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All sourcesNASA NTRSDOE OSTI
DOE OSTI2015

System overview and characterization of a high-temperature, high-pressure, entrained-flow, laboratory-scale gasifier

The high-temperature, high-pressure, entrained-flow, laboratory-scale gasifier at the Colorado School of Mines, including the primary systems and the supporting subsystems, is presented. The gasifier is capable of operating at temperatures and pressures up to 1650 °C and 40 bar. The heated section of the reactor column has an inner diameter of 50 mm and is 1 m long. Solid organic feedstock (e.g., coal, biomass, and solid waste) is ground into batches with particle sizes ranging from 25 to 90 μm and is delivered to the reactor at feed rates of 2–20 g/min. The maximum useful power output of the syngas is 10 kW, with a nominal power output of 1.2 kW. The initial characterization and demonstration results of the gasifier system with a coal feedstock are also reported.

09 BIOMASS FUELS↗
DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends with Washed and Unwashed Legacy Coals and Other Waste Fuels to Generate White Hydrogen

The objective of this effort, primarily funded by the United States Department of Energy (DOE), and led by the Electric Power Research Institute, Inc. (EPRI), with support by Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), has been to qualify coal, biomass, and plastic waste blends based on performance testing of selected fuel pellet compositions in a pilot-scale updraft moving-bed (UDMB) gasifier. The testing provided relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are the focus. The gasifier used for testing is HMI’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips (biomass). However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The three feedstocks were densified and pelletized by California Pellet Mill (CPM) to meet the feedstock size required by Sotacarbo’s 30mm ID UDMB gasifier, under contract to HMI. The technical tasks and results from this two-year research project included: (1) Feed Procurement and Preparation: Nine different tri-fuel pellets were prepared from varying compositions of fresh mined PRB coal, corn stover biomass, and car fluff waste plastics. Tri-fuel pellets were produced by CPM and shipped to Sotacarbo’s test facility in Carbonia, Sardinia, Italy. (2) Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different UDMB gasification tests to be performed in Sotacarbo’s 12-inch ID pilot scale gasifier, the process monitoring instrumentation used, and the extractive samples recovered for analysis of the total gasification process mass and energy balance. (3) Gasifier Testing: Nine different gasification runs were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstock compositions generated from varying mixtures of PRB coal, biomass, and plastic wastes. The testing generated performance data on gasification reaction efficiency and performance, yielding relevant data for models used to scale up the gasifier design. This task also included work to refurbish and reassemble the pilot gasifier at Sotacarbo and perform a baseline 100% PRB coal run. (4) Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results are reported in the project’s final report, published in March 2024. The results show that all tri-fuel pellets gasified well and maintained structural integrity throughout the gasification process. The syngas generated can be shifted to hydrogen by using commercial syngas shifting technologies. (5) High Fidelity computational fluid dynamics (CFD) Simulation: The National Energy Technology Laboratory (NETL) team performed CFD simulations of the UDMB gasifier for two of the tri-fuel pellets gasified in Sotacarbo’s pilot scale gasifier. The kinetic mechanisms for the pyrolysis of each constituent, PRB coal, corn stover biomass, and waste plastics are based on thermogravimetric analysis performed by Sotacarbo. The gasification model was validated by comparing the predicted syngas composition at the exit of the gasifier with the measured syngas composition. In addition, the reactor’s measured internal temperature profile agreed well with the predicted internal reactor temperature profile. These results validate that the model can be used to predict the performance of the updraft moving bed gasifier for different feedstocks and operating conditions. This paper summarizes the results of the completed work in which the pelletizing procedure was validated to ensure the viability of the tri-fuel pellets for the gasification runs performed at Sotacarbo’s 30 mm UDMB gasifier. The gasification performance data from this series of nine runs will enable modeling of a full-scale HMI industrial scale gasifier supporting both combined heat and power, and Hydrogen production from coal (both fresh mined and legacy) combined with various biomass and waste plastics. Additionally, plans and progress on a follow-up project, being executed by the same project team, will be presented. In this project, a total of twenty (20) different feedstocks are being prepared from varying compositions of biomass (both woody biomass and corn stover) with a mixture of legacy coal waste, plastic waste, and refuse-derived fuel (RDF). The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design to 50 megawatt electric (MWe) (equivalent hydrogen production). Tests will also be performed on a bench-scale fluidized-bed gasifier for comparison purposes. The results of this testing will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends.

