IGCC for Power generation

N.T.P.C GAS PLANT DADRI

 Total installed capacity over 1,00,000 MW

Thermal power generation has emerged as the principal source of electric power in India contributing to about 70% Coal fired thermal stations are in predominance and share about 84% of the total thermal installed capacity. It is prudent and economical to develop methods and process for efficient utilization of low-grade Indian coals for power generation.

 Gasification of coal is the cleanest way of utilization of coal, while combined cycle power generation gives the highest efficiency. Integration of these two technologies in IGCC power generation offers the benefits of very low emissions and efficiencies of the order of 44-48%. The comparative indices show that in case of IGCC, emission of particulate, NOx and SOx are:

7.1%, 20% and 16%, respectively, of the corresponding emissions from PC plant.

 Environmental performance of IGCC thus far exceeds that of conventional and even supercritical plants. Three major areas of technology that will contribute to improvements in IGCC are : hot gas de-sulfurisation hot gas particulate removal advanced turbine systems

 Commercialization of IGCC needs technology demonstration at an intermediate scale of about 100 MW to address the issues such as: hot gas clean ups and system optimization and to establish reliability and performance. This would also enable to design an optimum module for air blown gasification, which in multiples would constitute a commercial size plant in the range of 300-600 MW. The present study addresses these issues and suggests suitable technologies for Indian Coals.

VISION 2020 PROGRAM

Gasification using + fluidized bed, moving bed or Entrant bed Gasifiers In-combustion Clean-up Fluidized bed combustion (CFBC, PFBC, AFBC)
Post combustion Clean-upDesulfurization (FGC systems) Supercritical

Pre combustion Cleanup beneficiation/washing

CLEAN COAL TECHNOLOGIES

Technologies for utilization of Coal for Power Generation with minimal pollutants discharged to the atmosphere (Reduced CO2, Sox, Nox, SPM) at high conversion efficiency.W.C.I.

Schematic Layout of the Integrated Gasification Combined Cycle

Steam Flue Gas to Stack

BFW
Steam Coal

HRSG

Steam

Steam Turbine

Compressed Air
Hot Gas Gasifier
Fuel gas Gas Cleanup

Gas turbine

Power

Ash

Sulfur

Air

Comparison of various Power Plants

Power Plant Concepts
PC fired Thermal CC Plant

Major Components
Boiler, Steam turbine, Coal handling and other BOP Gas turbine, Steam turbine, Waste hear recovery boiler Coal preparation unit, gasifier, steam turbine, Gas cleaning GT, WHTSG

Efficiency %

Cost per MW (Rs. Crore/MW

3.8-4.0 3.2-3.4

34-37 40

IGCC (Coal) IGCC (Pet Coke)

Super Critical

46* (estimated)
48* (with G/H class Gas turbines) 37.5-39.5

4.86-4.95**

Air separation unit GT, ST, WHRSG, Gas Clean up

As for PC fired Thermal plus spiral tubes and high temp alloys

4.25-4.30**

3.95-4.10

High efficiency coupled with low emission (SPM: 7%, Sox:16%, Nox:21% of corresponding PC Plant) ** For Indigenous Units through systematic transfer of Technology

Identified R&D Areas are:

Process process optimization of selected gasification

Improvement of design and reliability of plant components & Resource Optimization Optimization of overall plant heat integration and layout Hot gas cleanup

COAL GASIFICATION SELECTION OF GASIFICATION PROCESS

The fluidised bed process has many technical and environmental advantages over the moving bed process, such as, The fluidised bed can use any amount of fines whereas in the moving bed only 10% of fines can be used. In the fluidized bed process, hydrocarbon, liquid byproducts such as tar, oil and gas-liquor are not produced and, hence, the pollution is reduced. High ash coals can also be successfully gasified in the fluidised bed.

BENEFITS EXPECTED FROM IGCC

India endowed with large coal reserves over 200 billion tonnes.

Environmental benefits due to higher efficiency of conversion and reduced SPM, SOx, NOx levels can be achieved using coal based IGCC technology.
Retrofit/Re-power options for gas based CCGT plants by installing only coal based gasifiers are cost effective (opportunity cost low) and are environmentally benign. Adoption of IGCC technology in India has Global as well as National benefits.

