Gasification of High Ash Coals BHEL's Success Story

COAL GAS 2013 New Delhi

By Sreenivasu G

Bharat Heavy Electricals Limited

Combined Cycle Demonstration Plant

Coal Research

Tiruchirappalli

BHEL Operating Business Areas

BHEL Activity Locations

Contents

BHELs Moving Bed Gasification 18TPD Fluidized Bed Gasification(FBG) 6.2 MW FBG Advanced Pressurized FBG GOIs Initiative on IGCC Future Plans

Syngas an alternative for CC Plants

Worldwide Oil crises struck during the 1970s given opportunities to explore alternate fuel for Combined Cycle (CC) Plants Across the globe, various projects were launched with the aim of developing new energy technologies that would lead to reduced dependency on oil Coal Gas(Synthesis Gas), a product of Coal Gasification is the alternative for the CC Plants BHEL Initiated Coal Gasification program in 1983 after Oil Crisis
NG/ Oil

Contents

BHELs Moving Bed Gasification

18TPD Fluidized Bed Gasification(FBG) 6.2 MW FBG Advanced Pressurized FBG GOIs Initiative on IGCC Future Plans

Indigenous Development of First IGCC Plant

A 6.2 MWe IGCC - Moving Bed Process @ BHELs Tiruchy unit Coal Feed Capacity 150 TPD GT - 4.0 MWe(Imported) ST 2 MWe (BHEL make) Gasifier - BHELs in-house design It is the first IGCC plant in Asia to run with low Btu coal gas The gasifier - water jacketed construction without any refractory lining Gasification carried out with air and steam mixture

6.2MWe IGCC with Moving Bed Gasification (MBG)

COAL

1 BFW FROM 13 4

TAR OIL

LEAN LIQUOR

FLARE

540 C 6 2 TAR SEPARATOR 5 SETTLER DRUM 9 4Mwe 10 11 7 8 16

3 AIR

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

COAL LOCK GASIFIER ASH LOCK DRUM AIR STEAM MIXER GAS COOLER TAR QUENCH VENTURI SCRUBBERS COMBUSTION CHAMBER COMPRESSOR GAS TURBINE HRSG DEAERATOR STEAM TURBINE BOOSTER COMPRESSOR SYSTEM PRESSURE CONTROL COAL AIR STEAM GAS WATER ASH

12 ASH

14 15

~
2.2Mwe 13

TO 4

Experimentation on MBG
Gasifier performance : Actual Vs Design better by optimizing the steam to air ratio Trials carried out with varying steam Higher Steam - decline of the gas CV & DGY Lower Steam - clinkering & ash extraction problem Modifications To improve plant reliability and continuous operability Tar and phenols formation Flow issues in the D/S Tackled by Water Scrubber But lose of Gas Sensible heat recovery

Summary of operation- 6.2MWe MBG IGCC

Longest Continuous Operation, Hours Cumulative Operation, Hours Total No of Gasification Runs Total No of Operations in IGCC Mode Type of coal Tested Power Exported to Grid 635 5500 20 7 Singareni (37% ash) 1,000,000 Units

Gains of MBG Operation

Design experience of Gasification systems Operating experience of Both stand alone and IGCC mode operation Process Constraints & Process Control philosophy

Disadvantages of MBG
Unit capacity limitation: Low through-put per unit area Sized coal required : 6 30 mm : non utilization of fines Tar , phenols formation requires special gas cleaning system along with ETP Overall efficiency is less No sensible heat recovery Gasifier consists of moving elements inside (Grate + Coal Distributor)

Contents

BHELs Moving Bed Gasification

18TPD Fluidized Bed Gasification(FBG)

6.2 MW FBG Advanced Pressurized FBG GOIs Initiative on IGCC Future Plans

Process and Equipment Development Unit (PEDU)

The pilot plant was designed with in-house expertise Established for assessment of gasifier and subsystems performance 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

Schematic of PEDU with PFBG

COAL WATER

12

AIR 1 9 10 8 3 2 TO ETP 11

AIR 13 AIR 7 5 STEAM 4 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

PEDU Parameters

Coal throughput Gasification media Gasification Temp. Gasification Press Gas calorific value Coal size

18 T / DAY AIR / Steam mix 1000 Deg C 11 kg / cm2 1150 Kcal / Nm3 Upto 6 mm

PEDU - Phased Developmental Studies

Phase - I Phase - II

Performance Testing and Reliability

System Optimization

Phase - III

Performance optimization and Reliability of gasification process under elevated system pressure

