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