Slide 1

Good morning, everyone. (Speak individually)

My name is Kuntaphon Lerssubsuree
My name is Wanee Seesamrittipon
My name is Ittisak Promma
Today, we are here to present “The integrated coal gasification combined cycle
power generation plant design”.

Slide 2
Firstly, this is our outline. Our presentation contains 5 parts which are
introduction, objective and scope of work, literature review, methodology and the
last one, work plan.

Slide 3
Let’s get started with an introduction, this slide shows the share of power
generation by fuel in Thailand. Natural gas is the most proportion fuel that uses
to produce electricity in Thailand which is sixty percent. In case of coal and
lignite, it is eighteen percent. Due to the lack of natural gas in 20 years, we have
to consider power generation from coal and lignite.

Slide 4
This slide expresses an increasing of using coal to produce power from 1986
(nineteen-eighty six) until now such as on the slide in 2016, Power generation
from coal is about thirty seven thousand gigawatt-hour and it tends to increase in
the future. It can be said that coal and lignite gain more popularity in the recently
years.

Slide 5
There are also many advantages which can be concluded into 5 main parts as
followed, number one reliability coal quantity can be guaranteed to supply during
peak electricity usage,
number two affordability coal is inexpensive, so electricity from coal is cheaper
when comparing to the others,
number three abundance, the plenty of coal assured that coal power plant is
possible from now on and over 200 years,
number four coal power technologies are general for almost regions,
finally, coal power plant is more out of danger than others.
So, we can say that it’s worth to invest in this plant.
Slide 6
Then, we’re going to talk in detailed about coal power plant. There are two main
types of coal power plant which are pulverized coal-fired power plant (or briefly
PC) and integrated gasification combined cycle process (or briefly IGCC
process). Nowadays, almost power plants are operated as PC while IGCC is
considered as a new technology. The big difference between PC and IGCC is
environmental parameters, you can notice that IGCC gives better value, for
example, sulfur dioxide emission is reduced from o point six to o point o six
kilogram per mega watt-hour. Moreover, its efficiency is higher than PC so it is
obvious that we have to choose IGCC before PC.

Slide 7
Next, .our goals is to design and simulate a preliminary Integrated Coal
Gasification Combined Cycle Power Generation Plant (IGCC) using the Shell
gasifier and to suggest profitable operating condition for the process. For scope
of work, we are going to use Aspen plus V 8.8 to simulate the plant and the dry-
fed Shell gasifier is considered. For economic analysis, CAPCOST is used to
demonstrate cash flow analysis, IRR and payback period.

Slide 8
The following part is block diagram for IGCC process, (Click)
Starting with coal and air at the top, coal and air passed through two units
separately. (Click) Coal fed into feed preparation, after that we got pulverized
coal and (Click) air flew to air separation unit so that to we gain pure oxygen and
pure nitrogen to use for later unit.
(Click) Then, coal and oxygen were fed to coal gasification plant to produce syn
gas (carbon monoxide and hydrogen) with impurities and undesirable product
which is slag. Therefore, water is added to the process to crystallize the slag and
then we can remove the slag easily. (Click) Moreover, gas cleanup and cooling
process are needed for syngas to remove H2S and CO2 from it. (Click) Then, we
had clean syngas put into combined cycle power plant (Click 2 times) that
contained of steam and gas turbine to generate the electricity. (Click) And we
have boiler feed water to exchange heat between CGP and CCPP and another one
is between CCPP and gas cleanup and cooling process.
Slide 9
First unit is Air separation unit (ASU).
As we told before, we obtained pure nitrogen and pure oxygen that will be used
for the other units.
(Click) For low pressure nitrogen, it went to coal feed preparation to convey the
pulverized coal, went to CGP to quench the product from CGP, and went to CCPP
to control quantity of NOx production, respectively.
(Click) For high pressure nitrogen, it went to gas cleanup and cooling process to
separate fly ash from syngas stream.
(Click) For oxygen, it went to CGP to occur gasification reaction.
(Click) And in CCPP we fed ambient air into the process, and we would extract
some air to ASU then we can reduce the energy consumption resulted from inlet
air compressors.

Slide 10
For ASU design, the important unit is distillation column that separate nitrogen
and oxygen from others, (Click) so we spotted on normal boiling point of oxygen
and nitrogen. (Click) As you see nitrogen’s boiling point is less than oxygen’s so
nitrogen’s concentration is more and more when going upwards to the top of the
column (the direction of the pink arrow) (Click) whereas oxygen’s concentration
is more when going downwards according to the direction of purple one.
(Click) And it’s correspond with the orange one that temperature is increased
when going to the bottom of the column.

