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

October 2007
Hyung-Taek Kim, Ph.D.
Professor in Energy Engineering, Ajou University
Expert Advisor, Korea Energy Management Corporation
 Contents
™ Introduction

™ Pilot-scale 3 TPD Gasification System

ƒ Plant Description
ƒ Results of Continuous Run
ƒ Criteria for the Candidate Coal Selection

™ National Program of Demonstration IGCC Plant

ƒ Background
ƒ Present Status

™ Summary
Introduction
Introduction
 Why coal now?
™ Remaining Ultimate Recoverable Fossil Fuel Resources

Oil Natural Gas Coal

Conventional Unconventional

1.7×1012 toe 4.4×1012 toe 1.7×1012 toe 55×1012 toe

Source : Shell Coal Gasification Process, Chhoa, 2003

 International Utilization Sector of Coal

Other
8%
12% Industry
Other
16% Industry
12%
Residential 3% 1%
Power Residential
3%
geneartion 1%
Power
geneartion 79%
69%

2002 2030

™ Amount of Coal Utilization in Power Generation is steadily increase.

™ Requirement of Low-Pollution, High-Efficiency CCT.
 Conceptual Process of IGCC

Coal Gasifier System Syngas Sulfur

Heat
Heat
Purification
Gasifier
Gasifier Exchanger
System
Exchanger
Slag
Steam
Oxygen

Combined Cycle
A S U
Air S/T Power G/T Power
Generation Generation

Electricity
Application Area of Gasification Technology
CO2 Reduction with Different Fuels in Power Plant
 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 Plant

P.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
 Pilot-scale
Pilot-scale
33 TPD
TPD Gasification
Gasification System
System
3 TPD Gasification System
Process & Flow Diagram of Gasification System
Initial Operation Condition of Gasifier
Operation Data of Gasification (Baiduri, 26 atm.)
Gasification of Baiduri (Gas Composition)
Gasification of Baiduri (Efficiency)
 Carbon Conversion (Baiduri, 26 atm.)

- Fly ash 3(Scrubber, dry) : 0.04kg(C: 34.34%)

- Carbon in Scrubber : 0.0137kg (C : 0.003%)

- P.C.(as-feed) : 585 kg(M : 3.58%)

- P.C.(dry) : 564kg (C : 69.93%) - Fly ash 2(Cyclone 2, dry) : 0.49kg(C: 28.23%)
- Input Carbon : 394kg (C : 100%) - Carbon in Cyclone 2 : 0.138kg (C : 0.0035%)

- Fly ash 1(Cyclone 1, dry) : 0.23kg(C: 11.15%)

- Carbon in Cyclone 1 : 0.026kg (C : 0.007%)

Carbon
CarbonConversion
Conversion::99.95%
99.95%

- Slag : 11.0 kg (C : 0.31%)

- Carbon in Slag : 0.034 kg (C : 0.009%)
Operation of 4 Day Period
Carbon Conversion, Cold Gas efficiency
Elemental Analysis of Coals Used

C H O N S Ash
80 74.15
71.45 70.61 72.96 67.08 68.08 70.77
70 63.04
6054.4
50
40
30
20
10
0
e lli /kg) us /kg) on/kg) g h g) g g) o g) r o g) u rli/kg) kl/ykg)
b r t a n k
e c k
a k d s
rr4kca ato08kc id 70kc A d48kc Bai67k
/k / / /
s i kc y p kc
a l a l
a y6kca l l a l a l a l ca
o vkca
U ( 53 0 4
C(60 8 0 r
D(65 5 u
C(661 D ( 66 K ( 56 3 i(s713 9
(6
7 (6 n
De
Ash Fusion Temperature (Reducing State)

1800
1700
Ash Fusion temperature (oC,)

1600
1500
1400
1300
1200
1100
1000 li h ri y
e l us on g ng co ro u k
r t a a id s
sib yp ay r r t o
ide Ad a o v
U C Dr Cu Da K B
ni
s
D e
 Classification of Candidate Coal
3.0
Denisovsky(R)

