Development Status of the Transport Gasifier at the PSDF · 2016-01-25 · PSDF Power Systems Development Facility Development Status of the Transport Gasifier at the PSDF Gasification

PSDFPower Systems Development Facility

Development Status of the Transport GasifierDevelopment Status of the Transport Gasifier at the PSDF at the PSDF

Gasification Technologies 2001San Francisco, California

October 7-10, 2001

Southern Company Services -- Roxann Leonard,Luke Rogers, P. Vimalchand, Guohai Liu

Kellogg Brown & Root, Inc. -- Peter V. SmithNational Energy Technology Laboratory -- James Longanbach


Presentation OverviewPresentation Overview

1. The Power Systems Development Facility

2. Transport reactor operation

3. Commercial design study

4. Future plans


Power Systems DevelopmentPower Systems Development FacilityFacility

“America’s Advanced Coal Research Center”


US Department of Energy(National EnergyTechnology Laboratory)

SouthernCompanyServices

Electric PowerResearchInstitute

APFBC/Gas Turbine

ParticulateCollection Devices

Kellogg, Brown & Root

B.O.P. Designand

Construction

SouthernCompanyServices

TransportModule

(Gasif./PFBC)

Operation,Maintenance

& Testing

Combustion PowerSiemens-

Westinghouse

Southern Company Services•Project Management•Engineering Coordination

PSDF ParticipantsPSDF Participants

Foster WheelerSiemens-

Westinghouse

SCSAlabama Power

Company

ParticulateSampling

SouthernResearchInstitute


PSDF ScalePSDF Scale

Bench-scale&

Small PilotPlants

Several

CommercialDemonstrations

CCT ProgramPSDF

IntegratedSemi-Commercial

Scale


PSDF OverviewPSDF Overview

TOPPING COMBUSTOR(MASB)

KBR TRANSPORTREACTOR

PULVERIZER

GASCOOLER HTHP FILTER (PCD)

GASDISPOSAL

ASH / CHAR REMOVAL

HOT SYNGASHTHP FILTER (PCD)

HOT FLUE GAS

CHAR

FW CARBONIZER

FW PFBC ASH REMOVAL

ASH COOLER

HTHP FILTER (PCD)

