Dry Solids Pump Development Status

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1 Dry Solids Pump Development Status Alan Darby Program Manager Gasification Pratt & Whitney Rocketdyne A United Technologies Company Gasification Technology Council Conference October 31, 2012 Leveraging 50 Years of Rocket Engine Experience to Reduce Gasification Cost and Improve Plant Performance

2 Program Background and Opportunity Department of Energy (DOE) Funded PWR in 2006 to develop - A commercial solids pump as soon as possible Solids pump capable of PSI injection benefit gasification Reduce cost of IGCC, Coal-to-Chemical and Coal-to-Liquid plants Electric utilities in EPRI Coal Fleet identified solids feeding as #1 priority for successful commercialization of gasification plants Gasification Technology Council (GTC) analysis shows global gasification growth of 47,000 MW thermal by 2016 Equivalent to ~ 250 solids pumps Market growth expected to continue to 2030 and beyond Target date for commercial pumps available around 2015

3 Solids Feed System Development (The first phase) Successfully Verified Ultra-Dense Feeds System Performance Ultra-dense Feed System Initial Capability TPD (2007) Capability increased TPD (2010) Accomplishments - Flow 400 TPD at 1,200 psi - Standard utility grind feedstock - Multiple feedstocks - Eight and 16 burner configurations - No Plugging - Achieved uniform flow across injectors - Four percent variation - Validate computer models - Refine operating procedures - Developed design criteria Ultra-dense flow Flow splitters

4 Pump Test Development Program (The second phase) Pump program initiated in 2009 Feed Rate TPD Pump tests initiated in 2012 Development Goals: Meets PWR gasifier requirements Supports gasification industry requirements Test Objectives Discharge >400 TPD at 1000 psi Twice the efficiency of lock hoppers Goal of 500 hours test time Obtain life data (wear rates) Test multiple feedstocks Two grind sizes Higher moisture contents Validate computer models Refine operating procedures

5 Pump Major Components FLOW Inlet Valve Weight: 50 T Case side mount Microwave sensors 5.3 m Hydraulic Motor Fines Bin Outlet Valve Outlet Pressure Vessel Make up spool

6 Pump Mode of Operation Operation based on solids lock-up physics that has achieved 1,000 psi solids injection in prior DOE-funded tests Belt Belt Direction Design uses solids plug gas seal also proven in prior DOE-funded research Linear concept advantages: Higher efficiency Drive Shaft Tractive Normal Force Loads Normal Loads Scalable to large capacities Feed material flexibility Drive Shaft Direction Coal Plug Plug Gas Load + Friction Normal Shear Loads

7 Page 7 Pump Manufacturing Making very large and very heavy material blocks into large and heavy components

8 Pump Manufacturing High precision milling with heavy component assemblies Page 8

9 Pump Manufacturing & Assembly Assembling the track onto the strong-back

10 Pump Manufacturing & Assembly Putting it all together

11 Pump Manufacturing & Assembly The BIG lift! One 280 ton crane One 90 ton crane

12 Page 12 Pump Installation at Test Facility (EERC) A TIG HT Squ eez e!

13 Pump Installation Pump in the Test Stand Happy Customers - DOE NETL Program Managers with their Newly Named BABE

14 Pump Testing Status Shake-down testing started end of March - Verified system mechanical operation - Confirmed fundamental operating concept; - lock up and mechanical delivery - seal plug generation, gas seal at low pressure Identified mechanical issues degrading performance and increasing power Modified components for improved performance - Belt and link-to-link clearances Adding sensors for enhanced monitoring of internal pump component operation Testing resumed early October

15 Acknowledgement Development of the Dry Solids Pump is supported by the U.S. Department of Energy. Energy and Environment Solutions 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?