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“CONTINUOUS METERED INJECTION OF COAL INTO GASIFICATION AND PFBC
SYSTEM OPERATING PRESSURES EXCEEDING 38 Bar (560 PSI)”
Authors:Authors: Derek Aldred, Timothy Saunders Derek Aldred, Timothy Saunders -- Stamet Inc., Stamet Inc.,
International Freiberg Conference on IGCC & International Freiberg Conference on IGCC & XtLXtLTechnologiesTechnologies
June 16-18, 2005
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DOE Advanced Gasification Objectives:DOE Advanced Gasification Objectives:
• Expanding Coal-based power production.
• Efficient use of fossil-fuel resources, particularly coal.
• Minimizing emissions.
• Higher operating pressures for improved performance.
• Commercial acceptance.
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Gasification Feed Objectives:Gasification Feed Objectives:
• Provide a simple, accurate and reliable feed system.
• Establish controlled, continuous level delivery of coal.
• Minimize gas losses.
• Eliminate high maintenance costs and substantial risks of downtime for existing feed systems.
• Inject at pressures at and beyond 500 PSI (34 Bar).
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““FIRTH” Solids PumpFIRTH” Solids Pump
•First Prototype 1978
•Tested the week oil shale program cancelled!
•Concept idle for 10 years
•Stamet Inc., formed to develop concept
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Stamet Stamet ““PosimetricPosimetric®”®” Pump TechnologyPump Technology
• Unique concept named for “Positive Metering” of solids.
•One simple continuously rotating element, providing precise flow control.
•Configured machines can deliver solids directly into atmospheric or pressurized environments.
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Posimetric Pressure Pump ConfigurationPosimetric Pressure Pump Configuration
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First Posimetric First Posimetric Pressure FeederPressure Feeder
•Development Funded by US DOE Clean Coal Program (1994)
•Feeder achieved then record coal injection pressure - over 250 PSI (17 Bar) gas environment
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Current DOE Research ProgramCurrent DOE Research Program
• Two year Program schedule Gasifier Visits – define industry needs
– identify typical Coal specificationsSelect Commercial Fuel for Feeder Testing.
• Two-Phased approach:1. Develop semi-scale intermediate pressure feeder2. Develop semi-scale full pressure feeder
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Test Feeder Spool AssemblyTest Feeder Spool Assembly
• Shaft
• 2 Discs
• Hub Spacer
• 1 Bearing (of 2)
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Test Feeder BodyTest Feeder Body
• Side view showing seal and bearing location
• Body designed for ease of outlet removal and modification
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Test Feeder Rig AssemblyTest Feeder Rig Assembly
• Compact for portability
• Tested at multiple locations
• 600 Psi (40 Bar) Vessel pressure rating
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Phase 1 Successful Gas Pressure RunPhase 1 Successful Gas Pressure Run
First Run to 300psi
0
50
100
150
200
250
300
350
0 10 20 30 40
Time
Pre
ssur
e, p
sig
0
5000
10000
15000
20000
25000
30000
Torq
ue
Pout psi
Torque ft/lb 300psi Achieved24 Bar >
<33900 Nm
Torque
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Phase 1 Torque Effect on CoalPhase 1 Torque Effect on Coal
• Compacted Coal Extruded in Feeder Outlet
• High Torque Cause/Effect
• Plug Size 25mm x 50mm x 200mm
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Phase 1 Outlet ChangesPhase 1 Outlet Changes
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Phase 1 AchievementsPhase 1 Achievements
• Target Feeding into 300psi (20 Bar) Gas Pressure Successfully Achieved
• Optimization Reduced Torque 25%
• Delivery Linear across Full Pressure Range
• High Grip Achieved from Design - Potential for Reduced Machine Size
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PhasePhase 2 Objectives2 Objectives
• Develop, test and modify as required a machine for injection of coal into 500 PSI (34 Bar).
• Outline commercial Posimetric® Pump design for coal injection at 500 PSI (34 Bar).
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Phase 2 Flow AnalysisPhase 2 Flow Analysis
• Clear disc testing
• Beads used to identify flow regime
• Valuable visualization
of internal flow patterns
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Phase 2 Outlet ChangesPhase 2 Outlet Changes
• Revised outlet produced by 3D techniques
• Smoothed transition for flow exiting discs
• Outlet length reduced progressively to determine effect on torque
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Phase 2 Success!Phase 2 Success!
