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GE Global ResearchEnergy & Propulsion Technologies (EPT)
Fuel Conversion Laboratory (FCL)
Advanced GasificationAdvanced Gasification--Combustion Combustion Technology for Production of HTechnology for Production of H22, Power , Power and Sequestrationand Sequestration--Ready COReady CO22
George Rizeq, Janice West, Arnaldo Frydman, Raul Subia, Vladimir Zamansky, and Kamalendu Das
Gasification Technologies ConferenceSan Francisco, CAOctober 15, 2003
October '03
UFP: Unmixed Fuel Processor for Coal
Acknowledgements Outline! Funding from the U.S.
Department of Energy
! Funding from General Electric Company
! GE Global Research project team
! Backgroundo UFP concept & R&D program taskso Technology development plan
! Results of bench-scale validation experiments
! Overview of pilot-scale design and construction
! Summary and future activities
October '03
DOE’s Vision of the 21st Century Power Plant
GE’s UFP conceptPotential integration with other GE technologies
October '03
UFP Program Objectives
•Develop Unmixed Fuel Processor (UFP) technology to simultaneously convert coal, steam, and air into separate streams of:
"High purity hydrogen"Sequestration-ready CO2"High T/P vitiated air (to produce electricity in gas turbine)
•Conduct bench and pilot tests to identify operating conditions that maximize achievable:
"Coal conversion efficiency"H2/electricity production"Separation of CO2 and pollutants from product gas
October '03
UFP Concept
Gas Turbine
•Liquefaction
•Fuel Cells
•Turbines
Sequestration
STEAM
Coal
AIR
Vitiated Air
CO2H2
RegenerationRegeneration OxidationOxidationGasificationGasification
STEAM
October '03
UFP Features
SteamAir
Fuel Cell
CO2
Sequestration
Compressor
R1
-Gas
ifier
R2
-CO
2 Se
para
tion/
R
egen
erat
or
R3
–H
eat
Gen
erat
ion
Fuel
Combined Cycle
Turbines
UFP System
Coal or coal -
biomass feed
SO2 inherently separated
Minimal purification for FC and GT
H2
CO2 inherently separated
Fuel for CC GT and FC
Hg in H2stream from R1
Elimination of turbine
combustion prevents NOx
formation
High system efficiency
System integration provides
steam
Solids transfer between reactors
Operation with air, not
with oxygen
October '03
Example of Integrated UFP Power Plant
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743 C 999 C 1361 C
939 C1112C
657 C
454 C
100 C
115 C
OTM
Air 400C
311 C
Advantages of UFP-3 bed over IGCC
# Eliminates need for O2plant. Uses OTM
# Third stream directly sent to Brayton (gas) / Rankine (steam) cycle
# Cost competitive, especially if CO2capture is needed
1st StreamCooled to RT
3rd Streamdirectly
sent to B-R cycle
CO2 Separation
October '03
UFP Development Plan2000-2004 2004-2006 2006-2008
Phase I UFP Program (0.2MW)• Show proof of concept• Perform lab-, bench-, and pilot-scale studies• Conduct process modeling, engineering and economic studies• Analyze integration of UFP with V21 power plant
Phase II UFP Program(0.2MW)• Resolve operability/ reliability issues• Conduct longer-term testing of pilot plant• Optimize operating conditions• Analyze economics to improve cost-competitiveness
Phase III UFP Program (3-5MW)• Work with industry partner to build prototype system for power generation• Demonstrate reliability of process• Optimize bed material usage/handling
2013-Commercialization of UFP technology
2009-2012Phase IV UFP Program (30-50 MW)• Build and operate demonstration plant
October '03
Phase I Program Tasks OverviewExperimental
AnalysisEconomic Evaluation
Fluidization Model
Kinetic Model
Thermo-dynamic
Model
Bench-Scale
System
Pilot-Scale System
Model Validation with Experimental Data
Reactor Design
Test Planning EHS EvaluationConstruction
Experimental Testing
Market Assessment
Capital/ Operating
Costs Assessment
Modeling
Lab-Scale System
System Design
Data Analysis to guide larger-scale efforts, model validation and economic analysis
October '03
Bench-Scale Test FacilitiesBenchBench--Scale SystemScale System! High temp, pressure operation! Ability to feed coal, air, steam, and N2! Single bed mimics conditions of R1, R2, and
R3 separately! Able to characterize:
o Coal gasificationo CO2 absorption/releaseo O2-transfer material oxid./red. cycle
Cold Flow ModelCold Flow Model• Simulates pilot plant fluidization/ solids transfer• Allows visualization of behavior• Able to characterize:
– Solids transfer flow rate– Differences in bed height
October '03
Bench-Scale Testing Approach
Slurry
R1Gasifier
R2Regenerator
R3Oxidizer
Steam Steam Air
H2 CO2 N2
Coal
Bench Scale Reactor
Product
Gas Feed
Coal Feed
Solids transfer
Solids transfer
The single-reactor, semi-batch bench-scale system is used to characterize and optimize specific reactions and cycles that are part of the continuous UFP process.
