudi Arabia 40,380 (90) Tanzania60 (1) Yugoslavia 490 (5) Turkey 4,968 (17) Syria 5,131 (13) Iraq 3,883 (16) China Iran 8,240 (22) 18,402 (45) Pakistan 3,105 (19) Qatar 149 (1) U.A.E. 2,033 (12) Bangladesh 90 (6) Thailand 21,112 (30) India 5,627 (26) Canada 241 (4)

Korea 6,291 (44) U.S.A. 855 (10) Japan 294,082 (1,920) Taiwan 21,185 (69) Bahamas 197 (2) Jamaica 635 (2) Dominica 900 (3) Venezuela 7,071 (14)

Liberia 30 (1) Nigeria 91 (1)

Hong Kong 11,864 (22) Macao 190 (2) Philippines 7,735 (16) Brunei 380 (2) Singapore 206 (4) Indonesia 7,061 (34) Australia 1,084 (8)

Mexico 26,698 (44) El Salvador 277 (2)

Colombia 525 (1) Ecuador 884 (5) Brazil 4,551 (30) Peru 276 (6)

Malaysia 3,959 (19)

Chile 3,104 (11) New Zealand 825 (1)

Topics
1. Supercritical Coal-Fired Boiler 2. Boiler Design Features 3. Integrated coal Gasification Combined Cycle (IGCC)

1. Supercritical Coal-Fired Boiler

Customers Requirements for Utility Power Boilers

1. High Performance (High Efficiency and Low Emission) 2. Operability (WSS, DSS and 2 shift operation) 3. Less and Easy Maintenance 4. Wide Fuel Range (Wide Coal Range)

Trend of Steam Condition

600 538 566 593

600

Temperature ()

500

24.1MPa(g) 16.5MPa(g)

30.0

400

20.0

300
Temperature Pressure

10.0

200
0

1910 1920 1930 1940 1950 1960 1970 1980 1990 2000

Pressure (MPa(g))

24.5MPa(g)

31.0MPa(g)

History of Steam Pressure and Operation in Japanese Utility Power Plant

140 120 Unit Output (GW) 100 80 60 40 20 0 1960 1965 1970 1975 1980 1985 1990 1995 2000

Sliding Pressure Supercritical Unit is mainstream.

C o m m e rc ia l O p e ra tio n Y e a r

V a ria b le P re s s u re O p e ra tio n S u p e rc ritic a l C o n s ta n t P re s s u re O p e ra tio n S u p e rc ritic a l S u b c ritic a l

2. Boiler Design Features

Furnace Water Wall Configuration & Operation Results

What is required to the Latest boiler design?

(1) Higher Plant Efficiency Supercritical Pressure with high steam temperature

TARGET
Simple Structure Less Welding point (2)Easy maintenance (3)Easy Construction (4)Middle Load Operation (5)Partial Load Efficiency Sliding Pressure Operation

Furnace Waterwall Design

Vertical Water Wall (with Rifled Tube) Spiral Water Wall

Tube: BASE Velocity: BASE

Tube: Less Velocity: Higher

Merits of Vertical WW to Spiral WW

(1) Simple Structure - Easy Manufacturing and Construction - Shorter Installation Period - Less Thermal Stress (2) Low Pressure Drop of Water Wall - Low Auxiliary Power Consumption - Low Temperature Imbalance (3) Easy Removal of Slag - Less Slag Accumulation - No Local Concentration of Slag

Mitsubishi Super Critical and Supercritical Coal Fired Boiler with Vertical Water Wall
Chugoku EPCO. Misumi P/S 1,000MW 24.5MPa600/600 (1998) Kansai EPCO. Maizuru P/S 900MW 24.5MPa595/595 (2004) Soma Joint EPCO. Shinchi P/S 1,000MW 24.1MPa538/566 (1995)

Kyushu EPCO. Matsuura P/S 700MW 24.1MPa538/566 (1989)

Tohoku EPCO. Haramachi P/S 1,000MW 24.5MPa566/593 (1997)

Tokyo EPCO. Hirono P/S Kobe steel IPP Kobe P/S 700MW 24.1MPa538/566 (2002) Chubu EPCO. Hekinan P/S 700MW 24.1MPa538/566 (1991) 600MW 24.5MPa600/600 (2004)

Tokyo EPCO. Hirono #5 Unit 600MW Coal-Fired Supercritical Plant

BTG and AQCS supplied by Mitsubishi
Steam Pressure (MPa(g)) Steam Temp. (deg-C) Evaporation (kg/h) Fuel
2003/8/22

25.4 604 / 602 1,770,000 Coal Fuel-Oil (30%) Jul.2004

Commercial Operation

Single Responsibility by MHI for Hirono #5

Turn key contract of Boiler, S/T and AQCS
Stack

S/T
FGD

Steam Turbine & Generator

Boiler
(incl. fan, AH,mill) ESP Boiler & SCR

SCR

dry ESP

FGD
(wet scrubber)

