Overview of Gasification Activities at GE George Rizeq GE Global Research ACERC Annual Conference 2007 BYU, Provo, UT 27 th Feb 2007 Presented at GTC 2006 by Monte Atwell (GE Energy)
Technology Drivers Reference Plant System Design Concept • Reduce Capital Costs • Optimized Design Integration Performance – System/Component • Efficiency & Operability • Reliability, Availability, Maintenance (RAM) Time to Maturity 2
Leveraging The “Bigger GE” Houston Global Technology Team Houston, TX – Process & Product Design & IGCC Experience Niskayuna, NY – Materials, Design, System Analysis Shanghai, China – Materials, Chemistry, Instrumentation China Schenectady, NY/ Salem, VA – Controls, Simulation Bangalore, India – Computational, Experimental Greenville, SC – Design, Adv Materials & Manufacturing India Irvine, CA– Gasification Modeling & Experimental Activities > 300 Engineers & Scientists 3
New Product Introduction Strategy Models Lab Tests Field Tests Materials Validation Data Coal Slurry Spray Injection Test Metal Coatings & Refractory Gas Flow & Heat Gasification Kinetics Recovery Field Optimization TG1 TG2 TG3 TG4 TG5 TG6 TG7 Toll-gated NPI Process 4
Systems Integration System Level View • Plant Level Performance & Optimization • Specification flow-down to sub-systems • Sub-system integration Sub- Systems Owners Subsystem Ownership and Tollgate Process to Drive Design Integration at the System Level 5
Reference Plant NPI Programs CO 2 Recycle ASU Steam Oxygen Slurry Turbine Injectors CO2 Recycle Gas turbine Syngas Cooler Controls Refractory 6
NPI Value Propositions – Feed Injector Case ↑ Carbon Conversion Specification Target Conversion +30% ↓ Fines in Slag ↓ Heat Rate Tip life +100% Turndown • Lower frequency of Lock- • Increased conversion � need to 50% Capability hopper dumps for less fuel input to gasifier • Reduced O&M of slag/carbon • Greater net plant output separation equipment ↓ Recycled ↓ Gasifier Operating Fines Temperature • Reduction in chemical usage • Slag production is lower; the due to reduced solids loading gasifier can be operated at a in settlers lower temperature • Reduced solids carry-over to • Refractory life extension due grey water tank increasing to lower temperatures the life of downstream components 7
Feed Injector Program Models Lab Tests Field Tests Injector D1 Injector D2 8
Syngas Cooler Program Define Measure Validation Design Cycle Fouling Samples Fleet Leader Analytical Models & Experimental Instrumentation S2 Validation Analyze Optimize Cost vs. Risk vs. Performance Design Deposition Modeling Spray Quench Goals – CAPEX Reduction & Increased RAM 9
Syngas Cooler Modeling CFD & FEA Modeling Design to Cost Efforts Flow & thermal modeling 1 Cost SGC 2 SGC 3 Trans SGC Trans Trans Const Const Const Risk Deposition Modeling Size Reduction = Cost Reduction Sample Testing Fouling Physics Based Modeling Factor Spatial Distribution Transportation & Construction System level optimization for cooler, construction, & transportation 10
Syngas Cooler Design Validation Create Collect Update Validate Models Data Model Model Real Time Testing • Distributed flow and temperature data • Start up and shut down data for transients • Corrosion testing for CEILING materials and fabrication • Deposit sampling e P rs o 1 n Drop Tube Furnace • Full pressure/ temperature to simulate Ref Plant • Ability to run different feedstock 0’ FLOOR • Materials testing P e rs n o 1 11
Refractory Life Extension Program Slag (Cr,Al) 2 O 3 Cr Al Fe Mg Chemical mapping reveals interaction between slag and refractory surface Slag penetrates the grain boundaries within the refractory brick Solids Gasifier Refractory Brick Identifying/understanding failure mechanisms 12
Refractory Reliability Model • Understand Failure Mechanisms – Corrosion/Erosion – Thermo mechanical forces • Focus programs to mitigate failures • Match interval w/major GT outage Temperature 13
Engineering Simulation/Operator Training ∂ ∂ ∂ Engineering Class v 2 T T T ρ + υ − κ + − + σε − = 4 4 h h h Ac c A U A ( T T ) A ( T T ) 0 ∂ ∂ ∂ h p h p h h h w h w Simulation for 2 t x x Syngas Tube Controls Operability ∂ ∂ 2 T T ρ − κ + − + − = & Operator Training w w Ac A U A ( T T ) U A ( T T ) 0 Metal Wall ∂ ∂ w p w 2 h w h c w c t x ∂ ∂ κ ∂ v 2 H H A H ρ + υ − + − = Water Tube h h c h A U A ( T T ) 0 ∂ ∂ ∂ c 2 c c w t x c x p Instructor Station Operator Simulation Control Training Model Software Simulator Engineering Simulator Control Hardware Emulator Generate Physics Based Transient Equipment Models 14
Summary • Plant Level Technology Needs Driving Program Selection • NPI Processes in Place to Assure Consistency and Technical Rigor • Understand Physics • Leverage Broad Teams and Tools • Validate 15
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