Section I – Executive Summary and Project Overview

Executive Summary

ES-1

General

ES-1

ii.

Process Overview

ES-1

iii.

Operating Overview

ES-3

iv.

Significant Findings and Modifications

ES-5

Environmental

ES-6

Air Separation Unit

ES-7

Coal Handling

ES-7

Gasification

ES-8

High Temperature Heat Recovery

ES-9

Particulate Removal

ES-9

Low Temperature Heat Recovery

ES-10

Acid Gas Removal

ES-11

v.

Plant Performance

ES-11

vi.

Economics and Commercialization

ES-13

vii.

Conclusions

ES-16

1.0

Introduction

1-1

1.1

Objectives

1-3

1.2

General

1-5

1.3

Project Phase Description

1-8

1.3.1

Phase 1 Activities – Engineering and Procurement

1-8

1.3.2

Phase 2 Activities – Construction

1-9

1.3.3

Phase 3 Activities – Demonstration Period

1-10

1.4

Project Organization

1-11

1.5

Project Location and Original Equipment Description

1-12

1.6

Permitting and Environmental Activities

1-14

2.0

Technology Description

2-1

3.0

Detailed Process Description

3-1

3.1

Air Separation Unit

3-2

3.2

Coal Handling

3-3

3.3

Gasification

3-4

3.3.1

Gasification and Slag Handling

3-4

3.3.2

Syngas Cooling, Particulate Removal

3-6

3.3.3

Low Temperature Heat Recovery, Chloride Scrubbing, and Syngas Moisturization

3-7

3.3.4

Acid Gas Removal

3-8

3.3.5

Sulfur Recovery

3-9

3.3.6

Sour Water Treatment

3-10

3.4

Power Block

3-11

Section II – Operations and Economics

4.0

Demonstration Period

4-1

4.1

Operation, Maintenance, and Technical Impacts

4-2

4.1.1

Air Separation Unit

4-7

4.1.2

Coal Handling

4-15

4.1.3

Gasification

4-20

4.1.3.1

Gasification and Slag Handling

4-20

4.1.3.2

Syngas Cooling, Particulate Removal and COS Hydrolysis

4-32

4.1.3.3

Low Temperature Heat Recovery and Syngas Moisturization

4-48

4.1.3.4

Acid Gas Removal

4-53

4.1.3.5

Sulfur Recovery

4-58

4.1.3.6

Sour Water Treatment

4-65

4.1.4

Power Block

4-68

4.2

General Information

4-71

4.2.1

Stream Data

4-71

4.2.2

Alternative Fuel Testing

4-74

4.3

Critical Component Failure Report

4-85

Technical Performance

5-1

Air Separation Unit

5-4

5.1.1

Air Compression System

5-4

5.1.1.1

System Modifications

5-5

5.1.1.2

Operating Experience Overview

5-7

5.1.1.3

Summary and Conclusions

5-8

5.1.2

Water Wash System

5-12

5.1.2.1

System Modifications

5-13

5.1.2.2

Operating Experience Overview

5-13

5.1.2.3

Summary and Conclusions

5-14

5.1.3

Air Purification System

5-15

5.1.3.1

System Modifications

5-16

5.1.3.2

Operating Experience Overview

5-16

5.1.3.3

Summary and Conclusions

5-18

5.1.4

Air Cooling and Liquefaction

5-21

5.1.4.1

System Modifications

5-22

5.1.4.2

Operating Experience Overview

5-24

5.1.4.3

Summary and Conclusions

5-24

5.1.5

Cryogenic Distillation System

5-27

5.1.5.1

System Modifications

5-28

5.1.5.2

Operating Experience Overview

5-28

5.1.5.3

Summary and Conclusions

5-30

5.1.6

Oxygen Mixing System

5-32

5.1.6.1

System Modifications

5-33

5.1.6.2

Operating Experience Overview

5-33

5.1.6.3

Summary and Conclusions

5-35

5.1.7

Nitrogen Handling and Storage System

5-36

5.1.7.1

System Modifications

5-38

5.1.7.2

Operating Experience Overview

5-38

5.1.7.3

Summary and Conclusions

5-38

5.1.8

Oxygen Compression System

5-42

5.1.8.1

System Modifications

5-42

5.1.8.2

Operating Experience Overview

5-44

5.1.8.3

Summary and Conclusions

5-46

5.2

Coal Handling

5-48

5.2.1

Coal Hopper System

5-48

5.2.1.1

System Modifications

5-13

5.2.1.2

Operating Experience Overview

5-13

5.2.1.3

Summary and Conclusions

5-14

5.2.2

Rod Mill System

5-51

5.2.2.1

System Modifications

5-52

5.2.2.2

Operating Experience Overview

5-53

5.2.2.3

Summary and Conclusions

5-54

5.2.3

Slurry Storage Tank System

5-56

5.2.3.1

System Modifications

5-57

5.2.3.2

Operating Experience Overview

5-57

5.2.3.3

Summary and Conclusions

5-57

5.2.4

Slurry Feed System

5-58

5.2.4.1

