Pratt & Whitney Rocketdyne (PWR) Compact Gasification System

Transcription

1 (PWR) Compact Gasification System Jim Hartung Director, Energy Systems Alan Darby Program Manager, Gasification A United Technologies Company GTC Annual Conference October 2007 Leveraging 50 Years of Rocket Engine Experience to Reduce Cost and Improve Plant Performance 1

2 PWR is Developing Compact Gasification System Objectives Reduce capital cost Improve plant availability Increase efficiency Gasify all ranks of coal (also petcoke and biomass blends) Enable low cost sequestration 2

3 PWR Compact Gasifier Reduces Cost and Improves Plant Performance Current Market Leaders Source: Shell paper (2004) Source: DOE paper (2006) PWR Compact Gasifier 90% size reduction 50% lower cost (gasification system) 99% availability (gasification system) 99% carbon conversion 80% to 85% cold gas efficiency Dry feed system Low oxygen consumption Gasify all ranks of coal, petcoke, and biomass High pressure / water spray quench Ideal for H 2 production Low cost CO 2 sequestration 3

4 Compact Gasifier Leverages PWR Rocket Engine Experience Gasification Components Rocket Engine Experience - Rapid Mix Injector - Cooled Nozzle Wall - Rapid Spray Quench Dense Phase Flow Splitter Rapid Mix Injector 04CP Injector Rapid-spray Quench Chamber Liner Coolant 04CP Gasifier with Cooled Wall Rocket Rocket engine engine cost cost < $10 $10 per per kw kw thermal thermal (much (much less less than than current current gasification gasification systems) systems) Rapid Spray Quench 4

5 PWR Gasification System Low Pressure Hopper Dry Dry Solids Solids Pump Pump Compact Compact Gasifier Gasifier High Pressure Hopper Particulate Removal (Cyclone + Candle Filter) Yellow Yellow Items Items are are Key Key Development Development Items Items Other Other Items Items are are Commercially Commercially Available Available 5

6 Technology Development and Demonstration Roadmap Risk Reduction Tests ( ) Demonstration Plant ( ) Pilot Plant ( ) Proof of Concept Test ( ) Rapid-spray Rapid-spray Quench Quench System Validation in a Commercial Environment Injector Injector Chamber Chamber Liner Coolant Liner Coolant 04CP CP Feed System & Pump Test ( ) 6

7 Gasifier Development Status Performed Performed Tests Tests to to Screen Screen Design Design Options Options and and Reduce Reduce Risk Risk Constructing Constructing Pilot Pilot Plant Plant at at GTI GTI Flex Flex Fuel Fuel Test Test Facility Facility (18 (18 TPD) TPD) Designing Designing Commercial Commercial Size Size Gasifier Gasifier Rapid-spray Quench Rapid-spray Quench Injector Injector Rapid Mix Gasifier Chamber Chamber Liner Coolant Liner Coolant 04CP CP Quench System CANMET Gasification Test Facility Expect to initiate testing in 2009 Design is scalable to 3000 TPD Fixed length Inside diameter: - 1 ft for 400 TPD - 3 ft for 3000 TPD 7

8 Candidate Materials Tested in CANMET Gasification Facility CANMET Gasifier Test Articles Before Test Test Articles After Test Tube in Test Test Test Results Used Used to to Select Select Materials for for the the Pilot Pilot Plant Plant 8

9 Dry Solids Pump and Feed System Development Status Constructed Constructed Feed Feed System System Test Test Facility Facility at at EERC EERC (400 (400 TPD) TPD) Tested Tested Feed Feed System System & Flow Flow Splitters Splitters in in (400 (400 TPD) TPD) Testing Testing of of Dry Dry Solids Solids Pump Pump will will Start Start in in (400 (400 TPD) TPD) EERC Facility Feed System Test Facility Flow Splitter Design is Scalable to 3000 TPD Throat area: - 10 in 2 for 400 TPD - 75 in 2 for 3000 TPD 9

10 Tested 400 TPD Feed System and Flow Splitters at EERC 1x6 Flow Splitter 1x18 Flow Splitter Twelve Test Cases Completed Coal Types Tested Illinois #6, 2% moisture PRB, 8% moisture Gasifier Pressure 1000 psi, 800 psi, 600 psi Flow Rate 400 Tons Per Day Demonstrated dense dense phase phase feed feed system Achieved uniform flow flow splitting 10

11 Reliability, Availability, and Maintainability Approach Long life components Standard materials Metal temperatures < 1000ºF Rapid repair capability Compact design Fast component replacement Short scheduled outages No long downtime maintenance items Rapid replacement of limited life components 99% 99% Availability Appears Achievable for for Gasification System in in Mature Mature Plant Plant 11

12 PWR Business Model PWR PWR Licenses Licenses Technology Technology & Provides Provides Key Key Components Components EPC EPC Contractors Contractors Design Design & Construct Construct Plants Plants End End Customers Customers Own Own & Operate Operate Plants Plants Compact Gasifier Dry Solids Pump Oil Companies Electric Utilities Industrial Gas Suppliers Chemical Companies Business Model Provide Provide Licensees Licensees with: with: - License License Technology Technology to: -Key Components Components to: - --End End Customers -Integration Support Support Customers - --EPC EPC Contractors -Aftermarket Services Services Contractors --Gasification Gasification System System Providers Providers Team Team with with Industry Industry Leaders Leaders 12

13 Acknowledgement Development of the Compact Gasification System is supported by the U.S. Department of Energy under Award No. DE-FC26-04NT42237 However, any opinions, findings, and conclusions expressed herein are those of the authors and do not necessarily reflect the views of the DOE Questions? 13