03 APEC-Clean Fossil Energy Technical & Policy Seminar

CCT Experience of Tong-Hae CFB Boiler Using Korean Anthracite

Combustion & Thermal Engineering Group, Power Generation Laboratory, KEPRI, KEPCO J. M. Lee, J. S. Kim, J. J. Kim
KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Introduction
Need to activate a domestic coal industry
Coal Consumption [thousand ton]

30000

Electric Power [MW]

25000 20000 15000 10000 5000 0

Nuclear Coal-fired LNG-fired Oil-fired Hydro

60000 50000 40000 30000 20000 10000 0 bituminous coal anthracite coal

1999

2000

2005

2010

2015

'99 '00 '01 '02 '03 '04 '05 '06 '07 '08 '09

Year

Year

Electric Power Generation with Energy Source

Consumption of Imported and Domestic Coal

Tonghae Circulating Fluidized Bed Boiler - Electric Power Generation : 1, 2 units 200 MWe (693 Steam t/h) - Using Korean Anthracite - The First and Largest CFB boiler using Low Quality Coal KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Plan of the Tonghae Thermal Power Plant CFB

Unit # Start Engineering Start Site Excavation Start Steam Generator Steel Erection Initial Firing Synchronization Commercial Operation #1 Unit 1994. 12 1995. 2 1995. 10 1997. 10 1998. 1 1998. 10 #2 Unit 1994. 12 1996. 4 1996. 12 1999. 1999. 1999. 3 7 10

Participants in the Tonghae CFB Project

KEPCO : KOPEC : ABB-CE : DOOSAN :

End User - (Korea East-West Power Co.) Project Architectural Design Basic Design Boiler Equipment Fabrication and Procurement KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Commercial CFB Boiler Location in Korea

C apacity Steam C ategory (M W ) (T/H ) C hem ical Textile Textile R efinery 12.5 27 25 9.2 Fuel Start Supplier

C om pany(L ocation) O riental C hem ical (Inchon) Sunkyung(Suw on) Sunkyung(U lsan) H yundai O il (Susan)

CFB Boiler in Korea

120 B itu. C oal, Pet. C oke 1985 H yundai /A hlstrom 130 B itu. C oal 1988
Susan Inchon Suwon Tonghae CFB Boiler 200X2 MWe

200 B itu. C oal, Pet. C oke 1989 120 210 Pet. C oke B itu. C oal 1989 1989

L GC hem ical (Y ochon) C hem icals Petrochem ical Service C o C ogen. (U lsan) Sunil G lucose(Inchon) D yeingC om plex(Taegu) Jeil Sugar (Seoul ) H ansol Paper (Jeunju) D yeingC om plex(Pusan) K oreaEnergy(U lsan) Food D ye Food Paper D ye M etal

Taegu

250 B itu. C oal, Pet. C oke 1990 60 B itu. C oal, H eavyO il 1991 B itu. C oal B itu. C oal B itu. C oal

Jeunju Yochon Ulsan Pusan

54.1 130x3 5.4 23 43.5 40 130

1986 Sam sung/B abcock 1988 1990 D aew oo/B & W H anjung/L urgi

80 B itu. C oal, H eavyO il 1991 175 693 B itu. C oal A nthracite 1991

K EPC O(Tonghae #1, #2) Electricity 200x2

1998 H anjung/A B B -C E

By Lee

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Complete View of the Tonghae Power Plant

Ash Pond

Indoor Coal Yard

CFB Power Block

Main Office

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Power Generation Process of the Tonghae CFB

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Tonghae CFB boiler

Type

- CFB, Indoor - Natural Circulation - Balanced Draft System

Leading Specification

- Steam Flow : 693 T/H

- Max. Operating P @ T: 169.6 kg/cm2, 541oC

Emission Control Designed

- SO2 (O2:6%) : 180ppm /150ppm

- NOx(O2: 6%) : 250ppm /350ppm

Ash Distribution

- Fly Ash : 50% - Bottom Ash : 50%

Rectangular Furnace Design

- More than 2:1 Aspect Ratio : to Allow for Good Fuel Mixing - Size : 32m (H) x 19m (W) x 7m (L) - Start-up Burner (Side Wall) : 4 - Lance Burner : Side-2, Rear-3

