CFB Market Growth in the World. Coal Conversion Technology

Transcription

1

2 Coal Conversion Technology CFB Market Growth in the World Ref) Carl Bozzuto, Alstom, France, 2007 Coal Conversion Tech. Trend Stable & Economic Electric Power Supply high efficiency, large scale [SC/USC] CO 2 Reduction Measures Preparation high efficiency, Co-combustion, CCS Optimum Tech. : CFB Conversion Tech. : optimum for fuel flexibility : highly adaptable to SC/USC Once-Thro. Ref) Doosan HI Report, Korea, 2014 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

3 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]

4 CFB Boilers in Korea Company / Location(City) Year Capacity (steam t/h or MWe) Fuel Category Supplier /Design Oriental Chemical / Incheon 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 t/h Coal Co-Gen Hyundai HI/ Ahlstrom Hyundai Oil / Daesan t/h Coke Co-Gen Hyundai HI/ Ahlstrom Petrochemical Service Co./Uls an t/h Coal Co-Gen Hyundai HI/ Ahlstrom Dyeing Complex / Busan t/h Coal Co-Gen Daewoo HI Korea Energy / Onsan t/h Coal Co-Gen Doosan/Lurgi Sam Yang GENEX / Incheon t/h Coal Co-Gen Hyundai HI/ Ahlstrom EWP/ Tonghae 1998/99/ t/h 2 (200 MWe 2) / 30MWe Anthracite +Biomass/ Biomass Electric Doosan/Alstom/ Andritz /Posco Kumho Petrochem. / Yeosu t/h Coal Co-Gen Hyundai HI Dyeing Complex / Daegu t/h Coal Co-Gen Hyundai HI Gunjang Energy / Gunsan 2007/ t/h 2 / 250 t/h Coal Co-Gen Hyundai HI Hanhwa Energy / Yeosu t/h 3 Coal Co-Gen F/W

5 CFB Boilers in Korea Company / Location(City) Year Capacity (steam t/h or MWe) Fuel Category Supplier /Design BASF/ Gunsan t/h Coal Process Hyundai HI Hansol / Jeonju MWe Biomass/ RPF Co-Gen AF Sweden (BFB) Gunjang Energy #3, #4 / Gunsan KOEN / Yeosu Yeosu Co-gen Plant / Yeosu Hyundai Oil Bank #8, #9, #10 / Daesan Gimcheon Community Energy / Gimcheon Han Ju Corp. / Ulsan GS EPS / Dangjin 2011/ / t/h 2 Coal /Pet. Coke Co-Gen Hyundai HI 1040 t/h 2 (340MWe 2) Coal/Biomass Electric Doosan t/h 2 Coal Co-Gen Hyundai HI 2012/2014 / t/h t/h 1 Pet. Coke Co-Gen Hyundai HI t/h Coal Co-Gen Hyundai HI t/h Coal Co-Gen Hyundai HI MWe Biomass Electric FW KOMICO / Wonju MWe RDF Co-Gen OCI/ Gunsan KOSPO / Samcheok 2016 Hansol Seentec / KIER MWe 2 Coal Co-Gen Doosan /FW 1,572 t/h 4 (500MWe 4) Coal/ Biomass Electric Hansol / Jeonju MWe Biomass/ RPF Co-Gen Hansol Seentec /FW Kawasaki (ICFB) Hanhwa Energy / Gunsan MWe Coal Co-Gen FW

6 Cebu CFB Donghae CFB Yeosu CFB Samcheok CFB Capacity 100MW x 2units Commercial Op. #1 : #2 : Designer Foster Wheeler Feature Compact Cyclone INTREX Sub-bituminous Prob.: Erosion Capacity 200MW x 2units Commercial Op. #1 : #2 : Designer Alstom Feature FBHE FBAC Korean Anthracite Prob.: Coal supply Capacity 300MW x 2units Commercial Op. #1 : #2 : 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 : #2 : Designer Foster Wheeler Feature USC-CFB type 257bar/603 o C 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

7 SamCheok CFB Boiler Capacity 2units : [500MWx2-CFB x 1-TBN] x 2 Designer /Manufacturer Foster Wheeler / Hansol Seentec Feature USC-CFB type (257bar/603 o C) Combustor : 39.6(W) x 10(L) x 52(H)m 8-Cyclones & Loopseals 8-INTREXs - FSH(4), FRH(4) Convective Backpass (PRH(b) 3 rd 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 SO 2 50ppm, NOx 50ppm, Dust 20ppm Efficiency [at 100% NR] Plant : 41.54% Boiler : 85.26%

8 Ash Drain from Furnace Fuel Feeding System Sand Feeding System LS Feeding System Solid Removal from INTREX 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 : 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) Rotational Symmetry/Wall Pocket

9 Milestone Contract Start Construction Pressure Part Installation #1 Hydraulic Test #1 Firing #1 Power Generation #2 COD 6/30 8/31 2/5 10/11 4/15 2/26 8/8 12/16 4/30 Steel Structure #1 COD Installation 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.

10 Relatively Stable Operation Lower bed temperature (840~870 o C) than those of other CFBs in Korea Lower emission of SO 2 and NOx than expected Lower formation of clinker and fouling in the CFB boiler Plan to apply various fuel co-combustion (anthracite, biomass, etc)

11 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; CO 2 /steam lines, air temp. & long term storage of coal control, rupture disk etc.

12 Large Temp. Difference Between R-L Side INTREXs during Start-up (Ref. Kang (KOSPO), 2017) 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 Heat Absorption Difference Between Design & Operation Conditions #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.)

13 Cyclone Inlet Refractory (Ref. Kang (KOSPO), 2017) Refractory damages around cyclone inlet duct roof changing refractory construction (casting/gunning ramming) Cyclone Lower Part Tube Damages (Ref. Kang (KOSPO), 2017) 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

14 Major Research Projects in Korea USC-CFB Development by KEPCO & Doosan Group Capacity : 600MWe (steam condition - more than 600 o C/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 & CO 2 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)

15