Novel Gas Cleaning Conditioning for Integrated Gasification Combined Cycle. Base Program Final Report

Novel Gas Cleaning Conditioning for Integrated Gasification Combined Cycle. Base Program Final Report - August 2001

Richard A. Newby
Eugene E. Smeltzer
Thomas E. Lippert
Rachid B. Slimane
O. Mehmet Akpolat
Keyur Pandya
Francis S. Lau
Javad Abbasian
Brett E. Williams
Dennis Leppin

Abstract				ii
1	INTRODUCTION			1
	1.1	Ultra-Clean Gas Polishing Process Concept		2
	1.2	Base Program Objectives and Scope		3
2	EXECUTIVE SUMMARY			4
3	EXPERIMENTAL - LABORATORY SORBENT TESTING			6
	3.1	Thermodynamic Considerations		8
		3.1.1	Syngas Simulation	8
		3.1.2	Materials Selection for Chloride Removal Stage I and II	10
		3.1.3	Materials Selection for Sulfur Removal in Stage I and II	13
	3.2	Materials Selection and Acquisition		17
	3.3	Laboratory Simulation of the Ultra-Clean Gas Polishing Process		23
	3.4	Results and Discussion		32
		3.4.1	Screening Tests of Stage I Dechlorination Materials	32
		3.4.2	Screening Tests of Stage I Desulfurization Materials	36
		3.4.3	Combined Chloride/Sulfur Removal Tests Using Iron Oxide Byproduct/Trona Mixtures	41
		3.4.4	Analysis of Iron Oxide Byproduct/Trona Sorbent Mixture	44
		3.4.5	Combined Chloride/Sulfur Removal Tests Using Zinc Titanate/Trona Mixtures	47
		3.4.6	Preliminary Stage II HCl Removal Tests	53
		3.4.7	Priorities for Experimental Testing for Balance of Base Program	55
		3.4.8	Feeding HCl as a Liquid Rather than a Gas	58
		3.4.9	Screening Tests for Stage II HCl Sorbents	59
		3.4.10	Evaluation of Stage Ii H₂S Sorbents	68
		3.4.11	Combined Chloride/Sulfur Removal Tests Using G-72E/G-92C Sorbents	70
	3.5	Comments on Effect of Reactor Pressure		74
	3.6	Recommendations		75
		3.6.1	Recommendations for Stage I Operating Conditions	75
		3.6.2	Recommendations for Stage II Operating Conditions	76
4	CONCEPTUAL PROCESS EVALUATION			79
	4.1	Evaluation Basis		80
		4.1.1	Applications	80
		4.1.2	Process Evaluation Boundaries	82
		4.1.3	Gas Cleaning Requirements	83
		4.1.4	Specific Evaluation Basis	84
		4.1.5	Raw Gas Conditions and Composition	85
		4.1.6	Equipment Sizing and Specification	87
		4.1.7	Economic Criteria	88
	4.2	Conventional Syngas Cleaning or Synthesis Applications		90
		4.2.1	Process Description	91
		4.2.2	Process Material & Energy Balances and Overall Performance	98
		4.2.3	Process Economics	107
	4.3	Conventional Fuel Gas Cleaning for SOFC		110
		4.3.1	Process Alternatives	110
		4.3.2	Process Descriptions	110
		4.3.3	Process Material & Energy Balances for Overall Performance	110
		4.3.4	Process Economics	115
	4.4	Novel Syngas Cleaning for Synthesis Applications		121
		4.4.1	Process Alternatives	121
		4.4.2	Process Descriptions	124
		4.4.3	Process Material & Energy Balances for Overall Performance	135
		4.4.4	Process Economics	149
	4.5	Novel Fuel Gas Cleaning for SOFC Power Generation		153
		4.5.1	Process Alternatives	153
		4.5.2	Process Descriptions	154
		4.5.3	Process Material & Energy Balances for Overall Performance	157
		4.5.4	Process Economics	161
	4.6	Conceptual Market Evaluation		165
	4.7	Results and Discussion		167
5	CONCLUSIONS AND RECOMMENDATIONS			173
6	REFERENCES			177
7	BIBLIOGRAPHY			180
8	ACRONYMS AND ABBREVIATIONS			181

APPENDICES
A	Trace Level HCl Gas Sampling Techniques and Methods			182
B	Trace Level H₂S Gas Sampling Techniques and Methods			191