PWR Compact Gasifier Dry Feed System Development

Transcription

1 PWR Compact Gasifier Dry Feed System Development Kenneth M. Sprouse & David R. Matthews, 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 CP5-8-1

2 Acknowledgement Acknowledgement This presentation was prepared with the support of the U.S. Department of Energy (DOE), under Award No. DE-FC26-04NT 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. CP5-8-2

3 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 CP5-8-3

4 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 CP5-8-4

5 GASIFIER THERMODYNAMICS Significant Efficiency Advantages with Dry Feed Gasifiers -- CEA 1994 CARBONACEOUS SOLID KENTUCKY 9/14 HVAB ASSAY (AS REC'D) PROXIMATE ANALYSIS WT% MOISTURE 2.00 WT% ASH WT% VOLATILES WT% FIXED CARBON ULTIMATE ANALYSIS WT% MOISTURE 2.00 WT% CARBON WT% HYDROGEN 4.92 WT% NITROGEN 1.49 WT% SULFUR 4.14 WT% ASH WT% OXYGEN 8.16 HHV (BTU/LBM) 12,360 SOLID DENSITY (LBM/FT3) BULK DENSITY (LBM/FT3) INPUT CONDITIONS GASIFIER PRESSURE (PSIA) 1,000 STEAM TEMPERATURE ( F) 700 CP5-8-5

6 GASIFIER KINETICS High Flame Temperatures Produce Compact Size PWR PWR Kinetic Kinetic Models Models Developed Developed Under Under DOE DOE and and IR&D IR&D Funding Funding Since Since See, See, e.g., e.g., AIChE AIChE Journal, Journal, 26, 26, (1980) (1980) & & Comb. Comb. Flame, Flame, 43, 43, (1981) (1981) Both Both 1-D 1-D and and Multi-Dimensional Multi-Dimensional Capability Capability modified modified FLUENT FLUENT codes codes Correlation Correlation with with Rocketdyne Rocketdyne Hot-Fire Hot-Fire Data Data From From s s CP5-8-6

7 ROCKET ENGINE TECHNOLOGY Ultra-Dense Phase Feeding and Rapid-Mix Injectors Key WATER QUENCH SONIC NOZZLE GASIFIER 1-TO-6 SPLITTER 6-ELEMENT INJECTOR LAX THERMODYNAMICS LABORATORY SETUP Compact Gasifier Testing From 1978 (24 tons/day and 100 psia) CP5-8-7

8 Ultra-Dense Phase Dry Feed System Simple Dry Bingham Fluid Flow System for Rapid-Mix Capability DRY PULVERIZED COAL INLET ATMOSPHERIC PRESSURE STORAGE SILO TRANSPORT GAS INLET COAL PUMP MULTI-ELEMENT INJECTOR METERING VENTURI REGULATOR HIGH PRESSURE (1,200-PSIA) DISCHARGE TANK CP5-8-8

9 BATCH MODE TEST FACILITY Flow Splitting Demonstrated to Non-Uniformities of 1% RSD SANTA SUSANA BOWL FACILITY COLD FLOW TEST SCHEMATIC 3/8 TUBES 1-TO-3 SPLITTER High High Pressure 3/4 TUBE to to 1,500 1,500 psia psia Coal Coal Flow Flow Rates Rates to to tons/day Multi-Element Flow Flow Splitters CP5-8-9

10 CONTINUOUS FLOW TEST FACILITY Component Life Demonstration at Near Commercial Scale TO STACK CASCADE NOZZLE BAGHOUSE REGULATOR CYCLONE SEPARATOR GN2/AIR RECYCLE COMPRESSOR MAKE-UP GN2 MULTI-ELEMENT INJECTOR (PWR) 1,500-PSIA (1,000-GAL) GN2/AIR STORAGE TANK METERING VENTURI 1,000-GAL ATMOSPHERIC PRESSURE STORAGE SILO SOLIDS PUMP 1,300-PSIA HIGH PRESSURE DISCHARGE TANK 700-GAL High High Pressure Pressure to to 1,000 1,000 psia psia Coal Coal Flow Flow Rates Rates tons/day tons/day Multi-Element Multi-Element Injectors Injectors REGULATOR CP5-8-10

11 EERC FLOW FACILITY First Phase Construction Nearly Complete Cascade Nozzle & Cyclone (6th Floor) Facility Construction February 2007 (Floors 1 thru 5) HPDT Exit Piping Assembly CP5-8-11

12 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 MPa) CP5-8-12

13 HIGH EFFICIENCY DRY SOLIDS PUMP Phase 2 Effort for Continuous Operation at 400-tons/day Minimum Work Required For Pumping a Pulverized Solid ~ 6 kj/lbm at 1,200 psia discharge pressure W isen ηlh = = ( P d P atm ) ρ ( 1 ε) ηc s Mechanical Efficiency for a Single Pair of Cycling Lock Hoppers ~ 25% at 1,200 psia discharge pressure ( γ 1 )( 1 + ε ) n γ P d P atm 1 γ 1 n γ P atm P d 1 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 CP5-8-13

14 DRY SOLIDS EXTRUSION PUMP 400-Tons/Day Tractor Mill (Phase 2) REDUCTION GEAR BOXES ELECTRIC DRIVE MOTORS DRY GRANULAR SOLIDS INLET EXTRUSION PUMP BREAKER MILL DRY GRANULAR SOLIDS OUTLET Development Development Schedule Schedule Completion Completion Dates Dates CFD CFD Performance Performance Model Model Programming Programming July July Preliminary Preliminary Design Design September September Detail Detail Design Design March March Fabrication Fabrication January January Testing Testing December December CP5-8-14