Coal Gassification Fm Korea

8/6/2019 Coal Gassification Fm Korea

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Day 2 Tuesday 16 October 2007

Session 8: FBC/ USC/ IGCC/ CCS

Speech 5 Korea

Analysis of 3-TPD Coal Gasification System in Korea

Dr. Hyung Taek Kim

Professor

Division of Energy System

Ajou University

Korea


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Status of IGCC R&D Program in Korea< Operation Experiences of 3 TPD Gasifier Systemand Planning of 300 MW Demonstration Plant >

October 2007Hyung-Taek Kim, Ph.D.

Professor in Energy Engineering, Ajou UniversityExpert Advisor, Korea Energy Management Corporation


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Introduction

Pilot-scale 3 TPD Gasification System Plant Description

Results of Continuous Run

Criteria for the Candidate Coal Selection

National Program of Demonstration IGCC Plant

Background Present Status

Summary

Contents


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IntroductionIntroduction


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Why coal now? Remaining Ultimate Recoverable Fossil Fuel Resources

Source : Shell Coal Gasification Process, Chhoa, 2003

OilConventional Unconventional

Natural Gas Coal

551012 toe.71012 toe 4.41012 toe 1.71012 toe


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International Utilization Sector of Coal

Amount of Coal Utilization in Power Generation is steadily increase. Requirement of Low-Pollution, High-Efficiency CCT.

69%

12%16%

3%

2002

Powergeneartion

Other

Industry

Residential

3%

79%

8%

12%

1%

2030

Power

geneartion

OtherIndustry

Residential1%


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Conceptual Process of IGCC

Gasifier Systemasifier SystemGasifierasifier

Coal

Slag

A S US UOxygen

SyngasPurificationSystemSyngasPurificationSystem

Combined Cycleombined CycleS/T PowerGenerationS/T PowerGeneration G/T PowerGenerationG/T PowerGeneration

Steam

Sulfur

Air

Electricity

HeatExchangerHeatExchanger


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Application Area of Gasification Technology


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CO2 Reduction with Different Fuels in Power Plant


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Comparison of Pollutant Emission IGCC Process emits minimal amounts of pollutant. IGCC recognized as future power plant option.

SOx ( ppm ) NOx ( ppm ) Particulate( mg/Nm3 )Emission standards 100 250 40

Boryung Power PlantP.C. 502 227 176

P.C. + FGD 150 200 40

Demkolec IGCC 15 63 1.5

Wabash IGCC 7 32 6.6

Vacuum Residue IGCC 84 ( * ) 33 4


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Pilot-scale3 TPD Gasification SystemPilot-scale3 TPD Gasification System


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Process & Flow Diagram of Gasification System


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Initial Operation Condition of Gasifier


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Operation Data of Gasification (Baiduri, 26 atm.)


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Gasification of Baiduri (Gas Composition)


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Gasification of Baiduri (Efficiency)


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Carbon Conversion (Baiduri, 26 atm.)

- P.C.(as-feed) : 585 kg(M : 3.58%)- P.C.(dry) : 564kg (C : 69.93%)- Input Carbon : 394kg (C : 100%)

- Slag : 11.0 kg (C : 0.31%)- Carbon in Slag : 0.034 kg (C : 0.009%)

- Fly ash 1(Cyclone 1, dry) : 0.23kg(C: 11.15%)- Carbon in Cyclone 1 : 0.026kg (C : 0.007%)

- Fly ash 2(Cyclone 2, dry) : 0.49kg(C: 28.23%)- Carbon in Cyclone 2 : 0.138kg (C : 0.0035%)

- Fly ash 3(Scrubber, dry) : 0.04kg(C: 34.34%)- Carbon in Scrubber : 0.0137kg (C : 0.003%)

Carbon Conversion : 99.95%Carbon Conversion : 99.95%


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Operation of 4 Day Period


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Carbon Conversion, Cold Gas efficiency


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Elemental Analysis of Coals Used

54.4

71.45 70.6172.96

67.08 63.04 68.0870.77 74.15

01020304050607080

Usib

ell

Cyprus

Dray

ton

Curra

g

Daton

Kide

co

Adaro

Baid

ur

Deniso

vsk

C H O N S Ash

(53

04kc

al/kg)

(60

80kc

al/kg)