08 HYDROGEN↗
DOE OSTI2022

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing will provide relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes have not been prepared and gasified together. The feedstocks will be prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks and current status for this two-year research project are: Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill and shipped to Sotacarbo’s test facility in Italy. Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. Gasifier Testing: Tests are currently being performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing will provide information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also include work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results to be reported. The results will be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. This paper will be summarize the pelletizing procedure that insures the viability of the tri-fuel pellets for the gasification runs that are being performed at Sotacarbo’s 30mm up draft moving bed gasifier. Initial gasification tests have been conducted, and all the lab scale tri-fuel pellet gasification runs will be completed by the fall of 2022. Performance data will enable modeling of a full-scale HMI industrial scale gasifier supporting both CHP and Hydrogen production.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

Real Time Flame Monitoring of Gasifier and Injectors

This project is a multistage effort with the final goal to develop a practical and reliable nonintrusive gasifier injector monitor to assess burner wear and need for replacement. The project team included the National Energy Technology Laboratory (NETL), Gas Technology Institute (GTI), North Carolina State University, and ConocoPhillips. This report presents the results of the sensor development and testing initially at GTI combustion laboratory with natural gas flames, then at the Canada Energy Technology Center (CANMET), Canada in the atmospheric coal combustor as well as in the pilot scale pressurized entrained flow gasifier, and finally the sensor capabilities were demonstrated at the Pratt and Whitney Rocketdyne (PWR) Gasifier and the Wabash River Repowering plant located in West Terre Haute, IN. The initial tests demonstrated that GTI gasifier sensor technology was capable of detecting shape and rich/lean properties of natural gas air/oxygen enriched air flames. The following testing at the Vertical Combustor Research Facility (VCRF) was a logical transition step from the atmospheric natural gas flames to pressurized coal gasification environment. The results of testing with atmospheric coal flames showed that light emitted by excited OH* and CH* radicals in coal/air flames can be detected and quantified. The maximum emission intensities of OH*, CH*, and black body (char combustion) occur at different axial positions along the flame length. Therefore, the excitation rates of CH* and OH* are distinct at different stages of coal combustion and can be utilized to identify and characterize processes which occur during coal combustion such as devolatilization, char heating and burning. To accomplish the goals set for Tasks 4 and 5, GTI utilized the CANMET Pressurized Entrained Flow Gasifier (PEFG). The testing parameters of the PEFG were selected to simulate optimum gasifier operation as well as gasifier conditions normally resulting from improper operation or failed gasifier injectors. The sensor developed under previous tasks was used to assess the spectroscopic characteristics of the gasifier flame. The obtained spectral data were successfully translated into flame temperature measurements. It was also demonstrated that the reduced spectral data could be very well correlated with very important gasification process parameters such as the air/fuel and water/fuel ratio. Any of these parameters (temperature, air/fuel, and water/fuel) is sufficient to assess burner wear; however, the tested sensor was capable of monitoring all three of them plus the flame shape as functions of burner wear. This will likely be a very powerful tool which should enable significant improvements in gasifier efficiency, reliability, and availability. The sensor technology was presented to the project's industrial partner (ConocoPhillips). The partner expressed its strong interest in continuing to participate in the field validation phase of GTI's Flame Monitor Project. Finally the sensor was tested in the PWR (Pratt & Whitney Rocketdyne) gasification plant located at GTI's research campus and at the ConocoPhillips industrial scale gasifier at Wabash River Indiana. The field trials of the GTI Gasifier sensor modified to withstand high temperature and pressure corrosive atmosphere of the industrial entrain flow gasifier. The project team successfully demonstrated the Gasifier Sensor system ability to monitor gasifier interior temperature maintaining unobstructed optical access for in excess of six week without any maintenance. The sensor examination upon completion of the trial revealed that the system did not sustain any damage and required minor cleanup of the optics.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Performance Testing of a Moving Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI. The technical tasks for this research project included: • Feed Procurement and Preparation: Nine different feedstocks were prepared from varying compositions of PRB coal, corn stover biomass, and car fluff waste plastics. Fuel pellets were produced by California Pellet Mill (CPM) and shipped to Sotacarbo’s test facility in Italy. • Test Plan Development: A test plan was created to define the test runs to be performed. The test plan detailed the different tests that were run, instrumentation used, extractive samples taken, and relevant figures of merit. • Gasifier Testing: Tests were performed in the pilot-scale gasifier at Sotacarbo using nine different fuel feedstocks generated from varying mixtures of coal, biomass, and plastic wastes. The testing provides information on gasification reaction efficiency/performance, yielding relevant data for models used to scale up the gasifier design. This task will also included work to reassemble the gasifier at Sotacarbo and perform a baseline 100% coal run. • Data Analysis and Reporting: Review of the data, determination of figures of merit, and interpretation of the results was reported. The results can be used to specify the range of feedstock blends that can be successfully gasified as well as quantify gasifier outputs based on specific blends. The tri-fuel pelletizing conducted at CPM and gasification testing results from Sotacarbo’s 30mm up draft moving bed gasifier are significant. Providing data for an established gasifier to help accelerate its updated design to be able to accommodate feedstocks composed of coal, biomass, and plastic waste. This should ultimately lead to development and commercialization of a lower cost, white hydrogen generation system.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

