Bulletin of GTSJ 2003 Gas Turbine Technology in Japan

The Large Capacity Gas Turbine for Pressurized Fluidized Bed Combustion (PFBC)
Boiler Combined Cycle Power Plant
SATOH Tomo
Hitachi, Ltd.
1. Introduction
This paper outlines gas turbines with a focus on the
As the global environment becomes an ever-greater is-
250MWPFBC plant used at the Chugoku Electric Power
sue worldwide, there is a demand for PCF plants to re-
Company Osaki Power Station (power station 1-1 of unit 1),
duce CO2 emissions through more efficient power plants,
in which project the authors participated (see Fig. 2).
and reduce levels of SOx, NOx, and dust in boiler exhaust
through the development of new power generation sys-
tems [2] [3].
PFBC technologies have gained attention as an efficient,
low-pollution technology enabling efficient use with
low-grade coal. Outside Japan, 70 MW-class test and
commercial power plants have been operational since the
early 1990s. Japanese manufacturers are also developing
power plants using PFBC technologies, and have been
operating 70 to 80 MW-class test and commercial power
plants since the late 1990s. Starting in 2000 to 2001, a
succession of 250 and 360 MW plants the worlds high-
Fig.2 The Osaki power station unit 1
est-capacity began commercial operation.

2. PFBC Plant Overview 3. Gas Turbines

A PFBC plant is a combined cycle power-generation A PFBC gas-turbine has the following equipment features:
system that turns a steam turbine by means of steam * Gas-turbine layout
generated from a PFBC boiler installed inside a pressur- * Dust filtering system
ized vessel, while at the same time turning a gas turbine * Large gas shut-off valve
by means of the same gas [4] [5] . * Highly dust resistant turbine
Fig. 1 provides a conceptual diagram of the PFBC plant * Gas turbine start-up system
architecture, while Table 1 lists the main specifications Gas-turbine layout
used for large-capacity utility power plant in Japan. Gas from the pressurized fluidized bed combustion boiler
passes through headers arrayed on either side, and is led to
Cyclone
Hot gas piping a multi-inlet gas pass, after which it is fed to the gas turbine
Heat exchanger
(see Fig. 3).
for recovering
A-furnace
pressure
B-furnace
pressure gas turbine
waste heat
Dust collection system
vessel
vessel
A dust filtering system is installed to remove dust con-
Lime-
stone BM tank BM tank Bag filter
tained in the combustion gas from the pressurized fluidized
Gas turbine
bed combustion boiler. A total of 12 cyclone elements are
Water
A- B-
furnace furnace
Main
arrayed in each pressure vessel. These elements serve two
Coal
steam Air
Steam turbine

purposes: to remove coarse dust (primary cyclone), and to

Condenser
reduce abrasion to the turbine blades (secondary cyclone).
Compressed air
The system reduces dust levels to no more than 1,000
Fig.1 Conceptual diagram of PFBC system mg/Nm3 at the turbine inlet, with a maximum particle
diameter of 10 microns (see Fig. 4).
Hitachi, Ltd. Power & Industrial Systems Division
3-1-1 Saiwaicho,Hitachi-shi Japan
TEL:+81-294-55-3070

Copyright 2003 by GTSJ

 Bulletin of GTSJ 2003 Gas Turbine Technology in Japan

Table-1 Main specifications of 250MW PFBC plant

Chugoku Electric Power Kyushu Electric Power Co. Hokkaido Electric Power Co.
Name of facirities Co. Osaki Power Station Karita Power Station Tomato - Atsuma
Power Station
Commencement 2000/11 2001/7 1998/3
of commercial operation
Plant output 250MW 360MW 85MW
ST/GT output 215MW/44MW 290MW/75MW 73.9MW/11.1MW
Steam conditions 16.6MPa 566/593 24.1MPa 566/593 16.6MPa 566/538
Two-stage cyclone + bag Two-stage cyclone + Elec-
Soot & dust removal system Cyclone + Ceramic Filter
filter trostatic precipitator
Desulfurization process Desulfurization of furnace Desulfurization of furnace Desulfurization of furnace
Denitrification process Catalytic + non-catalytic Catalytic denitrification Catalytic denitrification
denitrification
Gas turbine system Single shaft simple cycle Twin shaft simple cycle Single shaft simple cycle
Plant gross thermal efficiency 41.5 42.5 40.1