System Modifications

5-58

5.2.4.2

Operating Experience Overview

5-59

5.2.4.3

Summary and Conclusions

5-60

Gasification

5-61

5.3.1

First Stage Gasifier System

5-61

5.3.1.1

System Modifications

5-62

5.3.1.2

Operating Experience Overview

5-63

5.3.1.3

Summary and Conclusions

5-65

5.3.2

Second Stage Gasifier System

5-68

5.3.2.1

System Modifications

5-68

5.3.2.2

Operating Experience Overview

5-69

5.3.2.3

Summary and Conclusions

5-70

5.3.3

Raw Syngas Conditioning System

5-71

5.3.3.1

System Modifications

5-71

5.3.3.2

Operating Experience Overview

5-72

5.3.3.3

Summary and Conclusions

5-73

5.3.4

Slag and Solids Handling System

5-74

5.3.4.1

System Modifications

5-76

5.3.4.2

Operating Experience Overview

5-76

5.3.4.3

Summary and Conclusions

5-78

5.3.5

Syngas Cooling/Steam Generation System

5-79

5.3.5.1

System Modifications

5-80

5.3.5.2

Operating Experience Overview

5-82

5.3.5.3

Summary and Conclusions

5-83

5.3.6

Particulate Removal System

5-84

5.3.6.1

System Modifications

5-84

5.3.6.2

Operating Experience Overview

5-88

5.3.6.3

Summary and Conclusions

5-91

5.3.7

Chloride Scrubbing System

5-93

5.3.7.1

System Modifications

5-94

5.3.7.2

Operating Experience Overview

5-94

5.3.7.3

Summary and Conclusions

5-96

5.3.8

COS Hydrolysis System

5-97

5.3.8.1

System Modifications

5-97

5.3.8.2

Operating Experience Overview

5-97

5.3.8.3

Summary and Conclusions

5-99

5.3.9

Low Temperature Heat Recovery System

5-100

5.3.9.1

System Modifications

5-100

5.3.9.2

Operating Experience Overview

5-102

5.3.9.3

Summary and Conclusions

5-105

5.3.10

Syngas Moisturization System

5-106

5.3.10.1

System Modifications

5-106

5.3.10.2

Operating Experience Overview

5-106

5.3.10.3

Summary and Conclusions

5-107

5.3.11

Acid Gas Removal System

5-108

5.3.11.1

System Modifications

5-109

5.3.11.2

Operating Experience Overview

5-113

5.3.11.3

Summary and Conclusions

5-116

5.3.12

Sulfur Recovery System

5-118

5.3.12.1

System Modifications

5-119

5.3.12.2

Operating Experience Overview

5-123

5.3.12.3

Summary and Conclusions

5-131

5.3.13

Sour Water Treatment System

5-133

5.3.13.1

System Modifications

5-134

5.3.13.2

Operating Experience Overview

5-135

5.3.13.3

Summary and Conclusions

5-139

5.3.14

Cooling Tower System

5-141

5.3.14.1

System Modifications

5-142

5.3.14.2

Operating Experience Overview

5-142

5.3.14.3

Summary and Conclusions

5-143

Power Block

5-144

5.4.1

Combustion Turbine

5-144

5.4.1.1

System Modifications

5-145

5.4.1.2

Operating Experience Overview

5-145

5.4.1.3

Summary and Conclusions

5-146

5.4.2

Heat Recovery Steam Generator

5-148

5.4.2.1

System Modifications

5-148

5.4.2.2

Operating Experience Overview

5-148

5.4.2.3

Summary and Conclusions

5-148

5.4.3

Water Treatment/Handling System

5-150

5.4.3.1

System Modifications

5-150

5.4.3.2

Operating Experience Overview

5-150

5.4.3.3

Summary and Conclusions

5-151

5.4.4

Steam Turbine

5-152

5.4.4.1

System Modifications

5-152

5.4.4.2

Operating Experience Overview

5-152

5.4.4.3

Summary and Conclusions

5-152

Environmental Performance

6-1

6.1

Non-Proprietary Streams

6-4

6.2

Conclusions

6-18

6.2.1

Process Waste and Waste Water

6-18

6.2.2

Air Emissions

6-19

7.0

Economics

7-1

7.1

Actual Installed Costs for Wabash River

7-1

7.2

Forecast Costs for Year 2000 Installation

7-5

7.3

Operational Costs

7-6

7.3.1

Fuel Cost

7-6

7.3.2

Non-Fuel Operation and Maintenance Costs

7-6

7.4

Economic Analysis

7-7

7.4.1

Historical Perspective

7-7

7.4.2

Evaluation of Future Power Generation Projects

7-7

Section III – Commercialization and Recommendations

8.0

Commercialization Potential and Plans

8-1

9.0

Conclusions and Recommendations

9-1

9.1

Success of the Demonstration Project

9-1

9.2

Commercialization Barriers and Areas of Recommended Research

9-5

9.3

Outlook

9-9