Dynamic modeling of a single-stage downward firing, entrained flow gasifier

The gasifier is the heart of the integrated gasification combined cycle (IGCC), a technology that has emerged as an attractive alternative to conventional coal-fired power plant technology due to its higher efficiency and cleaner environmental performance especially with the option of CO{sub 2} capture and sequestration. Understanding the optimal performance of the gasifier is therefore paramount for the efficient operation of IGCC power plants. Numerous gasifier models of varying complexity have been developed to study the various aspects of gasifier performance. These range from simple one-dimensional (1D) process-type models to rigorous higher order 2-3D models based on computational fluid dynamics (CFD). Whereas high-fidelity CFD models can accurately predict most key aspects of gasifier performance, they are computationally expensive and typically take hours to days to execute on high-performance computers. Therefore, faster 1D partial differential equation (PDE)-based models are required for use in dynamic simulation studies, control system analysis, and training applications. A number of 1D gasifier models can be found in the literature, but most are steady-state models that have limited application in the practical operation of the gasifier. As a result, 1D PDE-based dynamic models are needed to further study and predict gasifier performance under a wide variety of process conditions and disturbances. In the current study, a 1D transient model of a single-stage downward-fired GE/Texaco-type entrained-flow gasifier has been developed. The model comprises mass, momentum and energy balances for the gas and solid phases. The model considers the initial gasification processes of water evaporation and coal devolatilization. In addition, the key heterogeneous and homogeneous chemical reactions have been modeled. The resulting time-dependent PDE model is solved using the well-known method of lines approach in Aspen Custom Modeler®, whereby the PDEs in the spatial domain are discretized and the resulting differential algebraic equations (DAEs) are then integrated over time using a dynamic integrator. The dynamic response results of the gasifier performance parameters to certain disturbances commonly encountered during practical operation are presented. These disturbances include ramp and step changes to input variables such as coal flow rate, oxygen-to-coal ratio and water-to-coal ratio among others. Comparison of model predictions to available dynamic data will also be discussed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

