Prof. Steve(Chung-Hwan) Jeon

Director, Pusan Clean Coal Center

Pusan National UniversityE-mail: chjeon@pusan.ac.kr

Nottingham University, UK

11 February, 2015

UK-Korea CCT/CCS Workshop

Clean Coal Research in Korea

Outline

• Dr. Park’s brief was to provide a summary of the following issues :

• Policy trends of Clean Coal Technology in Korea

- Projected coal trends and electricity generation to 2025

• Current and future planning for coal fired power plants in Korea

- IGCC 300MW (w/o CCS) power plant at TaeAhn

- World’s first USC CFB(1000MW) boiler at SamCheuk

- Korea’s first USC PC boiler at Shin(New)Boryeong

- 10 new units of USC PC boiler in Korea

• Research Activities to deploy Clean Coal Technologies in Korea

• Summary

1. Position of Coal in Korea’s Electricity Supply

• 7th among the ten countries that account for more than 85% CO2 emissions from coal through the production of electricity.

• ~40% of Korea’s electricity derives from coal.- 68% from thermal including gas & oil - 10% excess of facility capacity

• The fleet in Korea has one of the largest shares of super‐ or ultra‐supercritical coal power generation in a single country.

• The steep increase of coal‐fired power plants in Korea over the last 20 years requires special consideration in terms of designing new power plants in a way that would allow for cost‐effective CCS in the future.

Nuclear28.0%

coal

40.0%

Gas25.0%

Oil3.0%

1.5% 1.7%

Power Generation (2013)

Total: 509,574GWh

• Korea indicators above 100%

perform better than average.

But in order of coal performance,

the Nordic countries, UK,

Japan, Germany, all perform

better than Korea.

- the major reason is the high of

Indonesian coal(out of range coal)

in super‐ or ultra‐supercritical plant.

- blending issues in terms of IDT, slagging,

NOx, and plant efficiency

• Korea has the lowest electricity prices in

OECD countries. Residential prices more

highly than industrial.

- Low electricity prices are a commercial

barrier to new technologies.

2. Coal Issues in Efficiency and Electricity Price

3. ‘Clean Coal’ Strategies in Korea

• Adoption of high efficient power plants - A $15 billions is to be invested in PC power stations such as IGCC and USC 1000MW class- Coal performance, cost, and reliability demonstrations are required in advanced power technologies

CO2 emission 150Mt in power sector

- USC plant outputs 40% among coals

- 2.5~3.5% CO2 Reduction; 4.2Mt

- Shortage of emission allowances; 42.3Mt

- 10% can be covered by adoption of high

efficient plants

• Improve efficiency of existing power plants- $1.2 billions is needed for Korean standard power stations of 500MW, 30 units- Retrofit existing plants with improved technology; target of 1~2% increased efficiency

• Fuel Switching- Fuel blends, coal upgrading strategies- Co-firing coal/biomass, Hybrid coal etc.- RPS raising up to 10% in 2022

• Carbon sequestration - CO2 capture and utilization(CCSU)

4. Future Planning for Coal-fired Power in Korea

Location map of coal-fired thermal power facility in Korea(by Pusan Clean Coal Center)

YeonHeung(KOSEP)(+800MW 6 units)

DangJin(EWP)(500MW 8units)

TaeAn(WEST)(500MW 8units)

BoRyeng(KOMIPO)(500MW 8units)

SeCheon(KOMIPO)(200MW 2units)

Existing power plant

USC Under construction

SamCheonPo(KOSEP)(500MW 6 units)

HaDong(KOSPO)(500MW 8units)

YeoSu(KOSEP)CFB 300MW 2 units

HoNam(EWP)250MW 2 units

YeonDong(KOSEP)(150MW 2 units)

DongHae(EWP)(CFB 200MW 2 units)

ecoGP(KOSEP)

USC 1000MW 2 Units

POSCO Power

USC 1000MW 2 Units

SamChuck(KOSPO)

CFB USC 1000MW 2 Units

New BoRyengUSC 1000MW 2 Units

USC 1000MW

Unit 9,10& IGCC 300MW

New DangJinUSC 1000MW 2 Units

• Installed capacity : 26.15 GW

• No. of power plants : 56 units - Standard units : 500MW 30 units

• Power source % composition (2013)- 28.9% power facility capacity basis - 40.0% power generation basis

