Gasification Based Biomass Co-Firing, Phase I, Final Report September 2002

DISCLAIMER				i
ABSTRACT				ii
EXECUTIVE SUMMARY				vii
1	Introduction (623KB)			1
	1.1	Background Information		1
	1.2	Gasification based Cofiring Concept		2
	1.3	Western Kentucky Energy Case		2
	1.4	TXU Energy Case		4
	1.5	Primenergy Gasifier		4
	1.6	Phase I Organization, Tasks and Schedule		6
2	Technology Evaluation (489KB)			10
	2.1	Overview of Co-firing Technologies		10
		2.1.1	Low Percentage Co-Firing	10
		2.1.2	Direct Combustion Co-Firing with Separate Feed Systems	10
		2.1.3	Issues remaining to be resolved with co-firing	11
	2.2	Gasification Technologies		12
	2.3	Hot Gas Filtration System		14
	2.4	Environmental Impact of Gasification		14
		2.4.1	Comparison of Coal vs. Litter Burn	16
3	Project Evaluation (2.62MB)			18
	3.1	WKE Case		18
		3.1.1	WKE Reid Plant	18
		3.1.2	Reid Plant Boiler Data	20
		3.1.3	Gasifier Material and Energy Balance	20
		3.1.4	Gasifier Boiler Integration	22
		3.1.5	Overall Plant Energy Balance	23
		3.1.6	Solids Handling Systems	24
		3.1.7	Permit Issues	25
		3.1.8	Fuel Contracts	28
		3.1.9	Major Equipment List	29
		3.1.10	Equipment Layout	31
	3.2	TXU Energy Case		32
		3.2.1	TXU Monticello Plant	32
		3.2.2	Monticello Unit 1 Boiler Data	33
		3.2.3	Gasifier Material and Energy Balance	34
		3.2.4	Gasifier Boiler Integration	36
		3.2.5	Overall Plant Energy Balance	36
		3.2.6	Solids Handling Systems	37
		3.2.7	Permit Issues	41
		3.2.8	Fuel Contracts	43
		3.2.9	Major Equipment List	43
		3.2.10	Gasification Plant Layout	45
4	Economic Analysis (442KB)			46
	4.1	Reid Plant Case		46
		4.1.1	Capital and O&M Cost Estimate	46
		4.1.2	Financial Pro Forma	48
		4.1.3	Sensitivity Analysis for Reid Plant Case	49
	4.2	Monticello Unit 1 Case		52
		4.2.1	Capital and O&M Cost Estimate	52
		4.2.2	Financial Pro Forma	55
		4.2.3	Sensitivity Analysis for Monticello Case	56
5	Results and Discussion (323KB)			57
	5.1	Infrastructure/Fuel Supply and Alternative Fuels		57
	5.2	Merits of the Project		58
		5.2.1	Energy Benefits and Impacts	58
		5.2.2	Environmental Benefits and Impacts	58
		5.2.3	Economic Benefits and Impacts	59
		5.2.4	Infrastructure/Fuel Supply Benefits and Impacts	60
	5.3	Project Sustainability and Opportunities for Replication		60
6	Conclusions (145KB)			62
7	References & Bibliography (60.8KB)			65
	7.1	References & Bibliography		65

APPENDIX A - WKE CASE (1.88MB)
APPENDIX B - TXU CASE (3.26MB)
APPENDIX C - BB Power Report on Boiler Penetraions (2.01MB)

LIST OF FIGURES
Figure 1-1		Gasification Based Biomass Co-Firing System Diagram		2
Figure 1-2		Poultry Supply in Vicinity of Reid Plant		3
Figure 1-3		Primenergy Gasifier - simplified sketch		6
Figure 1-4		Project Organization Chart		7
Figure 1-5		Interrelationships of Tasks in Phase I		8
Figure 1-6		Project Milestone Schedule		9
Figure 3-1		Reid Plant Boiler Schematic		19
Figure 3-2		Heat input to the boiler with cofiring		26
Figure 3-3		Expected NO_x emissions with cofiring		27
Figure 3-4		Expected SO₂ emissions with cofiring		27
Figure 3-5		Monticello Plant Unit 1		32
Figure 3-6		Heat Input to the boiler with cofiring		41
Figure 3-7		Reported NO_xand SO_x emissions at Monticello Plant		42
Figure 4-1		COE Sensitivity to Fuel Price and Ash Credit		51

LIST OF TABLES
Table 1-1		Poultry production estimate by Texas Agricultural Department (1997)		4
Table 2-1		Selected Greenhouse Gases Prior to 1850 vs 1994		15
Table 2-2		Unabated Emissions Data for Poultry Litter Test Gasification Run		16
Table 2-3		Coal and Litter Composition and Expected Emissions		17
Table 3-1		Reid Plant Boiler Operating Data		20
Table 3-2		Material Balance for the Gasifier		21
Table 3-3		Energy Balance for the Gasifier		22
Table 3-4		Energy Balance and Power Production for Reid Plant		24
Table 3-5		Gasifier Island Equipment List		30
Table 3-6		Material Handling System Equipment List		31
Table 3-7		Design Specifications for Monticello Unit 1		33
Table 3-8		Monticello Boiler Fuel Analyses		34
Table 3-9		Material Balance for the gasifier		35
Table 3-10		Energy Balance for the gasifier		36
Table 3-11		Energy Balance and Power Production for Monticello Case		37
Table 3-12		Gasifier Island Equipment List		44
Table 3-13		Material Handling Equipment List		45
Table 4-1		Capital Cost Estimates for the Fuel Storage and Conveying		46
Table 4-2		Total Capital Cost for WKE's Case		46
Table 4-3		Operation, Maintenance and Fuel Cost Estimate - WKE Case		47
Table 4-4		Input Financial Parameters		48
Table 4-5		Levelized Cost of Electricity for WKE Case		49
Table 4-6		COE Sensitivity Analyses for Reid Case		50
Table 4-7		Capital Cost Estimates for Fuel Storage and Conveying		52
Table 4-8		Total Capital Cost for the Monticello Plant		53
Table 4-9		Operation, Maintenance and Fuel Cost Estimate - Monticello Case		54
Table 4-10		Levelized Cost of Electricity for Monticello Case		55
Table 4-11		COE Sensitivity Analyses for Monticello Case		56