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Phase 2 FlowPhase 2 Flow--rate Linearityrate Linearity
02-113 DOE Pressure Injection -Test 216. Feeding at 500 psi
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50
Cumulative Revs
Wei
ght
Pum
ped,
lbs
0
100
200
300
400
500
600
700
Ou
tlet
Pre
ssu
re, p
si /
%
Sp
eed
.
Outlet Pressure
Weight Pumped
% Speed
< 48 Bar45 Kg >
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Phase 2 Gas ConsumptionPhase 2 Gas Consumption
Make-up Gas Consumption vs Outlet Pressure
0
0.25
0.5
0.75
1
1.25
1.5
200 250 300 350 400 450 500 550
Outlet Pressure, psi
Mak
e-u
p G
as C
on
sum
pti
on
, scf
m
^38 Bar
0.04 M3 >
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Phase 2 Geometry Optimization ResultsPhase 2 Geometry Optimization Results
Outlet Pressure vs Drive Torque Requirements
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000
0 100 200 300 400 500 600
Outlet Pressure, psig
Dri
ve T
orq
ue,
ft.
lbs.
Phase 1 Start
Phase 1 Final
Phase 2
^41 Bar
27000 Nm>
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Phase 2 Coal ConditionPhase 2 Coal Condition
• Coal extrusion showing little consolidation.
• “Log” breaks up easily indicating minimal impact from pressure rise.
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Phase 2 AchievementsPhase 2 Achievements
• Record pressure level achieved – 560 PSI (38 Bar).
• Very consistent feeder performance.
• Torque reduced 70% over Phase 1.
• Continued linear output against pressure.
• No problems stopping or starting against pressure.
• Coal at outlet little changed from that at inlet.
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Phase 2 DeliverablesPhase 2 Deliverables
• Commercial design arrangement finalized.
• Semi-commercial test location identified.
• Off-line site tests anticipated before yearend 2005.
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Economic Benefit AnalysisEconomic Benefit Analysis
• Pump Performance data Provided to DOE
• DOE/Parsons Undertaking Benefits Analysis
• Study of Capital and operating cost Savings for Transport and Oxygen Blown (Shell) Gasifiers
• Stamet Pump Eliminates Coal Slurrying/Drying
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Plant Capital Cost AnalysisPlant Capital Cost Analysis
Transport Gasifier
Plant Area ($000’s) Design W/Stamet
Coal Prep and Feed 44,473 17,069
Engineering & Contingency 11,118 6,828Auxiliary Power 835 1,988
TOTAL CAPITAL COSTS 56,426 25,885
Balance of Gasifier Island 75,942 75,942
Total Gasifier Island 132,368 101,827
TOTAL GASIFIER ISLAND ($/KW) 437 339
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Plant Capital Cost AnalysisPlant Capital Cost Analysis
Shell Gasifier IGCC
Plant Area ($000’s) Design W/Stamet
Coal Prep and Feed 35,670 11,856
Engineering & Contingency 8,918 4,742Auxiliary Power 546 1,300
TOTAL CAPITAL COSTS 45,134 17,898
Balance of Gasifier Island 113,116 113,116
Total Gasifier Island 158,249 131,014
TOTAL GASIFIER ISLAND ($/kW) 611 516
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Plant Operating Cost AnalysisPlant Operating Cost Analysis
Transport Gasifier
Plant Output (kWe) Design W/StametGas Turbine Power 197,000 197,000
Steam Turbine Power 140,540 144,000
Auxiliary Load 35,770 39,923
Net Plant Power 301,770 301,077
Net Plant Efficiency (HHV) 40.5% 40.7%
Net Plant Heat Rate (HHV) 8,416 8,386
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Plant Operating Cost AnalysisPlant Operating Cost Analysis
Shell Gasifier IGCC
Plant Output (kWe) Design W/StametGas Turbine Power 197,000 197,000
Steam Turbine Power 105,292 107,600
Auxiliary Load 43,150 44,240
Net Plant Power 259,142 260,360
Net Plant Efficiency (HHV) 40.6% 40.9%
Net Plant Heat Rate (HHV) 8,411 8,345
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Phase 3 ProgramPhase 3 Program
Expectations:
• 1000 PSI (69 Bar) target for DOE Phase 3.
• Further torque reductions anticipated from
ongoing optimization program.
• Commercial 500 PSI (34 Bar) feeder in 2005.
• 1300 PSI (90 Bar) commercial target requested.
Proposal Submitted – Awaiting Award!