P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Introduction
Today, people can impossibly live without the electricity. It lights up buildings, streets, mostly everything, and it also supplies power for most equipment at those buildings and even machines in factories or plants. Coal has been used as an energy source for hundred years now, and until now it still plays the most important role as the most widely used fuel for generating electricity. There are three types of coal that are used in the power plant, bituminous coal, subbituminous coal, and lignite coal. In this report, there are two different processes of coal power generation: conventional coal fired power plant and integrated-gasification combined cycle (IGCC) power plant, which will be evaluated and compared from several aspects including the advantages and disadvantages for each of it.

Conventional Coal Power Plant

Process Summary A conventional coal-fired power plant consists of two basic components. The first component is a boiler, which is by using water circulation and steam, the pulverised coal to be burned and the freed heat energy to be captured. The second component is steam turbine generator, which converts the heat energy captured by the steam into electrical energy. The outlet from the turbine is exhaust steam, which is cooled and condensed back into water, and then go back to the steam generator to do the process over from the start. However, the conventional coal fired power plant is divided into three classes based on the types of pulverised coal boiler temperature and pressure, which is: subcritical, supercritical, and ultrasupercritical. The higher the pressure and the temperature, so does the efficiency, which means that ultra-supercritical has the highest efficiency (41%-45%). Diagram Block Flow Diagram

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Process Flow Diagram

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Process & Instrumentation Diagram

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Process description: In this case, the subcritical coal power plant & bituminous type of coal were chosen. Step 1 : The coal which is brought to the site plant will be pulverised before being fed into the boiler. Step 2 : After fed into the boiler, the purified water combined in the boilers wall tube system is converted into steam. Step 3 : The steam from boiler which is high in temperature and pressure enters the steam turbine. Steam rushing from the high pressure boiler to the low pressure condenser drives the turbine blades, which powers the electric generator. Step 4 : The steam turbine powers up the electric generator which produces electricity, and then it is sent to the grid. Step 5 : Low pressure steam leaving the steam turbine enters the condenser and is condensed on the condenser tubes. The condenser tubes are held at a low temperature by the flow of cooling water. Step 6 : Cooling towers or pools are used to lower the temperature of the water leaving the condenser tubes. After the water temperature is lower, then it is sent to boiler (steam cycle). Step 7 : There are several gases such as SO2, NOx, and CO that are produced by the combustion process, these gases are sent through a FGD scrubber to remove some of these pollutants.

Reasoning Including the Control and Instrumentation Parts As we can see from the P&ID, there are several controller installed in order to fulfill the objectives for conventional coal power plant. 1. Temperature Controller : To maintain the temperature out from the boiler, since in the steamwater route, the boiler supplies high temperature steam to a turbine that produces electricity, and in order for the turbine to keep works, the steam needs to keep at high temperature. 2. Pressure Controller : The boiler steam pressure needs to be controlled, in order to have maximal performance of the turbine, which is at high pressure. The pressure controller input variable is the coal feed flow rate and the output variable is steam pressure.

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3. Level Controller : The cooling water level needs to be restored in order to enter the water purification. Analysis of the Process The main equipment on the conventional power plant process are: 1. Boiler : The most developed technology of boilers reach to 250 bar of pressure and 600 C of temperature. The boiler water must be deoxygenated, because oxygen dissolved in the circulation water in the boiler pipe can cause serious corrosion at the raised temperatures and pressure to which it is exposed. Also, the boiler are made up from special steels due to its conditions. The output up to 1000 MW.

2. Steam turbine Maximum efficiency: 43%-45%. Newest supercritical design: 55%. Steam turbines consist of series of sets of blades, named stages. Each stage consists of another series, named nozzles, which controls the steam flow to the next stage. Coal fired power plant uses several multiple-stage turbine. Usually divided into three turbines, high-, medium-, low-. Multiple turbines can have output over 1000 MW. Material justification : a. High pressure turbine blades: to be able to resist extreme temperature and pressure; to be able to withstand the abrasive force of steam. b. Low pressure end of turbine train: to be able to resist centrifugal forces exerted in it.

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Intregated-Gasification Combined Cycle Power Plant

Process Summary IGCC is the newest technology of coal power plant and known as the more efficient coal power plant, if compare to the conventional type. The reason is, instead of using the boiler, IGCC uses gasifier to convert coal into a mixture of hydrogen and carbon monoxide. The gasifier then generates substantial amount of heat. After that, the heat can be used to generate steam to cause the steam turbine produces electricity. Meanwhile, the gas produced is cleaned and then to be burned on gas turbine to produce further electricity. Besides having bigger efficiency, IGCC power plant also has lesser wastes and pollutions. Diagram

Block Flow Diagram

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Process Flow Diagram 8

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Process & Instrumentation Diagram

P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Process description: The basis chosen for IGCC is the bituminous coal. Step 1 : The coal which is brought to the site plant will storage after it is crushed to a very precise size. From the storage, the coal is injected into the gasifier. Step 2 : Coal enters the gasifier depending on the gasifier condition, whether it is in dry form by nitrogen transport or in slurry form by mixing with water. In this process, the coal feed is in slurry form. In the gasifier, it converts the coal into a raw syngas or raw synthesis gas. The gas produced is mostly composed of CO and H2 and has a much lower heating value than natural gas. Step 3 : To make the reaction occur, the gasifier must use an oxidant. Generally, a cryogenic ASU (Air Separation Unit) supplies high purity oxygen needed for the reaction. Step 4 : In order to increase the efficiency, the hot raw syngas leaving the gasification process, it enters to gas cooling/shift. The gas leaving the cooler is called sour syngas. Step 5 : The now cooled raw syngas then enters the particulate removal system (particulate scrubber). In the particulate scrubber, it eliminates the charred particles in the syngas stream along with other damaging materials. Step 6 : The sour syngas leaving the particulate then enters the acid gas removal equipment, which is in this process it casts the sulphur away. But the sulphur can be recovered as elemental sulphur or sulphuric acid for resale. Step 7 : The sweet syngas, which is leaving the acid gas removal, is delivered to a gas turbine for production of electricity. Step 8 : While the exhaust gas from the gasification process is captured in a heat recovery steam generator and used to drive a second turbine. The second turbine are supplied by hot steam for additional electricity generation.

