Company Brochure

Table of contents

1. Company Profile / Company Description...................... 3

2. Scope of Services.................................................... 4

3. Gasification............................................................. 6

4. Feedstocks and by-products..................................... 7

5. History of gasification process................................... 8

6. The PRENFLO® Process

with Steam Generation (PSG).................................. 10

7. Syngas application................................................. 12

8. SNG production..................................................... 13

9. IGCC plants for electric power generation................. 14

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1. Company Profile / Company Description

KEPCO-Uhde Inc. is a technology company which offers ThyssenKrupp Industrial

Solutions PRENFLO® PSG (PRENFLO® with Steam Generation) gasification process to the
market. The main business areas are global gasification projects for Integrated Gasifica-
tion Combined Cycle (IGCC), Synthetic Natural Gas (SNG) and polygeneration concepts of
plants. KEPCO-Uhde offers licenses, Basic Engineering Packages (BEP) and technology
services to its customers. Furthermore, KEPCO-Uhde is active in technology develop-
ment of its process.

KEPCO-Uhde is a joint venture between KEPCO, the largest utility in South Korea, and
Germany based ThyssenKrupp Industrial Solutions, one of the largest technology-driven
EPC contractors. The company has been in operation since July 2011.

KEPCO-Uhde Inc. is poised to build together with KEPCO the largest IGCC power plant
and become a global front runner in Integrated Gasification Combined Cycle, Synthetic
Natural Gas, polygeneration and Carbon Capture & Storage which are strong in
economics, efficiency and environment-friendliness.

Shareholders

KEPCO has 66 % share of the joint venture which are distributed between KEPCO itself
(45 %) and the 5 power generation companies of KEPCO, KEPCO E&C as well as KEPCO
KPS with 3 % respectively. ThyssenKrupp Industrial Solutions is holding 34 %.

KEPCO is a top class utility & engineering company in the world which is not only the
largest electricity producer in South Korea but also strenuously expanding its busi-
ness overseas. ThyssenKrupp Industrial Solutions is a globally recognized technology-
oriented EPC contractor for the chemical industry which holds essential know-how in
gasification technology.

Kepco Group
66%

ThyssenKrupp Industrial Solutions

34 %
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2. Scope of Services

KEPCO-Uhde is dedicated to providing its customers with a wide range of services and to supporting them in their efforts to suc-
ceed in business. We place particular importance on interacting with our customers at an early stage to combine their ambition
and expertise with our experience. Upon potential customers' requests, we are always willing to give them the opportunity to
visit operating plants.

We aim to build our future business on the confidence our customers place in us. We remain in contact with our customers even
after project completion. KEPCO-Uhde is committed to becoming a byword for partnership.

We would like to cultivate our business relationships and learn more about the future goals of our customers. Our aftersales
services include regular consultancy visits which keep the owner informed about the latest developments or revamping
options. KEPCO-Uhde and its partners stand for tailor-made concepts and international competence.

Licensing and Engineering

KEPCO-Uhde Inc. is the technology provider for the manufacturing and construction companies, ThyssenKrupp
PRENFLO® PSG gasification process. It offers licenses of the Industrial Solutions and last but not least KEPCO-Uhde itself.
PRENFLO® PSG process and corresponding engineering
services such as Basic Engineering Packages (BEP). Figure 1 on the right illustrates that the fleet delivers com-
plete project solutions to customers. This includes EPC for
Furthermore KEPCO-Uhde delivers services such as: the complete plants as well as solutions for the operation
& maintenance of the plant. Financing assistance and equity
commissioning of the plant investment by the KEPCO group are also possible. Further-
feasibility studies more, the KEPCO Fleet can offer packages including trans-
training of operating personnel mission and natural resource development. KEPCO-Uhde
after-sales services delivers the gasification technology for the projects and is the
marketing and sales representative of the KEPCO Fleet.
The major areas of activities are IGCC plants with and without
Carbon Capture & Storage (CCS) technology as well as plants
for the production of SNG. Research & Development

