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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.
Evaluation for Gasifier
relativelysmallasyatong (China)orea
(3T/D)
CharFormationSlaggingPotential
Coal
60~700~100
Cold GasEfficiencyCarbonConversion
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Characteristics of Zone C Coal
needflux
ref.
Evaluation for Gasifier
CO : 60~70H2 : 30~35
GasComposition
relativelyhighifficultyrayton
(Australia)Korea(3T/D)
CharFormationSlaggingPotentialCoal
63~700~100
Cold GasEfficiencyCarbonConversion
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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
Cold GasEfficiencyCarbonConversion
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
Research & Development & Demo. Program
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%
Research & Development & Demo. Program
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)
Research & Development & Demo. Program
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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
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