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Fluidizing Nozzle
T-Style Fluidizing Nozzle : ABB-CE Patented : Minimize Potential Nozzle Plugging Large Opening : Minimize Pressure Drop To Preclude Backsifting

Cyclones and Sealpots

3 Layer Refractory Lined - Insulating, Firebrick, Erosion Resistant Brick layer Provided Vortex Finder Loop seal (Sealpots) - to Prevent Material Back-up

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Fluidized Bed Heat Exchanger (FBHE)

Ash Control Valve (ACV)

3-External FBHEs : EVA., RH. and SH. : To be capable of operation below 30% Load : Independently controllable solids flows by ACV : Control furnace temp. KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Convective Backpass
Steam cooled backpass wall and convective backpass tubes Desuperheater stations, and retractable soot blowers

Air Heater

Air - Gas - Over Tubular Type Three Major Section : : Primary Air (PA) and Secondary Air (SA) - Furnace : Fluidizing Air (FA) - to FBHE, FBAC, Sealpots

Fuel Feed System

6-Fuel feed system (950~1000 kcal/m2s), 3-Coal silo (16 hour capacity) Gravimetric feeders (10 : 1 Turn down ratio)

Lime Feed System

2-Limestone blower, 2-Limestone silo (12 hour capacity) KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Circulating Fluidized Bed Combustion

Solid Fluidization

Backpass

Gas Flow Gas Flow

Coal Silo Cyclone Boiler

Solid Flow

- Lower part of furnace : dense phase - Upper part of furnace : dilute phase - Annulus and core structure - Furnace Cyclone Loopseal (FBHE) Furnace

Emission Control - Desulfurization in combustor

Solid Flow

Air

FBHE Air
Windbox

: CaCO3(fed) + SO2 + 1/2O2 CaSO4 + CO2 - Low operation temperature (<900oC) : low NOx emission - Without additional emission control system

FBAC

Advantage

Primary Air

Air

- Fuel flexibility - Wide size distribution of fuel - Easy to handle solid particles - High heat transfer rate - Stable for external thermal shock

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Analysis of Korean Anthracite

Dogae Moisture VM FC Ash C H O N S Ash SiO2 Al2O3 Fe2O3 CaO MgO Na2O K2O TiO2 HGI 3.26 3.90 60.86 31.98 63.21 0.77 2.16 0.39 0.41 33.06 53.41 34.82 2.60 0.80 0.65 0.16 4.65 2.14 93 Dongwon 3.07 4.33 51.00 41.60 52.58 0.77 3.01 0.36 0.36 42.92 54.36 31.53 4.40 0.86 0.70 0.33 4.93 1.83 93 Samchuk Kyungdong Proximate analysis 3.60 3.76 3.89 3.92 58.44 65.32 34.07 27.00 Ultimate analysis 60.76 68.79 0.82 0.82 2.41 2.41 0.43 0.43 0.24 0.24 35.34 35.34 Ash analysis 56.41 52.58 31.38 32.99 2.53 6.10 0.58 0.99 0.65 0.72 0.34 0.20 4.08 3.71 2.02 2.24 105 73 Jangsung 2.82 5.00 47.02 45.16 49.41 0.80 2.48 0.40 0.44 46.47 54.51 32.54 4.17 0.72 0.62 0.23 4.77 2.24 Hanbo 4.46 4.09 60.40 31.05 63.74 0.79 2.10 0.46 0.41 32.50 52.37 33.67 5.60 0.84 0.44 0.14 4.0 2.77 82 Taebak 4.15 3.68 61.58 30.59 64.38 0.80 2.16 0.50 0.22 31.92 54.20 32.27 4.39 0.92 0.78 0.24 4.13 1.95 -

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Size Distribution of Korean Anthracite