KEPCO-Uhde Inc. is active in research and development

Marketing & Sales in its field of technology. Together with its strong parent com-
panies, KEPCO and ThysssenKrupp Industrial Solutions, the
KEPCO-Uhde Inc. is part of the KEPCO group and is an es- process is developed further.
sential part of the so-called KEPCO Fleet.
KEPCO-Uhde, together with KEPCO, is currently executing
The KEPCO Fleet has been established to deliver to cus- its first R&D project with the goal of optimizing the overall
tomers world wide a one stop package solution for gasification flowsheet for IGCC and SNG plants based on its gasification
based IGCC, SNG and polygeneration plants. The KEPCO technology. Through this R&D, KEPCO-Uhde is aiming at
Fleet consists of KEPCO, the 5 power generation companies providing an optimized plant concept which suits customers
of KEPCO, KEPCO E&C (a reputable and experienced needs to the maximum extent.
engineering company in the energy sector), KEPCO KPS (a
reputable and experienced maintenance company), Korean
 5

Figure 1:

KEPCO Fleet KEPCO Fleet delivers one stop

package to customers world wide.

KEPCO

Customers Needs
ThyssenKrupp Industrial Solutions

IGCC
KOSEP

KOMIPO CCS

KOWEPO
SNG
KOSPO
One Stop Package Polygeneration
EWP Financing & Equity*
KEPCO E&C EPC
Operation
KEPCO KPS & Maintenance

Manufacturers Transmission and Natural

Resource
Construction Companies Development

* Financing assistance as well as

equity investment by the KEPCO group are
possible.
6

3. Gasification

ELCOGAS S.A., Why gasification?

Puertollano, Spain.
Gasification is mainly a high-temperature partial oxidation pro-
The world’s largest
IGCC power plant uses Kepco-
Gasification processes offer a number of upstream and cess for converting carbonaceous materials into a synthesis
Uhde’s downstream advantages to customers faced with rising oil gas composed mainly of carbon monoxide and hydrogen. A
PRENFLO® process. and gas prices, dwindling energy reserves and a need to meet number of chemical reactions are in-volved, some exothermic
increasingly stringent environmental legislation. With proper and some endothermic:
preparation a variety of carbon-
based materials can be easily gasified to produce syn- Exothermic:
thesis gas (syngas) for the subsequent production of C + ½O2      CO C + O2      CO2
energy, chemicals and liquid fuels. Gasification is particularly
clean and efficient. Endothermic:
C + CO2      2 CO C + H2O      CO + H2
Gasification is also flexible with respect to feedstock quality
and the use of mixed feedstocks. The gasification of low-value During the gasification process, the sulphur present in the
or waste materials is also an attractive option. Even otherwise feedstock reacts to produce mainly hydrogen sulphide (H2S)
problematic materials can be gasified together with the main and carbonyl sulphide (COS):
feedstock.
S + H2      H2S
As coal is much more abundant than oil and gas and global S + C + ½ O2      COS.
availability ensures security of supply and relative price stabil-
ity for the foreseeable future, coal will play an ever greater Sulphur can therefore be readily recovered in its el-emental
role in power generation, the chemical industry (e.g. in South form or as sulphuric acid, both marketable commodities.
Korea, India, China and Africa) and in the production of liquid
fuels (gasoline, diesel, etc.). Coal gasification technology
offers environment-friendly, efficient solutions for these ap-
plications. In power generation, for example, gasification can
Worldwide Gasification Capacity and Planned Growth
achieve high thermal efficiencies and also forms a basis for Commulative by Year
Carbon Capture and Storage (CCS).

KEPCO-Uhde’s proprietary PRENFLO® with Steam Generation

(PSG) technology provides an optimal gasification solution for
a variety of applications.

What is gasification?
 7

4. Feedstocks and by-products

Coal, lignite and wood

PRENFLO® gasification with dry dust feed is able to handle gasification of solids produces: slag, fly ash and, after sub-
all types of coal (hard coal, lignite, anthracite) as well as sequent gas treatment, elemental sulphur or sulphuric acid.
petroleum coke, char and biomass (e.g. chicken litter, sew- Slag, a non-leachable product, can be used in road building
age sludge, wood). In addition to the main product (syngas), or to manu- facture bricks while fly ash is a base product of
gasification produces by-products of economic value. The choice for the cement industry.

