EXPERIENCE OF BHEL

IN USING IGCC TECHNOLOGY FOR

COAL GASIFICATION BASED POWER GENERATION
 BHEL’s Gasification & IGCC Development
Programme
To gain
6.2 Mwe Developmental
testing experience in
IGCC with Start
Commg Compln gasification and
Mar 1988 Sep 1992
moving bed July 1983 IGCC plant
gasifier operation

Process & Design and

Equipment fabrication of
Developmental
Development testing major
Compln equipment and
(PEDU)pilot Start
Commg Jan 1997 development of
May 1988
plant based May 1986 PFBG
on PFBG technology

Data generation
6.2 Mwe for scaled-up
IGCC Developmental
gasifier and its
Commg testing
retrofitted Start Jan 1996 Is in progress integration with
Sep 1993
with PFBG CC
 100 MWe IGCC demonstration plant
Proposed
100 MWe
TO HRSG

VENTURI SCRUBBERS HX-1 HX-2

COAL C YCLONE

HRB
SORBENT QC
KD
CYCL ONE

ECO
LOCK
C YCLON E
SYSTEM LOCK ETP
SY STEM ASH
CFBC W ATER
GASIFIER DA
. .
.
. . . . ASH
. . . .
. .
.
.
CFBC
.
. . .
. . DA
. .. .
.
. .
.
.
.. . . ASH
. .
.
. .
CFBC DA
. . .. . CFBC

CCDP,Trichy
. . .
.. . . . . . . . . ... . . . .. . . . . .. . . .
.
. DA
. .
.
.
.
.
. .
CC
. . .
. .. . . ASH
. . . ..
.

C GT
CFBC
DA
H2 S REMOVAL SYSTEM
ASH
CFBC

( 6.2 Mwe )
COAL GAS
DA
FROM
COND. STEAM
STD BC AIR

WATER
H2 S
COND FROM
TO DA
HRB TO DA
FROM DA

STG
STACK
BC BOOSTER COMPRESSOR
C COMPRESSOR
FROM DA
COND.
COND CONDENSER
ECO ECONOMISER
DA DEAERATOR
HRSG
COND GT GAS TURBINE
HRB HEAT RECOVERY BOILER
HX HEAT EXCHANGER
QC QUENCH COLUMN
ST STEAM TURBINE

Scale up:
18 tpd Geometrical - 1: 2
PFBG Capacity - 1: 8.33

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

PEDU, Corp. R&D,

Hyderabad
 SCHEMATIC OF PEDU PILOT PLANT

COAL 12

WATER

AIR
1
9 11
10

2
TO ETP

AIR
13
AIR 4
7 6

5 1 COAL FEED LOCKS

2 COAL ROTARY FEEDER RECYCLE
STEAM COAL
3 GASIFIER
4 AIR PLENUM AIR
5 SCREW ASH EXTRACTOR STEAM
6
6 ASH LOCK WATER
7 AIR STEAM MIXER ASH
8 CYCLONE COAL GAS
9 QUENCH PIPE SLURRY

ASH ASH 10 GAS QUENCH VESSEL

11 VENTURI SCRUBBER
12 FLARE STACK
13 CLEAN GAS COMPRESSOR
Schematic of 6.2 MWe IGCC plant with PFBG
168tpd PFBG based IGCC plant
Panoramic view of BHEL’s IGCC Plant at Trichy
 
 
100 MWe – IGCC BLOCK DIAGRAM
  SORBENT
TRANSPORT
AIR
SORBENT

COAL
COAL FLARE

ST G
C GT G
PFBG
PFBG STACK
(AIR
(AIR BLOWN)
BLOWN)

BOTTOM   
ASH HRSG
HRSG

TO
PREHEATER

PRIMARY
PRIMARY IMPORT FROM DA
GAS
GAS CLEANING
CLEANING STEAM
(CYCLONES)
(CYCLONES) CLEAN
CLEAN GAS
GAS BLEED AIR
HEATER
HEATER COOLER
(CGH)
(CGH)
FLY ASH

TO DA
FROM GASIFIER
CONDENSER TO
 COLD
 COLD GAS
GAS DA CGH
HEAT
HEAT RECOVERY
RECOVERY CLEAN
CLEAN –– UP
UP &
&
BOILER
BOILER H
H22S
S REMOVAL
REMOVAL
ST BC ST of BC
(CGCU)
(CGCU)

CHAR
CHAR
COMBUSTOR
COMBUSTOR FROM DA

TO COAL
TRANSPORT
TO ASH TO CHAR
FROM DA &
SULPHATOR COMBUSTOR
CONDENSER
& DISPOSAL
PROCESS FLOW SCHEMATIC - 100MWe - IGCC PLANT
TO HRSG

