[email protected] - ProcessEng · - CFB annual growth - 12% - SC[USC] ... Ref) Carl Bozzuto, Alstom, France, 2007 Ref) Doosan HI Report, Korea, 2014 . Status of CFB in the World Note)

[email protected]

Coal Conversion Technology

Coal Conversion Tech. Trend • Stable & Economic Electric Power Supply high efficiency, large scale [SC/USC]

• CO2 Reduction Measures Preparation high efficiency, Co-combustion, CCS Optimum Tech. : CFB Conversion Tech. : optimum for fuel flexibility : highly adaptable to SC/USC Once-Thro.

CFB Market Prospect • Since ’95, more than 500 CFB units BD • Increase of SC[USC] CFB : ‘11~’18, - CFB annual growth - 12% - SC[USC]-CFB annual growth - 36% • Increase of CFB market share : more than 17% market share to ‘20

CFB Market Growth in the World

Ref) Doosan HI Report, Korea, 2014 Ref) Carl Bozzuto, Alstom, France, 2007

Status of CFB in the World

Note) CFB total unit and capacity from 1980 to 2013: 1145 Units, 116.5GW / Based on Construction Stat Year [ ‘14 McCoy Report Data]

CFB Boilers in Korea

Company / Location(City) Year Capacity

(steam t/h or MWe) Fuel Category

Supplier /Design

Oriental Chemical / Incheon 1984 120 t/h Coal Co-Gen Hyundai HI/ Ahlstrom

SK / Suwon & Ulsan 1988/89 25/200 t/h Coal Co-Gen Hyundai HI/ Ahlstrom

LG / Yeocheon 1989 210 t/h Coal Co-Gen Hyundai HI/ Ahlstrom

Hyundai Oil / Daesan 1989 120 t/h Coke Co-Gen Hyundai HI/ Ahlstrom

Petrochemical Service Co./Uls

an 1990 250 t/h Coal Co-Gen Hyundai HI/ Ahlstrom

Dyeing Complex / Busan 1991 80×2 t/h Coal Co-Gen Daewoo HI

Korea Energy / Onsan 1991 175 t/h Coal Co-Gen Doosan/Lurgi

Sam Yang GENEX / Incheon 1990 60 t/h Coal Co-Gen Hyundai HI/ Ahlstrom

EWP/ Tonghae 1998/99/

2013

693 t/h ×2 (200 MWe ×2) /

30MWe

Anthracite

+Biomass/

Biomass Electric

Doosan/Alstom/

Andritz /Posco

Kumho Petrochem. / Yeosu 2003 305 t/h Coal Co-Gen Hyundai HI

Dyeing Complex / Daegu 2004 160 t/h Coal Co-Gen Hyundai HI

Gunjang Energy / Gunsan 2007/ 2010

200 t/h × 2 / 250 t/h

Coal Co-Gen Hyundai HI

Hanhwa Energy / Yeosu 2009 400 t/h × 3 Coal Co-Gen F/W

CFB Boilers in Korea

Company / Location(City) Year Capacity

(steam t/h or MWe) Fuel Category

Supplier /Design

BASF/ Gunsan 2009 180 t/h Coal Process Hyundai HI

Hansol / Jeonju 2010 10 MWe Biomass/ RPF Co-Gen AF Sweden (BFB)

Gunjang Energy #3, #4 /

Gunsan 2011/ 2014

250 t/h × 2 Coal /Pet. Coke Co-Gen Hyundai HI

KOEN / Yeosu 2011 / 2016

1040 t/h × 2 (340MWe × 2)

Coal/Biomass Electric Doosan

Yeosu Co-gen Plant /

Yeosu 2012 350 t/h × 2 Coal Co-Gen Hyundai HI

Hyundai Oil Bank

#8, #9, #10 / Daesan 2012/2014

/2017 220 t/h × 2 330 t/h × 1

Pet. Coke Co-Gen Hyundai HI

Gimcheon Community

Energy / Gimcheon 2012 330 t/h Coal Co-Gen Hyundai HI

Han Ju Corp. / Ulsan

2015 250 t/h Coal Co-Gen Hyundai HI

GS EPS /

Dangjin 2015 105 MWe Biomass Electric FW

KOMICO / Wonju 2015 10 MWe RDF Co-Gen Hansol Seentec

/ KIER

OCI/

Gunsan 2015 150MWe × 2 Coal Co-Gen Doosan /FW

KOSPO / Samcheok 2016 1,572 t/h × 4

(500MWe × 4) Coal/

Biomass Electric Hansol Seentec /FW

Hansol / Jeonju 2017 30 MWe Biomass/ RPF Co-Gen Kawasaki

(ICFB)