Products from PRENFLO® slag Sulphur

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5. History of gasification process

PRENFLO® coal gasification

Fürstenhausen, Germany
coal-to-syngas

Koppers-Totzek gasification
Modderfontein, South Africa
coal-to-ammonia/fertilisers

PRENFLO® IGCC
Puertollano, Spain
petcoke/coal-to-energy/hydrogen

Development of KEPCO-Uhde’s PRENFLO® PSG

process with plants successfully completed.
 9

KEPCO-Uhde builds on ThyssenKrupp Industrial Solutions’ experience of over 65 years in the de-
velopment, design and construction of gasification plants. ThyssenKrupp Industrial Solutions’ list of
references already includes over 100 gasifiers worldwide based on different gasification technolo-
gies covering a variety of feedstocks, and the expertise continues to grow.

Krupp Koppers, who merged with Uhde in 1997, de-

veloped the first entrained-flow gasification system
(Koppers-Totzek process) in the early 1940s and built the first
commercial Koppers-Totzek plants at the be-ginning of the
1950s. The German patent shown on
the right was issued in 1952 for an uncooled refractory-lined
Koppers-Totzek gasifier. The cooled gasifier was designed
some years later.

Most other entrained-flow gasification systems are refine-

ments of the Koppers-Totzek process – for example, the Shell-
Koppers gasification process, an entrained-flow gasification
process at elevated pressure. This process was demon-
strated at a plant in Hamburg,
Germany, in the early 1980s.

The PRENFLO® technology marks a further development of

this process in the late 1980s. Tests at a demonstration plant
in Fürstenhausen, Germany, proved that PRENFLO® can ac-
commodate coals from all over the world as well as petroleum
coke without the need for modification. In addition, extensive
tests were performed to determine suitable materials of
construction.

In the late 1990s the world’s largest solid-feed-based IGCC

with PRENFLO® technology started operation in Puertollano,
Spain.

The above entrained-flow processes are based on dry dust

feed. German patent for Koppers-Totzek
process issued in 1952

ThyssenKrupp Industrial Solutions has additional experience

with a variety of gasification process such as fluidized bed
technologies as well as slurry technologies. This experience
is used to offer the most competitive gasification technology
to the market.
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6. The PRENFLO® Process

with Steam Generation (PSG)

Main process data:

Gasification pressure:
40 bar and higher

Gasification temperature:
> 2,000 °C

Gas temperature at
outlet of gasifier:
1,350  - 1,600 °C

Carbon conversion:
> 99 %

Typical raw gas

composition:
CO + H2 > 85 vol. %
CO2 2-4 vol. %
CH4 < 0.1 vol. %

Flow diagram of the

PRENFLO® (PSG) process

The PRENFLO® (PRessurised ENtrained-FLOw) process, which operates at elevated

pressure, can be used to gasify all types of solid feedstocks (coal, petroleum coke and
biomass).

It is a further development of the Koppers-Totzek process developed in the 1940s, which operates at atmos-
pheric pressure. PRENFLO® can look back on more than two decades of operating experience, providing a
wealth of lessons learnt which have formed the basis for subsequent successful applications.
 11

PRENFLO®
gasifier/boiler (PSG)

Process description

First, the feed dust is prepared in the feed preparation unit.

Approximately 80% of the dust is smaller than 0.1 mm and
has a water content of approx. 1-2 wt.% in the case of hard
coals and approx. 8-10 wt.% in the case of lignite. This
feed dust is then gasified in the PRENFLO® gasifier using Quench
oxygen and steam as gasification agents. The gasification gas
temperature is higher than the ash melting temperature,
which allows the coal ash to be removed as slag. The
cooled-type gasifier is equipped with multiple, horizontally
arranged burners.
Oxygen
In the PRENFLO® Process with Steam Generation (PSG), the feed

raw gas produced, which contains mainly carbon monoxide

and hydrogen, is cooled in the waste heat boiler, generating
steam. The gas is then dedusted in a candle filter and fur-
ther treated in a Venturi scrubber.

The slag from the gasifier can be used as a construction

material and the fly ash from the candle filter as a base pro-
duct in the cement industry.