Stack

Kansai EPCO. Maizuru #1 Unit 900MW Coal-Fired Supercritical Plant

BTG supplied by Mitsubishi
Steam Pressure (MPa(g)) Steam Temp. (deg-C Evaporation (kg/h) Fuel
2003/8/22

25.4 598/598 2,570,000 Coal Fuel-Oil (30%) Aug.2004

Commercial Operation

Design Coal for Maizuru #1

- 107 kinds of coal from all over the world 100 Meta-anthracite

Fixed Carbon (Dry/Mineral-Matter-Free Basis, %)

Various Sources of Coal

Australia USA Canada Indonesia South Africa China Columbia Russia New Zealand
High Volatile C Bituminous or Subbituminous A
11000 10000

Anthracite
90

Semianthracite Low Volatile Bituminous Medium Volatile Bituminous

80

70

60

50

High Volatile A Bituminous

40
16000 15000 14000

High Volatile B Bituminous

13000 12000

SubBituminous B,C
9000 8000

Lignite
7000 6000

Gross Calorific Value (Moist,Mineral-Matter-Free Basis,btu/lb)

Boiler efficiency as HHV basis (%) Boiler Efficiency (%)

Operation Results of Maizuru #1 Boiler - Boiler Efficiency 95 Test Result 90

Guarantee

85 150

300

450

600

750

900

Boiler Load (MW)

NOx atNOx (ppm ; 6%O2)as 6%O2) SCR outlet (ppm

Operation Results of Maizuru #1 Boiler - NOx Emission 50 40 30 20

Test Result #2 Test Result #1 Test result Base) (SCR operation:#1 (base)

0.075 NOx (lb/mmBtu)

0.050

0.025

10 Test result #2 (high molar ratio) (SCR operation: Low NOx Mode) 0 150 300 450 600 750 900

Boiler Load (MW)

3. Integrated coal Gasification Combined Cycle (IGCC)

Why IGCC
Higher plant efficiency with Less emission
Net Plant Efficiency(%,LHV) 50 IGCC +5%(abs.)
Conventional Coal Fired Unit 1500C GT

45

40
566

600

600 550

35 1990

500 1995 2000 2005 2010 2015 2020

Main steam temp.()

Why IGCC
Higher plant efficiency with Less emission
140% 120 100 80 60 40 20 0 Plant Efficiency CO2 Ash Emission
Waste Water

Coal fired USC Plant =100%

Principle of MHI Air-blown Gasifier

Syn gas CO:30%,H2:10% HHV 1,100kcal/m3N

Char

Ruductor (Gasification) Coal

Coal Air

Combustor
(Combustion)

Air

Slag
Water 200t/d gasifier Appearance of Slag

Schematic Diagram of IGCC

MHI supplies all the key components of gasifier, clean-up system and C/C.
Coal Washing Wet Desulfurization Gasifier High Temp. Filter Gas Turbine Air Steam Turbine Gypsum recovery

HRSG Air Booster

M

Comparison of Gasifier System

Difference in Net Plant Efficiency(abs.)

Air-blown Lower auxiliary power needed than O2 blown Dry coal feed Lower heat loss than slurry feed

+5 +4 +3 +2 +1

base

-1
O2
Wet

Highest efficiency

Gasification Agent

O2 Dry

Air Dry MHI

Coal Feed

Development of IGCC in Japan

5000

1700t/d Demo. Plant (250MW-class )

Commercial Plant (600MW-class )

1000

Fuel Capacity( t/d )

500

100 50

200t/d Pilot Plant (Nakoso)

10 5

2t/d PDU (Yokosuka)

1 1980 1985 1990 1995 2000 2005 2010

250MW IGCC Demonstration Plant

HRSG,Stack Gasifier

GT / ST

Desulfurization

Key Dates 2002.4 Project Start 2004.9 Erection Start 2007.9 - 2010.3 Demonstration Run

Project Scheme
METI
30% subsidy

Joint Project Agreement

70% contribution researchers
Hokkaido EPCo. Tohoku EPCo. Tokyo EPCo. Chubu EPCo. Hokuriku EPCo. Kansai EPCo. Chugoku EPCo. Shikoku EPCo. Kyushu EPCo. J-Power CRIEPI

Clean Coal Power R&D Co., Ltd.

MHI Single Point Responsibility

METI EPCo. CRIEPI : Ministry of Economy, Trade and Industry : Electric Power Company : Central Research Institute of Electric Power Industry

250MW IGCC Demonstration Plant

Specification Gasifier Desulfurization Gas turbine Coal feed Plant Efficiency (LHV) Emission (16%O2,dry) Dry feed,Air blown,Entrained flow type Wet clean-up 1,250C Class 1,700 t/day 48%(Gross) 42%(Net) SOx : 8ppmV NOx : 5ppmV Dust : 3.3mg/m3N

Performance of Commercial Plant

% 52 Plant Efficiency (Net,LHV) 50 48 46 44 Demo.Plant 42 40
140 140 42

650MW

MW
600

470MW 48 250MW 45
330 330 230 230

500 400 300 200

D-Series G/T (1,200C)

F-Series G/T (1,350C)

G-Series G/T (1,500C)

Gross Output

Conclusion
1. We can supply and construct whole coal fired plant and IGCC plant with single responsibility. 2. Reliability and high performance of MHIs latest design for supercritical boiler (600/600C) with vertical water wall have been confirmed. 3. Air blown IGCC achieves higher plant efficiency. MHI will be ready for the design of commercial plant immediately after 250MW demonstration run in 2007.