Development and Testing of Prototype Commercial Gasifier Sensor

This report presents the results of the sensor development and testing at the Wabash River gasifier. The project work was initiated with modification of the sensor software (Task 2) to enable real time temperature data acquisition, and to process and provide the obtained gasifier temperature information to the gasifier operators. The software modifications were conducted by the North Carolina State University (NCSU) researchers. The modified software was tested at the Gas Technology Institute (GTI) combustion laboratory to assess the temperature recognition algorithm accuracy and repeatability. Task 3 was focused on the sensor hardware modifications needed to improve reliability of the sensor system. NCSU conducted numerical modeling of the sensor probe’s purging flow. Based on the modeling results the probe purging system was redesigned to prevent carbon particulates deposition on the probe’s sapphire window. The modified design was evaluated and approved by the Wabash representative. The modified gasifier sensor was built and installed at the Wabash River gasifier on May 1 2014. (Task 4) The sensor was tested from the startup of the gasifier on May 5, 2015 until the planned autumn gasifier outage starting in the beginning of October, 2015. (Task 5) The project team successfully demonstrated the Gasifier Sensor system’s ability to monitor gasifier temperature while maintaining unobstructed optical access for six months without any maintenance. The sensor examination upon completion of the trial revealed that the system did not sustain any damage.

47 OTHER INSTRUMENTATION↗
DOE OSTI2012

A one-dimensional transient model of a single-stage, downward-firing entrained-flow gasifier

The integrated gasification combined cycle (IGCC) technology has emerged as an attractive alternative to conventional coal-fired power plant technology due to its higher efficiency and cleaner environmental performance especially with the option of CO{sub 2} capture and sequestration. The core unit of this technology is the gasifier whose optimal performance must be understood for efficient operation of IGCC power plants. This need has led a number of researchers to develop gasifier models of varying complexities. Whereas high-fidelity CFD models can accurately predict most key aspects of gasifier performance, they are computationally expensive and typically take hours to days to execute on high-performance computers. Therefore, faster one-dimensional (1D) partial differential equation (PDE)-based models are required for use in dynamic simulation studies, control system analysis, and training applications. A number of 1D gasifier models can be found in the literature, but most are steady-state and have limited application in the practical operation of the gasifier. As a result, 1D PDE-based dynamic models are needed to further study and predict gasifier performance under a wide variety of process conditions and disturbances. In the present study, a 1D transient model of a single-stage downward flow GE/Texaco-type gasifier has been developed. The model comprises mass, momentum and energy balances for the gas and solid phases. The model considers the initial gasification processes of water evaporation and coal devolatilization. In addition, the key heterogeneous and homogeneous chemical reactions have been modeled. The resulting time-dependent PDE model is solved using the well-known method of lines approach in Aspen Custom Modeler®, whereby the PDEs are discretized in the spatial domain and the resulting differential algebraic equations (DAEs) are then solved to obtain the transient response. The transient response of various gasifier performance parameters to certain disturbances commonly encountered in the real world operation of commercial IGCC plants will be presented. These disturbances include ramp and step changes in input variables such as coal flow rate, oxygen-to-coal ratio and water-to-coal ratio, among others. Comparison of gasifier model predictions to available dynamic data will also be discussed.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2011

Effect of Coal Properties and Operation Conditions on Flow Behavior of Coal Slag in Entrained Flow Gasifiers: A Brief Review