October '03
Summary of Bench-Scale Test Results
! Reactor 1o CO2 is effectively removed by CAM (CO2-absorbing material)o CO is depleted by water/gas shift reaction o Stream containing > 80% of hydrogen can be produced
! Reactor 2o CAM is effectively regenerated at higher temperature releasing CO2
o OTM (O2-transfer material) is effectively reduced
! Reactor 3o OTM is effectively oxidized in a highly exothermic process
All UFP components function as expectedAll UFP components function as expected
October '03
Pilot Plant Design PlanDesign of Pilot-Scale FacilityDesign of PilotDesign of Pilot--Scale Facility
Dimensions & Operating Conditions
Process ControlProcess Control
Design steps progressed through rigorous analysis and Design for Six Sigma methods
Process AirProcess Air
SamplingSampling
Steam FeedSteam Feed
System EvaluationSystem Evaluation
SafetySafety
Scale Facility
Reactor DesignReactor Design
Experimental Test PlanExperimental Test Plan
Emissions ControlEmissions Control
Instrumentation PFD, P&IDInstrumentation PFD, P&ID
Performance Test Plan
Bed TransferBed Transfer
Dist. PlateDist. Plate
Sub-Systems
ToolboxScaleScale
October '03
Reactor Design Methodology
T1 T2 T3 T4 Tout
ID reactor = 10”1st Layer = 1 3/8”2nd Layer = 2 1/8”
Insulation Blanket = 0.5”Metal Shell (SS304) = 0.5”
Shell temperatures:• R1 = 390oC (734oF)• R2 = 420oC (788oF)• R3 = 520oC (968oF)
KAO TAB-95
KAOLITE 2300-LI
SS 304L
KAOWOOL #8
Spreadsheets for fluidization correlations, UFP chemistry requirements, heat loss and mechanical stress analysis
Fluidized Bed R2(Cross-section)
Gas Distributor Assembly
Core
Refractory layer (inner insulation)
Reactors Specifications:" ID = 10”" Height = 8 ft" Bed height ≈ 20 in" Coal feed = 50-100 lb/h
(0.6-1.2 MMBTU/h)
October '03
CO2O2-depleted
air
H2 CO2 N2
RE
AC
TO
R 2
CO
2R
EL
EA
SE
RE
AC
TO
R 1
GA
SIFI
CA
TIO
N
RE
AC
TO
R 3
HE
AT
GE
NE
RA
TIO
N
Superheated Steam Superheated Steam
Key Criteria Impo
rtan
ce
Rat
ing
1 Low heat losses 52 Minimize solid residence time in transfer ducts 53 Low fabrication cost 44 Minimize back flow of gases and solids to the reactor 45 Minimize cross flow of gases from one reactor to the next 46 Minimize cross flow of gases from one reactor to the next 47 Solid residence time in reactors from 15-30 min 38 Homogeneous solid composition in reactors and ducts 3
Importance Rating LegendHigh 5Low 1
Pugh-matrix to Compare 10 Solid Transfer Configurations
The configuration selected involves moving solids from the bottom of one reactor to the next by vertical fluid eduction.
