Overview of IGCC R&D

Project in Korea

Sung Chul, Kim

2011.10.12

Agenda

- Introduction to KEPCO

- Overview of Korea IGCC Project

- Construction Plan of IGCC Plant in Korea

- Introduction of On-going Gasification Projects

Electric Power Companies in Korea

Korea Electric Power Corp. (KEPCO)

Mother Company. Transmission &

Distribution. Oversea Business

Hydro & Nuclear Power (KHNP) Hydro (0.5GW) &Nuclear (17.7GW)

Korea South-Eastern Power (KOSEP) Thermal Power Generation

- Steam Power : Coal & Oil

- NGCC- 8 Gwe (each company)

Main Coal Power Stations:- 6~10 units / one site

East-Western Power (EWP)

Western Power (WP)

Korea Middle Power (KOMIPO)

Southern Power (KOSPO)

Korea Power Engineering Co. (KOPEC) Engineering Company

Korea Electric Power Research Institute (KEPRI)

Research Wing

• Background

Korean government decided the goal of new & renewable energy usage to increase from the current 2% to 10% by 2022.

Korean government designated IGCC as one of new energy category, with the RPS incentive, encourages to install the IGCC plant in Korea (RPS factor 0.25).

In order to facilitate the research, development, demonstration and deployment of IGCC, the government program under the support of Ministry of Knowledge Economy (MKE) was launched in December, 2006.

Korea IGCC R&D Program

Title“Design and Construction of 300MW IGCC

Demonstration Plant for the Development of Korea IGCC technology ”

ConsortiumPartners

• Contractor :• Korea Western Power, Doosan Heavy Industries• Institutes (KIER, IAE)• Universities (10)• Engineering & Construction Company

Period• 1 phase: : 2006.12~ 2010.4(Finished)• 2 phase : 2011.2 ~ 2016.7 (5.5 years)

Budget

• Total : 1.4 Billion US$- Government : 0.1Billion US$- Participant : 1.3 Billion US$

Overview of IGCC Project in Korea

• To secure 300MW IGCC Technology through Engineering , Manufacturing,Construction & Operation

Ultimate Goal

• Thermal Efficiency: 42%(HHV, Net) • NOx: less than 30 ppm• SOx: less than 15 ppm• Self-Reliance of Technology : >90%• Localization of Facility Manufacture : >90%

Quantitative Target

Ther

mal

Ef

fici

ency

(%

)

37.5

39.741.4

42.0

40.3

Tampa(1996)

Wabash(1995)

Buggenum(1994)

Japan(2007)

Korea(2016)

Objective of Korea IGCC Program

Division Characteristics Remark

Output 300MW (Net) Gross : 380MW

Feed StockCoal

(sub. Bit.~Bit.)

Moisture : ≤ 25%

Calorific value : ≥ 5,242kcal/kg

Thermal Efficiency 42% Base: HHV

Gasifica-tionPlant

ThermalEfficiency

93.89%(Design) 90.0%(Guarantee)

capacity 530 Gcal/hr HHV

Availability Over 85 % Whole IGCC plant

Emission Requirements

• SOx : Below 15 ppm

• NOx : Below 30 ppm

• Dust : Below 5 mg/Nm3

Summary of Taean IGCC Plant in Korea

. Coal consumption : 30.9 kg/s (2,600 Ton/Day)

. Syngas Amount : 59.5 kg/s (5,140 Ton/Day) Plant Area : 76,000 ㎡

Gasification Process SCGP (Shell Gasification Process)

Feed Stock Sub. Bituminous or Bituminous

Coal Feeding Dry Feeding (Lock Hopper System)

Solid Removal DSR (Dry Solid Removal, Ceramic Filter)

Acid Gas Removal Sulfinol- M

Sulfur Recovery Shell –Paques (biological Process)

ASU• Cryogenic Air Separation Process

(Purity: more than 95%)