Integrated gasification combined cycle (IGCC) is a potentially promising clean technology with an inherent advantage of low emissions, since the process removes contaminants before combustion instead of from flue gas after combustion, as in a conventional coal steam plant. In addition, IGCC has potential for cost-effective carbon dioxide capture. Availability and high capital costs are the main challenges to making IGCC technology more competitive and fully commercial. Experiences from demonstrated IGCC plants show that, in the gasification system, low availability is largely due to slag buildup in the gasifier and fouling in the syngas cooler downstream of the gasification system. In the entrained flow gasifiers used in IGCC plants, the majority of mineral matter transforms to liquid slag on the wall of the gasifier and flows out the bottom. However, a small fraction of the mineral matter (as fly ash) is entrained with the raw syngas out of the gasifier to downstream processing. This molten/sticky fly ash could cause fouling of the syngas cooler. Therefore, it is preferable to minimize the quantity of fly ash and maximize slag. In addition, the hot raw syngas is cooled to convert any entrained molten fly slag to hardened solid fly ash prior to entering the syngas cooler. To improve gasification availability through better design and operation of the gasification process, better understanding of slag behavior and characteristics of the slagging process are needed. Slagging behavior is affected by char/ash properties, gas compositions in the gasifier, the gasifier wall structure, fluid dynamics, and plant operating conditions (mainly temperature and oxygen/carbon ratio). The viscosity of the slag is used to characterize the behavior of the slag flow and is the dominating factor to determine the probability that ash particles will stick. Slag viscosity strongly depends on the temperature and chemical composition of the slag. Because coal has varying ash content and composition, different operating conditions are required to maintain the slag flow and limit problems downstream. This report briefly introduces the IGCC process, the gasification process, and the main types and operating conditions of entrained flow gasifiers used in IGCC plants. This report also discusses the effects of coal ash and slag properties on slag flow and its qualities required for the entrained flow gasifier. Finally this report will identify the key operating conditions affecting slag flow behaviors, including temperature, oxygen/coal ratio, and flux agents.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

CFD modeling of commercial-scale entrained-flow coal gasifiers

Optimization of an advanced coal-fired integrated gasification combined cycle system requires an accurate numerical prediction of gasifier performance. Computational fluid dynamics (CFD) has been used to model the turbulent multiphase reacting flow inside commercial-scale entrained-flow coal gasifiers. Due to the complexity of the physical and chemical processes involved, the accuracy of sub-models requires further improvement. Built upon a previously developed CFD model for entrained-flow gasification, the advanced physical and chemical sub-models presented in this paper include a moisture vaporization model with consideration of high mass transfer rate and a coal devolatilization model with more species to represent coal volatiles and the heating rate effect on volatile yield. The global gas phase reaction kinetics is also carefully selected. To predict a reasonable peak temperature of the coal/O{sub 2} flame inside an entrained-flow gasifier, the reserve reaction of H{sub 2} oxidation is included in the gas phase reaction model. The enhanced CFD model is applied to simulate two typical commercial-scale oxygen-blown entrained-flow configurations including a single-stage down-fired gasifier and a two-stage up-fired gasifier. The CFD results are reasonable in terms of predicted carbon conversion, syngas exit temperature, and syngas exit composition. The predicted profiles of velocity, temperature, and species mole fractions inside the entrained-flow gasifier models show trends similar to those observed in a diffusion-type flame. The predicted distributions of mole fractions of major species inside both gasifiers can be explained by the heterogeneous combustion and gasification reactions and the homogeneous gas phase reactions. It was also found that the syngas compositions at the CFD model exits are not in chemical equilibrium, indicating the kinetics for both heterogeneous and gas phase homogeneous reactions are important. Overall, the results achieved here indicate that the gasifier models reported in this paper are reliable and accurate enough to be incorporated into process/CFD co-simulations of IGCC power plants for system-wide design and optimization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

Performance Testing of a Moving-Bed Gasifier Using Coal, Biomass, and Waste Plastic Blends to Generate White Hydrogen