PEDU - Summary of operations

Phase I
Development of distributor design Start up with charcoal Testing with coals of 3540 %ash Cumulative operation: 1200 hrs

Phase II
Parametric studies Testing with coals of 28-52 % ash Specific gas yield: 2.1-2.7 Nm3/ kg Gas calorific value: 9001000kcal/Nm3 Cumulative operation: 800 hrs

Phase III
Hot gas start up implemented Recycle of cyclone ash tested Improvement in gas CV upto 1020 kcal/ Nm3 Cumulative operation: 500 hrs

Learnings
Equipment performance at design pressure proved Process tested Start up to be modified Refractory lining changed Bench marking of parameters to suit coal types Hot gas start up improved ignition and change over Recycling Improved carbon conversion and gas yield

Comparison of MBG and PFBG

Parameter
Coal Feed Size Limitation Gasification medium Raw gas heat recovery for HP steam generation Med.temp./ hot gas clean-up In-bed desulphurisation Effluents

Moving Bed
6-30 mm

PFBG
upto 6 mm

Remarks
Loss of 20-30% (<6 mm) coal reduces raw coal utilization

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

Air-Steam Possible Loss of efficiency due to sensible heat loss Improved overall efficiency In-bed desulphurization is less expensive Effluent treatment is complex and expensive

Possible Easy

Tar, oils, phenols and liquors

Dry ash

Contents

BHELs Moving Bed Gasification 18TPD Fluidized Bed Gasification(FBG)

6.2 MW FBG
Advanced Pressurized FBG GOIs Initiative on IGCC Future Plans

6.2 MW PFBG at CCDP

6.2 Mw MBG plant at CCDP(Trichy) retrofitted with PFBG Technology Experience and data obtained from PEDU utilized for Design and Development of 6.2 MW PFBG Existing systems utilized for reducing CAPEX of the project are: Gas Cooler , Gas Cleaning section, Combined Cycle loop, BoP Coal Handling System modified in order to meet coal size requirement Coal feed capacity: 150 170 tpd

6.2 MW PFBG at CCDP..

Coal feeding Gasifier Cyclone Bottom ash removal Gas cooling system Fly ash disposal Gas cleaning system : Through locks and ejectors : Refractory lined : Three in series Refractory lined : Through cooler, extractor and lock : Heat recovery boiler and Gas cooler : Through dry discharge system : Through existing wet scrubbing

6.2 MWe IGCC Demo Plant at Trichy ( CCDP)

Summary of operation- 6.2 MWe PFBG

100 Nos of Plant Run Successfully completed to meet various objectives Plant has logged about 10,000 hours of operation Longest continuous operation logged is about 340 hrs Continuous operation of the demo plant was carried out to confirm the operational reliability & performance of the gasifier During operation reliability studies Gasifier was operated for more than 200 days Hot box-up and restart procedure established in gasification mode

Experiences in 6.2 MW PFBG

Parameters for trouble free operation of the Process established Procedure established for planned shut down, hot restart Identified issues hampering longer / reliable operation large pieces of castable refractory detaching and falling in the fluidized bed causing defluidization ball valve wear inadequacy in the capacity of bottom ash handling system, service air, instrument air, cooling water, coal handling lack of redundancy in fly ash handling system

Modifications in 6.2 MW PFBG

Gasifier System Refractory brick lining High resistance coating of existing ball valves Addition of imported ball valves 5 Nos. Addition of bottom ash cooler, extractor Enhancement in coal handling system Addition of Fly Ash Pump Others Addition of Instrument & Service air equipment Addition of cooling water pumps

6.2 MW PFBG Test Runs for various Objectives

Reliability Run ( Gasification Mode) To train the newly joined Executives/Supervisors To show case the Technology to Govt Officials like PSA, DRDO To Show case the capability to Customers like APGENCO Testing of systems developed in Corp R&D

Contents

BHELs Moving Bed Gasification 18TPD Fluidized Bed Gasification(FBG) 6.2 MW FBG

Advanced Pressurized FBG

GOIs Initiative on IGCC Future Plans

Advanced Pressurized FBG (APFBG)

Coal capacity Pressure Temperature Gas cleanup Coal Ash

: 2.0 TPD : 3 kg/cm2 : 1000-1050 Deg C : Dry gas cleanup : 35 42%

Gasification medium : Air/Enriched air + Steam Coal feed size Location : 0-4mm : BHEL Corp. R&D, Hyderabad