IGCC Plant Configuration (Gasification Block)

Ministry of Knowledge Economy(Korea Institute of Energy Technology Evaluation & Planning)

IGCC R&D OrganizationSteering

Committee

3rd Sub Project1st Sub Project 2nd Sub Project

Integrated Design of Gasification

Plant

Construction of 300MW IGCC

Plant

Development of Operation

technology for 300MW IGCC

Plant

Organization of Korea IGCC Project

Phase I

’06.12~’10.4(Basic Design)

Phase II

’11.2~’16.7( Construction & Commissioning)

• Environmental Impact Assessment

• Gasifier Process Licensor Contract

• Basic Design of 300MW IGCC plant

• Installation of 20 Ton/Day Test Bed

• Procurement of Major Equipment

• Construction and Commissioning of 300MW IGCC Plant

• Development of Simulator & On– line

Monitoring system for 300MW IGCC Plant

Phase Description of IGCC Program

1st SubProject

Integrated design of 300MW gasification plant based on self-reliant development

Contractor • Prime : Doosan Heavy Industries• Sub : Institute, Universities(Busan, Youngnam, Seonggungan)

ProjectGoals

• Engineering of Korea 300MW Gasification Plant• Self-Reliant Development in Gasification Process Engineering• Procurement & Manufacture

Exhaust Gas Cleaning

Gasification Plant EngineeringFeed Preparation

Gasifier/Syngas CoolerIntegrated

Design

Project contents

<Internal Manufacture & Assembly of core parts>

Design of core IGCC parts Internals Manufacture Assembling of core parts

13 3

Tube Welding

4

Tube Coiling

Gasifier Internal

Quench Pipe Internal

2 2

1 1

2 2

3 3 3 3

Coiling Assembly Transfer Duct Internal

4 4

Tube Coiling Syngas Cooler Internal

2nd SubProject

Development of engineering, manufacturing, and construction technology for the 300MW IGCC plant

Contractor• Prime : Korea Western Power• Sub : Institute, Construction & Engineering Company, Universities

Project Goals

• Successful Construction of the most competitive IGCC plant• Construction and Test Run of Gasification Test Bed (20T/D class)

IGCCSite

Seoul

Taean

3rd SubProject

Development of operation technology for Korea 300MW Class IGCC Plant

Contractor• Prime : Korea Western Power• Sub : Universities(Seoul, Hanyang, Inha, Hanbat)

Project Goals

• Development of operation technology of Korea 300MW • Enhance the availability and reliability• Development of combustion diagnostic & tuning Technology

for gas turbine

Coal-Gas Combustion Test Operator Training SimulatorGasification Facilities(KEPRI, IAE, KIER)

PhasePhase I(Design)

Phase II(Construction & Operation)

Year 2006.12 ~2010.4 2011 2012 2013 2014 2015 2016

PowerBlock

GasificationBlock

EnvironmentalImpact

Assessment

Excavation

CommercialOperation

S/T Installation

Demo.Operation(‘15. 12~‘16. 7 )

Installation ofGasifier

Syn. GasStart-up

Contract ofLicensor

G/T Installation

Milestone of Taean IGCC Project

Year Plant siteCapacity[MW]

2015.12 Taean 300

2017.12 Youngnam 300

2019.12 Gunjang 300

Total [MW] 900

– 2020: Possibility of retrofit for decommissing power plants (10 GW)– Three IGCC power plants are planned until 2019 (900 MW)– Power Companies have a plan to install IGCC plant to prepare for

obligation of new & renewable energy allocation from 2012• RPS Factor of IGCC plant: 0.25

<Source : 5th perspective electricity supply &demand plan, Ministry of Knowledge Economy , 2010.12>

Construction Plan of IGCC Plant in Korea

KIER Project : CTL(Coal To Liquid) Process

Clean coal technology to produce Diesel/Naptha using syngas from coalgasification CTL : Energy Tech. that can produce a substitute for high-price oil,

so that it secures stable national energy supply

Sasol’s (South Africa) technological policy : No-open & no-sale: KIER has been developing its own CTL process since 2007

