PWR Compact Gasifier Dry Feed System Development · freiberg may 8-12, 2007/kms continuous flow test facility component life demonstration at near commercial scale solids pump 1,300-psia

Pratt & Whitney RocketdyneCP5-8-1

Freiberg May 8-12, 2007/kms

PWR Compact Gasifier Dry Feed System Development

Kenneth M. Sprouse & David R. Matthews Pratt & Whitney Rocketdyne, Inc. (PWR)

Greg F. Weber University of North Dakota

Energy & Environmental Research Center (EERC)

Presented at the 2nd International Freiberg Conference on IGCC and XtL Technologies

8th – 12th May, 2007



Acknowledgement

This presentation was prepared with the support of the U.S. Department of Energy (DOE),

under Award No. DE-FC26-04NT42237.

However, any opinions, findings, conclusions, or recommendations expressed herein are those of the author(s)

and do not necessarily reflect the views of the DOE.

Acknowledgement



PROGRAM OBJECTIVES Two Phase Effort

• Phase 1• Scale-up of the PWR 100-ton/day (1,500 psia) feed

system -- U.S. Patent 4,191,500 (1980) – to commercial sizes above 1,200-tons/day

• Demonstrate uniform “two-tier” coal injector flow splitting with 18 elements – previous uniform splitting demonstrated “single tiers” with 3 and 6 elements

• Phase 2• Develop high pressure (1,200 psia) dry solids extrusion

pump at nominal 400-tons/day flow rate• Test pump and feed system continuously for 1,000 hours



PWR COMPACT GASIFIER SYSTEM Dry Compact Gasifier with Rapid Start & Shutdown Capability

COAL SILO

DRY SOLIDS PUMP

HIGH PRESSURE DISCHARGE TANK

COMPACT GASIFIER(with Rapid Quench)

CYCLONE SEPARATOR

CANDLE FILTERS



GASIFIER THERMODYNAMICS Significant Efficiency Advantages with Dry Feed Gasifiers -- CEA 1994

CARBONACEOUS SOLID

KENTUCKY 9/14 HVABASSAY (AS REC'D)

PROXIMATE ANALYSISWT% MOISTURE 2.00WT% ASH 10.46WT% VOLATILES 38.17WT% FIXED CARBON 49.37

ULTIMATE ANALYSISWT% MOISTURE 2.00WT% CARBON 68.81WT% HYDROGEN 4.92WT% NITROGEN 1.49WT% SULFUR 4.14WT% ASH 10.48WT% OXYGEN 8.16

HHV (BTU/LBM) 12,360SOLID DENSITY (LBM/FT3) 93.60BULK DENSITY (LBM/FT3) 38.78

INPUT CONDITIONS

GASIFIER PRESSURE (PSIA) 1,000STEAM TEMPERATURE (°F) 700



• PWR Kinetic Models Developed Under DOE and IR&D Funding Since 1977

• See, e.g., AIChE Journal, 26, 964 (1980) & Comb. Flame, 43, 265 (1981)

• Both 1-D and Multi-Dimensional Capability – modified FLUENT codes

• Correlation with Rocketdyne Hot-Fire Data From 1970-80’s

• PWR Kinetic Models Developed Under DOE and IR&D Funding Since 1977

• See, e.g., AIChE Journal, 26, 964 (1980) & Comb. Flame, 43, 265 (1981)

• Both 1-D and Multi-Dimensional Capability – modified FLUENT codes

• Correlation with Rocketdyne Hot-Fire Data From 1970-80’s

GASIFIER KINETICS High Flame Temperatures Produce Compact Size



ROCKET ENGINE TECHNOLOGY Ultra-Dense Phase Feeding and Rapid-Mix Injectors Key

6-ELEMENT INJECTOR LAX THERMODYNAMICS LABORATORY SETUP

1-TO-6 SPLITTER

GASIFIER

SONIC NOZZLE

WATER QUENCH

Compact Gasifier Testing From 1978 (24 tons/day and 100 psia)Compact Gasifier Testing From 1978 (24 tons/day and 100 psia)



Ultra-Dense Phase Dry Feed System Simple Dry Bingham Fluid Flow System for Rapid-Mix Capability

COAL PUMP

HIGH PRESSURE(1,200-PSIA)

