global activities for high efficiency thermal power ... activities for high efficiency thermal power...

© Hitachi, Ltd. 2013 All rights reserved.

September 4, 2013

Yasuo Fujitani CEO Thermal Power Systems, Power Systems Company, Hitachi, Ltd.

Global Activities for High Efficiency Thermal Power Generation Technology

© Hitachi, Ltd. 2013. All rights reserved.

Index 1. Hitachi Power Systems Company

2. Boiler Technology

3. Air Quality Control System Technology

4. Steam Turbine Technology

5. Future Clean Coal Technology


1. Hitachi Power Systems Company

© Hitachi, Ltd. 2013. All rights reserved. 4

Hitachi Global Portfolio

10％

8％

18％

13％

3％ 11％

Power Systems

Others

Financial Services

High Functional Materials & Components

Digital Media & Consumer Products

Information & Telecommunication Systems

9％

13％

7％

8％ Social Infrastructure & Industrial Systems

Electronics Systems & Equipment

Automotive Systems

Construction Machinery

Revenues 96.0 billion US$

（FY2012）


Power Business in Hitachi

Major Equipment of Coal-fired Thermal Power Plants Transmission & Distribution,

Renewable Energy and Other Businesses

Thermal Power Business Nuclear Power Business

ABWR: Advanced Boiling Water Reactor ESBWR: Economic and Simplified Boiling Water Reactor

Coal-fired Thermal Power Plants

Particle beam therapy systems

Boiling Water Reactor Nuclear Power Plants (ABWR・ESBWR)

Preventive Maintenance, Nuclear Fuel Cycle, etc.

Steam Turbines

Boilers

Wind Power Generation Systems

Photovoltaic Power Generation Systems

Hydroelectric Power Generation Systems, Drive Systems, Smart Grids, Power Semiconductors, etc.

Gas Turbines

Transmission & Distribution (T&D) Systems Air Quality Control System

FY2012 Consolidated

Revenues 9.6 billion

US$ 20%

60%

20%


Total System Technology

■Boilers (B)

■Air Quality Control System

■Steam Turbines and Generators (TG)

Boilers (B)

Turbines (T)

Generators (G)

AQCS DeNOx

Precipitators DeSOx CCS Systems Catalysts ○ ○ ○ ○ ○ ○ ○ ○

Low-pressure Turbines

Turbines and Generators

DeNOx Catalyst DeSOx (Spray Type)

Integrated supply of BTG + AQCS ⇒ Optimize entire plants


New Markets

Estimation on Thermal Power Generation Capacity

3,310

4,401

5,142 5,628

Other Areas Non-OECD ASEAN etc. India China OECD

Source : IEA WEO 2011

0

1,000

2,000

3,000

4,000

5,000

6,000

2009 2020 2030 2035

Unit : GW

7

Accelerate Business Development

Expand in emerging markets, particularly in Asia Coal-fired systems expand in emerging markets, and gas-fired systems in all regions

World Electricity Generation by Energy Source

Steady growth in coal-fired thermal power plants Increasing demand for AQCS due to

national regulation Accelerated adoption of renewable

energy Expansion of power transmission and

distribution market

Source: World Energy Outlook 2012

Nuclear

Renewable Energy

Coal

Oil Natural Gas

100% 117%

158% (Trillion kWh)

10

0

20

30

40

2010 2015 2030


2. Boiler Technology


Experiences of Wide Range Coal Properties

Wide Range of Coal Qualities Fired

0

10

20

30

40

50

60

70

80

0 10 20 30 40 MJ/kg

Vola

tile

Mat

ter (

dry

ash

free

basi

s)

Net Calorific Value kcal/kg 0 2,000 4,000 6,000 8,000

%

Lignites

Low Volatile Coals

Low LHV Lignites

Bituminous Coals


Boiler Supply Record

Africa South East Asia

Oceania

North America

Central & South America 12.3

15.3

4.5

4.1

5.8

Europe

11.5

1.2 West Asia

4.5

North Asia

Total Installed Capacity: 60.7 GW (except Japan)


Boiler Supply Record – Over 200MW

200-299 300-499 500-899 200-299 300-499 500-899 900-1050 0

2,000

4,000

6,000

8,000

10,000

12,000

14,000

16,000

18,000

6,612

14,380

1,200 1,400

4,915

19,554

Unit Output (MW)

Tota

l Out

put (

MW

)

