High-efficiency clean integrated gasification combined cycle thermal power cogeneration has been in operation in foreign plants for more than ten years. Based on foreign integrated gasification combined cycle (IGCC) practical production cases and the introduction of foreign advanced technology, after two years’ producing technology and market application investigation and research by both Chinese and American experts, this project is an advanced energy conservation and environment protection technical case that well suits heat and power cogeneration in northern regions of China. It overcomes difficulties of coal type applicability, construction and operating costs and overall economic benefits and explores a new way to promote integrated gasification combined cycle technology as soon as possible.
This technology uses bituminous coal accounting for 70% of national reserves as the basic coal resources and applies high-efficiency crushed coal pressurized gasification technology. It first separates tars out from the coal through pyrolysis (5-9% of the mixed coal used in the project), which are best raw material oils for diesel oils, supplementing crude oil resources shortage and beneficial for the economic profit increase of the project. After tars separation from the coal, raw gas is generated under the function of high temperature steam, air and pressure. The clean gas, after cleanup and desulfurization, is sent to gas turbine for power generation with the exhaust going into heat recovery steam generator. The steam produced is routed into steam turbine to generate power and heat, therefore achieving combined cycle with secondary power generation and heat supply to users. This technology fundamentally changes the conventional low-efficiency direct-coal-fired indirect power generation by the steam and the passive direct coal combustion technology that causes high temperature smoke pollution, which is treated afterwards. This internationally leading technology is a revolutionary reform just like the replacement of steam locomotive for diesel combustion locomotive. It improves coal utilization rate from 25-40% of direct coal combustion to 70-85% of combined cycle, with nearly zero particulate emissions, less than 60 mg/Nm3 SO2 emissions, over 50% decrease of NOx emissions and effective control of CO2 after over 50% reduction, which can completely meet the strict emission standards of European countries and the US.
The power generation capacity of Shandong province is about 50.05million kW, almost all of which are direct coal-fired power generation (over 95%), and coal-fired thermal power units of 15,000,000kW urgently need to be upgraded. There is a low city central heating coverage rate in Shandong province, even below 50% in some big cities. If this technology is used to upgrade and replace the existing coal-fired power plants and boilers, over 27 million tons standard coal can be saved each year in Shandong province, 2.25 million tons additional tars are generated each year, and 50% water will be saved while all environmental emissions will be greatly reduced. It can radically change the passive situation of energy conservation and emission reduction, complete and surpass the work targets of energy conservation and emission reduction, and realize clean production and sustainable development.
Through intense research and development in the past two years and by fully taking the advantages of information technology and resources from foreign experts in international energy field, a technical case of high-efficiency clean integrated gasification combined cycle heat, power and tar cogeneration has been formed with Shandong market resources characteristics based on gaining latest solution information from foreign partners and combining the national situation of our country. During these two years, we have received guide and assistance from relevant governments like national development and reform commission CDM management center, State Production Safety Supervision and Management Office, China Coal Industry Association Research Center, China Environmental Assessment Center of Environmental Science Research Institute, Shandong Provincial Development and Reform Commission, Shandong Provincial Economic and Trade Commission, the Association of Science and Technology of Shandong Province, Shandong Provincial Foreign Trade and Economic Cooperation Office, the Office of Science and Technology of Shandong Province, Shandong Provincial Environmental Protection Bureau, Engineering Consulting Institute of Shandong Province, Jinan Hi-tech Development Zone, Linyi Municipal Environmental Protection Administration, Linyi Municipal Foreign Economy Commission, Liaocheng Municipal Environmental Protection Administration, Liaocheng Municipal Foreign Economy Commission, Zaozhuang Environmental Protection Administration, Zaozhuang Municipal Foreign Economy Comission, Linyi Lanshan District Government, and received cooperation and supports from universities such as Tsinghua University, Shandong University, and Dalian University of Technology and professional agencies such as Nanjing Turbine & Electric Machinery (Group) Co., Ltd., Taiyuan Heavy Industry Mechanical Plant, Hangzhou Boiler Plant, Shaanxi Blower Factory, and Harbin 703 Research Institute, and Wuhan Turbine Plant.
By fully taking Sino-foreign cooperative advantages, this technology has three innovative points:
1. This technology optimizes tars separation out of the coal through pyrolysis by using bituminous coal in Shandong province, which improves the value of coal resources, thus the energy is conserved and pollution is reduced.
2.The Combination of High-efficiency Clean Integrated Gasification Combined Cycle (IGCC) and Thermal Power Cogeneration
On the basis of clean integrated gasification combined cycle (IGCC) technology, and by combining with thermal power cogeneration, the existing low-efficiency, high-consumption and multiple-pollution coal-fired power plants are transformed into high-efficiency clean combined cycle regional heat and power cogeneration ones, which fully use the coal resources, make the city regional energy resources supply system reasonable and lay a good foundation for thoroughly solving the conflict dilemma between the social sensitivity of urban heating price and market volatility of coal price.
3.Greatly reducing construction costs to make the technology more promotional with great value
During these two years’ investigation and negotiation for the project, the advantages of foreign technology R&D combined with domestic equipment manufacturing are focused on. The construction cost is optimized and the investment is saved through industrial teamwork and international engineering investment and financial management calculating method.
The following measures are applied to save the project investment:
①Foreign technology and domestic manufacturing is applied. The gasifier is designed by foreign experts and manufactured domestically through authorization. Sino-foreign cooperative intelligence property is created, and equipment-manufacturing costs are saved.
②Air-blown pressurized gasification technology saves a great amount of equipment investment and reduces operating costs.
Different from the popular rich-oxygen gasification technology in the world, the project adopts a gasification process using air and steam as the medium, saving a lot of investment equipment, which decreases the threshold of rapidly promoting IGCC thermal power plants in China.
③Unnecessary supporting engineering is reduced. High-efficiency clean integrated gasification combined cycle is made up of several main systems, namely, gasification island, gas turbine island, boiler island and steam turbine island. The equipment is relatively mature and complete, which greatly reduces construction costs. There is less construction workload with shorter construction period, 60% of conventional coal-fired thermal power projects.
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