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Novel Gas Cleaning/Conditioning for Integrated Gasification Combined Cycle.
Volume I Conceptual Commercial Evaluation and
Volume II - Process Development Unit Test Results.
Final Report - September 1, 2001 to December 31, 2005.

Horazak, Dennis A. (Siemens)
Newby, Richard A. (Siemens)
Smeltzer, Eugene E. (Siemens)
Slimane, Rachid B. (GTI)
Bush, P. Vann (GTI)
Aderhold, Jr., James L. (GTI)
Bryan, Bruce G. (GTI)

Siemens Power Generation, Inc.
Gas Technology Institute

Vol. I, Pages i - 144, 4.61 MB
Vol. II, Part 2, Pages i - 116, 4.72 MB
Vol. II, Part 3, Pages 117 - 164, 2.42 MB

Table of Contents

Part 1 Volume I Pages i 144, 4.61 MB

 

Table of Contents

vi

1.

Executive Summary

1

2.

Introduction

9

3.

Evaluation Basis

18

3.1

Plant Design Basis

18

3.2

Gas Cleaning and Conditioning Requirements

20

3.3

Material & Energy Balance Estimation and Process Equipment Sizing Approach

25

3.4

Economic Criteria and Cost Estimation Approach

26

4.

IGCC With Conventional Gas Cleaning

28

4.1

IGCC Plant Description with Conventional Gas Cleaning to meet Current Standards

29

4.2

IGCC Plant Description with Conventional Gas Cleaning to meet Future Standards

42

4.3

Conventional IGCC Power Plant Performance Estimates

49

4.4

Conventional IGCC Power Plant Cost Estimates

51

5.

IGCC With Filter-Reactor Novel Gas Cleaning

54

5.1

Fate of Contaminants and Waste Streams with Novel Gas Cleaning Technology

55

5.2

IGCC Plant Description with Novel Gs Cleaning to meet Current Standards

57

5.3

IGCC Plant Description with Novel Gas Cleaning to meet Future Standards

68

5.4

Description and Performance of Filter-Reactors

74

5.5

Performance Estimates for IGCC with Filter-Reactor Novel Gas Cleaning

87

5.6

Cost Estimates for IGCC with Filter-Reactor Novel Gas Cleaning

89

5.7

Assessment of IGCC with Filter-Reactor Novel Gas Cleaning

91

5.7.1

Performance Potential

91

5.7.2

Cost Potential

93

6.

Methanol Synthesis with Conventional Gas Cleaning

96

6.1

Description of Methanol Synthesis with Conventional Gas Cleaning

96

6.2

Conventional Methanol Synthesis Performance Estimates

111

6.3

Conventional Methanol Synthesis Plant Cost Estimates

113

7.

Methanol Synthesis with Novel Gas Cleaning

116

7.1

Description of Methanol Synthesis with Novel Gas Cleaning

116

7.2

Performance of Methanol Synthesis with Novel Gas Cleaning

132

7.3

Cost Estimates for Methanol Synthesis with Novel Gas Cleaning

135

7.4

Assessment of Methanol Synthesis with Novel Gas Cleaning

135

7.4.1

Performance Potential

135

7.4.2

Cost Potential

136

8.

Conclusions and Recommendations

139

9.

References

141

Volume II - Part 2, Pages i 116, 4.72 MB

 

Table of Contents

i

1.

Executive Summary

1

2.

Program Objectives

11

3.

Background

11

4.

Laboratory Supporting Studies

13

4.1

Sulfur and Halide Removal

13

4.2

Mercury Removal

15

5.

NGC Process Section Conceptual Design

18

5.1

Design Assumptions

19

5.1.1

Syngas Delivery Conditions

19

5.1.2

Test Conditions

19

5.1.3

Sorbents

20

5.1.4

Pressure Drops and Heat Losses

20

5.1.5

Auxiliaries

21

5.2

Computed Results

21

5.2.1

Filter-Reactor Conditions

21

5.2.2

Feed System Requirements

21

5.2.3

Sulfur Guard Bed

22

5.2.4

Waste Handling System Requirements

22

5.2.5

Auxiliaries

22

5.3

Conclusions

23

6.

Preparation of Pilot-Scale Facilities

24

6.1

Flex-Fuel Test Facilities

24

6.2

Novel Gas Cleaning (NGC) Process Section

30

7.

Test Plan

34

7.1

Conditioning Filter-Reactor Testing

34

7.2

Test Filter-Reactor Testing

37

8.

Sample Extraction and Conditioning Systems and Analytical Instrumentation

43

8.1

Hydrogen Chloride (HCI) Analysis

55

8.2

Hydrogen Sulfide and Carbonyl Sulfide Analysis

57

9.

Test Materials

58

9.1

Carbonaceous Feedstocks

58

9.2

Sulfur and Halide Sorbent Materials

63

9.3

Mercury Sorbent Materials

64

10.

Novel Gas Cleaning Optional Program Test Campaign #1 (NGC-OPT1)

64

10.1

Objectives

64

10.2

Process Flow Diagram for NGC-OPT1

65

10.3

NGC-OPT1 Sequence / Chronology

66

10.4

Results and Discussion NGC-OPT1

68

11.

Novel Gas Cleaning Optional Program Test Campaign #2 (NGC-OPT2)

83

11.1

Objectives

83

11.2

Process Flow Diagram for NGC-OPT2

83

11.3

Run Sequence / Chronology

84

11.4

Results and Discussion NGC-OPT2

89

11.4.1

NGC-OPT2A

91

11.4.2

NGC-OPT2B

102

11.4.3

FTIR Measurements

113

Part 3, Volume II Pages 117 164, 2.42 MB

12.

Novel Gas Cleaning Optional Program Test Campaign #3 (NGC-OPT3)

117

12.1

Objectives

117

12.2

Process Flow Diagram for NGC-OPT3

117

12.3

Run Sequence / Chronology

119

12.4

Results and Discussion NGC-OPT3

122

12.4.1

Gasifier and Filter-Reactor Operations

122

12.4.2

Summary

126

12.4.3

Gasifier Performance Determination Procedures

127

13.

Conclusions and Recommendations

144

14.

References

145

15.

Appendix A

NGC Process Section Piping and Instrumentation Diagram

146

16.

Appendix B

Gasifier Performance with Washed Indian Coal

155

17.

Appendix C

Analytical Report Samples

158