28 units

21,050 21 units

31 units

13 units

6 units 2 units

42 units

72 units / 22,192MW 71 units / 46,919 MW Natural Circulation Once-Through

20,000

22,000


Latest Boiler Supply

Once-Through, Benson 1,000 MW 2,870 t/h

Bit. & Sub-bit. Blend

Boiler Type : Generator Output : Main Steam Flow : Steam Conditions :

Commercial Operation : 2003 (#1), 2013 (#2) Fuel :

Tokyo Electric Power Co., Ltd Hitachi Naka Unit 1, 2

25.4MPa / 604oC / 602oC

Once-Through, Benson 853 MW 2,530 t/h

USA Sub-bituminous Coal

Boiler Type : Generator Output : Main Steam Flow : Steam Conditions :

Commercial Operation : 2007 Fuel :

MidAmerican Energy Company (USA) Walter Scott Jr. Energy Center Unit 4

26.2MPa / 570oC / 595oC


Latest Lignite Boiler Supply

P.S. Neurath F&G (BoA II) Output : 2 x 1,100MW Main Steam flow : 2 x 2,959 t/h

Superheater Steam : 600oC / 272 bar

Fuel : German Lignite

Reheater Steam : 605oC / 57 bar Plant in Operation : 2012

P.S. Boxberg R Output : 1 x 670MW Main Steam flow : 1 x 1,760 t/h

Superheater Steam : 600oC / 315 bar

Fuel : German Lignite

Reheater Steam : 610oC / 72 bar Commissioning : 2012


3. Air Quality Control System Technology


Air Quality Control System

Boiler

DeNOx(SCR) FGD

ESP

FGD : Flue Gas Desulfurization Boilers

DeNOx (SCR)

ESP

FGD

Stack

Hitachi is one of a few AQCS supplier for total system

AQCS Air Quality Control Systems Stacks

(Layout for 1000MW coal fired plant in Japan)

A/H


SCR (DeNOx) Supply Record

North America: 126GW

Japan: 116GW

Taiwan area: 24GW

Total:743GW Supply Experience in the world ⇒World Share 24% (No.1 in the World) (Dec 2012)

China: 348GW

Europe: 91GW

BHK

BHK 76%

BHK 16% BHK 24%

23%

21%

Korea: 32GW

BHK 47%

Germany, Mehrum No.3 700MW,Coal

Poland,PGNiG Siekierkie No.10,11,14,15 140MW×4,Coal

BHK Catalyst Manufacturing Facility in Japan (Akitsu Works)

BHK Catalyst Manufacturing Facility in China (BHHE)

USA,AES/ Somerset No.1 675MW,Coal

USA,LA DWP/ Haynes No.1 230MW LNG

Japan,TEPCO/ Hitachi Naka No.1 1000MW,Coal

31%

BHK

BHK

Japan,TEPCO/ Sodegaura No.1 1200MW,LNG


Feature of SCR Catalyst (Plate Type)

PLATETYPE

HONEYCOMBTYPE

REMARKS

ACTIVITY

EROSION RESISTANCEAGAINST DUST

CENTER METAL PLATE

PLUGGING RESISTANCE FEW CORNERS

PRESSURE DROP PRESSURE DROP

HANDLING COMPACT

CATALYST VOLUMEFOR INITIAL LOADING

SPECIFIC SURFACE

FOR LONG TERM OPERATION LONG LIFECATALYST STACKING

PLATETYPE

HONEYCOMBTYPE

REMARKS

ACTIVITY

EROSION RESISTANCEAGAINST DUST

CENTER METAL PLATE

PLUGGING RESISTANCE FEW CORNERS

PRESSURE DROP PRESSURE DROP

HANDLING COMPACT

CATALYST VOLUMEFOR INITIAL LOADING

SPECIFIC SURFACE

FOR LONG TERM OPERATION LONG LIFECATALYST STACKING

HONEYCOMB TYPEPLATE TYPE

CATALYST

GAS GAS

DUST DUST

CENTER METAL CATALYST

HONEYCOMB TYPEPLATE TYPE

CATALYST

GAS GAS

DUST DUST

CENTER METAL CATALYST

Catalyst Unit

Catalyst Element Meshed Center Metal

Catalyst Material

: EXCELLENT: ADVANTAGEOUS: AVERAGE

: EXCELLENT: ADVANTAGEOUS: AVERAGE

Features: Erosion Resistance, Plugging Resistance, Low Pressure Drop


SCR Catalyst Development and Supply

1990

1970

1980

2000

･World First Commercial Application for Large Utility

･1986 World First Commercial Application for Coal Fired Utility

Japan

･1987 Licensing of Technology for Siemens

･Development Plate Type Catalyst

･Development Catalyst for Anti-Arsenic

1963 Start Development of SCR Catalyst by Own Technology

2015

2004 Korea

1991 Taiwan 2000 China

1986 USA 1986 Europe

Poland, PGNiG Siekierkie No.10,11,14,15 140MW×4

Japan,TEPCO/ Hitachi Naka No.1 1000MW

USA Gavin Power Station Unit.1 1300MW

BHK Catalyst Manufacturing Facility in Japan (Akitsu Works) Established in 1987

BHK Catalyst Manufacturing Facility in China (BHHE) Established in 2012


FGD (DeSOx) Supply in Europe

Approx. 17 GW Equivalent in total

Poland Kozienice #11

(1075MW)