DISCHARGE TANK

MULTI-ELEMENTINJECTOR

ATMOSPHERICPRESSURE

STORAGE SILO

REGULATOR

TRANSPORT GAS INLET

METERING VENTURI

DRY PULVERIZED COAL INLET



BATCH MODE TEST FACILITY -- 1980 Flow Splitting Demonstrated to Non-Uniformities of 1% RSD

COLD FLOW TEST SCHEMATIC

SANTA SUSANA BOWL FACILITY

1-TO-3 SPLITTER

3/8” TUBES

3/4” TUBE • High Pressure• to 1,500 psia

• Coal Flow Rates• to 100 tons/day

• Multi-Element Flow Splitters

• High Pressure• to 1,500 psia

• Coal Flow Rates• to 100 tons/day

• Multi-Element Flow Splitters



CONTINUOUS FLOW TEST FACILITY Component Life Demonstration at Near Commercial Scale

SOLIDS PUMP

1,300-PSIAHIGH PRESSURE

DISCHARGE TANK700-GAL

MULTI-ELEMENTINJECTOR

(PWR)

1,000-GALATMOSPHERIC

PRESSURE STORAGE SILO

CYCLONESEPARATOR

BAGHOUSE

GN2/AIR RECYCLE COMPRESSOR

1,500-PSIA(1,000-GAL)

GN2/AIR STORAGE TANK

TO STACK

REGULATOR

REGULATOR

MAKE-UPGN2

METERING VENTURI

CASCADE NOZZLE


• Coal Flow Rates• 400 tons/day

• Multi-Element Injectors


• Coal Flow Rates• 400 tons/day

• Multi-Element Injectors



EERC FLOW FACILITY First Phase Construction Nearly Complete

Facility Construction – February 2007 (Floors 1 thru 5)

Cascade Nozzle & Cyclone (6th Floor)

HPDT Exit Piping Assembly



MULTI-ELEMENT INJECTORS Testing Starts May 2007 with 1x6 Multi-Element Injector

Flow Checkout of Ramsey- Granucor Velocity Sensors

(ThermoElectron Corp.)

1x18 Multi-Element Coal Injector Assembly (1,200 tons/day rating)

High Pressure Injector Chamber

(1,000 psia -- 6.9 MPa)



HIGH EFFICIENCY DRY SOLIDS PUMP Phase 2 Effort for Continuous Operation at 400-tons/day

( )( )ε−ρ

−=

1s

atmPdPisenW

( ) ( )

⎥⎥⎥

⎦

⎤

⎢⎢⎢

⎣

⎡

−γ

−γ

⎟⎟⎠

⎞⎜⎜⎝

⎛γ

⎟⎟⎠

⎞⎜⎜⎝

⎛−ε+−γη

=η

1n

1

atmPdP

n

dPatmP

111clh

• Minimum Work Required For Pumping a Pulverized Solid• ~ 6 kJ/lbm at 1,200 psia discharge pressure

• Mechanical Efficiency for a Single Pair of Cycling Lock Hoppers• ~ 25% at 1,200 psia discharge pressure

• Program Goal to Develop a 1,200 psia Discharge 400-tons/day Dry Solids Extrusion Pump At Mechanical Efficiencies Above 50% Without Blowback

• Stamet Inc. testing with Posimetric®

pump encouraging• CFD performance model -- AIChE Journal, 29, 1000 (1983) – nearing

completion



DRY SOLIDS EXTRUSION PUMP 400-Tons/Day Tractor Mill (Phase 2)

EXTRUSION PUMP

DRY GRANULAR SOLIDS INLET

ELECTRIC DRIVE MOTORS

REDUCTION GEAR BOXES

BREAKER MILL

DRY GRANULAR SOLIDS OUTLET

• Development Schedule – Completion Dates

• CFD Performance Model Programming

• July 2007• Preliminary Design

• September 2007• Detail Design

• March 2008• Fabrication

• January 2009• Testing

• December 2009

• Development Schedule – Completion Dates

• CFD Performance Model Programming

• July 2007• Preliminary Design

• September 2007• Detail Design

• March 2008• Fabrication

• January 2009• Testing

• December 2009

Documents

PWR Compact Gasifier Dry Feed System Development · freiberg may 8-12, 2007/kms continuous flow test facility component life demonstration at near commercial scale solids pump 1,300-psia