Twin IHI Gasifier(TIGAR ) Technology for Chemical Feedstock

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1 APEC Clean Fossil Energy Technical and Policy Seminar 2010 Twin IHI Gasifier(TIGAR ) Technology for Chemical Feedstock TIGAR:Twin Ihi GAsifieR 28 th October, 2010 TIGAR is under development. Power Plant Division

2 IHI coal gasification technology TIGAR Combustor Fluegas Syngas Fuel Steam Air Gasifier Circulating fluidized bed gasifier system Bubbling fluidized bed gasifier Circulating fluidized bed (CFB) combustor Complete seal of gas Gasifier Steam blown gasifier VM and part of char gasified High calorific gas (No contamination of air) Combustor Air blown combustor Char combustion Operate under atmospheric pressure 2

3 Components of TIGAR Components of TIGAR are combined mature CFB and BFB technology. Circulating Fluidizing Bed (CFB) Bubbling Fluidized Bed (BFB) Bubble Particles 3

4 Applications of TIGAR Products Application CO, H2 CO,H2 (Synthesis gas) GT,GE fuel Direct Reduction Iron Manufacture Coal Biomass Waste CO, H2 CO, H2 CO, H2 Shift reaction CO2 Synthesis H2 CH4 CTL Fuel cell Ammonia (NH3) H2 for direct CTL Substitute Natural Gas gas liquid Automobile fuel Gasifier Synthesis DME Methanol Chemical Raw Material TIGAR can be used for many applications. 4

5 Available feedstock of TIGAR Easy utilization of Coal and Biomass feedstock because of operating under atmospheric pressure Simple feeding system to gasifier Wood Available Feedstock Easy CO2 Reduction Bagasse Coal (LRC) Bark Palm Waste 5

6 Steam gasification of lignite Lignite can be easily gasified. Carbon conversion [mol/mol] Lignite Bituminous Sub-bituminous Gasification time [min.] Lignite steam gasification is faster than bituminous coal Steam gasification is suitable for lignite Steam gasification in lab. fluidized bed reactor (0.1MPa, 900degC) 6

7 Comparison of gasifier Gasification Process TIGAR Type T Type S Type L Gasifier type Operation press. Operation Temp. Oxidizer Coal Feeding Residue Efficiency (for lignite) Fluidized bed Entrained bed Entrained bed Moving bed MPa >3MPa > 3MPa 1-3 MPa 800-1,000 >1,400 >1,500 1,200 Steam Oxygen Oxygen Oxygen High availability Slurry Powder Bulk Dry ash Slug Slug Dry ash High Very low Moderate Low Low cost and Simple operation 7

8 Target of TIGAR Applied class of capacity and feedstock Low Volatile Anthracite Bituminous Sub-bituminous Entrained bed type gasifier Lignite TIGAR Low Rank Coal and Biomass Dry Feed Entrained bed type gasifier Biomass Higher Volatile 300t/d 1000t/d 2000t/d Capacity / 1 unit 8

9 Features of TIGAR TIGAR is suitable technology to use Indonesian low rank coal. Lower CAPEX and simple Operation & Maintenance Lower pressure and lower temperature in operating condition Small air separation unit (oxygen plant) High reliability and availability Based on mature fluidized bed technologies Multi-fuel application Low rank coal, biomass and their co-utilization Co-production Variable change of ratio of syngas to power generation 3000t/d Coal gasification plant image 9

10 Development schedule At present FY D view of TIGAR R (Prototype Plant 50t/day) TIGAR R CONFIDENTIAL FL 36m Simulation and small scale facility testing Bench scale facility testing Pilot Plant stage 50t/d Incinerator PRELIMINARY Settling pond Buffer tank Ash and Sand storage yard Coal storage yard Gas cooler Combustor FL 23m Coal conveyer FL 13m Prototype Plant stage FL 0m G-IDF Gasifier HRA for Gasifier Cooling water pump HRA for Combustor GAH FDF BFP Bag filter Control Room Cooling Tower LPG tank 0.1t/d IHI Yokohama Now Indonesia 300~1000t/d Commercial Plant Laboratory scale gasification facility 10

11 6t/d Pilot Plant Confirmation of TIGAR R technology with full process ~2008 Gasification test with TIGAR R ~2009 Modification 2010~ Official tests Gasification area Gas Clean up area Gasification Gas cooler Bagfilter Fan Stack Modified / Additional Area Coal bunker Waste Water treatment area Cyclone Sand Feeder Combustor Hopper Conveyer Reformer Gas cleanup Flare stack Gasifier Fan Air Steam Fan Boiler Tar decanter Waste Water treatment 11

12 Performance of 6t/d Pilot Plant Gasification performance of lignite is higher than its of sub-bituminous. H2 rich syngas has broad utilization. Carbon Conversion Lignite Sub-bituminous CO2 19% CH4 9% CO 18% Other HC 3% H2 51% H2 CO CO2 CH4 Other HC Tg Carbon Conversion vs. Gasifier Temperature Gas Compositions (N2 < 1%) 12

13 Operation of 6t/d Pilot Plant Lignite and sub-bituminous coals show stable gasification performance. Load Combustor temp. Cold gas efficiency Gasifier temp. Carbon conversion Operation time [min] 13

14 Future plan Indonesia energy aspect Indonesia has big amount of resources of Row Lank Coal. Indonesia has also big amount of resources of Natural gas. The demand for Natural Gas is in particular big by the fertilizer industry. Coal Natural Gas 4% (310) 6% (464) 4% (306) 0.5% 2% (90) 1.1% (150) (39) Policy of Indonesia energy supply Sub bituminous 26.7% Anthracite 0.3% Lignite Bituminous 58.7% 14.3% Indonesia Coal Resources Fertilizer 7% (562) 11% (884) 11% (914) 5% (443) 49% (3935) Export Natural gas Total:8,095.5MMSCF consumption in Indonesia (2006,MMSCFD) For Indonesia, gasification of LRC as the backup of Natural Gas is required. For Japan also, gasification of LRC contributes to energy security. 14

15 Future plan apply to the existing fertiliser plant IHI studied feasibility of TIGAR applying existing fertilizer plant Change! Natural Gas Reformer Ammonia Process Urea Process Lignite Gasifier TIGAR Pupuk Sriwidjaja Ammonia 1499 Urea 2262 Pupuk Iskandar Muda Ammonia 762 Urea 1170 Pupuk Kalimantan Timur Ammonia 1848 Urea 2980 PUSRI group Fertilizer plant Pupuk Kujang Ammonia 713 Urea 1156 Petrokimia Gresik Ammonia Urea 462 Capacity 1,000t/y (2008 Pusri Annual Report) 15

16 Summary Twin IHI Gasifier (TIGAR ) is being developed for lignite gasification. TIGAR can stably produce syngas with higher heating value from Lignite coal. 6t/d Pilot Plant test indicated that TIGAR system is proven technology for lignite gasification. CO2 can be captured from syngas using coal gasification, and TIGAR can utilize the biomass as feed stock easily, so can suppress the production of the CO2. We are planning to apply TIGAR to Indonesian fertilizer plant as the first step of the commercial stage. 16

17 Thank you! 17

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