Compact Gasification System Development Status

Transcription

1 Compact Gasification System Development Status Alan Darby Program Manager, Gasification Jim Hartung Director, Energy Systems A United Technologies Company GTC Annual Conference October 2009 Leveraging 50 Years of Rocket Engine Experience to Reduce Cost and Improve Plant Performance 1

2 Key Design Features of the Compact Gasification System Low Pressure Hopper Dry Dry Solids Solids Pump Pump Compact Compact Gasifier Gasifier High Pressure Hopper Ultra-dense Ultra-dense Feed Feed System System 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 2

3 Key Development Partners PWR teamed with ExxonMobil Research and Engineering (EMRE) to develop and commercialize the technology DOE is cost-sharing development of the Dry Solids Pump and Feed System under a Cooperative Agreement AERI (Alberta Energy Research Institute) is cost-sharing definition of a demo plant for an Alberta location and funding tests with Alberta petcoke Zero Emission Energy Plants, Inc. (ZEEP) is a launch customer to build a demo plant and purchased a global license to use the technology 3

4 Technology Roadmap Risk Reduction Tests ( ) Pilot Plant at GTI (2009 startup) Demonstration 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 Test Facility at EERC (2007 startup) 4

5 Advantages of the Compact Gasification System Current Market Leaders Source: Shell paper (2004) Source: DOE paper (2006) Compact Gasification System 90% size reduction (gasifier) 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 blends High pressure / water spray quench Ideal for H 2 production Low cost CO 2 sequestration 5

6 Pilot Plant Under Construction at GTI (Gas Technology Institute) Pilot Plant at GTI 18 TPD Startup in 2009 Pilot Plant Gasifier Test Objectives Demonstrate performance Carbon conversion Cold Gas Efficiency Protective slag layer Multiple feedstocks Verify operating environments Validate computer models Obtain life data (time & cycles) Refine operating procedures Objective is is to to obtain obtain data data for for larger larger scale scale gasification plants plants 6

7 Pilot Plant Feed System Checkout Testing Completed Pneumatic conveyor transports coal to Day Bin Screener removes oversize particles as coal flows from Day Bin to T-213 T-211 Feed Tank has 2 hours (3,000 lb) coal capacity Day Bin provides 8,000 lb coal storage capacity T-213 Lockhopper has 1,500 lb coal capacity, cycles every ½ hour Granucor flow meters measure dense phase flow 7

8 Pilot Plant Feed System Activation Successfully Completed Dense Phase Feed Testing Preliminary dp vs Flow Test Summary 1500 lb/hr baseline flow Test runs typically 60 minutes 54 tests completed No plugging Start-up and flow control procedures verified Delta Pressure (psid) Illinois #6 Alberta Petcoke Flow (lb/hr) 8

9 Gasifier Manufacturing Completed September 2009 Injector Assembly Cooled Liner 18 TPD Gasifier 9

10 Feed System Test Facility at EERC (Energy & Environmental Research Center) Initial Capability TPD (2007) Growth TPD (2010) Flow Splitter Tests in Pump Tests to Start in 2010 Test Objectives Demonstrate performance Ultra-dense flow (no plugging) Flow splitters (uniform flow distribution) Dry solids pump (to 1200 psia) Multiple feedstocks (standard utility grind) Validate computer models Obtain life data (erosion rates) Refine operating procedures Objective is is to to obtain obtain data data for for the the commercial scale scale demo demo plant plant 10

11 Dry Solids Pump Component Tests Complete to Support Pump Design Pump Design Activity Pump Component Testing Nearly Complete Developed Dry Solids Pump Design Criteria Final Design of Prototype Pump Underway Testing begins 4Q 2010 at EERC Moving Wall Test Rig Pump Design Principles of Operation Confirmed 11

12 Independent Studies Confirm Benefit of PWR Gasification System Type of Plant IGCC IGCC H2 H2 Compared Versus GE Shell GE GE Feedstock Coal Coal Coal Petcoke Capex Benefit 10% 20% 24% 20% Cost of Product Benefit 15% 21% 27% 25% Study Performed By NETL NETL NETL Jacobs 12

13 Initiated Project to Determine Effects of Biomass/Coal Blends on Solid Feed Systems Analyze Coal/Biomass Blends To Predict Transport Behavior Void Fraction, Permeability, Internal Friction Angle and Cohesion Coefficient Ultimate Analysis, Heating Value and True Solids Density Conduct Gasification Economic Analysis Biomass Milling Energy Consumption Used To Grind Samples Model Feed System and Pump Using Test Data Determine Extrusion Pump Size, Efficiency & Costs Select Most Promising Blend for Further Testing Pump Component Test Rig Validation 600-tpd Pump Testing at EERC 13

14 Biomass/Coal Blends Initial Results -200 Mesh Illinois #6 Coal -200 Mesh Corn Stover Matrix of 36 tests to be performed Biomass - Corn Stover, Switch Grass, and Wood Waste (Saw Dust) Coals - Illinois #6, PRB, and North Dakota Lignite Mixtures Tested 100%, 90%, 50% and TBD% coal (weight %) Initial Observations Biomass Internal Friction Angles Are 10 Degrees Higher Than Coal Biomass Void Fractions Are 2 Times Higher Than Coal Biomass Gas Permeabilities are More Than 2 Times Higher Than Coal 14

15 Acknowledgement Development of the Dry Solids Pump is supported by the U.S. Department of Energy. AERI is the strategic energy technology arm of the Alberta Government in the Ministry of Advanced Education and Technology. Its mission is to enhance the development of Alberta's energy resources through investment in research, technology and innovation in partnership with industry. However, the opinions, findings and conclusions expressed herein are those of the authors Questions? 15