VENTURI SCRUBBERS HX-1 HX-2

COAL CYCLONE

HRB
SORBENT QC
KD
CYCLONE

ECO
LOCK
CYCLONE
SYSTEM LOCK ETP
SYSTEM ASH
CFBC WATER
GASIFIER DA

OPTIONAL
. .
.
. . . . ASH
. . . .
. .
.
. CFBC TO FLARE
.
. . .
.
.
.
. DA
..
.
. .
.
.
.. . . ASH
. .
.
. .
CFBC/ DA
. . .. .
. . .
CFBC EXTN. STM
. . . . . . . . . . . . . . . . ... . . . ... . . .
.
. DA
. .
.
.
.
.
. .
CC
. .
. ASH
. .. . .
.
. . . .
.

C GT
CFBC
DA
H2 S REMOVAL SYSTEM
ASH
CFBC

COAL GAS
DA
FROM
COND. STEAM
STD BC AIR

WATER
H2 S
COND FROM
TO DA
HRB TO DA
FROM DA

STG
STACK
BC BOOSTER COMPRESSOR
C COMPRESSOR
FROM DA
COND.
COND CONDENSER
EXTN. STM
TO PROCESS ECO ECONOMISER
DA DEAERATOR
HRSG
COND GT GAS TURBINE
HRB HEAT RECOVERY BOILER
HX HEAT EXCHANGER
QC QUENCH COLUMN
ST STEAM TURBINE
 COMPOSITION OF UNWASHED NTPC-DADRI & SINGRULI COALS
Coal Characteristics
Size 0 –6 mm DADRI SINGRAULI
Type – E grade Coal

Proximate Analysis
Design Worst
Unwashed
Constituents
Wt% Wt%

Fixed Carbon 29.33 32.4 25.2

Volatile Matter 23.76 21.6 19.8
Ash 38.22 30.0 38.0
Moisture 8.69 16.0 17.0
GCV of coal (kcal/kg) 3692 4050 3300

Ultimate Analysis

Constituents
Ash 38.22 30.0 38.0
Moisture 8.69 16.0 17.0
Carbon 40.30 43.2 36.0
Hydrogen 3.19 2.5 2.1
Oxygen 8.20 7.23 5.97
Sulphur 0.50 0.27 0.23
Nitrogen 0.90 0.80 0.70
 RAW GAS COMPOSITION & GASIFICATION PARAMETERS

DADRI SINGRAULI
(UNWASHED) (WORST)
Coal, TPH 59.4 64.0
Steam, TPH 5.9 9.4
Air, TPH 112.4 119.2
Raw Gas produced 152.0 161.9

CONSTITUENTS RAW GAS AT 1000oC (%Vol)

Carbon Monoxide, CO 19.71 19.40

Hydrogen, H2 12.83 11.98
Carbon-dioxide, CO2 6.47 7.32
Methane, CH4 1.47 1.27
Hydrogen Sulfide, H2S 0.03 0.02
Nitrogen, N2 49.95 50.50
Water vapor, H2O 9.42 9.44
Molecular wt. 24.56 24.95
 CLEAN COAL GAS COMPOSITION

DADRI SINGRAULI
(UNWASHED) (WORST)

CO : 21.69 21.35

H2 : 14.17 13.19

CO2 : 7.12 8.06

H 2O : 0.35 0.35

CH4 : 1.62 1.40

H 2S : 0.03 0.03

N2 : 55.02 55.62

LCV , kcal/Nm3 : 1159 1104

HCV, kcal/Nm3 : 1241 1180

PRESSURISED FLUIDISED BED GASIFIER
 100 MW IGCC PARAMETERS
Dadri Singrauli

1 Site Ambient Temp., oC / Pressure, bar 27/1.0135 27/1.0135

2 (a) Coal Ash content, Wt% 38.8 42.12

(b) Coal HHV, Kcal/kg 3692 3300

3 Coal flow, tph 60.1 67.9

4 Steam flow, tph 5.97 5397

5 Air flow, tph 115.6 126.4

6 GT power output, MW 61.5 61.5

7 ST power output, MW 49.2 50.1

8 IGCC gross Power output, MW 110.7 111.6

9 IGCC net Power output, MW 107.3 108.1

10 Net Heat rate (HHV basis), kcal/kwh 2287 2318

11 Net overall IGCC efficiency 37.6 37.1

 100 MW IGCC PROJECT COST ESTIMATION (Rs Crores)
DADRI SITE

CGCU HGCU

1 Gasification Island 168.57 203.08

2 Power block 238.05 242.6

3 Plant Control & Instrumentation 13.7 15.1

ElectriElectricals
4 & Substation 5.4 5.4

5 Civil works, Township & Land Development 20.17 20.17

6 Technology fee & Engineering Expenses 8.43 10.15

8 Erection & Commissioning 15.49 17.05

9 Contingency @ 10% 57.19 62.58

  10 Project Cost 526.97 576.17

  11 Freight Insurance & Taxes + Duties 102.16 112.17
  12 Total Project Cost  
629.13 688.34
  13 Cost of electricity with 80% availability, Rs/kwh 2.99 3.36

