Compact GasificationCompact Gasification Development and Test Status

Steve Fusselman G ifi L dGasifier Lead

Pratt & Whitney Rocketdyne A United Technologies Company

GTC Annual ConferenceGTC Annual ConferenceOctober 2011

Leveraging 50 Years of Rocket Engine Experience to Reduce Cost and Improve Plant Performance

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Key Design Features of the Compact Gasification System Key Design Features of the Compact Gasification System

Low Pressure Hopper

Dry Solids Pump Compact Gasifier

High Pressure Hopper

Particulate Removal

Ultra-dense Feed System

(Cyclone + Candle Filter)

• Yellow Items are Key Development Items

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• Other Items are Commercially Available

Gasifier Development Partners Gasifier Development Partners

• PWR has teamed with ExxonMobil Research and Engineering (EMRE) to develop and commercialize the technology

• Alberta Innovates: Energy and Environment Solutions (EES) is cost-sharing definition of a demo plant for an Alberta location and funding tests with Alberta feedstock

• Zero Emission Energy Plants, Inc. (ZEEP) is a commercial launch customer with a global license for use of PWR technology in gasification plants

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Pilot Plant Gasifier Test Program

Pilot Plant at the Gas Technology Institute • Started Dec 2009

Test Objectives Completed • Started Dec 2009 • 18 tons per day • Demonstrated performance

• 99% carbon conversion • High cold gas efficiency • Formed protective slag layer • Demonstrated particulate

removal Tested 4 feedstocks• Tested 4 feedstocks

• Verified operating environments • Validated computer models • Obtained preliminary life data• Obtained preliminary life data• Established operating procedures

764 hours Hot Fire Testing

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GasifierInjector 764 hours Hot-Fire Testing through April 2011

Pilot Plant Gasifier Facility Process Flow DiagramPilot Plant Gasifier Facility Process Flow Diagramgg

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Pilot Plant Gasifier Successfully Processed Range of FeedstocksPilot Plant Gasifier Successfully Processed Range of Feedstocksgg

Illinois #6 Coal

Oil Sands Petcoke

Joliet Petcoke

Alberta sub-bit

coalcoalProximate Analysis (wet)

Moisture Content, % 5.73 0.43 0.23 7.46Volatile Matter, % 37.35 13.29 12.26 28.52

Ash, % 9.32 3.21 0.3 23.86Fixed Carbon % 47 6 83 07 87 21 40 16Fixed Carbon, % 47.6 83.07 87.21 40.16

Total 100 100 100 100Ultimate Analysis (dry)

Ash 9.89 3.23 0.3 25.78C 73.68 84.55 88.66 57.66H 4 96 3 47 3 79 3 4H 4.96 3.47 3.79 3.4N 1.32 1.59 1.64 0.85S 3.46 6.47 6.45 0.17O 6.69 0.69 0 12.14

Total 100 100 100.84 100HHV Bt /lb (d ) 12 690 14630 15070 9869

PWR gasifier technology successfully gasified very high ash content, high fluid temp Alberta sub-bituminous coal

HHV, Btu/lb (dry) 12,690 14630 15070 9869Slag Fluid Temp, °F 2270 2660 2600 2656

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high fluid temp Alberta sub bituminous coal

Excellent Mass Balance Closure Typical Over 6-Hour Mass Balance Period Excellent Mass Balance Closure Typical Over 6-Hour Mass Balance Period

Excellent agreement between measured outputs and inputs

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Excellent Raw Mass Balance Data Observed Throughout TestingExcellent Raw Mass Balance Data Observed Throughout Testingg gg g

110.00%Illinois #6 Coal

Alberta Oil Sands Coke

Joliet Coke

Alb S b Bi i

100.00%

105.00%Alberta Sub‐Bituminous

95.00%

100.00%

90.00%

85.00%

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80.00%0 10 20 30 40 50 60

Pilot Plant Data Anchors Gasifier Models Over Wide Operating RangePilot Plant Data Anchors Gasifier Models Over Wide Operating Rangep g gp g g

100

3' Pentad

6' Pentad

800

3' Pentad

6' Pentad

85

90

95

ersion

 (%)

3' Conic

3' Coarse

3' Fine

500

600

700

s (kJ/s)

6  Pentad

3' Conic

3' Coarse

3' Fine

70

75

80

Ash‐Based

 Carbo

n Co

nv

200

300

400

Actual Liner Heat Los

60

65

60 65 70 75 80 85 90 95 100

1‐D Model Carbon Conversion Prediction (%)

0

100

0 100 200 300 400 500 600 700 800

1‐D Model Liner Heat Loss Prediction (kJ/s)

• Models anchored to 53 operating points with 4 feedstocks • 1-D kinetic model for carbon conversion and heat load predictions • CFD model as scale-up and design tool

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• CFD model as scale-up and design tool• ~0.1 sec residence time reactor - not optimized for high conversion

Protective Slag Layer Formed on Liner SurfaceProtective Slag Layer Formed on Liner Surface

Coarse slag from Alberta sub-bit

Slag layer retained after 38 hours on low ash petcoke

(view looking down from gasifier injector) Alberta s b bit c clone fines

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Alberta sub-bit cyclone fines(magnified 1000x)

Pilot Plant Gasifier Achieved Technical Objectives Pilot Plant Gasifier Achieved Technical Objectives

Objective Prediction Results Impact

Carbon Conversion

90% (0.1 sec residence time)

91% Validates >99% conversion at commercial scale.

Heat Loss < 3 MMBTU/hr < 1 MMBTU/hr Heat flux within design limits. CGE benefit at comm’l scaleCGE benefit at comm l scale.

Multiple Feedstocks Tested

3 4 Feedstock flexibility demonstrated on petcoke, bituminous, sub-bituminous.

Test Data Points

>27 53 Supports CFD model validation.

Component Test Time

>400 hours >400 hours liner >700 hours

Slag layer formed. Environments consistent

injector with life goals. Particulate Removal

Non-leachable fines

Environmentally benign slag/fines streams.

Operations < 10 minute Fast response

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Operations < 10 minute start-up time

Fast response.Safety system demonstrated.

Results Validate PWR Compact Gasification System BenefitsResults Validate PWR Compact Gasification System Benefitsyy

Compact Gasification System Current Market Leaders

• 90% size reduction (gasifier) • 50% lower capex (gasification system) • 2 yr burner, 10 yr liner life look feasible2 yr burner, 10 yr liner life look feasible

• Supports > 99% gasifier availability • > 99% carbon conversion demonstrated • +3 4% CGE vs other dry feed gasifiers• +3-4% CGE vs. other dry feed gasifiers• Dry feed system to gasify all ranks of

coal, petcoke and biomass blends

Results validate 20%-25% cost of product reduction from

NETL, Jacobs studies

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Source: Shell paper (2004) Source: DOE paper (2006) NETL, Jacobs studies

Demonstration Plant Gasifier Design Is In Progress Demonstration Plant Gasifier Design Is In Progress

• CFD design tool validated with pilot plant data

• Advancing demonstration plant gasifier design

Pilot Plant

Demo Plant

Commercial Plant

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18 TPD 400 TPD 3,000 TPD

Acknowledgement Acknowledgement

• Energy and Environment Solutions is the strategic energy technology arm of the Alberta Government in the Ministry of Advanced Education and Technology. Its mission is to enhance the development of Alberta's energy resources through investment in research technology andenergy resources through investment in research, technology and innovation in partnership with industry.

• The Illinois Department of Commerce and Economic Opportunity provided funding in support of this effort under the Coal Competitiveness Program.

• However, the opinions, findings and conclusions expressed herein are those of the authors

Questions?

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