The Phase Inversion-based Coal-CO2 Slurry (PHICCOS) feeding system: Technoeconomic assessment using coupled multiscale analysis

Abstract Coal-CO 2 slurry feed is being examined as a way to efficiently feed coal into high-pressure reactors, such as gasifiers, in carbon capture-enabled plants. The preparation of a slurry of coal in liquid carbon dioxide is not trivial and the cost of solutions involving lock hoppers and cryogenic cooling is expected to be high. A novel method for preparing and feeding coal-CO 2 slurry has recently been proposed: the Phase Inversion-based Coal-CO 2 Slurry (PHICCOS) feeding system operates at ambient temperature, does not require lock hoppers, and inherently reduces the moisture and ash content in the feedstock. This work examines the technoeconomics of the PHICCOS feeding system for high and low-rank coal and compares them with those of commercial technologies. Coupled multiscale analysis, which integrates system-level modeling and component-level modeling, is used here to conduct, for the first time, an integral assessment of the PHICCOS feeding system. The analysis, which uses an Integrated Gasification Combined Cycle power plant as an example application, accounts for multiple aspects of the process that had only been considered individually in the past. Results show that the PHICCOS feeding system is competitive with coal-water slurry feed for bituminous coal gasification and is cheaper than dry feed for low-rank coal. Overall, PHICCOS is the most economic option across coal ranks and offers unique operational advantages, when compared to dry feeding systems, related to high-pressure operation and capability to process high-ash, and high-moisture coal.

[1]  Lora L Pinkerton,et al.  Cost and Performance Baseline for Fossil Energy Plants - Volume 3b: Low Rank Coal to Electricity: Combustion Cases , 2011 .

[2]  K. S. Weil.  Coal gasification and IGCC technology: a brief primer , 2010 .

[3]  Arnold E. Reif,et al.  The Mechanism of the Carbon Dioxide–Carbon Reaction , 1952 .

[4]  Kenneth B. Bischoff,et al.  Effectiveness factors for general reaction rate forms , 1965 .

[5]  T. Fletcher,et al.  Comparative Combustion Studies of Ultrafine Coal/Water Slurries and Pulverized Coal , 1987 .

[6]  Delani Njapha,et al.  Reaction kinetics of pulverized coal-chars derived from inertinite-rich coal discards: Gasification with carbon dioxide and steam , 2006 .

[7]  Anne-Gaëlle Collot,et al.  Matching gasification technologies to coal properties , 2006 .

[8]  D. Ren,et al.  Effects of operating pressure on coal gasification , 1990 .

[9]  D. G. Roberts,et al.  A kinetic analysis of coal char gasification reactions at high pressures , 2006 .

[10]  G. E. Klinzing,et al.  Development of a Computer Controlled Continuous System for the LICADO Process , 1992 .

[11]  F. J. Smit,et al.  Engineering development of advance physical fine coal cleaning for premium fuel applications , 1995 .

[12]  G. R. Somayajulu.  A generalized equation for surface tension from the triple point to the critical point , 1988 .

[13]  G. Robbins,et al.  Agglomeration of low-rank coal as a pretreatment for direct coal liquefaction☆ , 1992 .

[14]  Kenneth Littlewood,et al.  Gasification: Theory and application , 1977 .

[15]  F. Glover,et al.  THE OPTQUEST APPROACH TO CRYSTAL BALL SIMULATION OPTIMIZATION , 2005 .

[16]  I. Smith,et al.  Intrinsic reactivity of petroleum coke and brown coal char to carbon dioxide, steam and oxygen , 1991 .

[17]  Arun S. Mujumdar,et al.  Drying of Low-Rank Coal (LRC)—A Review of Recent Patents and Innovations , 2011 .

[18]  Jd Blackwood,et al.  The carbon-steam reaction at high pressure , 1958 .

[19]  Cristina Botero,et al.  Impact of finite-rate kinetics on carbon conversion in a high-pressure, single-stage entrained flow gasifier with coal–CO2 slurry feed , 2013 .

