Clean Coal Seminar @ Warsaw

MHPS IGCC Power Plant

IGCC: Integrated  coal Gasification Combined Cycle

June 2, 2014

© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD.  All Rights Reserved.
Product of MHPS IGCC
IGCC Plants in Japan： IGCC: Integrated  coal Gasification Combined Cycle
・ 250MWe IGCC*1 @Nakoso(TK)  ：Commercial Operation since June 30,2013  (Demo. started 2008)
・ 166MWe IGCC*2 @Osaki             ：Demonstration,  Now under Construction  (Demo. will start 2016)
・ 540MWe x2 IGCC*1@Fukushima(TK)： Now under Project Development
*1: Air‐blown  ,*2: Oxygen‐blown    TK : Turn Key project

Integrated  coal Gasification Combined Cycle
(IGCC) Power Plant

© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD.  All Rights Reserved. 1
TEPCO develops 500MW class IGCC Plants in Japan
Tokyo Electric Power Company 
New Comprehensive Special Business Plan (extract)

the Joban Joint Power Co.(Iwaki City) ,

Source: Tokyo Electric Power Company  HP  Press release on 15 Jan.2014
Detailed Report of the New Comprehensive Special Business Plan

Project Schedule Plan  
・Environmental Impact Assessment 2014(started)
FUKUSHIMA
・Start  of  Construction    2016                      Fukushima

Tokyo
・Start  of  Operation         Beginning of 2020s TOKYO

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Learned form Nakoso 250MW IGCC Plant
Nakoso unit no.10 Nakoso 250MW Demonstration Project finished
Joban Joint Power Co. in end of March 2013 after achieving all the
(250MW IGCC) targets.
• Excellent Performance
(Highest Efficiency, Less Environmental impact)
• Higher Reliability
World record of continuous operation
• Fine Operability
• Fuel Flexibility (9kinds of coal used)
Bituminous coal(China, Indonesia, Colombia,Russia)
Sub-bituminous coal(USA, Indonesia)

⇒ 540MW Commercial Plants

have become “Ready.”

The plant was converted to

Gasifier the First Commercial Plant in Japan and
restarted operation from the summer of 2013

HRSG

JSME Medal for Technology

Gas Turbine Awarded
(JSME : Japan Society of Mechanical 
/ Steam Turbine Gas Clean-Up Engineering)

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Achievements of Nakoso 250MW IGCC Plant
Operability (Load Change) Reliability
Verified at 3%/min load change operation which Continuous full load operation from July to
is required as middle range operation December of 2013 without any forced outage

Average Load Factor >99%

Environmental Performance
50 Operation history and schedule  after the 
42.0 42.9
40
start  of commercial operation(June 30,2014).

30
Commercial Operation
20 Maintenance and equipment improvement(scheduled)

8 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9
10
1 5 3.4 4 ＜0.1 2013 2014
0
Net Efficiency SOx NOx Dust
(%-LHV) (ppm) (ppm) (mg/kg)

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Verification of Fuel Flexibility in Nagasaki
Gasifier Gas clean up
Many kinds of coals had been tested
in Nagasaki IGCC verification Plant.
・Bituminous coal
・Sub-bituminous coal
・ Lignite (USA/ Texas Lignite , Indonesian Lignite
Australia /Victoria Brown coal)

IGCC firing Lignite

Control room Gas turbine Lignite (Moisture: 50‐60%)
test facility
24t/d IGCC verification  plant in Nagasaki  Pre‐Drying
50 MHPS Gasification Pre‐dried lignite(Moisture<40%)
Experience

MHPS Pulverizing &

40
Ash (wt%‐as air dried)

Drying Experience
Pulverizer
30 IGCC portion verified by 
Gasifier NAKOSO unit no.10
Polish
20 Bituminous
Gas Clean‐up
Pre-Drying Polish Lignite
10 Gas Turbine

HRSG 
0
0 10 20 30 40 50 60
Polish bituminous is well within the MHPS gasification experience.
Total Moisture (wt%‐as received) Polish lignite up to  approx. 50wt% total moisture can be applied for IGCC without pre‐drying. 
Polish lignite more than 50wt% total moisture also can be applied for IGCC with pre‐drying. 