Large gas shut-off valve

On plant startup and shutdown, it is necessary to initiate
or cut off the flow of combustion air to the boiler, and the
flow of gas from the boiler to the gas turbine. For this rea-
son shut-off valves are placed on the process air supply
side, and another on the gas side, and combined with a
bypass valve that connects outlet of compressor and inlet
of turbine. All system valves were installed on ordinary
gas turbines. (See Fig. 5).
Highly dust resistant turbine
The gas turbine is designed in accordance with the ex-
haust-gas volume using a boiler for the existing F7EA gas
turbine. Since the boiler produces exhaust gas at a lower
temperature than standard turbines (about 850deg-c), the
cooling air and seal air in each part is reduced, and
changed the turbine blade profile to set pressure of com-
Primary cyclone Secondary cyclone
bustion gas properly. Additionally, the specifications of the
blade coating were changed, in order to resist erosion due Fig. Cross section of cyclone-type dust collector
to dust contained in the high-temperature gas. (See Fig. 6)

Fig. Bird view of gas turbine facilities Fig. Cross section of gas shut-off valve

Copyright 2003 by GTSJ

 Bulletin of GTSJ 2003 Gas Turbine Technology in Japan

to improve environmental performance as well, and levels

The dust collector, cyclones, and other facilities work well
of SOx, NOx, and dust all meet planned values. and it has
been in commercial operation since November 2000. As of
November 2003, it has undergone an inspection for the
first time.
350-MW PFBC plant delivered to the Kyushu Electric
Karita Power Plant [7] by IHI/Toshiba/Alstom power has
been operating commercially since July 2001.
85-MW PFBC plant delivered to the Hokkaido Electric
Tomakomai Higashi Azuma Power Plant [6] by Mitsubishi
has been operating commercially since March 1998.
Fig. Gas turbine first stage nozzle assembly
5. Conclusions
Gas turbine startup system This paper has showcased PFBC gas turbines, with a
An electric startup motor and gas-turbine startup com- focus on major equipment. Power plants constructed in
bustor are used together to start the gas turbine. Japan are operating well. A future task will be to build up
The outline of startup procedure is as follows. 1)Start an operating track record, improve them operationally
like a standard gas turbine by the electric starter motor. (including expanding the types of coal that can be used),
2)Accelerate till rated speed using startup combustor. and confirm the long-term reliability of plants featuring
3)Parallel in to the electric power system. 4)Startup com- PFBC systems.
bustor is extinguished. It becomes motoring operation at In the future, it is expected that further developments in
first until the load of the plant goes up to high. gas-turbine utilization technologies and related equipment,
based on a favorable track record for pressurized fluidized
4. Operating Conditions bed combustion power plant systems, will meet the needs
The 250-MW PFBC plant delivered by Hitachi Ltd. for of society.
the Chugoku Electric Power Company Osaki Power Sta-
tion was jointly developed using the 4 MWth test facility at References
the Chugoku Electric Thermal Power Generation Tech- 1) Horiuchi,etal.:Report on Test Operation of Osaki Pres-
nology Center. surized Fluidized Bed Combustion Combined Cycle
Construction of the plant began in November 1995. Per- Power Plant, Japan Society of Mechanical Engineers
formance tests of the plant carried out during test opera- 7th Power Energy Technology Symposium (10/2000).
tion have confirmed approximately 10% better efficiency 2) Nakagawa,etal.:Next-generation Thermal Power Plant
Systems Using Coal,HitachiReview,76,3,23-28 (3/1997).
than PCF plants with the same output scale. (see Table-2).
3) Mishima,et al.: Next-generation Thermal Power Plants
Using Coal, Hitachi Review, 76, 10, 9-14 (10/1994).
Table-2 The Osaki PFBC plant performance
4) Koike, et al.: Pressurized Fluidized Bed Combustion
Planned Measured
Item
value value
(PFBC) Combined Cycle Power Plants, Thermal and
Nuclear Power Generation, Vol. 49 No. 10, Oct. 1998
Plant gross thermal efficiency 41.5% Above 42%
5) Omura, et al.: Advanced Coal Utilization and Envi-
Desulfuri- SOx concentration at flue inlet 76ppm 7.1ppm
zation Desulfurization efficiency >90% 97.7% ronmental Measures for Power Generation (1), (2)
Efficiency of non-catalytic
37% 38.0% Chemical Systems, May 1995, Apr. 1995
denitrification
Denitrific- 6) Kaneko, et al.: Development of PFBC Combined Cycle
Efficiency of catalytic denitri-
ation 85% 88.3%
fication Power Plants, Mitsubishi Heavy Industries Technical
NOx concentration at flue inlet <19ppm 14.4ppm
Cyclone efficiency 97.1% 97.2% Report Vol. 35, No. 1, 1-1998
Soot & Concentration at gas turbine 1000mg/ 533mg/m3
dust inlet m N
3 N
www.mhi.co.jp/power/product/compound/pfbc.htm
removal Concentration at bag filter
9mg/m3N
3.5mg/m3 7)www.kyuden.co.jp/company/kigyo/thirmal/k_hatsuden/k_
outlet N
karita.html

Copyright 2003 by GTSJ