[20]  Rory F.D. Monaghan,et al.  A dynamic reduced order model for simulating entrained flow gasifiers. Part II: Model validation and sensitivity analysis , 2012 .

[21]  Rory F.D. Monaghan,et al.  Dynamic reduced order modeling of entrained flow gasifiers , 2010 .

[22]  Jd Blackwood,et al.  The Reaction of Carbon with Carbon Dioxide at High Pressure , 1960 .

[23]  P. Walker,et al.  Combined effects of inorganic constituents and pyrolysis conditions on the gasification reactivity of coal chars , 1985 .

[24]  A. Rehmat,et al.  Gasification kinetics of Western Kentucky bituminous coal char , 1989 .

[25]  G. Klinzing,et al.  LICADO Process for Fine Coal Cleaning – Mechanism , 1989 .

[26]  K. Heek,et al.  Progress in the kinetics of coal and char gasification , 1987 .

[27]  Stephen Niksa,et al.  Coal conversion submodels for design applications at elevated pressures. Part II. Char gasification , 2004 .

[28]  Randall P. Field,et al.  Baseline Flowsheet Model for IGCC with Carbon Capture , 2011 .

[29]  Terence William Albert Rampling.  Kinetics of coal gasification at high pressure , 1983 .

[30]  S. Kajitani,et al.  Modeling of coal char gasification in coexistence of CO2 and H2O considering sharing of active sites , 2013 .

[31]  Wang Jia-ming.  Shell coal gasification technology and its application in China , 2006 .

[32]  H. Herzog,et al.  Coal-CO2 Slurry Feed for Pressurized Gasifiers: Slurry Preparation System Characterization and Economics , 2013 .

[33]  Rory F.D. Monaghan,et al.  Simulation of a Commercial-Scale Entrained Flow Gasifier Using a Dynamic Reduced Order Model , 2012 .

[34]  D. G. Roberts,et al.  Char gasification in mixtures of CO2 and H2O: Competition and inhibition , 2007 .

[35]  F. Takahashi,et al.  Some Theoretical Considerations on the Combustion and Disruption of Free Slurry Droplets , 1989 .

[36]  T. Fletcher,et al.  Improving the Accuracy of Predicting Effectiveness Factors for mth Order and Langmuir Rate Equations in Spherical Coordinates , 2000 .

[37]  J. Klosek,et al.  The Role of Oxygen in Coal Gasification , 1986 .

[38]  D. Keller,et al.  The Demineralization of Coal Using Selective Agglomeration by the T-Process , 1990 .

[39]  K. Gerdes,et al.  Quality Guidelines for Energy System Studies: Cost Estimation Methodology for NETL Assessments of Power Plant Performance , 2011 .

[40]  E. W. Thiele.  Relation between Catalytic Activity and Size of Particle , 1939 .

[41]  Hiromitsu Matsuda,et al.  Gasification rate analysis of coal char with a pressurized drop tube furnace , 2002 .

[42]  Prabir Basu,et al.  Biomass Gasification, Pyrolysis and Torrefaction: Practical Design and Theory , 2013 .

[43]  Klaus D. Timmerhaus,et al.  Plant design and economics for chemical engineers , 1958 .

[44]  Cristina Botero,et al.  Performance of an IGCC Plant with Carbon Capture and Coal-CO2-Slurry Feed: Impact of Coal Rank, Slurry Loading, and Syngas Cooling Technology , 2012 .

[45]  C. Satterfield,et al.  Effectiveness Factor for Porous Catalysts. Langmuir-Hinshelwood Kinetic Expressions , 1965 .

[46]  L. Diamond,et al.  Solubility of CO2 in water from −1.5 to 100 °C and from 0.1 to 100 MPa: evaluation of literature data and thermodynamic modelling , 2003 .

[47]  W. Wakeham,et al.  The Transport Properties of Carbon Dioxide , 1990 .

[48]  Dennis R. Moss,et al.  Pressure Vessel Design Manual , 2004 .