Slide 11
To make it easy, we can spilt this one column into two different pressure column,
the top one is low pressure (LP) column and the below one is high pressure (HP)
column. (Point to the right before the left one.)
First, air and extraction air as we mentioned before, passed through air filter, then
two different phases of air flew into HP column and the product is liquid nitrogen
at the top with purity ninety-nine point eight mol percent. They are separated to
2 streams (LP nitrogen and HP nitrogen) and crude oxygen at the bottom. Crude
oxygen is sent to LP column to purify the concentration to meet design
specification at ninety-five mol percent.
Since the minus temperature that needed to operate this column, there is an
Internal reboiler to recover and save energy as much as possible.
Internal reboiler acts as condenser for the HP column, heat from condensing
nitrogen can be used to heat oxygen for the top column so, internal reboiler is
rebolier for the LP column. After distillated, we will get the oxygen as the bottom
product. (The purple arrow)
Slide 12
We move to the next unit which is coal gasification plant (CGP)
We chose an entrained-flow gasifier which operates at high temperature and
pressure causing rapid feed conversion so high oxygen concentration and small
size particle of feed are required this is the reason why we need ASU in our plant.
So, we got high concentration of oxygen (purple arrow) to supply to this unit.
And we need feed preparation unit to mill and dry the coal feed to get the
pulverized coal. (LP nitrogen from ASU is used in feed preparation unit too.)
Coal and oxygen reacted together to give syngas, then the stream is quenched and
passed through heat recovery unit where steam is generated. Before going to later
unit, we need to remove fly slag from syngas. Finally, you will see that we have
a recycle stream to quench the product from gasifier but in this case we will use
LP nitrogen from ASU instead (the pink arrow).

Slide 13
Next, for gasifier part from our problem statement and based on the information
via many sources, our data that we have correspond to shell coal gasification
process (SCGP). Its advantages are wider range feedstock and give the highest
plant efficiency.
Its disadvantage is the highest cost of electricity and capital cost.
When we get oxygen and nitrogen, we do CGP (Coal gasification plant).

Slide 14
And gasification product depends on the proportion between oxygen and
moisture free coal feed. If syngas is primary product, the proportion is about zero
point eight to one point three. Definitely, we got impurities in product stream
which are carbon dioxide H2S COS and ammonia. So, it's necessary to have the
following up unit, Gas clean up unit.

Slide 15
Next, we are going to talk about the gas cleanup system. This system can be
installed before or after the combined cycle power plant. Comparing between two
cleanup systems, the before installation system or pre-combustion cleanup system
is more efficient and costs less. It is because, for the post-combustion clean up
system, air is added to CCPP for complete combustion reaction that increase mass
flow rate of the outlet stream significantly and make bigger equipment. Moreover,
the pressure of the gases for pre-combustion cleanup is higher, which directly
reduces the volumetric flow rate lead to smaller size of vessel and other
equipment, then it affects to lower capital cost.

Slide 16
Gas clean-up follows step by step. First, syngas enters to COS converter where
COS hydrolysis reaction occurs converting COS to H2S. Second, ammonia is
removed in the removal unit using water as an absorbent. The contaminated water
is treated and recycled to the ammonia removal unit. Third, H2S is removed by
using MEA as an absorbent. The H2S is stripped out and go to sulfur recovery
where claus reaction occurs to give sulfur as a product. After that, it is optional
which water-gas shift converter and carbon dioxide removal. The clean syngas is
sent to the last process Combined Cycle Power Plant (CCPP)

Slide 17
At CCPP, clean syngas and air are fed to combustor to complete a combustion
reaction. The exothermic reaction increases the temperature of flue gas which is
used for driving an expander. The power that the expander generate is used to
drive a air inlet compressor and generate electricity in generator. Nitrogen is also
fed from ASU to the combustor to prevent NOx production. Next, an expander
effluent pass through HRSG before leaving the process. HRSG is used to
recovery heat from the exhausted gas. The inside water is boiled to be steam and
it is sent to produce additional electricity via steam turbine.

Slide 18
Not only steam from HRSG unit, but also steam from Coal Gasification Plant
(CGP) and Gas Cleanup Process is used for generating additional electricity via
steam turbine. Condensate is recycled to these 3 units. By installation steam
turbine, an overall energy efficiency can increase from 45% up to 52-53% .
Slide 19
This is our methodology. Now, we already finished step 1 and 2 which are
studying the IGCC problem statement and analyzing data and recapping literature
review. The later, step 3, we going to Design and Simulate Preliminary IGCC
plant before correcting the input parameter to meet output specification in step 4.
Finally, step 5 and 6 equipment sizing, costing and economic analysis are done
respectively.
Slide 20 Methodology
This slide represent our work plan and now, we’re here at the third of September
so the next step we are looking forward to finishing the simulation of all parts
before the end of October.

Slide 21 End
Thank you for your attention. All questions and comments are welcomed.