END

Low NOx A-PM Burner for Maizuru#1 & Hirono#5 Boiler

Conc Weak Conc Oil Conc Weak Conc Conc: Fuel Rich

Weak: Fuel Lean Maizuru #1 Boiler

Operational Results - NOx vs. Unburned Carbon 5 Unburned Carbon in Fly Ash (%)
A-PM Burner Low NOx Burner

3 2 1 0 50

Low Volatile Matter Coal High Volatile Matter Coal

100 150 NOx at boiler outlet (6% O2) (ppm)

200

1000MW Utility Boiler

MRS (Mitsubishi Rotary Separator) Pulverizer Raw

Rotary Separator (MRS) Pulverized Coal Coal Driving Device of Separator Hydraulic Loading Device

Recirculation of Coarse Particles

Roller Grinding Table Hot Air

Fineness of Pulverized Coal - Maizuru #1 Boiler 8 100 mesh / 50 mesh residue (wt%) 6 4 2 0 60 70 80 200 mesh through (wt%) 90 100 100 mesh residue 50 mesh residue

Development Schedule of IGCC

Commercial Plant in US
ITEM 250MW Demo. Plant In Japan 2005 2006 2007 2008 2009
Manufacture/ Construction
Reflect for the FEED

on 2013
2010 2011 2012 2013

Operation US coal test (scheduled)

Commercial Plant
Output : 480MW GT : M501G Gasifier : 3,000t/day Structure : 1 on 1

Preliminary Design FEED Receive PO Design FEED start Manufacture/ Construction Operation Start

(Ref.) AEP 600MW Class IGCC

Design / Manufacture / Construction

Operation

FEEDFRONT END ENGINIEERING DESIGN

Feature of MHI Air-blown Gasifier

More reliable than oxygen-blown type
MHI Air-blown
Syngas, Char
Refractory

Oxygen-blown type
Coal Slurry Gasifier

Insulation

Membrane Waterwall
Coal Char Coal

Reductor

Refractory Lining

Radiant Cooler

Combustor Slag Syngas Char

Coal Feed Gasification Agent Burner Durability Reactor Durability Total Reliability

Dry Air >1 year (expected/lower heat flux) >2 years (expected/water wall furnace) Single Gasifier

Slurry Oxygen 60-90 Days(erosion by Slurry) <2 years(Refractory) Spare Gasifier needed

Coal Range for gasification

17 kinds of imported coal were successfully gasified. MHI air blown gasifier can adopt wider range of coals.
3.0
Australian Coal American Coal Chinese Coal

Ratio (=FC/VM)

2.5

South African Coal

Indonesian Coal Japanese Coal

US Eastern coal

Difficult to gasify

2.0

Suitable for IGCC

Suitable for PC Boiler

Fuel

1.5

1.0

US PRB coal
0.5 1,100

easy to gasify
1,200 1,300

Demo.Plant design coal

1,400 1,500 1,600 1,700

Ash Melting Temperature

FC : Fixed Carbon, VM : Volatile Matter

Demo. Plant Under Construction in Joban EPCo. Nakoso P/S

Gasifier manufacturing in Nagasaki Works

MHI can supply pressure vessels from our in-house factory.

ASTMs Coal Classification

Examples of MHI's Experience (by ASTM Coal Rank)

Philippine India Spain Mexico Petacalco China

Reliable and Proven Boiler Design to burn Wide Range of Coal

Summary of IGCC Demonstration Plant

Item Output (Gross) (Net) Gasifier Unit MW MW %, HHV % , HHV SOx NOx Particulate Matter Start of Operation lbs./mmBtu lbs./mmBtu lbs./mmBtu *without SCR Tampa U.S.A 322 250 Wabash River U.S.A 296 262 Nakoso Demo. Plant (Japan) 250 220 MHI Air blown Dry feed Wet C/U (MDEA) MHI M701D 46.0 40.5 0.06 0.03 0.01 2007 IGCC Commercial Plant 500 450 MHI Air blown Dry feed Wet C/U (MDEA) MHI M501G 51.0 46.0 0.06 0.03 0.01 2013
Higher plant Efficiency Higher plant Efficiency Lower SOx emission Lower NOx emission

Remark

O2 blown O2 blown Slurry feed Slurry feed Wet C/U (MDEA) F class 46.3 (measured) 36.5 (measured) 0.21 0.27* 0.01 1996 Wet C/U (MDEA) F class 42.7 (design) 39.7 (design) 0.31 0.22 * 0.03 1995

Clean up G/T Plant Efficiency (Gross) (Net) Emission