1

Introduction

1-1

2

Background

2-1

3

Program organization and management structure

3-1

Program Organization

3-1

Program Management Structure

3-3

Board of Control

3-4

Management Committee

3-5

The program Manager and the Program Office

3-7

Participant Responsibilities

3-7

4

General project description

4-1

Phase I – Preliminary Engineering

4-3

Preliminary Design Study

4-3

Coal gasification pilot plant tests

4-3

Permitting and Regulatory activities

4-4

Soliciting of participants

4-4

Phase II – Final Engineering

4-5

Phase III – Final Engineering

4-5

Phase IV – Testing and Operation

4-8

Phase V – Program Completion

4-11

5

Process and plant description

5-1

General

5-1

Existing site facilities

5-14

GCC Plant Sections

5-14

Coal Receiving, Storage and Handling

5-14

Coal grinding and slurring

5-19

Coal Gasification

5-23

Oxygen Plant

5-28

Gasification Process Effluent water treatment

5-28

Ash and slag handling

5-33

Sulfur removal (Selexol)

5-33

Sulfur Recovery

5-34

Power Generation

5-41

Steam, Condensate and boiler feedwater system

5-44

Plant Electrical Systems

5-46

Other Supporting Systems

5-52

Flare system

5-52

Cooling and Make-up water systems

5-52

Plant Air

5-55

Auxiliaries

5-56

Fire Protection

5-58

Pollution control facilities

5-58

Buildings

5-60

System design considerations

5-61

Plant configuration and design requirements

5-62

Integrated Plant Control

5-66

Plant Load/Pressure control

5-66

Operation Guidance

5-69

Plant protective coordination

5-73

Control Analysis

5-74

Power System Requirements

5-74

Loss of generation-System islanding – emergency conditions

5-75

Load Following Capability

5-76

Load Turndown

5-76

Load Rejection Performance

5-77

Data Acquisition System

5-77

6

Plant Performance Projections

6-1

7

Cost Estimate and Funding

7-1

Basis and Assumptions

7-1

Program Funding Plan

7-1

Source of Funds

7-3

8

Progress report and schedules

8-1

Pilot plant tests

8-1

Montebello

8-1

Oberhausen

8-1

Engineering

8-2

Procurement

8-9

Construction

8-9

Operations Planning

8-11

Milestone Schedule

8-12

9

Regular Tory Requirements

9-1

Overview of Regulatory review process

9-1

Summary of California Energy Commission Permit Process

9-1

Summary of the California Public Utilities Commission Process

9-3

Summary of the Environmental Protection Agency’s Prevention of Significant Deterioration Permit Process Environmental Permit Conditions and Monitoring

9-5

10

Test and Demonstration Plans

10-1

General

10-1

Test Plan Outline

10-2

Planned Tests and Evaluations

10-2

System (Steady State)

10-2

Dynamic Tests

10-5

Materials and Equipment Tests

10-6

Environmental Tests

10-8

11

References

11-1