14 Cost of electricity with 65% availability, Rs/kwh 3.51 3.97

OVERALL LAYOUT OF PROPOSED 100 MWe IGCC PLANT
(TENTATIVE)
GASIFICATION ISLAND LAYOUT
 APPROACH FOR SITE SELECTION
 A TEAM OF ENGINEERS FROM NTPC AND BHEL ARE TO BE
IDENTIFIED FOR CARRYING OUT SITE SELECTION AND
PREPARING FEASIBILITY REPORT BASED ON INFRASTRUCTURE
AVAILABLE AMONGST NTPC’S SITES.

 SITE SELECTION WOULD ENABLE

• PREPARATION OF SITE SPECIFIC DETAIL PROJECT REPORT

• PRECISE ESTIMATION OF TOTAL PROJECT COST

• ALTERNATE FUEL IDENTIFICATION DEPENDING ON SITE

FOR DESIGN OF GT

• PROJECTION OF FUND REQUIREMENTS

• IDENTIFICATION OF BOUGHT OUT COMPONENTS

 APPROACH FOR SELECTION OF GAS CLEANING SYSTEM
CRITERIA GT SPEC * HOT GAS CLEAN-UP (HGCU) COLD GAS CLEAN-UP (CGCU)
(MEDIUM TEMP: 250 to 550oC) (TEMP: <250OC )

i. PARTICULATE 2ppmw WILL MEET SPECS. CAN MEET SPECS

MATTER >10m : 0% ENDURANCE TEST REQD.
2-10 : 7.5%
0-2 : 92.5%
ii. ALKALI (Na + K) 0.06 ppmw - CAN MEET SPECS < 400OC CAN MEET SPECS.
O
- >400 C NEEDS ALKALI
CAPTURE

iii.H2S + COS 25.0 ppmw - CAN MEET IF Na+k UPTO CAN MEET SPECS
0.06ppm
- IF >0.06ppm
DESULPHURISATION IS
REQD.

iv. HCL,HF 1 ppmw - CAN MEET SPECS IF CAN MEET SPECS

HALIDES ARE AS ALKALI
HALIDES
- WILL NEED CHLORIDE
GUARD IF Cl2 > ALKALIES

* Ref : GEI-41040E : PROCESS SPECIFICATION FUEL GASES FOR COMBUSTION IN HEAVY DUTY GAS TURBINES
 ENVIRONMENTAL LIMITS OF POLLUTANTS

POLLUTANT LIMIT * HGCU CGCU

SOX 2000mg/Nm3 CAN MEET SPECS CAN MEET SPECS

NOX 750mg/Nm3 NEEDS GT AMMONIA GETS

COMBUSTION REMOVED IN
CONTROL / SCR SCRUBBING
PM 50mg/Nm3 CAN MEET SPECS CAN MEET SPECS

* Ref : IEA COAL RESEARCH, CCC/12, Dec 1998

 SELECTION CRITERIA FOR GAS CLEAN-UP SYSTEMS
COLD GAS CLEAN-UP SYSTEMS
TECHNOLOGY STATUS AVAILABLE AS B O I

b) HOT GAS CLEAN-UP SYSTEMS

 BARRIER FILTERS FOR PARTICULATE REMOVAL

• COMMERCIALLY DEMONSTRATED IN ENTRAINED FLOW GASIFICATION SYSTEM AT
TEMPERATURES BELOW 400oC.
• CERAMIC CANDLE FILTERS USED UPTO 260OC (@ BUGGENUM, NETHERLANDS AND IN
PUERTELLANO, SPAIN)
• SINTERED METAL FILTERS ARE IN USE UPTO 370OC (@ WABASH RIVER IGCC, USA
• TOBE PROVED FOR PFBG APPLICATION WITH HIGH ASH COALS. TEST ANALYSIS TO BE
EVALUATED FOR
- ASH BRIDGING
- POSSIBILITY OF PERMANENT ASH COATING DUE TO CHEMICAL REACTIONS
- MECHANICAL AND THERMAL DEGRADATION
 HOT GAS DESULPHURISATION
• NOT YET ESTABLISHED COMMERCIALLY
• MORE R&D DEMONSTRATION NECESSARY
 Contd
SELECTION CRITERIA FOR GAS CLEAN-UP SYSTEMS

 GT SPECIFICATION LIMITS FOR Na + K

• GAS TURBINE : (Na + K)  0.06 ppm ( MAX. GAS CLEAN-UPTEMP.  434 OC )