(65

56kc

al/kg)

(66

14kc

al/kg)

(66

08kc

al/kg)

(5670

kcal/kg)

(67

48kc

al/kg)

(6367k

cal/k

g)

(71

39kc

al/kg)


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Ash Fusion Temperature (Reducing State)

100011001200130014001500160017001800

Usib

ell

Cyprus

Dray

ton

Curra

g

Datong

Kide

co

Adaro

Baid

ur

Deniso

vsky

AhFoempaue(C


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Classification of Candidate Coal

0.0

0.5

1.0

1.5

2.0

2.5

3.0

1100 1200 1300 1400 1500 1600

Zone A

Zone B

Zone C

Zone D

A : Australia

CA : Canada

CH : China

IN : Indonesia

J : Japan

R : Russia

S : South Africa

U : USA

: 3/ (/)

: 2/ ()

Ash Fusion Temp.

FuelRat

io

(FC/VM)

CH)

Black Water (A)

Kleinkopje (S)

South Black Water (A)

Blair Athol (A)

Moura (A)

Warkworth (A)

Lemington (A)

Ulan (A)

Ermelo(S)

Wambo (A)

Pittsburgh (U)

Plateau (U)Drayton(A)

Denisovsky(R)

Curragh(A)

(J)

Usibelli(U)

Baiduri(IN)

Cyprus(A)Obed (CA)

Adaro(IN)

Illinois #5 (U)

Drayton (A)

(CH)

Coal Valley (CA)

Kideco(IN)

Datong (CH)


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Characteristics of Zone A Coal

Usibellicausingfoulingproblems inheatexchanger

ref.

Evaluation for Gasifier

Cyprus (USA)

Baiduri(Indonesia)

Kideco(Indonesia)

Usibelli (USA)

Korea(3T/D)

Coal

smallasy

smallasy

smallasy

smallasy

CharFormation

SlaggingPotential

60~755~100O : 55~60H2 : 30~35

60~703~100O : 60~67H2 : 22~33

60~750~100O : 50~70H2 : 20~28

60~700~100O : 60~65H2 : 20~28

Cold GasEfficiency

CarbonConversion

GasComposition


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Flyslag Fouling in the Exit section of Gasifier

Coal : Alaska UsibelliOperating Pressure : 15 kg/cm2


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Characteristics of Zone B Coal

CO : 60~65H2 : 20~30

GasCompositionref.


relativelysmallasyatong (China)orea

(3T/D)

CharFormationSlaggingPotential

Coal

60~700~100

Cold GasEfficiencyCarbonConversion


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Characteristics of Zone C Coal

needflux

ref.


CO : 60~70H2 : 30~35

GasComposition

relativelyhighifficultyrayton

(Australia)Korea(3T/D)

CharFormationSlaggingPotentialCoal

63~700~100



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Denisovsky (Russia)

Characteristics of Zone D CoalEvaluation for Gasifier

inadequatecoal forgasificationNeed char

recycle

ref.

CO : 55~60H2 : 20~25

CO : 60~65H2 : 18~22

GasComposition

40~605~80

42~580~90


Korea(3T/D)

high

highDifficult,Unburnedcharproblem

Curragh (Austraiia)

CharFormationSlaggingPotential

Coal


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Characteristics of Gasifier Operation

13.24enisovsky (R)8.09atong (C)

4.12daro (IN)5.32aiduri (IN)

10.99rayton (A)

1.68ideco (IN)17.37urragh (A)

3.96yprus (U)10.86sibelli (U)

Ash (%)oneoal CharProductionAshSlaggingGasific-ation

O

OO

O

O

Compat-ibility

Good Problem


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Commercial IGCC PowerPlant

Commercial IGCC PowerPlant


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Background Korean Governments Plan to increase NRE utilization

By the year 2012, 7% of total power generation will be covered by NRE

Power sector planning to construct # 1 IGCC power plant Construction of 300MW CCT will be completed by 2012

Strategy of acquiring the design and demonstration of IGCC plant License agreement with Gasifier Vender Detailed Design by Korean Engineering Company Manufacturing most of the equipment in Korea


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ObjectiveFinal objective

Design & Demonstration of 300MW class IGCC Plant Maximize the Korean Participation