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Air-blown IGCC System Configuration
540MW IGCC plant system configuration is same as Nakoso 250MW plant.
MHPS can supply whole IGCC plant with single point responsibility
Gasifier / Gas Clean-up : Clean fuel gas generation from coal with high efficiency
Highly Efficient Gasifier Wet Gas Clean-up (MDEA) Air
To Gypsum
Coal Feed Recovery
GGH Off‐Gas 
Incinerator
Char 
Removal & 
Recycle
Coal COS Scrubber NH3/Trace  H2S H2S
Converter Element  Regenerator
Washing Absorber
Char

Slag Combustor Air Steam  Stack

Turbine

Air ～ Heat
Gas  Recovery
Turbine Steam
Generator
Nitrogen Flare System
Oxygen
ASU Air
Compressor M
ASU for N2  Generation  *1 Highly Efficient Gas Turbine
＊１：ASU for N2 Generation：
• Inerting N2 for coal transportation is produced. Combined Cycle : Efficient Power Generation by fuel syngas
• O2 as a by-product is mixed with air and efficiently
utilized as gasification reaction enhancer.

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Principal Specification of MHPS 540MW IGCC Plant

Gas Turbine : DA ⇒ F4 MW
700 Major Specification
Item
540 MW 600 50Hz

Gross Output
50
500 Bituminous Coal &
Coal
Net Efficiency (LHV %)

Sub-bituminous Coal
48 400
48 % Output Gross 540 MW
250MW 300
46 Net 480 MW
200
Gasifier Oxidizer Air (O2 Enriched)
44
Coal Feed Dry

42 Acid Gas Clean-up Wet MDEA* 1

42 % 330
M701F4 ☓1
Gas Turbine
40 (1 on 1)
140
Net Efficiency (LHV) 48 %
38
Note: Plant performance like output and efficiency
Demo. Plant Commercial Plant depends on site conditions including coal
properties.
701DA 701F4
＊1 MDEA: Chemical absorption method using
methyldiethanolamine.
M701F4  The Most Experienced Gas Turbine
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Plot Area Comparison

Item Nakoso 250MW IGCC 540MW IGCC 800MW USC

Coal Feeding 
Gasifier

HRSG

195m
ASU Gas Clean Up
Gas Clean Up

385m
ＧＴ
ＳＴ

125m
Plot Plan ＧＴ
ＳＴ

Gasifier

HRSG

ASU

160m 100m
155m

Plant Area ※1 20,000m2 30,200m2 47,600m2 ※2

Plant Area
80m2/MW [Base] 56m2/MW [70%] 63m2/MW [79%]
(per MW)

※1：Excluding Utility equipment

※2：Power Block : 35,500m2 FGD Aeration(not indicated) : 12,100m2

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High Reliability Gasifier Concept

1. 2-Staged Gasification
- Combustor / Reductor Configuration
HP- Steam
① Stable Syngas Production for Wide
SGC
Variety of Coal
② Smooth Slag Discharge Capability
Syngas ③ No Necessity of Quench Gas

FW Chemical Quench (w/o

Reductor Quench Gas)
Reductor
occurs at 2nd Stage
Gasifier
１
Coal
２
Combustor

Temperature
Coal Combustor
Char

O2 enriched Air
2. Char Recycling System
Slag ① Minimize Unburnt Carbon in Slag
② No Black Water from Gasifier
9
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Proven Design Methodology for Gasifier
The scale‐up of the gasifier follows the established scale‐up law from the 200T/D 
pilot plant.  No critical issues expected.
Scale‐up 8.5 times

200T/D Pilot Plant
250MW (1700T/D) Nakoso #10
MHPS Verification Plant (former Demo. Plant)
2 times
As the result of successful 
demonstration,
• Scale‐up methodology was 
validated. 
• Same methodology is 
applied to the 500MW IGCC 
commercial plants at lower  3D‐CFD
scale‐up factor. Simulation
Gasifier for 540MW IGCC Commercial Plants

© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD.  All Rights Reserved. 10
MHPS Gas Turbine Global Experience

