1.0

Executive Summary

10

1.1

Background

10

1.2

Slipstream Project Description

11

1.3

Slipstream Test Objectives

12

1.4

Results

13

1.5

Conclusions and Technical Insights

15

2.0

Introduction

17

2.1

Overview of the Wabash River Gasification Facility

17

2.2

Wabash River Gasification Facility Operating History

18

2.3

Hot Gas Filter Startup and Operating History

18

2.4

Slipstream Program Objectives

22

2.5

Slipstream Test Program

23

2.5.1

Test Objectives

23

2.5.2

Basis for Test Selection and Prioritization

25

2.5.3

Test Evaluation Methods

26

2.5.4

Standard Operating Procedures

27

2.5.5

Test Matrix

27

3.0

Project Description

29

3.1

Project Overview

29

3.2

Process Overview

30

3.3

Filter Vessel

32

3.4

Blowback System

34

3.5

Char Transfer System

34

3.6

Backup Filter

35

3.7

Controls and Data Acquisition

35

4.0

Results

36

4.1

Test Methodology

36

4.1.1

Filter Blinding Life Predictions

36

4.1.2

Filter Efficiency

37

4.1.3

Isokinetic Gas Sampling

37

4.1.4

Filter Reliability

37

4.1.5

Corrosion Studies

38

4.2

Operating Summary

38

4.2.1

Cold Flow Testing

38

4.2.2

Test Campaign 1 (11/25 – 11/26/97)

40

4.2.3

Test Campaign 2 (2/10/98)

40

4.2.4

Test Campaign 3 (3/12 – 3/23/98)

41

4.2.5

Test Campaign 4 (3/31 – 4/28/98)

45

4.2.6

Test Campaign 5 (6/14 – 6/27/98)

48

4.2.7

Test Campaign 6 (8/17 – 10/11/98)

51

4.2.8

Test Campaign 7 (10/17 – 11/5/98)

55

4.2.9

Test Campaign 8 (1/12 – 1/19/99)

58

4.2.10

Test Campaign 9 (2/15 – 2/25/99)

61

4.2.11

Test Campaign 10 (6/28 – 7/10/99)

64

4.2.12

Test Campaign 11 (8/13 – 8/14/99)

67

4.2.13

Test Campaign 12 (8/22 – 9/3/99)

68

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4.2.14

Test Campaign 13 (9/14 – 9/28/99)

71

4.2.15

Test Campaign 14 (9/9 – 9/13/00)

74

4.2.16

Test Campaign 15 (12/11/00)

77

4.2.17

Test Campaign 16 (3/7 – 4/3/01)

77

4.2.18

Test Campaign 17 (7/14 – 7/21/01)

81

4.2.19

Test Campaign 18 (3/10 – 3/11/03)

84

5.0

Conclusions and Technical Insights

85

5.1

Slipstream Validation

85

5.2

Fail-Safe Development

85

5.3

Filter Development

85

5.3.1

Metallic Filters

86

5.3.2

Ceramic Filters

89

5.4

Isokinetic Sampling

90

5.5

Filter Hardware Configurations

90

6.0

Recommendations

92

APPENDICES

I

Original Proposed Slipstream Test Matrix

97

II

Characterization of Field-Exposed Iron Aluminide Hot Gas Filter

99