• GENCO : KOSEP, KOSPO, EWP, KOMIPO, WEST• IPP : GGP, ecoGP, POSCO with USC 1000MW

GGP(KOSEP)

USC 1000MW 2 Units

• No. of New USC 1000MW : 14 units

(Unit : MW)

FacilityMargin

FacilityCapacity

Max.Demand

USC 1000MW Class- CFB, PC boiler -

5. Energy Mix Prospect in Korea

GGP #1 (18.10)YH #7 (18.12)GGP #2 (19.4)

GEP #1 (19.4)GEP #2 (19.10)

DJ,TA #9 (15.12)NBR #1 (15.06)

DJ,TA #10 (16.06)NBR #2 (16.06) POSCO#1 (20.2)

POSCO#2 (21.7)

TaeAn#1(15.12)(IGCC 300MW)

SCGP#1,2 (15.12)(USC CFB)

Source : Presidential Council NEP(National Electricity Planning) in 2013, Korea

Fuel TypesUnit price(won/kWh)By Dec. 2013

Nuclear 39.07

Coal 58.84

Gas 157.76

Oil 221.70

Nuclear

24.5%Coal

28.2%

Gas

31.3%

Oil 8.5%

Hydra

5.2%

Renew2.3%

Year 2015

30,120

(24.1%)

43,890

(35.2%)

33,020

(26.5%)

8,440

(6.8%)

6,070

(4.9%)3,260

(2.6%)

Year 2020

35,920

(27.9%)

44,890

(34.9%)

31,220

(24.3%)

5,840

(4.5%)

6,070

(4.7%)

4,700

(3.7%)

Year 2025

Total: 100,180 MW Total: 124,800 MW Total: 128,640 MW

6.1 IGCC Power Generation in Korea

Power Output Gross 380 MW Net 300 MW GT: 235 MW / ST: 145 MW

Feed Stock HHV ≥ 5,242kcal/kg (Moisture ≤ 25%) 2,670 ton/day (Syn gas 5,140Ton/Day)

Target of Plant Efficiency Net 42% / Gross 48% Base: HHV

Air Pollutant Emission SOx<15ppm/NOx< 25ppm/Dust< 3㎎/S㎥ @15% O2

Specification

ConsortiumPartners

Contractor :• Korea Western Power/ Doosan Heavy Industries• Institutes (KIER, IAE : 20tpd test bed)• Universities (10)• Engineering & Construction Company

Period 1 phase : 2006. 12 ~ 2010. 4 (Finished) 2 phase : 2011. 2 ~ 2016. 7 (5.5 years)

Budget Total : 1.5 Billion US$

• Government : 0.2Billion US$• Participant : 1.3 Billion US$

Gasifier

Waste Water Treatment

Slag Shed

Commissioning test : June 2015

Source : Korean Western Power

• Korean Southern Power Company

(KOSPO)

• Located in Samcheok, Korea

• Design: AMEC Foster Wheeler

– Net plant efficiency (LHV): 42.4%

– Plant start up : December 2015

6.2 World’s first USC CFB 1000MW in Korea

DivisionCoal Power Plant

(500MW, Example)Lagisza CFB(460MW)

Samcheok CFB(500MW)

SteamCondition<@BMCR>

Flow (SH/RH)Pr.(SH/RH)

Temp.(SH/RH)

1,605/1,281 t/h255/53.78 bar569/596 ℃

1,300/1,102 t/h275/55 bar560/580 ℃

1,572/1,296 t/h255.5/52.8 bar

603/603 ℃

EnvironmentCondition

SOxNOxDust

40 ppm50 ppm15 ppm

69.9 ppm97.3 ppm

30 (mg/Nm3)

50 ppm50 ppm15 ppm

Design CoalAnalysis

Heating ValueTotal Moisture

AshSulfur

6,080 kcal/kg(HHV)10 %(AF)15 %(AD)0.72 %(AR)

5,015 kcal/kg(HHV)12 %(AF)

26.1 %(AD)1.2 %(AF)

4,250 kcal/kg(HHV)33.5 %(AF)4.5 %(AD)0.1 %(AF)

Source : Korean Southern Power(Oct..2014)

6.2 Status of CFB boiler up to 1000MW in Korea

Fuel Flexibility

• Circulating solids provides high thermal inertia for stable combustion over wide fuel range

