Abstract

1

1.0

Executive Summary

2

2.0

Conclusions

4

2.1

Process Development Unit

4

2.2

Parametric Performance Analysis

4

2.3

Secondary Coal Injection

4

2.4

Slag Fluxing Tests

4

2.5

Gasification Tests

4

3.0

Recommendations

5

4.0

Program Plan

6

4.1

Objective

6

4.2

Test Program

6

4.2.1

Secondary Coal Injector Development

6

4.2.2

Material Test Program

7

4.2.3

Gasification Test Series

7

4.3

Program Schedule

8

5.0

Technical Progress

10

5.1

Process Description

10

5.2

Performance Analysis

11

5.2.1

Zone A/Zone B Performance Analysis

11

5.2.2

Parametric Analysis for Gasifier with Secondary Coal Injection

16

5.2.3

31

5.3

Gasifier Design

31

5.3.1

Gasifier Sizing

31

5.3.2

Gasifier Configuration

31

5.3.3

Reactor Design

33

5.3.4

Gasifier Starter

37

5.4

Gasifier Fabrication

37

5.5 

Test Facility Design

41

5.5.1

Facility Modifications

41

5.6

Test Facility Assembly

45

5.7

Data Acquisition and Analysis

50

5.7.1

Material Measurement and Analysis

50

5.7.2

Levels of Material Balance

53

5.7.3

Data Acquisition and Analysis Systems

53

5.8

PDU Operation and Safety Assurance

56

5.9

PDU Checkout Tests

58

5.9.1

Coal Flow Tests

58

5.9.2

Start Sequence Development Tests

58

5.9.3

Gasification Checkout Tests

62

5.9.4

Test Curtailment

64

5.10

Secondary Coal Flow Splitting and Injection

64

5.10.1

Analysis and Design of Secondary Coal Injection System

65

5.10.2

Cold Flow Tests

74

5.11

Slag Fluxing Tests

78

5.11.1

Objectives of Slag Fluxing Test Program

78

5.11.2

Literature Review

78

5.11.3

Experimental Procedure

79

6.0

Company Sponsored Gasification Tests

87

6.1

Test Summary

87

6.2

Gasifier Configurations

88

6.3

Gasification Test Procedure

88

6.4

Gasifier Operation

89

6.5

Material Balance

90

6.6

Gasifier Performance

91

References

93