Novel Gas Cleaning/Conditioning for Integrated Gasification Combined Cycle. Volume I – Conceptual Commercial Evaluation and Volume II - Process Development Unit Test Results. Final Report

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)

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