High Reliability/Low Maintenance

• Minimized furnace corrosion and fouling

• No ash slagging

• Solids clean surfaces

Very Low NOx

• Low baseline NOx

• Excellent utilization of SNCR due to mixing in Solids Separator

• Can use SCR for lowest NOx and Ammonia slip

Sulfur Captured in Furnace

• Effective and economical sulfur capture in furnace using Limestone

• Calcium rich ash can be reactivated in dry scrubber

Low UBC

• Long Burning Time

• Even with low volatile fuels

Capacity• 100MW × 2units

Commercial Op.• #1 : ‘11. 2• #2 : ‘11. 5

Designer• Foster Wheeler

Feature• Compact Cyclone• INTREX• Sub-bituminous• Prob.: Erosion

Cebu CFB Donghae CFB Yeosu CFB Samcheok CFB

6 units over 100MW CFB boilers in Korea

Capacity• 200MW × 2units

Commercial Op.• #1 : ‘98. 9• #2 : ‘99. 9

Designer• Alstom

Feature• FBHE• FBAC• Korean Anthracite• Prob.: Coal Supply

Capacity• 300MW × 2units

Commercial Op.• #1 : ‘16. 3 (Cons.)• #2 : ‘11. 10

Designer• Foster Wheeler

Feature• Compact Cyclone• w/o INTREX• Wingwall Tube• Prob.: Erosion etc

Capacity• 2units [550MW×2-CFB × 1-Turbine]

Commercial Op.• #1 : ‘15. 12 (Cons.)• #2 : ‘16. 6 (Cons.)

Designer• Foster Wheeler

Feature• USC-CFB Type• 257 bar / 603 ℃• 3,900 kcal/kg

6.3 Korea’s first USC 1000MW power generation

1950 1970 2000 2010

538538

566

580

593

600

Japan/Europe Korea

Dangjin #9(1000MW,260/600)

Yeongheung #1(800MW, 241/566)

USC Korea(1000MW,265/610)

Skaerbak(400MW, 296/582)

Main

ste

am

Tem

pera

ture

(℃

)

Matsuura #2(1000MW, 255/593)

Misumi #1(1000MW, 255/600)

Isogo New #2(600MW, 255/600)

Advanced USC(550MW, 357/700)

566

2015 2020

The Characteristics of USC power plantIs having the highest thermal efficiency with the increment of the temperature and the pressure of the steam.※ USC is defined as the Main steam temp. is over 593℃, pressure is over 246kg/cm2

Start of Operation : 06. 2017Power output : 1020MW * 2 unitsUSC Condition : 265MPa, 610/621CNet efficiency : 44.2%SOx : <50ppm (Wet type De Sox)NOx : <45ppm (SCR)

USC 2 units

*KEPIC(Korea Electric Power

Industry Code) Development and

Application to USC standard

USCConsortium

Partners

Period : 03.2010-12.2015 Contractor : Korea Midland Power(KOMIPO)

Doosan Heavy Industries• Institutes (10) : KEPRI, PCCC etc.

6.3 Korea boiler history going up to USC

500 MW Standard type thermal powerOne pass / Corner

500MW New Standard

Two pass / Corner

870W Yeongheungunit 5, 6

Two pass / Opposite

1000MW Shin BYunit 1, 2

Two pass /Opposite

1000MW DangJinUnit 9, 10

Two pass / Opposite

S. Temp. : 541 / 541 ℃S. Press. : 255 / 40 kg/cm2

Design Coal : 6080 kcal/kg

569 / 596 ℃255 / 55 kg/cm2

6080 kcal/kg

569 / 596 ℃252 / 45 kg/cm2

5300 kcal/kg

613 / 624 ℃274 / 46 kg/cm2

5600 kcal/kg

603 / 603 ℃265 / 46 kg/cm2

5626 kcal/kg

Coal preparation

De-ashing, reformingand processing

Handling

Liquefaction

Gasification

Pyrolysis

High-efficiency combustion

Flue gas treatment

Coal cy

cle

Mining

Crushing

Reforming

Conversion

Combustion

Pollutantreduction

Preparation

Ash utilization

CCUSCCUS

Bench Scale

Pilot Scale

Demo. Scale

Comm.Scale

Degree of technological maturity

Diversification of energy

sources/expansion ofapplication fields

Ease of handling

More efficient use of energy/

CO2 reduction(global warming countermeasure)