PRENFLO® technology is used at the world’s largest solid-

feedstock-based IGCC power plant in Puertollano, Spain.

This plant operates with a mixture of petroleum coke and

coal. The following tables show the feedstock composition Slag
and an analysis of the raw gas produced.

Raw gas

Raw
Raw gas
gas analysis
analysis PSG
PDQ Main features of the PSG process:

Entrained-flow
Dry dust feed for high efficiency
Multiple burners with high availability and
long lifetime
Horizontally arranged burners for high
ppmv
ppmv
carbon conversion
Membrane wall with long lifetime
Waste heat boiler for efficient heat recovery
Operates above ash melting point
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7. Syngas application

The raw gas produced by gasification needs to be treated before it can be used for the
production of downstream products, such as SNG, electricity, hydrogen and other chemi-
cals.

There are various process routes available for obtaining the Rectisol.
desired syngas composition, which may be a mixture of
carbon monoxide and hydrogen or either pure hydrogen or KEPCO-Uhde’s gasification business is focused on SNG and
carbon monoxide alone. electricity production via IGCCs with and without carbon diox-
ide capture. For the downstream processing KEPCO-Uhde
Hydrogen, for example, can be used in the refinery in-dustry and ThyssenKrupp Industrial Solutions work closely together
to achieve lighter and cleaner liquid fuels or for new applica- using ThyssenKrupp Industrial Solutions’ vast experience in
tions such as fuel cells for power generation or cars. syngas-based chemicals plants.

Hydrogen-rich syngas can be produced via the “sour” CO

shift process. In this case, the CO in the raw gas produced by
gasification is shifted with steam to form hydrogen and car-
bon dioxide before the sour gas components are removed.

A number of processes are available for desulphurisation and

carbon dioxide removal, such as Genosorb, MDEA, aMDEA,

Chemicals
Residues

Liquid Fuels
Petcoke

Hard Coal H2

Lignite
IGCC/
Power
Biomass

SNG
 13

8. SNG production
Background on SNG Potential The production steps for SNG are shown in a block flow dia-
gram. After the gasification process a shift reaction to produ-
In 2013, the International Energy Outlook (EIA) projected that ce additional hydrogen is needed to satisfy the boundary
the world energy consumption will grow by 56 percent bet- conditions for the methanation process. Subsequently the
ween 2010 and 2040. Much of the growth in energy con- sulphur is removed from the process with a gas treatment
sumption occurs in non-OECD countries, where demand is process. Downstream of these units, the main reaction to
driven by strong long-term economic growth. SNG takes place. The product is then purified and is shipped
to battery limits. It is worth noting that the process chain is
Fossil fuels will continue to supply almost 80 percent of world overall exothermic and it is recommended to use the heat
energy use through 2040. Natural gas is the fastest-growing produced to generate electricity as shown in below Figure.
fossil fuel in the outlook. Global natural gas consumption
increases by 1.7 percent per year. The PRENFLO® PSG process is very well suited for this appli-
This increased demand for natural gas will have a significant cation since it is a highly efficient process reducing the feed-
impact on natural gas pricing. stock amount to a minimum. The steam produced in the
gasification section is used for electricity production as well
It is thus expected that the price and demand of gas will go up and makes the SNG plant power independent. Even power
gradually regardless of additional sources such as shale gas export is possible.
and this makes it attractive to produce natural gas based on
alternative fuels such as low rank coal. To give an impression of the size of the production plants,
please note that SNG production from one gasifier of over
Synthetic Natural Gas (SNG) has essentially the same 350,000 t/y is possible. One promising plant scheme is the
properties like natural gas and LNG. With a strong demand production of over 1.000.000 t/y of SNG using 3 PRENFLO®
for LNG e.g. in Asia, SNG is a valuable alternative which is PSG gasifiers and two trains of gas treatment processes. This
based on resources such as low rank coal and thus is looking set-up is using the optimal economy of scale of all needed
more and more attractive. This product is especially attractive process units.
in locations where natural resources are scarce.
As described in the Scope of Services, the optimization of this
SNG can be easily produced e.g. mine mouth and then trans- SNG plant concept is one goal of the currently executed R&D
ferred with the existing natural gas pipelines to industrial and task.
private customers. Essentially the same products produced
from natural gas can be also obtained from SNG such as
electricity and chemicals
(e.g. ammonia, methanol etc.).