Hanhwa Energy / Gunsan 2018 100MWe Coal Co-Gen FW

Cebu CFB Donghae CFB Yeosu CFB Samcheok CFB

Capacity • 100MW x 2units

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

Designer • Foster Wheeler

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

Capacity • 200MW x 2units

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

Designer • Alstom

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

Capacity • 300MW x 2units

Commercial Op. • #1 : ‘16. 9 • #2 : ’11. 10

Designer • Foster Wheeler

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

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

Commercial Op. • #1 : ’16. 12 • #2 : ’17. 4

Designer • Foster Wheeler

Feature • USC-CFB type • 257bar/603oC • 4,250 kcal/kg (HHV)

KEPCO group is aiming to expand overseas business further based on its experience. Philippines, South Africa, Botswana, Vietnam, Indonesia, Turkey, China etc

SamCheok CFB Boiler Capacity • 2units : [500MWx2-CFB x 1-TBN] x 2

Designer /Manufacturer • Foster Wheeler / Hansol Seentec

Feature • USC-CFB type (257bar/603oC) Combustor : 39.6(W) x 10(L) x 52(H)m 8-Cyclones & Loopseals 8-INTREXs - FSH(4), FRH(4) Convective Backpass (PRH(b) 3rd SH PRH(a) Eco SCR AH ESP Stack 4-Coal, 1-Biomass Silos, 2-limstone Silos

Design Fuel • Subbituminous Coal (4,250 kcal/kg) • Biomass (3770~4,040 kcal/kg) up to 5%

Emissions • SO2 50ppm, NOx 50ppm, Dust 20ppm

Efficiency [at 100% NR]

• Plant : 41.54% • Boiler : 85.26%

Front/Rear Openings 4 - Solid Return : 0.9m 8 - Coal Feeder : 1.5m 6 - Start up BNR : 2.75m 8 - Lower SA : 4.0m 8 - Limestone Feeder : 4.0 8 - Upper SA : 7.0m 6 - Sand Feeder : 7.5 (only front)

Side Openings 4 - Start up BNR : 2.75m (R-2, L-2)

Bottom Openings

16 - Ash Drain (2 - INTREX drain)

Fuel Feeding System Sand Feeding System LS Feeding System

Ash Drain from Furnace

Solid Removal from INTREX

Rotational Symmetry/Wall Pocket

Now, #1 and #2 Units are Under Commercial Operation. It was delayed about 1 year because of strikes by construction workers. Successful operation of units, up to full load (1,000MWe), in mid-Oct, 2016.

2011 2012 2013 2014 2015 2016 2017

Mile-stone

Start Construction

Steel Structure Installation

Pressure Part Installation

#1 Hydraulic Test

#1 Firing

#1 Power Generation

#1 COD

#2 COD

6/30 8/31 2/5 10/11 4/15 2/26 8/8 12/16 4/30

Contract

Relatively Stable Operation

Lower bed temperature (840~870oC) than those of other CFBs in Korea Lower emission of SO2 and NOx than expected Lower formation of clinker and fouling in the CFB boiler

Plan to apply various fuel co-combustion (anthracite, biomass, etc)

Coal Explosion in the Chain Conveyor

Coal Explosion Experiences in Commissioning Period Explosion occurred during restart after a long shut down in the coal chain conveyors.

due to coal property – high volatiles and some fine particles due to spontaneous ignition of coal in the silos & chain conveyors / smolder coal due to volatile release and ignition at coal chute : higher temp. of SA supplied to

prevent coal condensation at the coal chute than ignition temp. of coal Some measures was taken;

CO2/steam lines, air temp. & long term storage of coal control, rupture disk etc.

Large Temp. Difference Between R-L Side INTREXs during Start-up

Heat Absorption Difference Between Design & Operation Conditions

Steam pocket formation around the section of Economizer → Evaporator It caused start-up delays several times.

To solve the problem, Start up burner & Coal feeding control, FW MOV control, MS Pr./Flow Rate control

#1 (a)

Heat absorption difference Furnace heat absorption is larger than expected. It may affect coal consumption and flue gas temp. , which can restrict APH operation. (APH inlet temp. is higher than designed.)

(Ref. Kang (KOSPO), 2017)

Cyclone Inlet Refractory (Ref. Kang (KOSPO), 2017)

Cyclone Lower Part Tube Damages (Ref. Kang (KOSPO), 2017)

Refractory damages around cyclone inlet duct roof changing refractory construction (casting/gunning ramming)

Cyclone Tube damages due to concentration of thermal expansion and thermal stress around tube panel buckstay connection area changing the sealing type from V to Round sealing

Major Research Projects in Korea

USC-CFB Development by KEPCO & Doosan Group Capacity : 600MWe (steam condition - more than 600 oC/250 bar) Fuel : Co-combustion of more than 20% of Bio-SRF Plan to model development and design completion by the end of 2018 to demonstration of this after 2018 in Korea

FEP(Future Energy Plant) Development by KIER with Several Government Funded RIs Object : High efficiency & CO2 capture for Future Power Generation Main Tech. : Oxy Fuel CFB / USC / Environment (PM 2.5, SO2, NOX) / Water Recovery Research Period : Phase I (‘16~’18) & Phase II (‘19~’21)