GASTURBINE 4 MW OF

ELECTRICPOWER

STACK

CRUSHER

LIMESTONEDOLOMITE

COAL

ASH COOLER


SiemensSiemens-Westinghouse-Westinghouse Filter at the PSDFFilter at the PSDF

Transport Transport ReactorReactor

CoalLimestone

Air

ProcessGas

SpentSolids Spent

Solids

CoalLimestone

Air

ProcessGas

• Air blown

• Dry feed

• Excellent gas-solids contact

• Highly turbulent atmosphere

• High coal throughput

• High heat release rate

• Moderate gas temperatures

• No expansion joints






4. Future plans


Test RunCR01-04CCT1CCT2CCT3CCT4CCT5CCT6TC01TC02TC03TC04TC05GCT1GCT2GCT3GCT4TC06

1996 1997 1998 1999 2000 2001

Gasification

Combustion

1312559

7950

1429233

217184

2421025

0 (hours on coal)81

137

214

177279

0

PSDF Transport Reactor Operation HistoryPSDF Transport Reactor Operation History


Combustion OperationCombustion Operation

Operating Pressure 175 to 225 psia

Operating Temperature 1500 to 1650oF

Total Hours 4985 hours

Longest Run 471 hours


Combustion Operation ResultsCombustion Operation Results

• NOx emissions of less than 0.1 lb/mmBTU

• SO2 emissions of less than 20 ppm

• Carbon conversions of greater than 99.9% with coal

• Carbon conversion of 99.7% with pet coke

• Achieved higher than design coal throughput

• Demonstrated the viability of the reactor designwithout expansion joints


Transport Reactor as a CombustorTransport Reactor as a Combustor

Air

Syngasto PCD

Sorbent

Propane

Coal

Ash

Air


Transport Reactor as a GasifierTransport Reactor as a Gasifier

Air

Syngasto PCD

Sorbent

Propane

Coal

Ash

Air


Gasification OperationGasification Operation

Operating Pressure 175 to 255 psia

Operating Temperature 1600 to 1800oF

Total Hours 1900 hours

Longest Run >700 hours


0

300

600

900

1200

1500

1800

2100

0 100 200 300 400 500 600 7000

40

80

120

160

200

240

280

Mixing Zone Temperature

Riser Temperature

Reactor Pressure

Tem

pera

ture

(deg

F)

Pressure (psig)

July Aug-Sept

Relative Time (hrs)

Gasifier ConditionsGasifier Conditions


Gasification ResultsGasification Results

Excellent gasification performance on sub-bituminous coal:• Syngas heating value just right for combustion turbine• Very good carbon conversion• No tar production

Coal feed and ash removal systems operated well.Achieved throughputs higher than design.No clinkers or agglomerates formed.


0

20

40

60

80

100

120

140

160

0 100 200 300 400 500

Relative Time (hrs)

Cor

rect

ed L

ower

Hea

ting

Val

ue (B

tu/S

CF)

Corrected Syngas Heating ValueCorrected Syngas Heating Value


More Gasification ResultsMore Gasification Results

• Good control of reactor and oxygen level duringstartup, shutdown, and emergency shutdown

• Smooth transition from start-up fuels to coal feed• Good filter system operation with low pressure drop

and stable baseline differential pressure(Most gasification hours have been with metal candles.)


16:05 16:10 16:15 16:20 16:25 16:30 16:35

100

200

300

400

500

600

0

700

Pres

sure

(psi

g)

August 31, 2001

Bottom Plenum Backpulse Tank PressureTop Plenum Backpulse Tank Pressure Filter Differential Pressure

Filter System PressuresFilter System Pressures


Low Solids Low Solids RecirculationRecirculation

• Caused by poor performance of solids collection system• Contributed to high pressure drop across filter systembecause of high dust loading• Resulted in low carbon content in gasifier bed materialand lower carbon conversion• Corrected by adding loop seal in cyclone dipleg andlengthening disengager barrel(Modifications have decreased mean particle size to thefilter system.)


0

1

2

3

4

5

6

7

8

0 20 40 60 80 100 120 140 160 180

Relative Time (hrs)

Rea

ltive

Sol

ids M

ass F

lux

Conventional Dipleg

Loopseal

Gasifier Mass FluxGasifier Mass Flux


70

75

80

85

90

95

100

0 20 40 60 80 100 120 140 160

Relative Time (hrs)

Car

bon

Con

vers

ion

( %)

Conventional Dipleg

Loopseal

Gasifier Carbon ConversionGasifier Carbon Conversion


Tar FormationTar Formation

• Caused by low temperatures in gasifier duringtransition from startup burner to coal and during coalfeeder trips• Resulted in blocked gas sample lines• Resulted in high filter system temperature becauseof blocked syngas cooler• Resulted in high pressure drop across filter system• Corrected by adding a coke breeze feed system,rather than increasing the startup burner output






4. Future plans


Transport Reactor Integrated Gasification SystemTransport Reactor Integrated Gasification System

Booster Comp. GE 7FA Gas Turbine one pres. level

HRSG

1820 psi/1000°FReheat

Steam Cycle

Expander

to stack

to stack

TransportGasifier

Syngas Cooler

Vitiated AirCooler

heat from coolersto Steam Cycle

SolidsCooler

Coal andSorbent Dry

Prep and Feed

coal sorbent

airair

750°FSyngasFilter

1000°FVitiatedAir Filter

ash to landfill

char

Multistage IntercooledAir Compressor

TransportCharCom-bustor


Commercial DesignCommercial Design

• Air-blown transport gasifier using PRB coal• Sorbent injection into gasifier to control SOx• Syngas filter operates at 750°F with metal

candles• Pressurized transport char combustor• Vitiated air filter operates at 1000°F with metal

candles• Clean vitiated air produces power through an

expander


Commercial Design (continued)Commercial Design (continued)