Curragh(A)
Kleinkopje (S)

Black Water (A)

2.5
Zone D
South Black Water (A)

Blair Athol (A)

Fuel Ratio (FC/VM)

대동CH)
2.0 Moura (A)

Ermelo(S)
Zone B Datong (CH)
Warkworth (A)

Drayton (A) Ulan (A)

1.5 신목(CH)
Wambo (A)
Lemington (A)

Zone A Coal Valley (CA)

Pittsburgh (U)
Drayton(A)
Plateau (U)
Illinois #5 (U)
Cyprus(A) Zone C
Obed (CA)
Baiduri(IN) Adaro(IN)
1.0 Kideco(IN)

Usibelli(U)
A : Australia
CA : Canada 태평양 (J)

CH : China

0.5 IN : Indonesia
J : Japan
R : Russia : 3톤/일급 가스화기 적용 탄종(한국/고등기술연구원)
S : South Africa
U : USA : 2톤/일급 가스화기 적용 탄종(일본)

0.0
1100 1200 1300 1400 1500 1600

Ash Fusion Temp.

 Characteristics of Zone A Coal

Evaluation for Gasifier

Coal ref.
Slagging Char Gas Carbon Cold Gas
Potential Formation Composition Conversion Efficiency

CO : 60~65
Usibelli (USA) easy small 90~100 60~70
H2 : 20~28

CO : 55~60 Usibelli
Cyprus (USA) easy small 85~100 60~75
H2 : 30~35 causing
Korea fouling
(3T/D) problems in
Kideco CO : 50~70 heat
easy small 80~100 60~75
(Indonesia) H2 : 20~28 exchanger

Baiduri CO : 60~67
easy small 83~100 60~70
(Indonesia) H2 : 22~33
Flyslag Fouling in the Exit section of Gasifier

Coal : Alaska Usibelli

Operating Pressure : 15 kg/cm2
 Characteristics of Zone B Coal

Evaluation for Gasifier

Coal ref.
Slagging Char Gas Carbon Cold Gas
Potential Formation Composition Conversion Efficiency

Korea relatively CO : 60~65

Datong (China) easy 90~100 60~70
(3T/D) small H2 : 20~30
 Characteristics of Zone C Coal

Evaluation for Gasifier

Coal ref.
Slagging Char Gas Carbon Cold Gas
Potential Formation Composition Conversion Efficiency

Korea Drayton relatively CO : 60~70 need

difficulty 80~100 63~70
(3T/D) (Australia) high H2 : 30~35 flux
 Characteristics of Zone D Coal

Evaluation for Gasifier

Coal ref.
Slagging Char Gas Carbon Cold Gas
Potential Formation Composition Conversion Efficiency

CO : 60~65
Curragh (Austraiia) high 80~90 42~58
H2 : 18~22 inadequate
Difficult, coal for
Korea Unburned gasification
(3T/D) char
problem Need char
recycle
CO : 55~60
Denisovsky (Russia) high 65~80 40~60
H2 : 20~25
 Characteristics of Gasifier Operation

Gasific- Ash Char Compat-

Coal Zone Ash (%)
ation Slagging Production ibility

Usibelli (U) A 10.86

Cyprus (U) A 3.96 O
Drayton (A) C 10.99
Curragh (A) D 17.37
Kideco (IN) A 1.68 O
Adaro (IN) A 4.12 O
Baiduri (IN) A 5.32 O
Denisovsky (R) D 13.24
Datong (C) B 8.09 O

Good Problem
Commercial
Commercial IGCC
IGCC Power
Power
Plant
Plant
 Background
™ Korean Government’s Plan to increase NRE utilization
ƒ By the year 2012, 7% of total power generation will be covered by NRE