Reasoning Including the Control and Instrumentation Parts From the P&ID, we can see there are master gasifier controller, which controls pressure, temperature and mass flow rate. Besides the master controller, there are pressure controller and temperature controller installed on the main path.

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P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

1. Master gasifier controller : In the gasification system, there needs to be installed the master of gasification process control, which controls the pressure, temperature, and mass flow rate inside the gasifier. The installation of the pressure controller on the master control is connected with the pressure controller on the main gas stream. The installation of pressure controller purpose is to maintain the balance between the syngas production (point 6) and the syngas consumption (gasifier). The second controller installed is the temperature controller, which put in order to maintain the temperature inside the gasifier, to reach the safe environment. And the flow controller is installed, so then the stable fluid flow rate inside the system is maintained. 2. Pressure Controller: As explained above, the pressure is maintained from the gasifier system in order the gas turbine to operate (which is needs to be in high pressure). 3. Temperature Controller: The outlet stream of acid gas removal temperature, needs to be maintained from the inlet stream, so thus the temperature entering gas turbine is fulfilling the gas turbine specification.

Analysis of the Process IGCC has several equipment, that are not exists on the conventional power plant. 1. Air Separation Unit: using high pressure cryogenic oxygen plant. 2. Gas Cooling: raw syngas is cooled in a series of heat exchangers and to be sent to acid gas removal. 3. Particulate Scrubber: removing ash particulates from the gasification process, but the particulates wastes are usually neglected. 4. Acid gas Removal: in the process, H2S, CO2, SO2, are removed to the sulphur recovery and are able to process into sulphur product. 5. Gas Turbine Operates at 80% of efficiency, along with the compressor. Must be able to accommodate extreme hot inlet gases.

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Evaluation of the Processes

The evaluation is to be addressed by comparing both processes, conventional coal power plant and IGCC power plant, by considering their advantages and disadvantages, and will be served on the table below. IGCC Capital costs : 1500-1800 $/kW (CEED) Advantages Disadvantages Conventional Coal Fired Power Plant Capital costs : 1400 $/kW (CEED) Advantages widely Disadvantages used Only around midin 30% of thermal

Higher efficiency, can The capital cost is Most accomplish up to 50% more expensive of thermal efficiency Lower rates of carbon The

technology generation

efficiency gas Higher rates of High

technology The

flue

dioxide emissions by doesnt have enough desulphurisation using fuel gas clean up

emissions.

proof that it can be (FGD) provides the levels of CO2, SO2, produced a cleaner best-proven method NOx, CO, and coal technology for removing up to other organic

99% of the sulphur compound emitted from coal-fired power to the atmosphere plants flue gas stream Produces conventional 50% of Some tars, on syngas Less expensive energy Coal is known the coal quenching, may be that can be sold for best for its effect to

power plant solid waste

formed, which make less in the market. damage gas clean up more Applicable complex commercial use The coal fired There is no for environment

Uses up to half less Lengthy start up times water of conventional coal power station

generation technology additional units to is well understood by remove dust and the producers electricity traditional acid emissions

of from the flue gases before they are

released into the atmosphere. Able to employ several Air separation unit Fast daily start up

of fuel, including heavy cannot start without

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P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

oils, petroleum cokes, gas turbine running and surely coals. Up to 100% of CO2 can Less be captured flexibility technique is near operational

IGCC can reduce NOx This emissions 50ppm to

below nowhere commercial application

Syngas produced from gasifier if it is

processed on the gas turbine can be an

electrical power (More power output)

Conclusion
As the conventional coal power plant is still widely used today, comparing the IGCC power plant, but in the future, the probability of using IGCC power plant as the main technology is big. The reason is, even though the plant cost of IGCC technology is more expensive than the conventional technology, but the IGCC technology has bigger efficiency and also have lesser waste and organic compound released to the environment. Perhaps, several years from now on there would be found ways to supress the IGCC plant cost without decreasing its efficiency.

References
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P&ID and Process Evaluation | Libbis Sujessy/7E3B2332

Bettina and Alexandre Szklo. 2011. Integrated gasification combined cycle and carbon capture: A risky option to migitate CO2 emissions if coal-fired power plants. Applied Energy 88(11): 39173929. doi:10.1016/j.apenergy.2011.04.002. Breeze, Paul A.. Power generation technologies. Oxford: Newness, 2005. Conventional coal-fired power plant encyclopedia article Citizendium. Welcome to Citizendium Citizendium. http://en.citizendium.org/wiki/Conventional_coal_fired_power_plant#The_steam_generator Miller, Bruce G. "Anatomy of a Coal-Fired Power Plant." In Clean coal engineering technology. Burlington, MA: Butterworth-Heinemann, 2011. 219-250. United States Environmental Protection Agency. 2006. Environmental Footprints and Costs of CoalBased Integrated Gasification Combined Cycle and Pulverized Coal Technologies. Washington, DC : Clean Air Markets Division, Office of Atmospheric Programs

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