• One modified GE 7FA gas turbine• Process air supplied by gas turbine extraction

and a supplementary air compressor• Steam generated in HRSG and in gasification

island• Combined cycle designed to operate on natural

gas as a backup fuel• SCR system in HRSG to reduce NOx


TRIGTRIG™™ Performance Performance

Syngas Nat. gas Gas Turbine Gross Output 197,000 162,000 kW Steam Turbine Gross Output 120,806 127,645 kW Char Combustor Gas Expander Output 5,193 0 kW Auxiliary Load 24,647 8,742 kW Net Power Output 298,351 280,903 kW Heat Input From Coal (LHV) 2,300 0 MMBtu/hr Heat Input From Natural Gas (LHV) 35 2,011 MMBtu/hr Net Heat Rate (LHV) 7,827 7,158 Btu/kW-hr Net Efficiency (LHV) 43.6 47.67 %


lb/MMBtu ppmv lb/MW-hrNOx 0.07 27 0.59SOx 0.10 27 0.78CO2 217 -- 1770CO 0.05 30 0.39VOC 0.01 3.0 0.06particulates 0.002 1.0* 0.014

* particulates concentration is reported in ppmw

TRIGTRIG™™ Emissions Emissions


Account Total(1000$) $/kW

Indirects 108,146 362 Site, General 16,872 57 Steam Generation Area 29,903 100 Turbine & Generator Area 60,278 202 Fuel Facilities 83,219 279 Emission Facilities 24,753 83 Plant Water Systems 12,773 43 Electrical Distribution & Switchyard 14,913 50 Plant Instrumentation & Controls 15,195 51 Other 48,627 163 TOTAL 414,678 1,390

TRIG Capital Costs by AccountTRIG Capital Costs by Account


TRIGTRIG™™ Capital Costs by Major Area Capital Costs by Major Area

(Costs in million$)

$106 $108

$88$112

Indirect costs

Gasificationisland

Combinedcycle

BOP, taxes,freight,contingency


TRIGTRIG™™ Design Evolution Design Evolution

0

200

400

600

800

1000

1200

1400

1st Plant - F Turbine 2nd Plant - F Turbine Nth Plant - H Turbine

Ove

rnig

ht C

apita

l Cos

t 200

1 $/

kW

0

2,000

4,000

6,000

8,000

10,000

12,000

BTU

/kW

h (L

HV

)

Capital Cost

Heat Rate

(η = 43.6 %) (η = 46.0 %)(η = 52.7 %)

2007 Startup 2012 Startup >2015 Startup






4. Future plans


Primary Objectives in New 5-Year PlanPrimary Objectives in New 5-Year PlanApril 2002 - March 2007April 2002 - March 2007

• Support DOE Vision 21

• Support commercialization of air blowntransport reactor power plant


• Continue air blown and O2 blown gasification development• Integrate O2 blown gasifier with advanced air separation technology• Integrate gasifier with existing combustion turbine• Develop multi-contaminate (SO2, Hg, HCl, etc.) controls• Evaluate novel CO2 and H2 separation systems (if timely)• Test advanced materials (in gasifier and CT test section)• Evaluate high temperature gas/particle sensors• Improve system integration and controls• Improve gas cooling technology• Improve coal/limestone feed systems and ash cooling systems

Major Planned ActivitiesMajor Planned Activities

PowerPowerSystemsSystems

DevelopmentDevelopmentFacilityFacility

Documents

Development Status of the Transport Gasifier at the PSDF · 2016-01-25 · PSDF Power Systems Development Facility Development Status of the Transport Gasifier at the PSDF Gasification