dry solids pump coal feed technologies...dry solids pump coal feed technologies doe/netl cooperative...
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DRY SOLIDS PUMPCOAL FEED TECHNOLOGIES
DOE/NETL Cooperative Agreement DE-FE0012062
> Timothy Saunders, Program Manager
> DOE Gasification and C&CBTL Workshop
Morgantown, WV
August 10, 2015
DOE C & CBTL Workshop 2DOE C & CBTL Workshop 2
Program Background
US Department of Energy (DOE) funded AR to develop:
- “A commercial solids pump as soon as possible”
Recognizing:
• Need for gasifier commercial solids pump capable of 500-1,000 PSI injection
– To reduce capital cost of Integrated Gasification Combined Cycle, Coal-to-Chemical and Coal-to-Liquid gasification based plants
• GTC analysis shows significant gasification growth to 2030 and beyond
– Electric utilities in EPRI “Coal Fleet” voted solids feeding as # 1 priority for successful commercialization of gasification plants
– Opportunity represents several 100’s solids pumps
Target date for availability of commercial pumps around 2017
DOE C & CBTL Workshop 3DOE C & CBTL Workshop 3
Program Objectives
Overall:
• Develop a solids pump that meets AR “Compact Gasifier” requirements
- 1200 psi, 400 TPD (demonstration)
• Develop a solids pump meeting commercial gasification industry requirements
- 500 psi, 600 TPD
Current Program :
•Design, develop, manufacture and test a prototype solids pump capable of
“Commercial scale” feed rate
• Test prototype to allow design optimization for commercial solids pump
Future:
• Manufacture and supply a solids pump for commercial validation
• Commence production of solids pumps for commercial sale
DOE C & CBTL Workshop 4DOE C & CBTL Workshop 4
Program Technical Approach
• Design prototype at “commercially defined” size
- 400 TPD Nominal, 600 TPD Maximum
• Utilize commercial components to maximum extent possible
• Utilize a manufacturing integrator for ensuring machine produceability
• Evaluate and test with commercially selected and supplied feed-stocks:
- Initially Illinois #6 and Powder River Basin coals,
- Then lignite, Pet Coke and coal/biomass blends
DOE C & CBTL Workshop 5DOE C & CBTL Workshop 5
Coal Feed Testing Program
To validate commercial-scale feeding system for gasifier demonstration plant
Feed Distribution System (Completed)
• Capability tested at 600 TPD (2010)
Solids pump (Underway)
- Discharge 400+ TPD at 1,200 psi
- Standard “Utility” grind PSD
- Testing multiple feed-stocks
Ultra-dense flow transport
(no plugging)
Flow splitters
(uniform distribution)
Pump
(accurate injection)
DOE C & CBTL Workshop 6DOE C & CBTL Workshop 6
Pump Operation
Normal
Loads
Normal
Loads
Tractive
Force
Track
DirectionTrack
Drive
Sprocket
Drive
Rotation
Solids Plug Load
(Gas + Friction)
System
Pressure• “Caterpillar” track moving walls
forming parallel sided duct
• Operation based on “solids lock-up” physics which achieved coal injection into 1,000 PSI in prior DOE-funded tests
• Design uses “solids plug” gas seal
also proven in prior DOE-funded
research
• “Linear” concept offers advantages over rotary solids pump:
– Higher energy efficiency
– Simply scalable to large capacities
– Feed material flexibility
Internal
“Bridges”
Carrying
Load to
Walls
Solids Flow
Direction of
solids
consolidation
DOE C & CBTL Workshop 7DOE C & CBTL Workshop 7
Prototype Pump Configuration
Inlet Isolation ValvePump Weight:
50 MT
Microwave sensors
Hydraulic Motors
Fines Bins
Outlet Pressure Vessel
Outlet Isolation Valve
Mounting
Hopper Flange
Gasifier System Flange
Pump Power
750 Kw
(2 x 375Kw)
Pump Height
5.3 m
DOE C & CBTL Workshop 8
Pump Internal Components
DOE C & CBTL Workshop 9
Pump Manufacture & Installation
DOE C & CBTL Workshop 10
Pump Installed in EERC Test Stand
DOE C & CBTL Workshop 11
Prototype Testing
• Shake-down testing initiated 2012
- Validated controls system and mechanical operation and characterization
- Confirmed fundamental operating criteria
- Identified performance limitations on certain components
• Modified select internal components for improved performance 2013
- Fines sealing around moving components
- Component clearance reductions for gas seal improvement
- Fines clearing and removal system upgrades
• Pump start-up and operation procedures developed