The objective of this DOE-funded project by the Electric Power Research Institute, Inc. (EPRI), Hamilton Maurer International (HMI) and Sotacarbo S.p.A. (Sotacarbo), is to qualify coal, biomass, and plastic waste blends based on performance testing of selected pellet recipes in a pilot-scale updraft moving-bed gasifier. The testing provides relevant data to advance the commercial-scale design of the moving-bed gasifier to be able to successfully use these feedstocks to produce hydrogen. In particular, the effects of the waste plastics on feedstock development (i.e., blending and pelletizing) and the resulting products (i.e., syngas compositions, organic condensate production, and ash characteristics) are a focus. The gasifier is Hamilton Mauer International, Inc. (HMI)’s moving-bed gasifier, which has been proven capable of gasifying nearly all coal ranks. It has also shown the ability in prior testing work to gasify wood chips. However, mixtures of these fuels with plastic wastes had not yet been prepared and gasified together. The feedstocks were prepared by California Pellet Mill (CPM) under contract to HMI.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2012

CFD modeling of entrained-flow coal gasifiers with improved physical and chemical sub-models

Optimization of an advanced coal-fired integrated gasification combined cycle system requires an accurate numerical prediction of gasifier performance. While the turbulent multiphase reacting flow inside entrained-flow gasifiers has been modeled through computational fluid dynamic (CFD), the accuracy of sub-models requires further improvement. Built upon a previously developed CFD model for entrained-flow gasification, the advanced physical and chemical sub-models presented here include a moisture vaporization model with consideration of high mass transfer rate, a coal devolatilization model with more species to represent coal volatiles and heating rate effect on volatile yield, and careful selection of global gas phase reaction kinetics. The enhanced CFD model is applied to simulate two typical oxygen-blown entrained-flow configurations including a single-stage down-fired gasifier and a two-stage up-fired gasifier. The CFD results are reasonable in terms of predicted carbon conversion, syngas exit temperature, and syngas exit composition. The predicted profiles of velocity, temperature, and species mole fractions inside the entrained-flow gasifier models show trends similar to those observed in a diffusion-type flame. The predicted distributions of mole fractions of major species inside both gasifiers can be explained by the heterogeneous combustion and gasification reactions and the homogeneous gas phase reactions. It was also found that the syngas compositions at the CFD model exits are not in chemical equilibrium, indicating the kinetics for both heterogeneous and gas phase homogeneous reactions are important. Overall, the results achieved here indicate that the gasifier models reported in this paper are reliable and accurate enough to be incorporated into process/CFD co-simulations of IGCC power plants for systemwide design and optimization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2015

TASK 3: PILOT PLANT GASIFIER TESTING

Aerojet Rocketdyne (AR) has developed an innovative gasifier concept incorporating advanced technologies in ultra-dense phase dry feed system, rapid mix injector, and advanced component cooling to significantly improve gasifier performance, life, and cost compared to commercially available state-of-the-art systems. Design, fabrication and initial testing of the pilot plant compact gasifier was completed in 2011 by a development team led by AR. Findings from this initial test program, as well as subsequent gasifier design and pilot plant testing by AR, identified a number of technical aspects to address prior to advancing into a demonstration-scale gasifier design. Key among these were an evaluation of gasifier ability to handle thermal environments with highly reactive coals; ability to handle high ash content, high ash fusion temperature coals with reliable slag discharge; and to develop an understanding of residual properties pertaining to gasification kinetics as carbon conversion approaches 99%. The gasifier did demonstrate the ability to withstand the thermal environments of highly reactive Powder River Basin coal, while achieving high carbon conversion in < 0.15 seconds residence time. Continuous operation with the high ash fusion temperature Xinyuan coal was demonstrated in long duration testing, validating suitability of outlet design as well as downstream slag discharge systems. Surface area and porosity data were obtained for the Xinyuan and Xinjing coals for carbon conversion ranging from 85% to 97%, and showed a pronounced downward trend in surface area per unit mass carbon as conversion increased. Injector faceplate measurements showed no incremental loss of material over the course of these experiments, validating the commercially traceable design approach and supportive of long injector life goals. Hybrid testing of PRB and natural gas was successfully completed over a wide range of natural gas feed content, providing test data to anchor predictions for commercial operation of hybrid coal/natural gas gasification plants.

01 COAL, LIGNITE, AND PEAT↗