Advantages:• allows solid feeding at middle-bed position• prevents back-flow of solids• prevents cross-flow of reactor fluids• vertical solid transport: minimum carrier flow
Solid Transfer Rate (Fs)determines the specs ofthe transfer ducts
Dou
t(i n
)
Din (in)
Contour curves of constant Fs (kg/h)
Experimental points
Din
Dout
Fluidized Sand Bed Water
barrel
Operational experience
mixing behavior
Transportregime
fluidization quality
recirculationrange
∆P changes
Steam Generator
bed height measurement
Specify transferducts
circulating fluidized beds
COLD FLOW MODEL
Distributordesign
Compressed Air Delivery System
ExperimentalMeasurements
Data Reductionon Design-Expert
Solids
in
900oC, 20 atm52-60 lb/h steam
Din: Orifice with Sarea equivalent to a 1” or ¾” φ circle
Dout = 1 ¼”orDout = ¾”
Solids out
1 ¼1R23/R32¾¾R12/R21Dout (in)Din (in)
Solids Transfer System
October '03
Reactor Gas Distributor Plate
! Main design factors:o Distributor plate pressure drop DPdist
o Bed expansion & agitationo Low cost ($)
! Assembly meets criteria
•Various plate designs were evaluated, using the Cold Flow Model (CFM)
•Distributor plate-1 provided largest bed expansion and agitation
Cross-Section
Plate
Sleeve
Seal
Distributor platedesign, used for all
three(3) reactors
Distributor platedesign, used for all
three(3) reactors
Nozzle
Distributor Plate-1
0%
10%
20%
0 50 100
Air Mass Flow (lb/hr)
Bed
Exp
ansi
on (%
)
Plate-3
Plate-2
Plate-1
Performance curves for various plates
Low-cost gas distributor can operate at high temperatures (> 800oC)
October '03
Cross-Sectional Drawing of Reactors with Solids Transfer Ducts
Bed solids enter R2
Bed solids from R1
Bed solids from R3
Gas distributor
plate
Insulating refractory
Fluidization Steam
Product gas
Steam
Steam
Bed solids exit R2
Reactor-1 (R1)
Reactor-2 (R2)
Reactor-3 (R3)
Steam Steam Air
Steam
Steam
Steam
H2 CO2 Vitiated Air
Coal Slurry
Recirculating bed
material96”
October '03
Reactor Refractory CastingBefore Casting 2nd Casting Layer1st Casting Layer
Kaolite 2300-LI RefractoryKao Tab–95 Refractory
Reactors cast with two layers of refractory to isolate reactor metal from high temperatures
October '03
Safety: Reactor Hydrostatic Test
0
100
200
300
400
500
600
700
100 200 300 400 500 600
Pressure (psi)
Shel
l tem
pera
ture
(o C
)
Hydrostatic testminimum conditionat near room temp.Predicted shell conditions
under actual reaction
Setup (R2 being tested)Setup (R2 being tested)
R2
All reactors were submitted to a 900 psig hydrostatic test to meetASME safety factor specifications. Joints and welds approved.$
October '03
Process Flow Diagram (PFD)
FEEDS:CoalSteamAir
H2-R
ichPRODUCTS
STREAMS (3)
CO
2-Ric
h
N2-R
ich
October '03
Pilot Plant Construction Status
Boiler/Superheater
3 main reactors
Emissions control (afterburner, quench
and scrubber)
High-pressure process air (compressor, receiving
tanks and pressure booster)
Second-stage superheaters
Control room (10ftx10ftx15ft)*
Bench-scale system
Covered work area
Storage shed
* Drawing is to scaleCurrently under construction/assembly. Shakedown & initial testing planned for 4Q03 (pending AQMD permit).
October '03
UFP Phase I SummaryAccomplishments! Designed & constructed bench-scale high-P, high-T fluid bed system! Completed bench-scale tests & established feasibility of:
o Coal gasification (~80% H2 purity for Temp.<800oC)o CO2 absorption/release (majority of CO2 absorbed)o Metal oxide oxidation/reduction
! Designed & constructed the cold flow model to assess fluidization & solids transfer
o Identified configuration of solids transfer ducts & range of carrier gas flow rates! Conducted economic assessment of UFP technology
o Comparison with IGCC costs shows cost-competitiveness! Designed pilot-scale system, procured components, & initiated construction
Plans for 3Q03 Plans for 3Q03 –– 2Q042Q04! Complete construction and assembly of pilot-scale system ! Conduct shakedown and testing to assess performance ! Continue development of process models; validate with experimental data
October '03
Niskayuna, NY
Shanghai, China
GE Global Research Locations
Thank You!Thank You!