Size (mm) > 9.5 5.6 9.5 4.75 5.6 2.8 4.75 2 2.8 1.0 2.0 0.6 1.0 0.25 0.6 0.1 0.25 0.075 0.1 < 0.075 Design PSD (wt.%) 0 0 1.0 2.0 16.0 31.0 16.0 17.0 10.0 2.0 5.0 #1 PSD (wt.%) 1.0 14.4 5.1 12.3 7.2 20.0 14.6 14.6 5.8 3.0 2.0 #2 PSD (wt.%) 0 5.0 1.2 2.9 2.4 14.0 20.0 26.0 17.9 3.1 11.0 #3 PSD (wt.%) 0 24.4 5.1 11.5 4.0 11.0 6.0 12.0 13.6 2.4 10.0

Size Change of Korean Anthracite

Devolatilization & Combustion

Effect of heating rate and particle size on fragmentation

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

1.0
Normalized Weight Loss [-]
1 .0

Combustion Characteristics of Korean Anthracite

0 .0 4 0 .0 2 0 .0 0 0 .8 -0 .0 2 -0 .0 4 0 .6 -0 .0 6 0 .4 -0 .0 8 -0 .1 0 0 .2 0 100 200 300 400 500 600 700 800 900 -0 .1 2 1000

0.8

0.6

W/Wo [-]

T e m p e r a tu r e [ o C ]

0.4
Normalized Weigh Loss [-]

0 .0 4 1 .0 0 .0 2 0 .0 0 -0 .0 2 0 .6 -0 .0 4 -0 .0 6 -0 .0 8 -0 .1 0 -0 .1 2 1000

0 .8

0.2 Tonghae Coal Bituminous coal 0.0 0 200 400 600 800

Ignition T : 500 - 600oC - very low combustion reactivity Chemical reaction control regime :

0 .4 0 .2 0 .0

1000

100

200

300

400

500

600

700

800

900

T e m p e r a tu r e [o C ]

Temperature [oC]

-3

900

800

700

600

550

dX 25767 = 1.492 1010 exp( ) PO2 (1 X ) 2 / 3 dt T -5

900

800

700

600

500

3-10 times lower than bituminous gas film C.R

-6

Shrinking Core M odel Fit Volumetric M odel Fit

-4
gas film control regime chemical reaction control regime E = 51.2 [kcal/mol] k o = 1.492x10 10 [s -1 ] pore diffusion control regime E = 23.5 [kcal/mol] 3 -1 k o = 1.695x10 [s ]

E 0 [kcal/mol] -4 -1 k o = 8.3601x10 [s ]

-5 ln K

-6

ln K

E = 0.5 [kcal/mol] k o = 0.024 [s -1 ]

-7

pore diffusion C.R E = 2.3 [kcal/mol] -3 -1 k o = 4.7472x10 [s ]

chemical reaction C.R E = 16.5 [kcal/mol] k o =11.2389 [s -1 ]

-8

-7

-8

-9

-9 0.0008

0.0009

0.0010
-1

0.0011

0.0012

-10 0.0008

gas film C.R E 0 [kcal/mol] k o = 2.6176x10 -4 [s -1 ] pore diffusion C.R E = 1.5 [kcal/mol] -4 -1 k o = 7.6937x10 [s ] chemical reaction C.R E = 14.5 [kcal/mol] k o = 0.9518 [s -1 ]

0.0009

0.0010

0.0011

0.0012

0.0013

0.0014

1/T [K ]

1/T [1/K]

KEPRI

dW/dT

dW/dT

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Characteristics of Korean Anthracite

Very low combustion reactivity High content of fine particles (<0.1mm :10 - 20%) high content of coarse particles High degree of fragmentation Low Volatile content - VM : 3.7-5.0% High Ash content - Ash : 27 - 42% Low heating value - 4,500-5,000 kcal/kg Relatively high HGI - about 90 - 110

Korean anthracite

Low combustion efficiency due to short residence time High temperature in freeboard and cyclones due to post-combustion

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Initial Experience of the Tonghae CFB Boiler

High temperature and Longer time during bed material heat up : in sealpots, cyclone inlet and outlet (1000-1100 oC) : in combustor (880~920 oC) Formation of clinkers, Fouling of fine particles Low circulation rate (upper P 100mmH2O design : 170~190mmH2O ) : higher temperature and unstable bed condition ( 900oC) : higher SOx emission (Ca/S mole ratio 3.0-3.5 (<150ppm)) Defluidization and clinker formation : due to nozzle back sifting and plugging in the combustor : unstable fluidization and particles segregation in FBAC, FBHE Low combustion efficiency : about 18~20% unburned carbon in fly ash

