Presented by:

Mr. Supachai Khonwong

Ms. Chanyanutch Setajit
Mr. Charuk Prathuangyukhan

Integrated Coal Gasification

Technical advisor
Combined Cycle Power Aj. Hong-ming Ku

Generation Plant Design English advisor

Proposal Presentation (23/9/17) Aj. Kwanchanok Pasuwat
OUTLINE

INTRODUCTION
OBJECTIVES & SCO
PROCESS & LITERA
METHODOLOGY
WORK PLAN

2
 INTRODUCTION
Global electricity consumption
Thailand
21191
20195
18544
Electricity consumption ( ×109 kWh)

17127
15037
13392
12266
11347
10531

3
 INTRODUCTION
29% 9%
Nuclear Power
Natural Gas

37%
Petroleum
World Energy Source
Consumption

In 2016 15%
10% Renewable
Energy Coal

4
 INTRODUCTION
Fuel selection

40 Years left for Petroleum

60 Years left for Natural Gas

200 left for

Years Coal
5
 INTRODUCTION
Coal based power plant
Cheapest 2
source  Located almost universally.
(Coal can be found over 70
& & Abundance countries in every region.)
Low Capital
 Price of coal is cheaper & Investment
affordable than other
energy sources.
 Spending low cost to build
1
the coal-fired power plant.
Known technologies
&
reliability  Technology is constantly
3 advancing and reliability.

6
 OBJECTIVES & SCOPE OF WORK
Objectives
1. To design and simulate integrated gasification combined cycle (IGCC)
power generation from coal.
2. To perform economic analysis based on the design.

Scope of work
1. Use Aspen Plus Version 8.8 to design process.

2. Use CAPCOST/Problem statement for costing all main equipment.

3. Economic evaluation includes cash flow analysis, payback period & IRR.

7
 PROCESS & LITERATURE REVIEW
Block flow diagram
1 3
Air LP N2 Combined cycle
Air Separation unit power plant
(ASU) (CCPP)

O2 HP N2
Clean
Fuel gas
2
Coal Coal Gas
Coal Preparation Pulverized Gasification Raw Clean-up
coal fuel gas

Coal gasification section (CGP) Slag Fly ash Sulfur

8
 PROCESS & LITERATURE REVIEW
Block flow diagram
1 3
Air LP N2 Combined cycle
Air Separation unit power plant
(ASU) (CCPP)

O2 HP N2
Clean
Fuel gas
2
Coal Coal Gas
Coal Preparation Pulverized Gasification Raw Clean-up
coal fuel gas

Coal gasification section (CGP) Slag Fly ash Sulfur

9
 PROCESS & LITERATURE REVIEW
1 Air separation section

LP N2 260 psia LP N2
Low P To CGP
Extraction air Heat 19 psia
from gas turbine Compressor
exchanger Remove CO2 & H2O
726 oF, 219 psia

O2 505 psia O2
Adsorber To CGP
Compressor
Ambient air
59 oF, 14.7 psia
Filter Cooler HP N2
High P HP N2 605 psia
Main air  To CGP
84 psia
compressor  To gas turbine
Remove dust Compressor  For gasifier quench
particles
Cryogenic
fractionation unit
10
 PROCESS & LITERATURE REVIEW
98.9%
B.P. (oF) LP N2
1 Air separation section Technology selection N2 -321 Liquid
Ar -303
N2

O2 -297
LP
Byproduct Purity limit Economic Column
Process Status
capability (%vol) range
Adsorption Semi-mature Poor 95 <150
19 psia Condenser
Chemical Developing Poor >99 No data
Condenser /Reboiler
Cryogenic Mature Excellent >99 >20 /Reboiler
95% O2
Membrane Semi-mature Poor 40 <20
99.8 %
ITM Developing Poor >99 No data 84 psia
HP N2
ITM = Ion transport membrane HP
Column

