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Refractory Wear During Gasification

Refractory Wear During Gasification. 1 Brigham Young University Provo, UT 2 Idaho National Laboratory * Idaho Falls, ID. Larry Baxter 1 , Shrinivas Lokare 1 , Humberto Garcia 2 , Bing Liu 1 Clearwater Coal Conference Clearwater, FL June 2, 2009. Gasification in the Literature.

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Refractory Wear During Gasification

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  1. Refractory Wear During Gasification 1Brigham Young University Provo, UT 2Idaho National Laboratory* Idaho Falls, ID Larry Baxter1, Shrinivas Lokare1, Humberto Garcia2, Bing Liu1 Clearwater Coal Conference Clearwater, FL June 2, 2009

  2. Gasification in the Literature

  3. Research by Country

  4. Levelized Cost of Power

  5. GE Energy Radiant 95% O2 Coal Slurry 63 wt.% Syngas 410°F, 800 Psia Composition (Mole%): H226% CO 27% CO212% H2O 34% Other 1% H2O/CO = 1.3 To Acid Gas Removal or To Shift Slag/Fines Design: Pressurized, single-stage, downward firing, entrained flow, slurry feed, oxygen blown, slagging, radiant and quench cooling

  6. ConocoPhillips E-Gas™ To Fire-tube boiler Syngas 1,700°F, 614 psia Composition (Mole%): H226% CO 37% CO214% H2O 15% CH4 4% Other 4% H2O/CO = 0.4 Syngas To Acid Gas Removal or To Shift Stage 2 Coal Slurry 63 wt. % (0.22) Design: Pressurized, two-stage, upward firing, entrained flow, slurry feed, oxygen blown, slagging, fire-tube boiling syngas cooling, syngas recycle (0.78) Char Slag Quench 95 % O2 Stage 1 2,500 oF 614 Psia Slag/Water Slurry

  7. Shell Gasification HP Steam Design: Pressurized, single-stage, downward firing, slagging, entrained flow, dry feed, oxygen blown, convective cooler Convective Cooler Soot Quench & Scrubber Gasifier 2,700 oF 615 psia Syngas Quench2 Syngas 350°F, 600 Psia Composition (Mole%): H229% CO 57% CO22% H2O 4% Other 8% H2O/CO = 0.1 Steam 650 oF To Acid Gas Removal or To Shift 95% O2 HP Steam Dry Coal Source: “The Shell Gasification Process”, Uhde, ThyssenKrupp Technologies Slag

  8. Transient Model Formulation

  9. Simulation – Gas Phase

  10. Simulation – Gas Phase

  11. Efficiency Calculation

  12. Impaction Efficiency Improvement

  13. Corrosion potential Chlorides condensation is a major step in corrosion initiation K Cl S Si Fe Ca

  14. Complex Inorganic Chemistry

  15. Complex Inorganic Chemistry

  16. Al2O3-CaO-SiO2 Chemistry Al2O3/SiO2 = 0.34

  17. Refractory-Slag Model

  18. Slag Importance

  19. Refractory Wear with Time

  20. Sensitivity to CaO content

  21. Refractory Chemical Corrosion

  22. Spalling Mechanisms

  23. Overall Refractory Wear Chemical dissolution rates depend in complex ways on diffusivities, viscosities, chemical reactions, and temperature. Spalling mechanisms and rates are not well understood, with quantitative models being mostly empirical. Net dissolution rates disproportionately depend on minor slag and refractory components, involving complex inorganic chemistry.

  24. Spalling Mechanisms Corrosion Spalling

  25. Spalling Mechanisms 1 2 3 6 4 5

  26. Refractory/Slag Profile

  27. Conclusions • Chemical dissolution and spalling account for most refractory wear. • Both mechanisms depend on temperature, slag/refractory composition, and slag flow rates, approximately in that order. • Temperature dependence arises from both transport and solubility issues. • Both immersion and spinning cup analyses provide good corrosion information, but neither simulates practical systems. • Temperature, not peak deposition rates, determine maximum corrosion location.

  28. Acknowledgements • PhD and post-doc students Shrinivas Lokare, Bing Liu developed many of the submodels. • Partial financial support from U.S. Department of Energy contract DE-AC07-05ID14517 and from corporate sponsors.

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