• FOR HIGHER CLEAN-UP TEMPERATURE HOT GAS ALKALI AND HALIDE
REMOVAL SYSTEMS ARE TO BE INSTALLED
• STUDY OF EFFECT OF NH3 VAPOURS IN COMBUSTION

 DESIGN CONSIDERATIONS:
• ALL CONTROL VALVES, SHUT-OFF VALVES AND PIPING SYSTEM ARE TO BE
DESIGNED FOR HIGHER TEMPERATURE

 O & M ISSUES
• FAILURE OF CERAMIC CANDLE ELEMENTS (BREAKAGE)
• FAST IDENTIFICATION OF DAMAGED ELEMENT AND ONLINE REPLACEMENT
TECHNOLOGY TO BE DEVELOPED
• SINTERED METAL FILTER OF IMPROVED PERFORMANCE IS YET TO BE
ESTABLISHED

 RECOMMENDATIONS:
• MORE EXTENDED R&D STUDIES REQD. TO ESTABLISH HOT GAS CLEAN-UP.
• COLD GAS CLEAN-UP IS ALREADY ESTABLISHED.
 APPAROACH FOR SIMULATION STUDIES

STEADY STATE AND DYNAMIC SIMULATION

• SIMULATION MODEL FOR POWER BLOCK IS AVAILABLE

• DEVELOPMENT OF STEADY STATE SIMULATION AND TRANSIENT

MODEL OF GASIFIER & GAS CLEANING SYSTEM

• INTEGRATION OF GASIFIER STAEDY STATE / TRANSIENT WITH THAT

OF POWER BLOCK USING STANDARD PACKAGE (ASPEN PLUS)

• VALIDATION OF THE STEADY STATE AND DYNAMIC SIMULATION

MODEL RESULTS WITH PLANT DATA
BHEL’S PROPOSAL TO THE COMMITTEE
 BHEL’S PROPOSAL
I. DECISION ON THE SITE SELECTION
• To enable BHEL to prepare site specific Detail Project Report
(DPR)
• To arrive at precise cost estimates and funding strategy
• Alternate fuel selection for dual fuel design of the GT
II. APPROACH FOR GAS CLEAN-UP
• While BHEL proposes to install cold gas clean-up equipment in
phase-I, funds should be allotted to go ahead for the development
of hot gas clean-up technology which is under development and may
be the ultimate solution for achieving higher efficiency
III. APPROACH FOR SIMULATION STUDIES

• BHEL proposes to carryout steady state & dynamic simulation

studies using packages like Aspen Plus and integrate the same with
the gasifier model being developed in-house.
Thank you
 100 MW IGCC PARAMETERS
(IMPROVED DESIGN WITH CHAR COMBUSTOR & ASH HEAT RECOVERY)
Dadri Singrauli

1 Site Ambient Temp., oC / Pressure, bar 27/1.0135 27/1.0135

2 (a) Coal Ash content, Wt% 38.8 42.12

(b) Coal HHV, Kcal/kg 3692 3300

3 Coal flow, tph 60.3 73.3

4 Steam flow, tph 6.0 10.8

5 Air flow, tph 114.1 136.5

6 GT power output, MW 61.5 61.5

7 ST power output, MW 49.2 50.1

8 IGCC gross Power output, MW 110.7 111.6

9 IGCC net Power output, MW 107.3 108.1

10 Net Heat rate (HHV basis), kcal/kwh 2210 2240

11 Net overall IGCC efficiency 38.9 38.4

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
 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 40

AIR FLOW 35
10000

30

8000
25

Coalflow-rpm
flow-kg/hr

COALFLOW (AROUND 6000 KG/H)

6000 20

15
4000

10
STEAM FLOW
2000
5

0 0
15 15.5 16 16.5 17 17.5 18
Time-hrs
Profile of gasifier and system pressures in
168 tpd PFBG

12
Gasifier pressure
11

10

9
PRESSURE- KG/SQ.CM

8 Pressure at gas cleaning exit

7
ressure
6

5
Press.Diff. Across system = 1.4-1.5 Kg / sq.cm
4

0
15 16 17 18
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)

SECOND LEVEL (2.35 m)

500
THIRD LEVEL (4.95 m)
0
15 16 17 18
TIME / HOURS
 168 tpd PFBG - Hot restart after box-up

1000 12 10000

9000
TEMP AIR
900 10
8000

800 8 7000

FLOW RATE, Kg/hr.

PRESSURE, Kg/cm sq.
6000
TEMP. IN DEG. C

700 6
5000
COAL
600 4 4000

3000
PRESSURE
500 2
2000
STEAM
400 0 1000

0
300 -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
REAL TIME, HOURS