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