[49]  Shiro Kajitani,et al.  CO2 gasification rate analysis of coal char in entrained flow coal gasifier , 2006 .

[50]  M. Valix,et al.  The intrinsic combustion reactivity of pulverised coal chars: The use of experimental pore diffusion coefficients , 1992 .

[51]  Kouichi Miura,et al.  Factors affecting the reactivity of coal chars during gasification, and indices representing reactivity , 1989 .

[53]  K. J. Hüttinger,et al.  The carbon-steam reaction at elevated pressure: Formations of product gases and hydrogen inhibitions , 1992 .

[54]  Ronald W. Breault,et al.  Gasification Processes Old and New: A Basic Review of the Major Technologies , 2010 .

[55]  M. Gray,et al.  Parametric study of the column oil agglomeration of fly ash , 2001 .

[56]  John Lucas,et al.  The effects of pressure on coal reactions during pulverised coal combustion and gasification , 2002 .

[57]  Edward S. Rubin,et al.  The outlook for improved carbon capture technology , 2012 .

[58]  Hartmut Spliethoff,et al.  Experimental investigation of high temperature and high pressure coal gasification , 2012 .

[59]  Juan Adánez,et al.  Kinetics of a lignite-char gasification by CO2 , 1985 .

[60]  Tadafumi Adschiri,et al.  Coal char gasification under pressurized CO2 atmosphere , 1992 .

[61]  G. Atesok,et al.  The effect of coal properties on the viscosity of coal–water slurries ☆ , 2002 .

[62]  K. Heek,et al.  Kinetic studies of steam gasification of char in the presence of H2, CO2 and CO , 1985 .

[63]  G. Sakellaropoulos,et al.  Mineral matter effects in lignite gasification , 2002 .

[64]  S. Gorard.  REVISITING A 90-YEAR-OLD DEBATE: THE ADVANTAGES OF THE MEAN DEVIATION , 2005 .

[65]  Rory F.D. Monaghan,et al.  A dynamic reduced order model for simulating entrained flow gasifiers: Part I: Model development and description , 2012 .

[66]  S. Kawatra,et al.  Coal Desulfurization: High Efficiency Preparation Methods , 2001 .

[67]  N. Holt,et al.  Integrated Gasification Combined-Cycle Power Plants , 2003 .

[68]  R. Good,et al.  Liquid bridges and the oil agglomeration method of coal beneficiation : an elementary theory of stability , 1991 .

[69]  J. Gadsby,et al.  The kinetics of the reactions of the steam-carbon system , 1946, Proceedings of the Royal Society of London. Series A. Mathematical and Physical Sciences.

[70]  Terry Wall,et al.  Mathematical modeling of coal char reactivity with CO2 at high pressures and temperatures , 2000 .

[71]  Hai Zhang,et al.  Kinetic studies of char gasification by steam and CO2 in the presence of H2 and CO , 2010 .

[72]  Muhammad Usman,et al.  Coal gasification in CO2 atmosphere and its kinetics since 1948: A brief review , 2011 .

[73]  D. G. Roberts,et al.  Char Gasification with O2, CO2, and H2O: Effects of Pressure on Intrinsic Reaction Kinetics , 2000 .

[74]  W. Wagner,et al.  A New Equation of State for Carbon Dioxide Covering the Fluid Region from the Triple‐Point Temperature to 1100 K at Pressures up to 800 MPa , 1996 .

[75]  J. Straub.  NBS/NRC steam tables. Von L. Haar, J. S. Gallagher und G. S. Kell. Hemisphere Publishing Corp., Washington–New York–London 1984. 1. Aufl., XII, 320 S., geb., $ 34.50 , 1985 .

[76]  D. G. Roberts.  Intrinsic reaction kinetics of coal chars with oxygen, carbon dioxide and steam at elevated pressures , 2000 .

[77]  WP Ola Maurstad.  An Overview of Coal based Integrated Gasification Combined Cycle ( IGCC ) Technology , 2005 .