™ Power sector planning to construct # 1 IGCC power plant

ƒ Construction of 300MW CCT will be completed by 2012

™ Strategy of acquiring the design and demonstration of IGCC plant

ƒ License agreement with Gasifier Vender
ƒ Detailed Design by Korean Engineering Company
ƒ Manufacturing most of the equipment in Korea
 Objective
Final objective
ƒ Design & Demonstration of 300MW class IGCC Plant
ƒ Maximize the Korean Participation

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

schedule
3phase ’12.12~’15.12(3yr)
2phase ’09.12~’12.12(3yr) Demon. Operation
1phase ’06.12~’09.12(3yr) Construction of IGCC
Design of IGCC - Operation of 300MW
- Construction of Demo. Plant
300MW IGCC Plant
- Gasifier vendor contract -Renovation of Design
-Development of through Operation
- Design of IGCC Demo Plant Operation Technology Experience, R&D
of Demo Plant
 Research & Development & Demo. Program
† Project 1 : Develop Design Capability of Gasifier
(Doosan, KAIST, Yonsei University)
y Acquisition of PDP through Liscence Agreement with Gasifier Vender
y PEP of Gasification/Purification Process is Digested by Doosan
y Manufacturing of Gasification/Purification Plant is Managed Domestically
※ PDP (Process Design Package)
※ PEP (Preliminary Engineering Package)

Plant Engineering

Domestic Plant
ASU Design Technology
Liscence PDP
PDP
Agreement G/T
G/T
(Foreign) Combined
Gasifier Combined
Cycle
Cycle
Development of Purification
Unit Process
(Domestic)
IGCC Plant Design
 Research & Development & Demo. Program
□ 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

{ Construction Roadmap
1st Stage (3 year) 2nd Stage (3 year) 3rd Stage (2 year)

Liscence Basic 300MW IGCC Plant 300MW IGCC Plant Pre Demo Operation
For
Agreement Design Engineering Procurements & Construction -Operation /설비개선

가스화 실시 발주
플랜트 종합설계
공정사
/ 환경영향 평가
계획
계약 기자재 제작/구매
선정 승인

건설 시
부지 준공
기본
정지
300MW 실증플랜트 건설 운
검사
플랜트 실증운전
계획 전
시뮬레이터 개발 및
설비 안정화 및 개선
시운전요원 교육
 Research & Development & Demo. Program
□ 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% Æ 92% [PC Plant]
• Optimozation of Gas Turbine Combustion
• Develop Real-time Operation Watching System
• Develop Operation Simulator, Train Operator
산소분리설비
14%

가스화기 가스터빈
23% 복합발전
56%

가스정제
7%

Operating Malfunction
Watching Program Simulator
 Research & Development & Demo. Program
□ 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

Pilot Gasifier (KEPRI, IAE, KIER) IGCC HT Filter

 Strategy
™ Government supported National Project
ƒ Government & KEPCO
• Project Management and financial support
ƒ Doosan Heavy Industry / KOPEC
• 300MW IGCC Design, manufacture and construction
ƒ Western Power CO
• Plant site, construction and operation
ƒ KEPRI
• Management & Technical support for whole project
™ License Agreement with Gasifier Vendor
ƒ candidate vendors
• Shell, GE Energy, ConocoPhillips, MHI
ƒ PDP introduced from the vendor, PEP from Engineering Company
ƒ Plant Design, manufacturing and construction of IGCC should be
conducted by Doosan and KOPEC
 SUMMARY
™ The position of coal as power generation fuel source
and coal-utilizing CCT technology is explained.

™ Because of IGCC’s high efficiency and clean

environment characteristics, IGCC is most advanced coal
utilization technology in the future power generation
market.

™ Baseline methodology for selecting candidate coal for

gasification is established with coal characteristics such
as fuel ratio and ash fusion behavior

™ Explain the Korean national project of for

design/construction/operation of 300 MW demonstration
IGCC plant
Members of Energy Process Laboratory
(Accredited Best Lab in NRE Area by MOCIE)

Professor

Hyung-Taek, Kim

Post Doc. Researcher Ph. D candidates

Hong yue, Wang 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
Chang