CoalGasifier Gas

CleaningF/T Diesel/Naptha

Unreacted Gas

Upgrade

GasTurbine

SteamTurbineH2S, COS, CO2, …

CO2

Electricity

KIER Project : CTL(Coal To Liquid) Process

The Interior of the KIER CTL Pilot Plant

Height : 22 mID : 0.36 m

KIER Liquefaction Reactor (15 bbl/d)KIER Coal Gasifier (10 T/D)

The Front View of the KIER CTL Pilot Plant

Height : 11 mID : 2.2 m

KIER Project(II) : CTL(Coal To Liquid) Process

Construction & Test Operation of 1.0 T/D Plant by 2009 Construction & Test Operation of 10.0 T/D Plant by 2011 Construction of 200 T/D Plant from 2013

Nov. 2010

Pilot Plant(30bar,10.0T/D)

2013

Demo Plant(200T/D)

Jun. 2009

Bench scale(30bar,1.0T/D)

Aug. 1993

Bench scale(1bar, 0.5T/D)

Nov. 2002

Bench scale(1bar, 1.0T/D)

수송유

SK Innovation Project : Low Rank Coal Gasification Process

Gasification Technology to reduce Capital Cost & CO2 emission Innovatively

GasificationFeedstock

HighRankCoal

F-TFTSynthesis

Economics/Environment

$100 / barrel

CO2 Emission :

1,500℃

Product

Diesel

화학제품Chemicals

천연가스

Innovation

Conventional

LowRankCoal

>2 times of Petroleum

$70 / barrel

CO2 Emission~Petroleum

Syngas(CO+H2)

Green Coal• CAPEX 50% Reduction1)

• CO2 Emission 50%Reduction

Chemical

Methanation

CH4

980℃IGCC

1) CTL Case: Gasifier, ASU, Gas-Cleaning - Gasification Block, versus Shell Dry Feed Gasifier

Electricity

SK Innovation Project : Low Rank Coal Gasification Process

July 2010

Bench(0.05T/D)

Oct. 2010

Pilot Plant(3T/D)

2013

Demo Plant(200T/D)

2015~

Commercial Plant(> 2,000T/D)

Daejeon, Korea Ulsan or Kwangyang, Korea Mongolia, China, Indonesia, Australia(mine-mouth)

SNG LNG

3

Kcal/Nm39,400 9 ,700~10,800

Methane(%) 98 85~98

Nitrogen(%) <1 <13

Sulfur(mg/Nm 3)<30 <30

POSCO Project : SNG(Synthetic Natural Gas) Production Process

SNG vs. LNG Clean coal technology to produce

synthetic natural gas (SNG) usingsyngas from coal gasification

Similar in quality to natural gas/SNG is a possible substitute for natural gas

Steam (H2O)

MethanatorCoal GasPurification

CoalGasification

Water-GasShift Reaction

Oxygen (O2)

Synthetic Natural Gas(SNG)

Syngas

(CO + H2)

CO2, SulfurCompounds

(CO+H2OCO2+H2)

ASU

(CO+3H2CH4+H2O]

CH4

CO

HH

C, H, O, N, S Coal Gasification,Gas Purification Methane Synthesis

Coal Syngas SNG

– To achieve the goal of raising new & renewable energy use in power generation from currently 2% up to 10% by 2022, IGCC is emerging an alternative technology to meet national goal

– IGCC is classified as a new energy in Korea and the RPS system stimulates the installation of IGCC plants (RPS factor: 0.25).

– Under the carbon constrained world, Korea would like to develop the economically sound IGCC plant with CCS. There might be opportunities in collaborating with GTC and technology-holders.

* PRS: Renewable Portfolio Standard

Closing Remarks

Thank you !For Your Attention!!