Poland Kozienice II & IV

(800MW x 2)


FGD Development and Supply

R&D / Pilot Commercial Plant (Total 15)

Commercial Plant (Total 9)

Commercial Plant (Total 52)

1962 1970 1975 1995 2000 2005 1980

PERFORATED TRAY TOWER SPRAY TOWER ADVANCED SPRAY TOWER

Initial Stage Improvement of Reliability

Targeting Low Utility and Cost Reduction of Utility

2010 2015

Simplification of the System

Meeting Middle Load Ope.

1985 1990

Total 76 Plants

Wet Limestone-Gypsum Process (Non-Toxic Solution)

Gypsum

Limestone

GypsumDewatering

from ESP

Stack

Absorber

WWTS

WWTS : Waste WaterTreatment System

High gradetreat

Water(or SeaWater)

Sea

Ash : 0.6ton/yTachibanawan No.2 1,050MW (Japan) Kozienice II Project

800MW (Poland)

Supply Experience

Advanced Spray Tower

LIMESTONE GYPSUM FGD SYSTEM

Perforated Tray Tower

Spray Tower


4. Steam Turbine Technology


Steam Turbine Supply Record

Total Installed Capacity: 56 GW (except Japan)

Africa

North Asia

South East Asia

Oceania

North America

Central & South America

4.8

20.6

4.5

11.2

3.3

Europe

3.6 2.4

West Asia

5.3


Steam Turbine Supply Record

Steam Turbine Generator under Contract since 2002

Rating output (MW)

Total 71 Sets (end of 2012)

Turbine Type


Latest Steam Turbine Supply

Tandem Compound Four Flow

790.1MW

3,000rpm

26.3MPa/ 600oC / 620oC

Turbine Type :

Generator Output :

Revolution:

Steam Conditions :

Netherland Rotterdam

Tandem Compound Double Flow

600MW

3,000rpm

25MPa/ 600oC / 620oC

Turbine Type :

Generator Output :

Revolution:

Steam Conditions :

Japan Isogo Unit No.2

Commercial Operation : 2009 Commercial Operation : 2013


5. Future Clean Coal Technology


Roadmap of Clean Coal Technology

• Hitachi has been developing two key technologies of CO2 capture from coal fired power plants; “CO2 Scrubbing”, and high efficiency plants “Advanced -USC”, “IGCC” and “CCS”

2010 2015 2020 2030 2025 Regulation

Road of Development

Hitachi Vision of

Technology Development

Capture Ready Partial Reduction Full

Reduction Pilot Testing

Plant Demonstration

Plant Commercial Plant Ultimately-

Clean Plant

CO2 Scrubbing -Reduce CO2 Emission by half

Advanced -USC Efficiency of 46%(HHV)

Oxy-Combustion -Reduce all of CO2 Emission-

Advanced -USC + CCS -High Efficiency -Zero Emission

IGCC + CCS -Ultimately Clean Coal Technology


Advanced USC (Ultra Super Critical)

The efficiency of the coal fired power plant has improved by making the steam condition a high temperature.

1960 1980 2000 2020

40

30

700

600

500

50

USC: 593oC

Advanced USC: 700oC

Net

effi

cien

cy (%

) S

team

tem

pera

ture

(o C)

State of the Art: 600oC/620oC

Next Generation Development Goal

is Net Efficiency 46-48%

Average Efficiency in the World 32%

Best Practice

Near future

Development matter - Material (Ni-base Alloy) - Design - Reliability


Development of Material for Advanced USC

　　

USC141: High Strength Ni-base Alloys (Upper Limit: 720oC)

FENIX700: Fe-Ni-base Alloys for Low Price, Large-scale Production (Upper Limit: 700oC)

Application Use; Turbine Moving Blade, Bucket Bolts, Boiler Tube

12.5 ton Stead Ingot for Turbine Rotor

Application Use; Turbine Rotor

Power source

Base metal

Y axisZ axis

Oscillationmotor

(θ axis)