Air
Liquid 35-40% O2

11
Ref: Smith, A., & Klosek, J. (2001). A review of air separation technologies and their integration with energy conversion processes. Fuel Processing Technology, 70, 115-134.
 PROCESS & LITERATURE REVIEW
Block flow diagram
1 3
Air LP N2 Combined cycle
Air Separation unit power plant
(ASU) (CCPP)

O2 HP N2
Clean
Fuel gas
2
Coal Coal Gas
Coal Preparation Pulverized Gasification Raw Clean-up
coal fuel gas

Coal gasification section (CGP) Slag Fly ash Sulfur

12
 PROCESS & LITERATURE REVIEW
2 Coal gasification section Feed preparation Gasification Gas cleanup

LP N2 HP N2 O2 NH3 & H2S

Milling & Pulverized Pressurized Raw fuel gas Gas Clean

Coal coal Gasification
Drying & Feeding cleanup fuel gas

Vent
Make-up Slag
gas
LP N2
Condensate Blower

Bag
Circulation gas
Heater filter
1700 psia
steam
Hot gas
Mill
Pulverized coal
Coal
13
 PROCESS & LITERATURE REVIEW
2 Coal gasification section Feed preparation Gasification Gas cleanup
Syngas: CO, H2
LP N2 HP N2 O2 NH3 & H2S
Impurity: H2O, H2S,
COS, NH3

Milling & Pulverized Pressurized Raw fuel gas Gas Clean

Coal coal Gasification
Drying & Feeding 1,540 oC, 2.5 MPa cleanup fuel gas

Slag

Pyrolysis Combustion Gasification

Volatiles + O2 CO2 + H2O
Coal Char (C) + Volatiles C + O2 CO2 C + CO2 2CO
C + 1/2O2 CO C + H 2O CO + H2

14
 PROCESS & LITERATURE REVIEW
2 Coal gasification section Gasification technology

Entrained flow Fluidized bed Fixed/Moving bed

Coal size (mm.) <0.1 0.5-5 5-50
1,250-1,550 (Wet)
T (oC) 800-1000 800-1,000
1,400-1,600 (Dry)
P (Mpa) 2.5-4 1-2.5 1-10
Residence time 1-10 s 5-50 s 15-30 m
Oxidant requirement (kg/kg coal) 0.7 (O2) 3.75 (Air or O2) 1.1 (O2)
Thermal efficiency (%) 95 92 94
CCE(%) 98-99.5 90-95 88-95
CCE (Carbon conversion efficiency) : percentage of C converted to a carbonaceous gas

Ref: Zheng, L., & Furinsky, E. (2005). Comparison of Shell, Texaco, BGL and KRW gasifiers as part of IGCC plant computer simulations. Energy Conversion and Management, 46, 1767-1779.
15
Khartchenko, N. V., & Kharchenko, V. M. (2013). Advanced Energy Systems (2nd ed.). CRC Press.
 PROCESS & LITERATURE REVIEW
2 Coal gasification section Shell coal gasification

 Feedstock flexibility
 Short residence time
 Low coal consumption
 High H2 production potential

T 1400-1,600 oC
P 2.5 - 4 Mpa
Syngas 25-30% H2
60-65% CO

Ref: Zheng, L., & Furinsky, E. (2005). Comparison of Shell, Texaco, BGL and KRW gasifiers as part of IGCC plant computer simulations. Energy Conversion and Management, 46, 1767-1779.
16
http://www.enggcyclopedia.com/2011/12/selection-gasification-process-type/
 PROCESS & LITERATURE REVIEW
2 Coal gasification section Milling & Drying Gasification Gas cleanup

LP N2 HP N2 O2 NH3 & H2S

Milling & Pulverized Pressurized Raw fuel gas Gas Clean

Coal coal Gasification
Drying & Feeding cleanup fuel gas

Slag

17
 PROCESS & LITERATURE REVIEW
2 Coal gasification section Milling & Drying Gasification Gas cleanup

Monoethanolamine
COS Hydrolysis H2O [MEA]
Quench gas HP N2 COS+H2O H2S +CO2 (Absorbent) (Absorbent)
Raw fuel gas
Boiler feed water (BFW)
from CCPP
Syngas
H2O
High P COS NH3 H2S
H2S Clean fuel gas
Impurity COS Filter Converter Removal Removal
NH3 HP Steam Ammonia
to CCPP H2S
solution