Bangalore, India Munich, Germany Irvine, California
October '03
Steam Feed SystemProcess Flow Diagram (PFD)
! Boiler capacity (900lb/hr) provides up to 3umf
* and carrier steam for solids transfer
•45KW electric furnaces(5) superheats boiler output to:T > 700oC (1252oF)
•Two overlapping coils are use to maximize heat transfer area and increasing residence time
Designed to Provide Up to 900lb/hr of Superheated Steam at 950oC/300PSIG
*umf: minimum fluidization velocity
October '03
Process Air Feed SystemProcess Flow Diagram (PFD)
• Other design criteria:Start-up air supply (for all reactors)Auxiliary air supply
! Air system provides 4umf to reactor-3 (380 lb/hr)
Staged Air System:
Staging Provides Low Cost Supply of High-Pressure Process Air(200CFM @ 120PSIG)
October '03
Emissions Control System
Since the system is not, fully integrated, the AQMD requires that the product streams be treated before they can be released
Process Flow Diagram (PFD)
Scrubber Packed Bed Material: Plastic Jaeger Tri-Packs®
900F
Process Gas
Air (2)
2,400F
2,600F
Afterburner
Emissions Control Assembly
IN
Meets AQMD emissions criteria for removal of CO and SO2
October '03
Gas & Solids Sampling System1 moles η (%) 99 3 moles split ratio 30 4 moles
H2 541.47 H2 541.47 78.75% H2 523.42H2O 7528.23 H2O 75.28 10.95% H2O 72.77CO 33.61 CO 33.61 4.89% CO 32.49CO2 33.61 CO2 33.52 4.88% CO2 32.41CH4 3.73 CH4 3.73 0.54% CH4 3.61O2 0.00 O2 0.00 0.00% O2 0.00N2 0.00 N2 0.00 0.00% N2 0.00Total 8140.65 Total 687.62 Total 664.70
2 moles 5 molesH2O 7452.95 H2 18.05 78.75%CO2 0.08 H2O 2.51 10.95%Total 7453.03 CO 1.12 4.89%
CO2 1.12 4.88%What do we want to determine? Composition 1 CH4 0.12 0.54%Expectation: O2 0.00 0.00%(a) Mist eliminator's performance is ideal (or near - define) N2 0.00 0.00%(b) Measure total flow 1 Total 22.92(c) Measure total flow 3
(d) Composition 3 ~ 7, and composition 1 is determined 6 moles 7 molesH2O 2.51 H2 18.05 88.51%
Alternative - worst case: CO2 0.02 H2O 0.00 0.01%(a) Mist eliminator's performance is far from ideal. Total 2.53 CO 1.12 5.49%(b) Measure 7 (total flow & composition) CO2 1.10 5.37%(c) Measure total flow 1 CH4 0.12 0.61%(d) Measure total flow 3 O2 0.00 0.00%(e) Measure total flow 5 (or less preferably, 4) N2 0.00 0.00%(f) Composition 3 = 5, and composition 1 is determined η (%) 99.9 Total 20.39
Mist Eliminator Sample split
Chiller
Bottom line conclusion:We need flow meters onstreams 1, 3, 5 and 7.If the mist eliminatorbehaves ideally, flowmeters 1 and 3 suffice.
To burner
ToCEMs/GC
CEMS MicroGC
On-lineAnalysis
Gases
TGA MossbauerSpectroscopy
XRD
SampleCollection
Solids
Materials Balance(dry basis)
Split fractionfor analysis
Treat andDischarge L & G
Bulk materials(S, L & G)
UFP materialsSolid, Liquid & Gas
Sampling: Gas & Solids
Sampling system is designed to provide material balance on the reactors gas products
and quantitative ratio speciation of solids