Research Technology Development

Project: Development of a Coal-CO2 Slurry Feeding System for Pressurized Entrained-Flow Gasifiers in Plants with Carbon Capture

Research Team: Cristina Botero, Randall Field, Howard Herzog, Ahmed Ghoniem

Sponsor: British Petroleum (BP)

Year: 2013

Abstract:
Integrated Gasification Combined Cycle (IGCC) power plants with carbon capture are attractive alternatives to Pulverized Coal (PC) plants for CO2-lean power generation from carbonaceous fuels such as coal. Entrained-flow gasifiers (EFG) operating at more than 40 bar are at the heart of these plants. These are also widely used for other applications such as the production of synthetic liquid fuels and chemicals from coal.

The feeding system of these reactors has proved to be a challenging and costly component since, unlike a liquid, a solid like coal cannot be pumped to a high pressure. Currently available technologies based on coal-water slurry or on lock-hoppers are expensive, inefficient, and have pressure and feedstock quality limitations.

This research uses multiscale analysis for the development and assessment of a novel feeding system, which can efficiently and economically feed pulverized coal into high-pressure reactors, such as gasifiers, in plants with carbon capture. The proposed Phase Inversion-based Coal-CO2 Slurry (PHICCOS) feeding system takes advantage of the availability of supercritical CO2 with liquid-like density in these plants. It operates at ambient temperature, without the use of lock hoppers, and can achieve very high pressures. Furthermore, the feeding system inherently reduces the moisture and ash content of the feedstock, which makes it especially attractive for low-rank and high-ash coal. The economics of the PHICCOS feeding system are better than those of commercial technologies for low-rank coal and are competitive with commercial solutions in the case of high-rank coal.

Publications:
Botero, C., "The Phase Inversion-based Coal-CO2 Slurry (PHICCOS) Feeding System: Design, Coupled Multiscale Analysis, and Technoeconomic Assessment," M.I.T. Ph.D. Dissertation, (2013). <PDF>

Botero, C., R. Field, H. Herzog, A. Ghoniem, "The Phase Inversion-based Coal-CO2 Slurry (PHICCOS) Feeding System: Technoeconomic Assessment using Coupled Multiscale Analysis," International Journal of Greenhouse Gas Control, Vol 18, pp 150-164, Oct (2013). Note: Subscription may be required to view article <Link to online journal article>

Botero, C., R.P. Field, H.J. Herzog and A.F. Ghoniem, “Coal-CO2 slurry feed for pressurized gasifiers: Slurry preparation system characterization and economics,” Energy Procedia, Vol 37, pp 2213-2223, Aug (2013). <PDF>

Botero, C., R.P. Field, H.J. Herzog, A.F. Ghoniem, "On the Thermal and Kinetic Performance of a Coal-CO2 Slurry-fed Gasifier: Optimization of CO2 and H2O Flow using CO2 Skimming and Steam Injection," Proceedings of the 38th International Technical Conference on Clean Coal & Fuel Systems, Clearwater, FL, June (2013). <PDF>

Botero, C., R.P. Field, H.J. Herzog and A.F. Ghoniem, "Impact of Finite-rate Kinetics on Carbon Conversion in a Single-stage Entrained Flow Gasifer with Coal-CO2 Slurry Feed," Applied Energy Vol 104, pp 408–417, April (2013). Note: Subscription may be required to view article <Link to online journal article>

Botero, C., R.D. Brasington, R.P. Field, H.J. Herzog and A.F. Ghoniem, "Performance of an IGCC Plant with Carbon Capture and Coal-CO2-Slurry Feed: Impact of Coal Rank, Slurry Loading, and Syngas Cooling Technology," Industrial & Engineering Chemistry Research, July (2012). Note: Subscription may be required to view article <Link to online journal article>

Botero, C., R.P. Field, H.J. Herzog and A.F. Ghoniem, "Impact of Finite-rate Kinetics on Carbon Conversion in a Single-stage Entrained Flow Gasifer with Coal-CO2 Slurry Feed," presented at the Clearwater Clean Coal Conference, June (2012). <PDF>

Patent Applications:
Botero, C., R.P. Field, H.J. Herzog, A.F. Ghoniem, Method For Conveying A Solid To A Dense, High Pressure State Via Phase Inversion With CO2, Massachusetts Institute of Technology, US Patent Application No. 61/829321, Filed (2013).

Botero, C., R.P. Field, H.J. Herzog, A.F. Ghoniem, Method for Preparing a Slurry of Pulverized Solid Material in Liquid or Supercritical Carbon Dioxide, Massachusetts Institute of Technology, US Patent Application No. 61/712954, Filed (2012).