Thermal efficiency: over 42% (HHV, Net) CO2 : 10% reduction, NOx: below 20 ppm, SOx: below 15ppm Domestic portion of Design: over 90% Korean Manufacturing of Equipment : over 90%

Target


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schedule

1phase 06.12~09.12(3yr)

2phase 09.12~12.12(3yr)

- Gasifier vendor contract

- Design of IGCC Demo Plant

- Construction of300MW IGCC Plant

-Development ofOperation Technology

of Demo Plant

- Operation of 300MW

Demo. Plant

-Renovation of Designthrough OperationExperience, R&D

Design of IGCC

Construction of IGCC

Schedule of the Project

Demon. Operation

3phase 12.12~15.12(3yr)


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Project 1 : Develop Design Capability of Gasifier(Doosan, KAIST, Yonsei University) Acquisition of PDP through Liscence Agreement with Gasifier Vender PEP of Gasification/Purification Process is Digested by Doosan Manufacturing of Gasification/Purification Plant is Managed Domestically

PDP (Process Design Package) PEP (Preliminary Engineering Package)

PDPPDP

G/T

Combined

Cycle

G/T

CombinedCycle

Gasifier

Purification

Liscence

Agreement

(Foreign)

Plant Engineering

ASU

Development of

Unit Process

(Domestic)

IGCC Plan t Design

Domestic PlantDesign Technology

Research & Development & Demo. Program

R h & D l & D P


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Project 2 : Design & Construction of IGCC Plant(Western Power, KOPEC) Design of Entire IGCC Plant except Gasifier and ASU Managing Engineering Procedure (EPC) Evaluation of Environmental Effect

/

/

300MW

300MW IGCC PlantEngineering

BasicFor

Design

300MW IGCC PlantProcurements & Construction

Pre-Operation

Demo Operation/

LiscenceAgreement

1st Stage (3 year) 2nd Stage (3 year) 3rd Stage (2 year)

Construction Roadmap


R h & D l t & D P


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Project 3 : Operation & Maintenance of Demo Plant- KEPRI, Power Co, KEPCO, SNU, Inha, Korea, Kunsan Management Technology of Demo Plant Develop IGCC Plant Manpower Availability: Increase 78~82% 92% [PC Plant] Optimozation of Gas Turbine Combustion Develop Real-time Operation Watching System Develop Operation Simulator, Train Operator

Operat ing Mal func t ion Watching Program Simulator

23%

56%

14%

7%


R h & D l t & D P


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Project : Pilot Test-Bed and Development of Unit Process- KEPRI, Power Co., KEPCO, Doosan, IAE, KIER, Ajou, Hongik, Suwon Develop Gasifier Parts with Pilot Gasifier Pilot Test-Bed [30TPD] Construction Coal Selection, Preliminary Operation, Trouble shooting, Reliability Test Develop Desulfurization & Dedusting Process

IGCC HT Filterilot Gasifier (KEPRI, IAE, KIER)



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Government supported National Project Government & KEPCO

Project Management and financial support Doosan Heavy Industry / KOPEC

300MW IGCC Design, manufacture and construction Western Power CO

Plant site, construction and operation KEPRI

Management & Technical support for whole project License Agreement with Gasifier Vendor

candidate vendors Shell, GE Energy, ConocoPhillips, MHI

PDP introduced from the vendor, PEP from Engineering Company Plant Design, manufacturing and construction of IGCC should be

conducted by Doosan and KOPEC

Strategy


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SUMMARY The position of coal as power generation fuel sourceand coal-utilizing CCT technology is explained. Because of IGCCs high efficiency and cleanenvironment characteristics, IGCC is most advanced coalutilization technology in the future power generationmarket. Baseline methodology for selecting candidate coal forgasification is established with coal characteristics such

as fuel ratio and ash fusion behavior Explain the Korean national project of fordesign/construction/operation of 300 MW demonstrationIGCC plant

Members of Energy Process Laboratory


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(Accredited Best Lab in NRE Area by MOCIE)Professor

Ph. D candidates

Young Shin, Jeon Li Hua, Xu Hyun Min,Shim

Master candidates

Joon Soo, Lee Su Young, Jung Young Hoon, Kim Hueon, Nam gung Na Hyung

Hong yue, Wang

Hyung-Taek, Kim

Post Doc. Researcher

Documents

Coal Gassification Fm Korea