IGCC DEVELOPMENT PROGRAM IN INDIA

Pioneering work on IGCC development in India taken up by BHEL in early eighties. Major Mile Stones Choice of gasification for high ash coals by BHEL 6.2 MW IGCC demonstration plant established by BHEL both with moving Bed and Fluidized bed. Coal characterization by BHEL & IICT for gasification application. Intensive data generated by IICT on oxygen-steam gasification in their moving bed gasifier. Task force CEA, CSIR, NTPC & BHEL constituted to assess technological maturity & financial requirement for a green field IGCC plant of 100 MW capacity at Dadri (NTPC). BHEL, CSIR & NTPC prepared proposal for setting up of this 100 MW IGCC demonstration plant.

 Experience on the fluidized bed process is, very limited in the country.
Internationally, the experience gained so far is only for low ash coals. Thus there is a need for taking up extensive R&D on IGCC Pilot Plant using high ash (4050% Ash) Indian Coals.

Technology-related issues in IGCC

Design of Advanced gasifiers (optimum gas composition, optimum scale-up etc.) Hot gas cleaning (de-sulphurisation and particulate removal) Advanced gas turbines (blade design to sustain ash laden gas)

CO2 emission abatement in IGCC Power Plants

Operating conditions of IGCC plants in transient stage Configuration of an optimized system for IGCC

Fuel related issues

In a Raw Pet-Coke and refinery residue based IGCC Plant
System optimization, particularly the balance of plant Optimized Heat balance diagrams Scaling up of gasifiers to optimum size

In a Coal/Lignite based IGCC Plant

Process & Plant conceptual design De-sulfurization of syngas of high sulfur coal and lignite Optimized Heat balance diagrams Super critical Vs IGCC in Indian context Application of ASME PTC-47 code for IGCC for high ash coals and lignite

SOME IMPORTANT FINDINGS

Reactive solid sorbent de-sulfurization combined with hot gas cleaning through ash and sorbent particle removal provides for higher energy efficiency to an extent of 4-7%. The current Capital cost of building an IGCC power plant is of the order of Rupees 6 crore/ MW. Improvements in hot gas cleaning coupled with Cycle optimization shall bring down the cost drastically to a level of $ 1000/kW or about Rupees 4.5 crore/MW

 The efficiency of refinery bottom based IGCC unit will be about 2% higher than that of coal based IGCC unit. Refinery based IGCC plants - Advantages Co-generation of steam Co-production of hydrogen gas & recovery of sulfur element No use of limestone, as required for CFBC technology No requirement of extra land for disposal of solid waste In the long run the refinery based IGCC technology is equally attractive to coal based IGCC from economic and environmental considerations.

SOME FINDINGS RELATED TO COMMERCIALIZATION OF TECHNOLGOY

At present it may be prudent to implement the project in phased manner to absorb the risk of gasifier in the total project wrap-up guarantees fig. 1 A Technology Transfer model for determination of velocity of Transfer of Technology (TOT) is an useful tool for TOT of a frontier technology from a developed economy to a developing economy fig. 2

Typical results of the velocity of TOT are : (With year 2000 as base)
IGCC (oxygen blown) - Pet coke Normal pace Accelerated IGCC (Air Blown) Normal pace Accelerated

----------------

5 years 2 years (Fig 3) Coal 7 years 5 years ( Fig 4)

Fig. 1

16

Fig. 2

Fig. 3

36

Fig. 4

Super Critical PC Power Plant (15 oC Amb.) 60 Super Critical PC Power Plant (Indian Condition) IGCC (15 o Amb) C IGCC (Indian Condition) Sub Critical PC Power Plant (Indian Condition) 1500 oC 1300o C 623 o C oC 600

Net Thermal Efficiency (%)

55

50
45 566 oC

40
1184o C

650o C
540oC

Ceramic gas turbine

35 30 1990

1995

2000

2005

2010

Year of commercial use

Fig.5 EFFICIENCY IMPROVEMENT FORECAST CONVENTIONAL Vs IGCC