Results of Our Research Efforts

Demonstration Test

Results of Demonstration Testing (Detailed)

1) IGCC System Stability: "Coal Gasification Adjustment Testing"
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Stable shutdown when plant malfunctions.

Test the interlocks to confirm safe plant shutdown.

 • Interlock testing confirmed stable shutdown when system malfunctions were simulated.
  • <Test Items (Excerpt)>
  • •  Comprehensive test of interlock performance when oil ignites.
  • • Comprehensive test of interlock performance when coal gas ignites.
 Confirmed that system is stable.
Objective accomplished
Test period: FY 2007
Status: Completed.
• Safe handling of coal gas. Check and adjust plant operating status, and confirm that coal gas is handled safely and that operation is stable under rated load.
  • • Ran various trials and adjustments, and confirmed that coal gas handling is always safe and that there are no operational errors.
  • • Confirmed system stability by demonstrating stable continuous operation at rated load (250 MW).
  • <Test Items (Excerpt)>
  • Gasifier
  • • Switched the fuel (kerosene → coal)
  • • Confirmed stable operating control of gasifier.
  • • Ran using cooperative control of gasifier and gas turbine.
  • Gas cleanup system
  • • Checked operation with oil gas and coal gas.
  • • Checked operation of off-gas combustion furnace.
  • • Checked sulfur-recovery equipment regulation.
  • Combined cycle power generation system
  • • Fast stopping of turbine.
  • • Checked purging of fuel-gas piping.
  • • Switched the fuel in the gas turbine (kerosene → coal gas).
  • • Regulation of gas-turbine combustion.
  • • Checked running condition of steam turbine.
Test period: FY 2007
Status: Completed.
2) Reliability of the facility: "2000-hours sustained operation"
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Running continuously for 2000 hours (equivalent to 3 months of summer). Run continuously for 2000 hours.
  • • Ran for 2000 consecutive hours, from 6/10/08 to 9/17/08.
  • • Operation was stopped to repair damaged ASU valve during run, but was restarted immediately after repair and run for 2039 consecutive hours; plant then shut down as planned to perform inspection.
 Achieved continuous-run target. Going forward, will also check durability over mid-to-long-term continuous operation.
Objective accomplished
Test period: FY 2008
Status: Completed.
3) Coal Type Acceptability: Change to Other Coal Type / Change to Out-of-Spec Coal Type
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Collecting data while running on coal types outside of the design specs. Check operation when using sub-bituminous coal (North American, Indonesian A).
  • • Ran at partial load; confirmed that adjustments in running parameters were sufficient to enable single-fuel firing of two coal types (North American and Indonesian A), and collected plant data while operation was in progress.
  • • In some cases, coal characteristics caused blockage in heat-transfer piping downstream of the gasifier.
 Analyzed operation when using three coal types outside the range of the design specs, collecting data to be used to support design of commercial-level facilities.

In some cases, SGC heat-transfer piping downstream of the gasifier became clogged.

Results made it clear that various countermeasures would be required to prevent problems caused by different coal types.
Objective accomplished
Test period: FY 2008
Status: Completed.
Check operation when using sub-bituminous coal (North American).
  • • Changed and readjusted the operating parameters, then checked operation using North American sub-bituminous.
  • • In some cases, coal characteristics caused blockage in heat-transfer piping downstream of the gasifier.
Test period: FY 2009
Status: Completed.
Run plant with the purpose of enabling use of mainstream coal types beyond those covered by the design specs, and of sub-bituminous types capable of single-fuel firing.
  • • Changed and readjusted the operating parameters, then checked operation using Indonesian B sub-bituminous.
Test period: FY 2010
Status: Completed
4) High Efficiency: "Operations Optimization Test"
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Achieving targeted thermal efficiency (LHV 42% at sending end). Verify efficiency; investigate whether reasonable to anticipate efficiency enhancements sufficient for commercial use. By adjusting running parameters, able to confirm an LHV of 42.9% at the sending side, surpassing the goal of 42% LHV. Confirmed high efficiency.
Objective accomplished
Test period: FY 2008
Status: Completed.
5) Durability : "Durability Confirmation Test"
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Running for long period, followed by overhaul inspection. Run for 5000 hours, then did overhaul inspection to evaluate durability.
  • • Ran for 5000 hours in one year.
  • • After confirming durability by running for 5000 hours, carried out inspection. Confirmed the absence of any critical device damage that would require large-scale remodeling. Confirmed the equipment used has an appropriate IGCC design.
 Confirmed that the tested equipment has an appropriate IGCC design. Going forward, will also check durability over mid-to-long-term continuous operation.
Objective accomplished
  • Test period: FY 2009, FY 2010
  • Status: Completed.
6) Economy: "Assessment of Cost-Effectiveness"
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Evaluating economic feasibility based on operational performance. Used operational performance as a basis for comprehensive evaluation of costs (construction costs, operating costs, maintenance costs, etc.); and evaluated whether this approach would be economically feasible in a commercial environment.
  • • While it seems that gasified-coal systems will have higher construction and repair costs relative to pulverized-coal systems, we expect that they will also deliver better thermal efficiency and low fuel costs.
 Based on the results, it seems quite possible that gasified coal may deliver power-generating costs equal to or lower than those for pulverized coal. But will need to enhance precision of these systems for lower repair costs.
Objective accomplished
Test period: FY 2010
Status: Completed.

New verification items and their contents

1) Reliability
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Confirm the mid-to-long term durability of the igcc facilities including countermeasures implemented during the past testing. These studies as follow conducted.
  • • Durability assessment on the countermeasures against the troubles in the past.
  • • Evaluation on time-related deterioration through the long time operation.
  • • Maintenance methods for reduction of the troubles in mid and long term.
  • • Coutermeasures to initial stage troubles are working well.
  • • Additional two countermeasures to mid-and-long rerm troubles were implemented and their durability would be verified in fiscal 2012.
 in progress
Confirm the mid-to-long term durability with te results of further operation in 2012. -
2) Coal Type Flexibility
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Establish the measures against the troubles accompanied by some coal types. Another types of bituminous coal, that is, columbian Russian and Indonesian coals are to be in use and operational data to be collected in 2011.
  • • Another types of bituminous columbian Russian and Indonesian coals were in use stably through adapting the operational parameters.
  • • Some coal type brought about clogging in SGC heat exchanger piping facility.
 in progress
Another types of coal are to be tested in 2012. -
3) Economy
Verification Items (Overview) Demo Test Results of Demonstration Testing Evaluation
• Increase in samples of maintenance and inspection results for analysing the maintenance cost which should be compatible with conventional purverized coal fired generation. Study on the cost reduction methods at commercial stage reflecting the operation and maintenance results in 2011.
  • • Design improvement in SGC Heat exchanger is underway.
  • • Prolongment of inspection periods under study.
 in progress
Cost reduction measures are to be worked out reflecting the operation and maitenance experiences in 2012. -

PAGE TOP