Reduction in SOx, NOx,

and waste(acid rain and global

warming countermeasures)

Target

Reference : NEDO, CCT classification

Conventional coal preparation techniques(jig, flotation, heavy media separation)

Drying, Upgrading, Briquetting

Coal liquid mixture (CWM)

Coal-derived liquids (direct, indirect)

IGCC, Coal to Gas

Carbonization

USC, Oxy-fuel, PFBC

Desulfurization, Dust removal

Coal ash utilization

Carbon capture, utilization/conversion, storage

7. Clean Coal Research Activities in Korea

Coal preparation

De-ashing, reformingand processing

Handling

Liquefaction

Gasification

Pyrolysis

High-efficiency combustion

Flue gas treatment

Coal cy

cle

Mining

Crushing

Reforming

Conversion

Combustion

Pollutantreduction

Preparation

Ash utilization

CCSCCS

Bench Scale Pilot Scale

Demo. Scale

Degree of technological maturity

Comm.Scale

Clean FuelTest bed Infra.*

Wet GasificationFT Syn.

Dry GasificationDME Syn.

Coal Drying

Coal Upgrading

Ash-freeCoal

Pre-CombustionWet CO2 Capture

Pre-CombustionDry CO2 Capture

• PI :KEPRI/ DOOSAN, Univ.(10)• 1st Stage : 2007~2010• 2nd Stage : 2010~2012년• 3rd Stage : YD plant Unit 1(125 MW) ongoing, now suspending

• 0.7MW Oxy-PC pilot system, 100MWe Real system

LRCGasifica

tion

SNGPlant

Oxy-PC

Carbonizer LRC regorming

500MW Retroit(LRC application)

• PI : KIER / IAE, PCCC• 1st Stage : 2013~2016• 1TPD AFC production process

(AFC : Ash under 200 ppm)

• PI : KIER/ EWP• Period : 2008~2012• 5TPD CUPOTM coal briquette• Demo scale : GS Con. FS for Real scale in Indonesia, 2016

7.1 Clean Coal Research Activities in Korea

• PI : DOOSAN/ KEPRI, PCCC• 1st Stage : 2011~2014 R&BD• 2nd Stage : 2015~2018 Real Plant Retrofit for Old 500MWPC Plant at KOMIPO site

• PI : POSCO / IAE, KIER • 1st Stage : 2009~2011 for 100 Nm3/h, SNG Syn. process

• 2nd Stage : 2012~2015 for 0.5mt SNG production, Comm. Scale

Burner development

(Pilot scale test, HIT)

Full scale boiler

simulation

Demonstration

test (KOSPO)

~ 2016.12

Horizontal bias combustor for De-NOx

Boiler retrofit ( 500MW-->550MW, 5300kcal/kg, De-NOx)

Low rank coal analysis Full scale boiler simulation Demonstration

test (KOMIPO, DOOSAN)

~ 2017.12

De-NOx burner

Air staging

(SOFA)

7.2 Pusan Clean Coal Center-Retrofit Existing 500MW

USC Boiler modeling

Future work : Advanced S/F Code(include shedding effect)

Full scale simulation

Combustion experiment

Slagging & Fouling experiment S/F UDF Code

Design coal : 5200kcal/kg

Furnace NOx : < 100ppm

7.3 Pusan Clean Coal Center- USC 870MW Boiler

8. Summary

• Korea has the clean coal policy focused on high efficient power plant

in terms of USC installation and retrofit existing plants

• Projected coal trends and electricity generation to 2025 may keep

going on “More Coal” with clean coal technology

• Current and future planning for CCS in Korea is preparing through the

IGCC 300MW power plant which may convert possible to CCS

• Korea and UK have a high potential collaboration in Research

Activities to deploy Clean Coal Technologies.

Steve(Chung-Hwan) Jeon

Clean Coal Technology

Pusan Clean Coal Center, Director

Energy Conversion System Lab.

Professor, Pusan National University

Phone: +82 (10) 9241 5909

+82 (51) 510 3051

Email: chjeon@pusan.ac.kr

http://ecos.org

http://pnupc3.org

Thank you

Ash behaviors in 1000MW Boiler by PCCC

(kg/s)

32~45 75~90um 150~180

0

Coal particle combustion by PCCC