overview of igcc r&d project in korea - globalsyngas.org · • construction and test run of...
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Overview of IGCC R&D
Project in Korea
Sung Chul, Kim
2011.10.12
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Agenda
- Introduction to KEPCO
- Overview of Korea IGCC Project
- Construction Plan of IGCC Plant in Korea
- Introduction of On-going Gasification Projects
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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
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• 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
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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
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• 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
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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 ㎡
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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)
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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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)
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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
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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)
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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
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– 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
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Thank you !For Your Attention!!