1.

Executive Summary

1

2.

Introduction

1

3.

Project Description

1

4.

Results

3

4.1

Performance Summary

3

4.2

WBS

3

4.3

1992 Accomplishments

4

4.4

Work to completed During Next Budget Period

4

5.

Environmental Discussion

7

5.1

NEPA Support

7

5.2

EMP

7

5.3

Environmental and Construction Permitting

7

5.4

Air Modeling

8

5.5

BACT

8

5.6

Air Permit

9

5.7

Plans for Other Environmental Permits

9

6.

Technical Discussion

6.1

IGCC Performance Studies

9

6.2

Computer Modeling

9

6.3

Heat Rate Sensitive Process Decisions

12

6.3.1

Gasifier Air Temperature

16

6.3.2

HRSG Stack Temperature

17

6.3.3

HRSG Feedwater Temperature Study

17

6.3.4

Supplemental HRSG Firing

18

6.3.5

Coal and Char Feed System Study

18

6.3.6

Process Steam Source Study

20

6.3.7

Cost Reduction Study Heat Rate Effects

20

6.3.8

HRSG Performance Study

21

6.3.9

Coal Preparation Alternate

24

6.3.10

Coal Feed Alternate

26

6.4

Design Basis

28

6.5

System Studies

30

6.5.1

Coal Feed

30

6.5.2

Pressurizing, Fluidizing, and Conveying Gas Study

31

6.5.3

Coal Mill outlet Temperature

31

6.5.4

Lockhopper and Feed Bin Digest

31

6.5.5

Lockhopper and Feed Bin Test

32

6.5.6

Material Handling Valve

32

6.5.7

Char Recycle System

33

6.5.8

Char Bagfilter

33

6.5.9

Char Vessel Material

33

6.5.10

Char Study

36

6.5.11

Hot Gas Cleanup

36

6.6

Heat and Material Balances

36

6.7

Process Flow Diagrams and Process Descriptions

37

6.8

Piping and Instrumentation Diagrams

43

6.9

Metallurgical Diagrams

45

6.10

Equipment Data Sheets

45

6.11

Gasifier and Heat Exchanger

46

6.11.1

Syngas Cooler Performance Studies

47

6.11.2

Initial Mechanical Design

49

6.11.3

Arrangement Drawings

49

6.11.4

Transportation Study

58

6.11.5

Construction Studies

58

6.11.6

Heat Exchanger Computer Program

59

6.11.7

Transient Studies

59

6.11.8

Circulation System

60

6.11.9

Superheater

60

6.11.10

Burner Development

61

6.11.11

Slag Tap

61

6.11.12

Slag Grinder

62

6.11.13

Gasifier and Syngas Cooler Cost Estimate

62

6.12

Balance of Plant

62

6.12.1

Coal Handling

62

6.12.2

Slag Removal and Handling

63

6.12.3

Sulfur Recovery

64

6.12.4

Booster Compressor

66

6.12.5

Gas Turbine

66

6.12.6

Steam Turbine

67

6.12.7

HRSG

68

6.12.8

Plant Layouts

68

6.12.8.1

Gasifier Island

68

6.12.8.2

Lakeside Building

70

6.12.8.3

Overall Site Plot Plans

71

6.12.9

CWL&P Interfaces

71

6.13

Cost Estimate

74

6.14

Cost Reduction Studies

74

6.15

Support Studies

74

6.15.1

Materials Studies

74

6.15.2

Permeability of Gasifier Char

75

6.15.3

Kinetic Extruder

76

6.15.4

Preliminary Hazard Analysis

76

6.15.5

Gasification Data

77

6.15.6

Lakeside Boiler Performance on LBG

77

6.16

Startup/Shutdown/Operating Procedures

78

6.17

Commissioning/Startup/Operation/Maintenance Plans

79

6.18

Test Plans

79

7.

Site Related Activities

80

8.

Project Management

80

8.1

Project Management Plan

80

8.2

Schedules

81