The objective of this study is to develop standardized air blown fixed bed gasification hot gas cleanup integrated gasifier combined cycle (IGCC) systems.

The cost estimate provided for the DOE sponsored study of Air Blown Coal Gasification was developed from vendor quotes obtained directly for the equipment needed in the 50 MW, 100 MW, and 200 MW sized plants and from quotes from other jobs that have been referenced to apply to the particular cycle. Quotes were generally obtained for the 100 MW cycle and a scale up/down factor was used to generate the cost estimates for the 200 MW and 50 MW cycles, respectively. Information from GTPro (property of Thermoflow, Inc.) was used to estimate the cost of the 200 MW and 50 MW gas turbine, HRSG, and steam turbines. To available the use of GTPro's estimated values for this equipment, a comparison was made between the quotes obtained for the 100 MW cycle (ABB GT 11N combustion turbine and a HSRG) against the estimated values by GTPro.

The cost estimate provided for the DOE sponsored study of Air Blown Coal Gasification was developed from vendor quotes obtained directly for the equipment needed in the 50 MW, 100 MW, and 200 MW sized plants and from quotes from other jobs that have been referenced to apply to the particular cycle. Quotes were generally obtained for the 100 MW cycle and a scale up/down factor was used to generate the cost estimates for the 200 MW and 50 MW cycles, respectively. Information from GTPro (property of Thermoflow, Inc.) was used to estimate the cost of the 200 MW and 50 MW gas turbine, HRSG, and steam turbines. To available the use of GTPros̀ estimated values for this equipment, a comparison was made between the quotes obtained for the 100 MW cycle (ABB GT 11N combustion turbine and a HSRG) against the estimated values by GTPro.

This appendix is a compilation of work done to predict overall cycle performance from gasifier to generator terminals. A spreadsheet has been generated for each case to show flows within a cycle. The spreadsheet shows gaseous or solid composition of flow, temperature of flow, quantity of flow, and heat heat content of flow. Prediction of steam and gas turbine performance was obtained by the computer program GTPro. Outputs of all runs for each combined cycle reviewed has been added to this appendix. A process schematic displaying all flows predicted through GTPro and the spreadsheet is also added to this appendix. The numbered bubbles on the schematic correspond to columns on the top headings of the spreadsheet.

This appendix is a compilation of work done to predict overall cycle performance from gasifier to generator terminals. A spreadsheet has been generated for each case to show flows within a cycle. The spreadsheet shows gaseous or solid composition of flow, temperature of flow, quantity of flow, and heat heat content of flow. Prediction of steam and gas turbine performance was obtained by the computer program GTPro. Outputs of all runs for each combined cycle reviewed has been added to this appendix. A process schematic displaying all flows predicted through GTPro and the spreadsheet is also added to this appendix. The numbered bubbles on the schematic correspond to columns on the top headings of the spreadsheet.

This report is a list of equipment of commercial gasification systems.

Computer models have been developed for evaluating conceptual designs of integrated coal gasification combined cycle power plants. An overall system model was developed for performing thermodynamic cycle analyses, and detailed models were developed for predicting performance characteristics of fixed bed coal gasifiers and hot gas clean up subsystem components. The overall system model performs mass and energy balances and does chemical equilibrium analyses to determine the effects of changes in operating conditions, or to evaluate proposed design changes. An existing plug flow model for fixed bed gasifiers known as the Wen II model was revised and updated. Also, a spread sheet model of zinc ferrite sulfur sorbent regeneration subsystem was developed. Parametric analyses were performed to determine how performance depends on variables in the system design. The work was done to support CRS Sirrine Incorporated in their study of standardized air blown coal gasifier gas turbine concepts.

CRS Sirrine (CRSS) is evaluating a novel IGCC process in which gases exiting the gasifier are burned in a gas turbine combustion system. The turbine exhaust gas is used to generate additional power in a conventional steam generator. This results in a significant increase in efficiency. However, the IGCC process requires development of novel approaches to control SO2 and NOx emissions and alkali vapors which can damage downstream turbine components. Ammonia is produced from the reaction of coal-bound nitrogen with steam in the reducing zone of any fixed bed coal gasifier. This ammonia can be partially oxidized to NOx when the product gas is oxidized in a gas turbine combustor. Alkali metals vaporize in the high-temperature combustion zone of the gasifier and laser condense on the surface of small char or ash particles or on cooled metal surfaces. It these alkali-coated materials reach the gas turbine combustor, the alkali will revaporize condense on turbine blades and cause rapid high temperature corrosion. Efficiency reduction will result. PSI Technology Company (PSIT) was contracted by CRSS to evaluate and recommend solutions for NOx emissions and for alkali metals deposition. Various methods for NOx emission control and the potential process and economic impacts were evaluated. This included estimates of process performance, heat and mass balances around the combustion and heat transfer units and a preliminary economic evaluation. The potential for alkali metal vaporization and condensation at various points in the system was also estimated. Several control processes and evaluated, including an order of magnitude cost for the control process.

The primary objective of the Phase I ERDA High-Temperature Turbine Technology (HTTT) Program was to provide a ''Program and System Definition'' of the three-phase program which would culminate in the testing of a Technology Readiness Vehicle (TRV) at the end of a six-year period. The TRV is designed for use in a combined cycle using coal-derived fuels at a firing temperature of 2600°F; growth capability to 3000°F is projected. The Phase I results reported are based on a 2600°F gas turbine burning coal-derived fuels. The following major areas are covered: overall plant design descriptions; systems design descriptions; turbine subsystem design; combustor design; phase II proposed program; and phase III proposed program. Details regarding final results of each of these areas are presented. It is concluded that the water-cooled gas turbine in combined cycle has been shown to be capable of extremely attractive levels of performance, both in terms of efficiency and specific output. Coupled with the ability to tolerate a wide range of coal-derived fuels with minimum fuel treatment, an extremely attractive system is presented for the generation of electric power. Future technology development of the high-firing-temperature water-cooled gas turbine is expected to result in the commercial introduction of this concept in combined cycles by the late 1980's or early 1990's.