Production Process

Power Power
Generation
Oxygen Steam

Coal PRENFLO CO-shift H2S CO2 Methanation Product SNG

PSG Removal Removal Purification

Sulphur CO2
Recovery

Elemental
Sulphur
14

9. IGCC plants for electric power generation

conventional power plant igcc plant

Supply and disposal flows

in 700 MWe hard-coal-fired
power plants

Solid feedstocks, such as coal, will continue to play an PRENFLO® (PSG) gasification technology using a mixture of
important role in power generation for the foreseeable future. high-sulphur petroleum coke and high-ash Spanish coal as
Integrated gasification combined-cycle (IGCC) technology the feedstock at the world’s largest solid-feedstock-based
offers an ideal method for cost effectively producing power IGCC plant in Puertollano, Spain.
from these feedstocks while offering substantial environmen-
tal benefits over other power generation technologies, such This IGCC plant is based on a highly integrated system in
as reducing CO2, SOx, NOx and particles emissions. The envi- which the total air for the air separation unit is taken from the
ronmental benefits can be improved even further by adding gas turbine compressor. The plant can be
biomass materials to the feedstocks. divided into three main parts:

The supply and disposal flows of a conventional power plant the gasification island, comprising the feed
are compared with those of an IGCC plant (see above). This preparation unit, the PRENFLO® gasification
comparison clearly shows how efficient and environment- unit, the gas treatment unit and a sulphur
friendly IGCC plants are. recovery unit
the power block, comprising the gas turbine,
ThyssenKrupp Industrial Solutions has designed and built the heat recovery steam generator and the
steam turbine
the air separation unit (ASU).
 15

Block diagram of an
IGCC power plant with PREN-
FLO® gasification

The figures show the average environmental data for opera-

ELCOGAS power plant
tion of the Puertollano plant with natural gas and petroleum
emissions in natural gas
coke/coal for the year 2013, and in addition the permissible EU Directive 88/609/EEC
combined-cycle and IGCC modes
EU Directive 2001/80/EC
limits under EU legislation. 292
ELCOGAS 2006 Environmental permit
EU Directive 2010/75/EU IED
250 ELCOGAS average 2013

IGCC technology allows for more effective CO2 removal and

155.9
Carbon Capture and Storage (CCS) applications than conven- 125

tional power plants with post-combustion CO2 removal.

29
13 NC 8 4 NC 0.5
KEPCO-Uhde Inc. is poised to build the largest IGCC power
plant with KEPCO and is aiming to become a global front run-
ner in Integrated Gasification Com-
bined Cycle and Carbon Capture & Storage which are
strong in economics, efficiency and environment-friend- 650 EU Directive 88/609/EEC
EU Directive 2001/80/EC
liness. The sizes of these days IGCC plants with one PSG 500 ELCOGAS 2006 Environmental permit
EU Directive 2010/75/EU IED
gasifier are in the range of 300 to over 450 MW net electrici- 400 ELCOGAS average 2013

ty production depending on customers needs. KEPCO-Uhde 300

together with KEPCO and ThyssenKrupp Industrial Solutions 200 200

111.9
aim their joint R&D to develop highly efficient IGCCs with an 8.3
50
5 20
0.2
output of approx. 500 MW from one gasifier.
Contacts

KEPCO-Uhde is dedicated to providing its customers with a wide range of services

and to supporting them in their efforts to succeed in business.

Together with ThyssenKrupp Industrial Solutions, KEPCO and the KEPCO Fleet members, we form
a strong team to deliver first-class solutions to our customers.

If you have any interest, please contact us at the following numbers and e-mail address.
We are looking forward to hearing from you.

KEPCO-Uhde Inc.
4F, Bubang Annex Bldg., 530,
Samseong-ro, Gangnam-gu,
Seoul 135-879, South Korea
Phone: +82 70 7862 1801-1805
Fax: +82 70 7862 1810
Email: [email protected]