Mamoon Asif || Zubia Saleem|| Mubeen Kamran Project Supervisor: Dr. Arshad Hussain Department of Chemical Engineering. SCME (NUST), Islamabad Abstract As Pakistan is moving deeper into the clutches of energy and natural gas cri- sis, it has become crucial to search for new sources to meet our increasing de- mands. Coal is believed to be the future energy carrier for the world; however, due to environmental hazards the pro- duction of electricity from coal is not being commercialized on a large scale. Integrated Gasification Combined Cycle (IGCC) process is the solution for this problem. Lignite is the most abundant coal present in Pakistan which has a very lower heating value. To utilize the full capacity of lignite, the coal-water slurry feed is converted into Coal-CO2 Slurry by the PHICCOS Process. This process increases the Net IGCC and Cold Gas Efficiency by 15%. IGCC uses the Pre- Combustion Technique to remove CO 2 hence protecting the environment. Motivation Coal is an alternative source for electricity production and with igcc less harm is done to the environment as copared to the con- ventional gasification processes. Entrained Flow Gasification is Environmen- tal Friendly. IGCC reduces the waste (clean and healthy Pakistan) Chemistry of Gasificaon C + 0.5O2 →CO C + H2O →CO + H2 C + 2H2 →CH4 CH4 +1.5O2 →CO + 2H2O CO + H2O→CO2 + H2 CO + 0.5O2 →CO2 S + H2 →H2S S + O2→SO2 CO + H2S →COS + H2 N2 + 3H2 →2 NH3 Selection Criteria Entrained Flow Gasifier Material Input Coal-CO 2 Slurry (kmol/ 10846.02 Oxygen Rich Stream 1677.63 Steam (kmol/hr) 524.63 Total 13048.28 Energy Input Materials Energy (kcal) Coal (CV) 3 x10 8 Enthalpy of steam in gasifier 2.735 x 10 6 Sensible Heat of CO 2 3.35 x 10 7 Total Energy of the input Feed 3.36 x 10 8 Thermal Efficiency 77% Cold Gas Efficiency 74.4% Hot Gas Efficiency 97.2% Syngas Composition Composition Mol % CO 6.68 CO2 32.3 O2 13.7 N2 0.448 H2 38.5 CH4 1.52 H2S 0.025 COS 0.1362 SO2 0.17 NH3 0.2605 H2O 5.86 Total 100 Selected Processes SECTION UNIT KEY FOCUS METHOD ASSISTANCE Entrained Flow Gasifi- er Process To convert the Coal-CO2 Slurry into syngas and slag Gasification Flame Fired Air Separation Unit Operation To separate air into N 2 and O 2 to ensure supply into Entrained Flow Gasifier and Combustor Cryogenic Distillation Carbon Molecular Sieves Shift Conversion Process Convert CO to CO 2 and maximum hy- drogen production Catalytic Shift Conversion Iron Oxide Catalyst, Copper Oxide Catalyst, Steam CO 2 and H 2 S Removal (AGR) Process To reduce concentration of CO 2 and H 2 S is also removed. Absorption SELEXOL Solvent COS Hydrolysis Process Conversion of COS to H 2 S and CO 2 Catalytic Bed Reactor Catalyst (Nickel Based) Combustor Process To combust the clean syngas in order to run the gas turbine Complete Combustion Clean Syngas as fuel Process Flow Diagram Results & Analysis Cost Estimation The major advantages of this project scheme are the efficient production of power using environmentally harm-free processes by re- ducing the emissions of sulfur dioxide, par- ticulates and carbon dioxide and efficient utilization of recovered heat from syngas cooling system and minimal waste produc- tion as the by-products are marketable. Conclusions References 1) SIMULATION AND ECONOMIC EVALUATION OF COAL GASIFICATION WITH SETS REFORMING PROCESS FOR POW- ER PRODUCTION by Zachary Hoffman 2) Technical Documentation: Integrated Gasification Com- bined Cycle Systems (IGCC) with Carbon Capture and Storage (CCS) Authors Edward S. Rubin, Michael B. Berkenpas, H. Christopher Frey, Chao Chen, Sean T. McCoy, and Constance EQUIPMENT COST (K$) Entrained Flow Gasifier 23000.11 ASU & Compressor 4000.68 HTSC 27.4 LTSC 13.682 AGR (Absorber) 4064 Convective Cooler 9661.7 Process Condensate Han- dling Section 16708.05 Energy Output Materials Energy (Kcal) Syngas (CV) 250 x 10 6 Enthalpy of H 2 O 8.81 x 10 6 Sensible heat of Syngas 67.7 x 10 6 Heat Loss 9.49 Total Output of Energy (KW) 3.36 x 10 8 Material Output Slag ((kmol/hr) 170.196 Syngas (kmol/hr) 12877.844 Total 13048.04 •Feed rate of 10,846 kmol/hr (80%-20%) Coal-CO 2 slurry results in a production of 267 mw Power. •The CO 2 that has been sequestered from the process is used in the preparation of CO2-Coal Slurry hence optimizing the process. •Pre-Combustion technique is more effi- cient than Post-combustion since CO 2 is at high partial pressure and is easily re- movable. •Entrained flow gasifier is the ideal choice for this gasification since the temperature is above ash slagging tem- perature and proper mechanism is avail- able for ash removal. Moreover, it can gasify all types of coal regardless of coal rank, caking characteristics or coal fines’ amount. Net Efficiency of the plant calculated is about 66% which is enough to meet the desired electricity needs. Capital cost is high but due to the modifications done and also less mar- ginal cost the process becomes feasible. Power Production Using Syngas From Coal-Water Slurry Calorifiic value of coal HHV (kJ/kg) 14551.161 LHV (kJ/kg) 12689.798 Net Plant Effi- ciency 66%