Wire

Ｍ

Wire heating Power supply

Tungsten electrode

Water cooled torch

Wire torch

Filler wire

Feeding motor

Power source

Base metal

Y axisZ axis

Oscillationmotor

(θ axis)

Wire

Ｍ

Wire heating Power supply

Tungsten electrode

Water cooled torch

Wire torch

Filler wire

Feeding motor

Sketch map of HST equipment

Narrow Gap Hot Wire Techinology


Reduction of CO2 Emission

Plan

t Eff

icie

ncy

(Rel

ativ

e va

lue

%)

0

2

4

6

8

10

700

800

CO2 D

isch

arge

(g

-CO

2/kW

h) 900

-5% -7%

【Assumption Ourselves】

Higher Thermal Efficiency, Lower CO2 Emission *HHV, Net output base

Sub SC USC Sub SC USC Abbr) Pressure

(MPa) Temperature

(oC)

Sub: Sub-Critical 16.7 538/538 SC: Super Critical 24.1 566/566 USC: Ultra Super Critical 25.0 600/600


CCS (CO2 Scrubbing)

Accelerate Commercialization 2005 2010 2015 2020 2025

Commercialization Demonstration Test Pilot Test

Joint Research by Power Companies (To 1995)

Conceptual Design of CO2 Scrubbing (800MW class) CCTF Project

Test with Organizations Overseas (2012)

30 *1 NCCC:National Carbon Capture Center *2 MEA:Standard Solvent *3 H3-1:Hitachi Solvent *4 SaskPower : Utility company in Saskatchewan, Canada

■ NCCC Test Result

Boundary Dam Power Station

■ Hitachi has participated in SaskPower CCS Project - Hitachi and SaskPower*4 have collaborated to design and built Carbon Capture Test Facility (CCTF, 120 t-CO2/day) at

Shand Power Station. - Hitachi supplies the newly-designed steam turbine and generator for Boundary Dam CCS Project.

(3000 t-CO2/day)


CCS (Oxy-fuel Combustion)

Fundamental Study - Laboratory Test - Basic Combustion Test (0.4MWth Test Facility)

Demonstration Test Feasibility Study - Trial Design of Actual Plant (500MW class) - Cost Evaluation

0.4MWth Test Facility

Furnace Burner

Furnace Burner

Verification Study - Large Scale Combustion Test (4MWth Test Facility) - Total System Check (1.5MWth Test Facility)

4MWth Test Facility

AQCS Furnace

30MWth Test Plant *1

Conceptual Design of Oxy-combustion (500MW class)

31 1.5MWth Test Facility

*1: Schwarze Pumpe (Vattenfall)： Hitachi has conducted burner combustion test.


IGCC (Oxygen-blown IGCC)

O2

Coal

Fuel Gas(CO,H2 )

HRSG* Gasifier

Steam Turbine

Gas Turbine

Shift Reactor(※)

CO2 Capture

H2

CO2,H2

※Shift Reaction CO + H2O -> CO2 + H2

CO,H2

1st Stage：IGCC (Oxygen-brown) 2nd Stage：CO2 Capture

3rd Stage： IGCC/IGFC + CO2 Capture

Fuel Cell

Steam

※HRSG Heat Recovery Steam Generator



Gasifier and Char Recycle Unit

Gas Clean-up Unit

Air Separation Unit

Gas Turbine Sulfur Recovery

Unit

Gasifier O2-blown Entrained Flow Gasifier (2-stage Spiral Flow Type)

Coal Feed Rate 150 t/day Gasification Pressure 2.5 MPa

Syngas Volume 14,800m3N/h Gas Clean-up Absorption with MDEA

Sulfur Recovery Limestone-Gypsum CO2 Capture Unit Capacity 1,000m3

N/h GT Output 8,000kW

CO2 Capture Unit (Sweet Shift + Chemical Absorption)


Gasifier 1,100 tons/day

Combined cycle

170 MW class

Stared the Construction in March 2013

34


Demonstration Test Area

Osaki CoolGen Project

2015 2020 2012 2025

Osaki CoolGen Project (Ministry of Economy, Trade and Industry Subsidy Project) IGCC (Oxygen-blown)/IGFC + Carbon Capture

IGCC (Oxygen-blown)

Carbon Capture

IGCC (Oxygen-blown) Commercial System

IGCC (Oxygen-blown) + CCS Commercial System

Early Commercialization with Accelerated Demonstration Test

global activities for high efficiency thermal power ... activities for high efficiency thermal power...

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