Project No: FE0007902
Performer: General Electric


Contacts
Jenny Tennant
Gasification Systems Technology Manager
National Energy Technology Laboratory
3610 Collins Ferry Road 
P.O. Box 880
Morgantown, WV 26507-0880
304-285-4830
jenny.tennant@netl.doe.gov

Patricia Rawls 
Project Manager
National Energy Technology Laboratory
626 Cochrans Mill Road
P.O. Box 10940
Pittsburgh, PA 15236-0940
412-386-5882
patricia.rawls@netl.doe.gov

Jeffrey Rader
Principal Investigator
GE Energy (USA), LLC
1333 W. Loop S.
Houston, TX 77027
818-237-3689
jeffrey.rader@ge.com

Duration
Award Date:  10/01/2011
Project Date:  03/30/2013

Cost
DOE Share: $695,194.00
Performer Share: $173,798.00
Total Award Value: $868,992.00

Performer website: General Electric - http://www.ge.com/

Advanced Energy Systems - Gasification Systems

Scoping Studies to Evaluate the Benefits of an Advanced Dry Feed System on the Use of Low-Rank Coal in IGCC Technologies

Project Description

The U.S. has large reserves of low-cost, low-rank coal, but use in IGCC systems is, to a large extent, limited by the capabilities of available coal feed systems. Conventional dry feed systems feed coal through a system of lock hoppers. This approach has high capital, operating, and maintenance costs and poor reliability, issues that are exacerbated as operating pressure increases. Slurry feed systems suffer an efficiency penalty resulting from the need to evaporate and heat the water contained in the high inherent moisture low-rank coals and the additional water added to form a pumpable slurry, thereby reducing efficiency.

Project personnel are preparing comparative techno-economic studies of two IGCC power plant cases: one with and one without advanced dry feed technology. A common basis of design is being developed. For both cost and performance comparisons, the baseline case (without advanced dry feed technology) is being developed using operational data from the Eastman Chemical Company’s Kingsport gasification facility in combination with data from the DOE case study for IGCC using a low-rank coal with 90 percent carbon capture. Advanced dry feed technology, based upon the Posimetric pump currently under development by GE, will be developed to match the proposed plant conditions and configuration, and analyzed to provide comparative performance and cost information to the baseline plant case. The scope of this analysis covers the feed system from the raw coal silo through the gasifier injector.


Program Background and Project Benefits

General Electric Company (GE) is evaluating and demonstrating the benefits of novel dry feed technologies to effectively, reliably, and economically provide feeding of low-cost, low-rank coals into commercial Integrated Gasification Combined Cycle (IGCC) systems. GE is completing comparative techno-economic studies of two IGCC power plant cases, one without and one with advanced dry feed technologies. A common basis of design is being developed so that overall assumptions and methodologies are common in the two cases for both technical and economic areas. The baseline case, without advanced dry feed technologies, will use operational data from the Eastman Chemical Company Kingsport gasification facility in combination with DOE/NETL's Cost and Performance Baseline Low-Rank Coal to Electricity IGCC study for both cost and performance comparisons. Advanced dry feed technologies, based upon the Posimetric® pump currently under development by GE, will be developed to match the proposed plant conditions and configuration, and will be analyzed to provide comparative performance and cost information to the baseline plant case. The scope of this analysis will cover the feed system from the raw coal silo up to, and including, the gasifier injector. Test data from previous and current testing will be summarized in a report to support the assumptions used to evaluate the advanced technologies and the potential value for future applications. This study focuses primarily on IGCC systems with 90 percent carbon capture, utilization, and storage (CCUS), but the dry feed system will be applicable to all IGCC power generating plants, as well as other industries requiring pressurized syngas. 



Accomplishments

The slurry feed Base Case study (Base Case) was completed. The Base Case plant configuration includes a conventional GE coal grinding and slurry preparation unit that feeds an aqueous slurry of Montana Rosebud Powder River Basin Coal to a single 1800 cubic foot (ft3 ) GE quench gasifier. GE in-house models of the gasifier, the gasification island, and the power island were used for simulating the Base Case plant.

The following items were completed or developed:

The slurry feed Base Case study (Base Case) was completed. The Base Case plant configuration includes a conventional GE coal grinding and slurry preparation unit that feeds an aqueous slurry of Montana Rosebud Powder River Basin Coal to a single 1800 cubic foot (ft3 ) GE quench gasifier. GE in-house models of the gasifier, the gasification island, and the power island were used for simulating the Base Case plant.

Heat and material balances, together with the down selected configuration for the Posimetric Feed System, were used to calculate auxiliary power consumption and overall plant efficiency for the Advanced Technology IGCC Case. On the basis of these results, a number of improvements were identified that will significantly increase overall plant efficiency. An optimization effort was initiated and is currently ongoing to integrate these improvements in the IGCC plant design.