Project No: FE0007952
Performer: Reaction Engineering International

Jenny Tennant
Technology Manager
National Energy Technology Laboratory
3610 Collins Ferry Road
P.O. Box 880
Morgantown, WV 26507-0880

Darryl Shockley
Project Manager
National Energy Technology Laboratory
3610 Collins Ferry Road
P.O. Box 880 PO3B
Morgantown, WV 26507-0880

Michael Bockelie
Principal Investigator
Reaction Engineering International
746 E. Winchester St., Suite 120
Salt Lake City, UT 84107
801-364-6925 X22

Award Date:  10/01/2011
Project Date:  06/30/2015

DOE Share: $1,130,386.00
Performer Share: $310,864.00
Total Award Value: $1,441,250.00

Performer website: Reaction Engineering International -

Advanced Energy Systems - Gasification Systems

Mitigation of Syngas Cooler Plugging and Fouling

Project Description

This Reaction Engineering International (REI) project will develop a better understanding of ash deposition onto refractory and metal surfaces associated with the syngas cooler used in integrated gasification combined cycle (IGCC) plants that incorporate a two-stage gasifier. Plugging and fouling of syngas coolers will be evaluated and specific mitigation methods validated. The successful completion of this project will result in improved availability and reliability of the syngas cooler and thereby improve the availability of the overall IGCC plant.

From left to right: Laminar Entrained Flow Reactor, Pilot Scale Entrained Flow Gasifier, Syngas Cooler CFD Model

Program Background and Project Benefits

This REI project is focused on developing a better understanding of syngas cooler plugging and fouling principles, in order to formulate concepts for mitigation of these problems to improve gasification plant availability and reliability. Improvements in availability and reliability of the syngas cooler would directly reduce the cost of electricity in integrated gasification combined cycle plants and costs of other products from syngas. Specifically, REI is conducting experiments and CFD modeling to develop designs for deposit removal, with the most promising concepts to be validated during field testing.

Project Scope and Technology Readiness Level

A team of experts in coal gasification, ash deposit formation, and coal gasification modeling will perform laboratory scale gasification experiments and develop practical solutions to ash deposition. Reaction Engineering International has teamed with the University of Utah (UofU) to perform the experimental work. Gasification equipment manufacturer(s) will also be involved with the project. Laboratory-scale experiments will evaluate the bond strength between deposits and metallic and refractory surfaces through a range of temperatures and fuels. Modeling will assist in test design and data interpretation to investigate deposition, plugging, and fouling in the syngas cooler section. Alternative process conditions and equipment designs will be evaluated to mitigate plugging and fouling of the syngas cooler. Promising concepts for deposit removal will be field tested during the final year of the program.

The Technology Readiness Level (TRL) assessment identifies the current state of readiness of the key technologies being developed under the DOE’s Clean Coal Research Program. In FY 12, this project was assessed a TRL of 3.

The TRL assessment process and its results including definition and description of the levels may be found in the "2012 Technology Readiness Assessment-Analysis of Active Research Portfolio”.