PWR Compact Gasification Development

Transcription

1 PWR Compact Gasification Development Presented to: 4 th International Freiberg Conference on IGCC & XTL Technologies May 3, 2010 Steven P. Fusselman, Timothy W. Saunders, Kenneth M. Sprouse Inc.

2 United Technologies Corporation UTC $53B Company in 2008 Pratt & Whitney Carrier Otis Hamilton Sundstrand Sikorsky UTC Fire & Security 2

3 PWR Compact Gasification System Feed Hopper Solids Solids Pump Pump Feed Feed Splitter Splitter High Pressure Hopper Compact Compact Gasifier Gasifier Ultra-dense Ultra-dense Feed Feed System System Particulate Removal (Cyclone + Candle Filter) Key Key Development Development Items Items in in yellow yellow Other Items are Commercially Available 3

4 Compact Gasification System Advantages Current Market Leaders Source: Shell paper (2004) Source: DOE paper (2006) Compact Gasification System 90% size reduction (gasifier) 30% 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 4

5 Compact Gasifier Rocket Engine Heritage Rocket Engine Experience - Rapid Mix Injector - Cooled Nozzle Wall - Plug Flow Gasifier Design Features Rapid mix injector assures fast and efficient combustion Active cooling system keeps metal temperatures below 1,000º F Plug flow provides uniform residence time for high carbon conversion 5,000 º F flame temperature gasifies most feedstock within three ft of injector Rapid spray quench reduces syngas outlet temperature to 700º F 5

6 Compact Gasifier Cost Advantages Power (IGCC) Power (IGCC) Hydrogen Hydrogen 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 (Worley Parsons) NETL (Worley Parsons) NETL (Worley Parsons) Jacobs Overall Plant Cost Savings 10% to 24% lower capital cost 15% to 27% lower cost of product Confirmed by Independent Analyses, NETL, Jacobs 6

7 Technology Roadmap Risk Reduction Tests ( ) Pilot Plant at GTI (2009 startup) Demonstration Plant Proof of Concept Test ( ) Feed System and Pump Test Facility at EERC (2007 startup) Candidate Locations China U.S. Canada 7

8 Pilot Plant Test Objectives Pilot Plant at GTI 18 TPD Dec 2009 startup Test Objectives Demonstrate performance Carbon conversion Cold gas efficiency Protective slag layer Particulate removal Feedstock flexibility Verify operating environments Validate computer models Obtain preliminary life data Refine operating procedures Injector Gasifier 8

9 Pilot Plant Test Status Initial test results are encouraging Over 40 short duration tests completed with Illinois #6 and petcoke Ultra-dense feed system operates reliably with no plugging Gasifier startup from cold condition requires less than 10 minutes Heat losses and metal temperatures are less than design basis Carbon conversion and cold gas efficiency are consistent with predictions Mechanical failures in gasifier and candle filter were easily repaired Long duration testing is required to verify short term test results Tests with additional feedstock planned to verify feedstock flexibility 9

10 Feed System Test Objectives Test Objectives Demonstrate performance Ultra-dense feed system (no plugging, less entrained gas) Flow splitters (uniform flow distribution) Dry solids pump (to 1,200 psia) Feedstock flexibility Validate computer models Obtain life data (erosion rates) Refine operating procedures Test Facility at EERC 2007 startup (400 TPD, short duration tests) 2009 upgrade (700 TPD) 2011 upgrade (pump installation, long duration tests) EERC Test Facility Test Stand 10

11 Feed System and Pump Test Status Test Status Short duration tests of ultradense feed system and flow splitters completed in Reliable operation, no plugging Uniform flow splitting Solids pump risk reduction tests performed in 2009 Integrated pump tests to begin in 2011 EERC test facility is being modified to enable long duration pump tests 1x6 Flow Splitter 1x18 Flow Splitter Solids Pump 11

12 Solids Pump Design Concept Based on proven solids lock-up and solids gas seal physics Key design features Linear track concept (efficient and scalable) Proven commercial components Maintainable (rapid parts replacement) High pressure capability (1,200 psia) Pump goals versus lock hoppers Lower capital cost (compact design) Lower operating cost (less pressurization gas) Higher efficiency (lower parasitic power) 12

13 Solids Pump Theory of Operation Pump operation relies on ability of bulk solids to form multiple stable bridges or arch between parallel walls. These bridges can support very large loads The material between the walls is in lock-up condition Extrusion or pumping occurs when sidewalls are moved mechanically Increasing load is transferred to sidewalls, making the bridge more stable. Material is released by separating the walls There is no slip or relative motion between material and moving walls when in lock-up Belt Drive Shaft Drive Shaft Direction Belt Direction Tractive Normal Force Loads Coal Plug Plug Gas Load + Friction Normal Loads Normal Shear Loads Design based on proven concepts and simple mechanical arrangement 13

14 Pump Design Anchored with Test Data Flow Tester Outlet design for deconsolidation Wall Tester Track Aspect Ratio Maximum duct solids pressure Friction Tester Outlet duct size for gas seal Link load stress analysis Permeability Tester Confirm seal duct length Leak rate at 1,200 psi pressure 14

15 Pump Prototype System Configuration Prototype Solids Pump Feed Rate: Nominal TPD Max TPD Width 8 Active Hopper Inlet Isolation Valve Pump Mounting Height 19 Pump Pressure Casing Hydraulic Drive Motors Outlet Pressure Vessel Outlet Isolation Valve 15

16 Pump Program Schedule 16

17 Scale-Up Approach Gasifier: Integrated hydrodynamic/kinetic model Pump: 2-D granular solids model Pilot Plant 18 TPD Demo Plant 400 TPD Commercial Plant 3,000 TPD Prototype (400+ TPD) Demo Plant (400 TPD) Commercial (1,000 TPD) 17

18 PWR Business Model PWR PWR Provides Technology, Components, and and Services Licensees Design, Construct, and and Operate Plants Plants Gasifier and Flow Splitter Pump and Feed System Potential Licensees Plant Owners Oil Companies Electric Utilities Industrial Gas Suppliers Chemical Companies Project Developers EPC Contractors Gasification System Providers 18

19 Key Development Partners PWR has 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 Alberta Innovates: Energy and Environment Solutions (AIEES) is cost-sharing definition of a demo plant for an Alberta location and funding tests with Alberta feedstock Zero Emission Energy Plants, Inc. (ZEEP) is launch customer with a global license to develop gasification plants 19

20 Summary PWR is developing a compact gasification system Working with industry leaders and government organizations System offers significant cost and performance advantages Development tests are meeting expectations Next step is to construct and operate a demonstration plant 20

21 THANK YOU