H‐15×6
M501J×26 M501G×69 M501F× 73 M501D×25
H‐25×159
M701J×2 M701G×11 M701F×124 M701D×92
H‐80×13
Total:28units Total:80units Total:197units Total:117units
Total:178units

Europe
48
9 220 227
Americas Middle East 33 45
』
& Africa Asia Japan
168
119 71
20

Oceania
7

All Units H series
(＊) As of  April 2014
All Units – 789 units
(including 189 units of Takasago Mfd. Mid&Small Class GTs)
M701F4  :  The Most Experienced Gas Turbine. 
11
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD.  All Rights Reserved.
Gas Turbine Trend for Fuel Gas Application

G and J Series GT J Series Natural Gas
Experience G Series Natural Gas

F Series GT  F Series Syngas
Experience
F Series Low BTU Gas (BFG)

F Series Natural Gas

D Series GT 
D Series Syngas
Experience
D Series Low BTU Gas (BFG)

D Series Natural Gas

1980 1985 1990 1995 2000 2005 2010

12
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Environmental Performance of 540MW IGCC Plant
The World Highest Efficiency and Lowest Emission for coal
can be achieved by MHPS IGCC.
(%)
140
Coal fired conventional power plant USC 
＋10~20% (Steam Temp. = 600℃) =100%
120 vs. USC

100

80
Flyash Grassy Molten Slag
(Conventional Boiler) (IGCC)
60 ▲10~20%
Approx. 60% decrease in volume
▲30%
40
▲60%
20

0
Circulating Utilization as a Utilization as a
Plant CO2 Ash Water pavement material concrete aggregate
Efficiency
Emission are possible.

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 Conclusion

 The 250MW IGCC demonstration plant has been successfully 
completed by achieving all of its purpose and targets , and was 
converted to the Commercial Plant in Japan as Nakoso unit No.10 of 
Joban joint Power Co. and restarted operation from the summer of 
2013.
 Based on the experience in the demonstration plant, MHPS is now 
capable of realizing 540MW‐class IGCC commercial plants with high 
reliability (availability) and economy by reflecting all the accumulated 
data and lessons learnt.
 A lot of IGCC’s advantages like higher plant efficiency and applicability 
of coal of lower rank are taken into account.
In addition, reduction of  CO2 emission, ash discharge and circulating 
water is envisioned, too.

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 “MHPS’s Contribution for
Energy and Environment Solutions”
© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD.  All Rights Reserved. 15
Apendix.1
MHPS Technology and Products for Power Generation and Chemicals
POWER PLANT & EQUIPMENT MHPS is a technology provider and OEM of
key components like gasifiers, gas turbines
and steam turbines.
Also supplies chemical plants and
equipments.

Combined Cycle Power Plant Boiler

Steam Turbine Gas Turbine

Gasifier 16

Compressor for Refuse Incineration Plant

Ethylene Plant

CO2 Recovery Plants CHEMICALMethanol

PLANT synthesis plant etc
& EQUIPMENT
IGCC
MHPS plays a role of the most reliable system integrator for IGCC based on our overall experience and technology.

© 2014 MITSUBISHI HITACHI POWER SYSTEMS, LTD.  All Rights Reserved.
Apendix.2
Lignite Coal Firing IGCC Plant
Lignite Coal Firing Boiler is relatively expensive as larger volume 
due to lower ash melting temp.
IGCC is suitable for Lignite Coal as the volume of the gasifier is 
almost same as the bituminous coal firing gasifier.

High Rank Coal Low Rank Coal High Rank Coal Low Rank Coal

Conventional Boiler Gasifier

Base X2.4

Base X1.06
Increasing volume as low rank Almost same volume

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Apendix.3
Low Calorific Gas Firing Projects Progress

2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013
BFG FIRING M701F x 1 +ST Total Operating Hours
Installation over 67,000 Hrs
Commissioning
Commercial Operation

VR- IGCC M701FV x 1 +ST

Oct ’02 Commissioning with Oil firing started Total Operating Hours
Commissioning with Syngas firing over 75,000 Hrs
June ’03 Commercial Operation Started

Coal IGCC M701DA x 1 +ST

Combustion test Total Operating Hours
Procurement over 22,000 Hrs
Process Construction
GT Installation
Commissioning

Operation

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