DOE/METC/SP-201

DE84003048

Distribution Category UC-90C

 

MORGANTOWN ENERGY TECHNOLOGY CENTER (METC)

 

TOPICAL REPORT

 

SURFACE COAL GASIFICATION

 

Gasification Development Section

Gasification Projects Branch

Coal Projects Management Division

 

This overview report, prepared by Morgantown Energy Technology Center staff, describes the historical development, current status, and technology crosscuts of the Surface Coal Gasification Program.

 

April 1983

 

 

TABLE OF CONTENTS

                                                                                                                                                                                            Page

1.0 INTRODUCTION

                1.1 Program Perspective                                                                                                                                      1

                1.2 Program Objectives                                                                                                                                       1

                1.3 Summary of Physical Facilities                                                                                                    3

                1.4 Discussion Format                                                                                                                                         4

2.0 BI-GAS TWO-STAGE ENTRAINED-FLOW GASIFICATION PILOT PLANT

                2.1 Project History                                                                                                                                               4

                2.2 Project Goals                                                                                                                                   5

                2.3 Process Description                                                                                                                                      5

                2.4 FY82 Accomplishments                                                                                                                                7

                2.5 Current Status and Projected Work                                                                                                            7

3.0 WESTINGHOUSE ASH-AGGLOMERATING FLUID-BED GASIFICATION PDU

                3.1 Project History                                                                                                                                               7

                3.2 Project Goals                                                                                                                                                   9

                3.3 Process Description                                                                                                                                      9

                                3.3.1 Gasifier System                                                                                                                            9

                                3.3.2 Cold Flow Scale-Up Facility                                                                                                      9

                3.4 FY82 Accomplishments                                                                                                                                10

                                3.4.1 Gasificr Tests                                                                                                                               10

                                3.4.2 Cold Flow Scale-Up Facility                                                                                                      11

                                3.4.3 Process Development Unit Modifications                                                                              11

                                3.4.4 Laboratory Support                                                                                                                    11

                3.5 Current Status and Projected Work                                                                                                            11

                                3.5.1 Gasifier Tests                                                                                                                               11

                                3.5.2 Cold Flow Scale-Up Facility                                                                                                      12

                                3.5.3 Laboratory Support                                                                                                                    12

4.0 MOUNTAIN FUEL RESOURCES ENTRAINED-FLOW GASIFICATION PDU

                4.1 Project History                                                                                                                                               12

                4.2 Project Goals                                                                                                                                                   12

                4.3 Process Description                                                                                                                                      14

                4.4 FY82 Accomplishments                                                                                                                                14

                4.5 Current Status and Projected Work                                                                                                            14

5.0 METC DRY-BOTTOM FIXED-BED  GASIFICATION PILOT PLANT

                5.1 Project History                                                                                                                                               14

                5.2 Project Goals                                                                                                                                                   16

                5.3 Process Description                                                                                                                                      16

                                5.3.1 Gasifier Systems                                                                                                                          16

                                5.3.2 Gas Cleanup System                                                                                                   18

                5.4 FY82 Accomplishments                                                                                                                                18

                5.5 Current Status and Projected Work                                                                                                            18

6.0 GRAND FORKS PROJECT OFFICE SLAGGING FIXED-BED GASIFICATION PILOT PLANT

                6.1 Project History                                                                                                                                               20

                6.2 Project Goals                                                                                                                                                   20

                6.3 Process Description                                                                                                                                      20

                6.4 FY82 Accomplishments                                                                                                                                23

                6.5 Current Status and Projected Work                                                                                                            24

7.0 GE FIXED-BED GASIFIER AND PERFORMANCE EVALUATION FACILITY

                7.1 Project History                                                                                                                                               25

                7.2 Project Goals                                                                                                                                   25

                7.3 Process Description                                                                                                                                      26

                                7.3.1 Gasification Subsystem                                                                                                             26

                                7.3.2 Gas Cleanup Subsystem                                                                                                            26

                                7.3.3 Turbine Simulator Subsystem                                                                                   26

                                7.3.4 Computer-Based Data Acquisition and Control System                                                      30

                7.4 FY82 Accomplishments                                                                                                                                30

                                7.4.1 Dynamic Characterization and System Simulation                                                                30

                                7.4.2 Process Stream Characterization and Environmental Compatibility                   30

                                7.4.3 Component Performance                                                                                                           30

                                7.4.4 Process Development                                                                                                                33

                7.5 Current Status and Projected Work                                                                                                            33

8.0 MINING INDUSTRIAL FUEL GROUP FIXED-BED GASIFIER

                8.1 Project History                                                                                                                                               35

                8.2 Project Goals                                                                                                                                                   35

                8.3 Process Description                                                                                                                                      35

                8.4 FY82 Accomplishments                                                                                                                                37

                8.5 Current Status and Projected Work                                                                                                            37

9.0 COMMUNITY AREA NEW DEVELOPMENT ORGANIZATION FIXED-BED GASIFIERS

(GASIFIERS-IN-INDUSTRY PROGRAM)

                9.1 Project History                                                                                                                                               37

                9.2 Project Goals                                                                                                                                                   38

                9.3 Process Description                                                                                                                                      38

                9.4 FY82 Accomplishments                                                                                                                                38

                9.5 Current Status and Projected Work                                                                                                            38

10.0 COAL GASIFICATION TECHNOLOGY CROSSCUT

                10.1 Introduction                                                                                                                                                  38

                10.2 Overview of Generic Gasification Systems Problems                                                                             40

                                10.2.1 Coal Feeding                                                                                                                              40

                                10.2.2 Char Recycle                                                                                                                              41

                                10.2.3 Residence Times                                                                                                                       41

                                10.2.4 Non-Slagging and Slagging Gasifiers                                                                                    41

                                10.2.5 Gasifier Design Specificity to Feedstock                                                                              52

                                10.2.6 System Integration                                                                                                                   52

                10.2.7 Environmental Activities                                                                                                                         53

11.0 BIBLIOGRAPHY                                                                                                                                                          54

APPENDIX A: GLOSSARY OF ABBREVATIONS AND ACRONYMS                                                     62