Water Sulfur
Fly ash Fly Ash Claus reactions
treating recovery H2S+3/2O2 SO2+H2O
2H2S+SO2 3S+2H2O
To recycle Sulfur
18
 PROCESS & LITERATURE REVIEW
Block flow diagram
1 3
Air LP N2 Combined cycle
Air Separation unit power plant
(ASU) (CCPP)

O2 HP N2
Clean
Fuel gas
2
Coal Coal Gas
Coal Preparation Pulverized Gasification Raw Clean-up
coal fuel gas

Coal gasification section (CGP) Slag Fly ash Sulfur

19
 INTRODUCTION
PROCESS & LITERATURE REVIEW
3 Combined cycle power plant
Steam

Steam turbine
power plant

Exhaust Steam Steam Steam

heat generator turbine
Gas turbine
power plant Eff: 35-42%

Coal Fuel gas

Gasifier Gas turbine Efficiency : 50-60%
Overall efficiency of the plant
Eff: 20-30%
Fuel costs & carbon emissions

20
 PROCESS & LITERATURE REVIEW
3 Combined cycle power plant Electricity

STEAM TURBINE

Clean fuel gas

GAS TURBINE HP MP LP LP

Generator

LP N2 MP steam
Combustor

Extraction air HP Steam

from CGP
HEAT RECOVERY STEAM GENERATOR Exhaust
Electricity (HRSG)
Gas turbine to Stack
Generator Air Expander Exhaust
Compressor

Treated ambient air

21
 METHODOLOGY
Start
Estimate size of all main
equipment
Study IGCC process &
Review the literature

Estimate costs of equipment

Calculate input parameters to

satisfy the output specifications
Perform an economic analysis

Develop simulation model - Payback period

- Internal rate of return Finish
- Cash flow analysis
22
 WORK PLAN
Week
Detail August September October November
3 4 5 1 2 3 4 1 2 3 4 1 2 3 4 5
1. Process study
1.1 Design problem study
1.2 Literature review
2. Process design & simulation
2.1 Preliminary process design
2.2 Process simulation
3. Equipment sizing and costing
3.1 Equipment detailed design
3.2 Cost estimation
4. Economic analysis
4.1 Economic evaluation
23
 THANK YOU
FOR Y UR ATTENTION
 Air pollutants standard emission from industry
Limitations
Pollutant Emission source Danger
No fuel combustion Fuel combustion

1. Total Suspended Fuel source - Lower water quality, less ability to hold
Particulate (TSP) - Oil 240 O2=no life exist
(mg/m3) - Coal - 320 - Clog fish gills
- Biomass 320
- Others 320
2. H2S (ppm) General production 100 80 - Exposure high conc.=quickly lead to death

3. CO (ppm) General production 870 690 - Displace O2 in blood=lose consciousness

and suffocate
4. SO2 (ppm) Fuel source - Acid rain: harms vegetation and water life
- Oil 950
- Coal - 700
- Biomass 60
- Others 60
5. NOx (ppm) Fuel source - Impacts on respiratory conditions (Long
- Oil 200 term: decrease lung function)
- Coal - 400 - Leaf damage and reduce growth of
- Biomass 200 vegetation
- Others 200
25
่
Ref: การกาหนดค่าปริมาณสารเจือปนในอากาศทีระบายออกจากโรงงาน พ.ศ. 2549
 BACKUP
Selection of coal type
IGCC gasifier
- long-term continuous operations =>
low ash coal required
- Min. slag-plugging problem
- Min. unburned carbon through flyash
and slag

Lignite: Low-rank coal

- Lowest heating value
- Higher moisture content (Low cost)

Anthracite: Rare

Commercial coal : Bituminous &

Sub-bituminous

26
Ref: https://www.netl.doe.gov/research/coal/energy-systems/gasification/gasifipedia/coal
 BACKUP
Type of gasifier

27