APFBG
Objective: To create a research facility with maximum flexibility for carrying out fundamental development work Additional facilities Candle filter for medium temperature gas cleaning PC based control and data acquisition system Bottom ash carbon burn up system Inbed gas sampling facility Provision for Radio tracer studies Recycle of cyclone fines

Contents

BHELs Moving Bed Gasification 18TPD Fluidized Bed Gasification(FBG) 6.2 MW FBG Advanced Pressurized FBG

GOIs Initiative on IGCC

Future Plans

GOIs Initiative on IGCC

Nov 2002: Prime Ministers Office (PMO) initiated through Principal Scientific Adviser (PSA) Jan 2003: R&D committee formed by PSA (Composition: BHEL, NTPC, DST, CSIR and HWB) The R&D Committee noted that the IGCC plant, based on PFBG, was ideally suited for the high ash (35% to 45%) Indian coal Feb 2003: R&D committee visited 6.2 MWe PFBG Plant at Tiruchi during its first meeting and formed Working Group (composition: BHEL, NTPC and HWB) for design validation of the BHELs 100 Mwe Performance parameters selected for 100 MWe plant: Carbon conversion ~ 85% CV ~ 1000-1100 Kcal/ Nm3 Cold gas efficiency ~71% Gross efficiency ~ 39%

Summary of BHELs Joint Studies with Working Group

A large number of experiments on APFBG , PEDU and 6.2 MWe PFBG to optimize the external parameters (air to steam ratio, air to coal ratio, coal size, etc.) and internal parameters (temperature, residence time distribution, superficial velocity, etc.) RTD Studies through radio tracer techniques X-ray radiography studies for bubble hydrodynamics Intermediate gas measurements composition, Porosity and moisture content

Gas contaminant analysis by neutron activation techniques Reviewed the past data on BHELs R&D plants Developed Artificial Neural Network (ANN) and phenomenological models to interpret the performance

Results of the Experiments & Conclusions of R&D Committee

Results of 6.2 MWe PFBG experiments during 2005
Carbon conversion : 88-89% Cold gas efficiency : 68.8%. CV : 1100 Kcal/Nm3

Conclusions
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 is established

Performance Comparison of PFBG plants in BHEL

Parameters Gasifier coal capacity Gasification temperature Gasification Pressure Gasification media Gas Cleaning System CO+H2 CH4 Gas CV percent percent Unit TPD Deg C Kg/cm2 Semi Pilot Scale APFBG 1.2 1050 3 Air + Steam Dry 32.7 1.00 PEDU 18 950-1025 11 Air + Steam Wet 33.4 0.87 950-1095 PFBG 168 950-1050 12.5 Air + Steam Wet 32.6-34.2 1.70 1000-1150

Kcal/Nm3 900-1080

Outline of all Gasification Facilities

6.2 Mwe IGCC with moving bed gasifier
Start July, 1983 Commg Mar 1988 Compln Sep, 1992

To gain experience in gasification and IGCC plant operation

Compln Jan, 1997

PEDU pilot plant based on PFBG

Start May, 1986

Commg May, 1988

Design and fabrication of major equipment and development of PFBG Tech PFBG integration to IGCC and data generation for scalescale-up

6.2 Mwe IGCC retrofitted with PFBG

Start Sep, 1993

Commg Jan, 1996

Advanced Fluidized Bed Gasification (APFBG) plant

Start 1996

Commg 1997

For conducting vast number of experiments

Contents

BHELs Moving Bed Gasification 18TPD Fluidized Bed Gasification(FBG) 6.2 MW FBG Advanced Pressurized FBG GOIs Initiative on IGCC

Future Plans

Future Plans
6.2 MW PFBG (CCDP) Refurbishment Subsystems check for Reliability & Availability CO2 capture System (In-house developed by Corp R&D Group) testing on CCDP slip stream Parametric sensitivity for optimization Testing of different coals Medium Temperature Gas Clean up

Summary
In India , coal will be the dominating fuel feed stock for IGCC MBG & FBG are the only technologies adaptable for Indian coal Owing to advantages, fluidized - bed gasification is more energy - efficient and economical compared to moving - bed gasification BHEL is the only organization in India to have hands on experience in design, engineering, fabrication, erection and testing of both MBG & FBG systems and their integration Equipped with hands on experience in design and operation, BHEL is fully geared up in commercializing this technology for IGCC and for other applications.

Thank You