Technical approach to solve the problems

Modification of the System - Cyclone, Nozzle, FBAC drain line, etc Optimization of the Operation Cold CFB Reactor, IEA-FBC simulation Characterization of the Coal Lab. Scale CFB Combustor, TGA KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Modification of the System of the Tonghae CFB boiler

o High temperature, Clinker formation in Sealpots and Cyclones Grease (aeration) air line at sealpot (35 places at each sealpot) Grease air line around ACV at sealpot (10 places at each ACV) Observation windows at sealpot (1 window at each sealpot) Duct water spray nozzle at cyclone inlet (1 spray nozzle at each cyclone) o High temperature in combustor, Longer time during heat up bed material Injection port of bed media (3 places furnace) Lance burner in a furnace (5 places - dense bed region in furnace) o Low circulation rate Cyclone modification (Vortex finder, inlet duct width change) o Defluidization and Clinker formation Fluidizing nozzle modification (Nozzle orifice angle and shape change) Solid drain line (7 places at fluidizing air line) Solid drain line at FBAC (Hot and cold region, respectively) Bed media management system (FBHE media drain and sieve system) o Low combustion efficiency Ash reinjection system (from A/H & EP hopper to combustor)

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Example of System Modification (Ash reinjection system)

Ash Hopper for Reinjection

Reinjection Port of Combustor

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Current Status of the Tonghae CFB boiler

Cyclone inlet T 30 Combustor Height [m] 25 20 15 10 5 0 700 annulus before modification after modification

core

750

800

850

900
o

950

1000 1050

Temperature [ C]

before ash reinjection

after ash reinjection

Bed Temperature Design : < 900oC Before : 900oC After : 850 - 870oC Cyclone inlet Temperature Design : 900oC Before : 960 - 1020oC After : 910 - 930oC Cyclone outlet Temperature Design : 927oC Before : 980 - 1020oC After : 940 - 960oC Sealpot Temperature Before : 960 - 1000oC After : 900 - 930oC Bed Temperature Difference Somewhat decrease

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Current Status of the Tonghae CFB boiler

before modification after modification
Sampling from Stack

30 Combustor Height [m] 25 20 SO2 15 10 H2O 5 0 0 5 10 15 20 0 10000 20000 0 500 1000 Gas Concentration [%] Gas Concentration [ppm] CO2 CO NOx O2

SO2 emission : decrease Ca/S mole ratio (150ppm) : Before : 3.5 After : 2.5-3.0

Current Emission Level - SO2 (150) : < 110 ppm - NOx (350) : < 50 ppm - Dust (50) : <10 mg/Sm3

KEPRI KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Current Status of the Tonghae CFB boiler

Power Generation (1, 2 units)
- Power Generation at 2002 : about 2,400,000MWh - Overall Efficiency for Power Generation : 36.88 % * Other Power Plant using Korean Anthracite : 30~34% (Combustion Efficiency : >90%) - Coal Consumption : 1,214,000 ton/year : shows Good Performance for Economical and Environmental efficiency

Future Work for Optimization

- Reduce UBC in Fly ash : Unburned Carbon in fly ash 15~18% (bottom ash 3%) - Complete Perfect Fluidization : Unstable Fluidization in FBAC

KEPRI

03 APEC-Clean Fossil Energy Technical & Policy Seminar

Conclusions

Initial experience of the Tonghae CFB boiler using Korean anthracite

Higher temperature in sealpots, cyclone inlet and outlet Lower circulation rate and unstable bed condition Higher SOx emission (Ca/S mole ratio 3.0-3.5 (<150ppm)) Lower combustion efficiency

Modification of the system and Optimization of the operation

Cyclone Modification Addition of Ash Reinjection System Nozzle Modification ..

Current Status of the Tonghae CFB boiler

Good Performance and Efficiency for Combustion of Korean Anthracite Good Environmental Efficiency (Gas emission and Ash utilization ) Stable Operation and Power Generation

KEPRI