• DOE contract concluded end 2013
DOE C & CBTL Workshop 12
Coal Feed Technologies, CFT Program
Follow-on CFT program agreed with DOE with completion late 2016
Target 500 hours of prototype operation addressing:
- Short-term testing at pressures up to 300 PSI
- Performance mapping tests to understand and control upset conditions
- Additional feedstock tests to validate pump operation with wider range of fuels
- Long duration testing at pressures up to 1200 PSI
- Define prototype component modifications for commercial pump design
DOE C & CBTL Workshop 13
CFT Program Prototype Testing
Testing undertaken to confirm:
- Pump loading and seal plug formation
- Seal plug permeability/leakage
- Feeding at 50 t/hour into 100 psi
-450
-400
-350
-300
-250
-200
-150
-100
-50
0
50
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
45,000
50,000
0 1 2 3 4 5 6 7 8 9 10
Scra
pe
r St
rain
(u
in/i
n)
Torq
ue
(ft
-lb
f)
Tile #
Ill#6 - Plug Generation1 scfm Sparge Gas, 3.5 RPM/min -Target 40,000 ft-lbf
Ave Torque
Center Strain
Corner Strain
-800
-700
-600
-500
-400
-300
-200
-100
0
100
200
300
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
0 200 400 600 800 1000 1200 1400 1600 1800
Scra
pe
r St
rain
(uin
/in
)
Torq
ue
(ft-
lbf)
Time (seconds)
CTB-2b - 15 PSIG Ill#6 - 1 scfm Sparge Gas1 RPM/0.092 ft/sec - 40 Hz Blower Motor
Ave Torque
East Corner Strain
East Center Strain
Scraper Temp
-1000
-800
-600
-400
-200
0
200
400
0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
0 200 400 600 800 1000 1200 1400 1600
Scra
pe
r St
rain
(uin
/in
)
Torq
ue
(ft-
lbf)
Time (seconds)
HPTA-1-15-55-2 - Cut on Torque - 45 seconds short of Hopper Duration1 RPM/0.092 ft/sec - 40 Hz Blower Motor
Ave Torque
East Corner Strain
East Center Strain
Scraper Temp
DOE C & CBTL Workshop 14
CFT Prototype Operational Issues
Tile-to-Tile Leak paths
Coal accumulation on drive sprockets affects
track trajectory
-1300
-800
-300
200
700
1200
-30,000
-10,000
10,000
30,000
50,000
70,000
90,000
0 10 20 30 40 50 60 70 80 90 100
Scra
pe
r St
rain
(uin
/in
), T
en
sio
ne
r P
res
(psi
g)
Torq
ue
(ft-
lbf)
Tile #
ETS-2 - 15 PSIG Ill#6 - 1 scfm Sparge Gas1 RPM/0.092 ft/sec - 30 Hz Blower Motor
Ave Torque
East Corner Strain
East Center Strain
West Tensioner Pres
Coal consolidation impacted by flow discontinuity
DOE C & CBTL Workshop 15
CFT Program Initial Results
Pump fundamentals demonstrated in CFT Prototype testing at EERC:
- Plug consolidation to density of 60 lb/ft3 repeatable
- Motor torque required – 80,000 ft-lbf
- Static plug sealed 300 psig for planned 30 minutes
- Dynamic extrusion against 55 psig for 27 minutes at 51 TPD
Coal plug delivered against gas pressure of 97 psig
Issues limiting prototype performance:
- Coal transition irregularities from dynamic to stationary zones disrupting seal
- Leakage between tiles and casing impacting track trajectory
- Plug generation beyond optimum location in flow path causing high torque
Prototype feed pressure capability and feed rate shown limited
The most effective solution to these challenges sought
DOE C & CBTL Workshop 16
Semi-scale Program
Prototype pump size, weight - has been a challenge for development:
- One year to design, build, install and test initial component modifications
- Development at full scale found schedule and cost prohibitive
Options to accelerate development evaluated:
- Small-scale pump built and tested successfully
- Semi-scale pump program selected, approx. 1/15th scale
- Design and SOA SLM manufacture undertaken
DOE C & CBTL Workshop 17
CFT Semi-scale Rig in Test
SLM Tiles and Outlet
DOE C & CBTL Workshop 18
CFT Semi-scale Initial Testing
Initial Tile-sidewall Leakage Addressed by Side Seals and Vacuum Clearing Ports
DOE C & CBTL Workshop 19
CFT Semi-scale Initial Test Results
• Reliable coal flow into pump by active hopper confirmed at semi-scale
• Coal lock-up in active pump duct confirmed
• Consolidated and repeatable coal plug in outlet confirmed
• Drive system modification in work to allow low-speed track operation
• Second generation SLM tiles to improve seal performance in manufacture
• Additional SLM scraper configurations in manufacture
- SLM allows low-cost manufacture of complex components quickly
• Data acquisition system sensor mod’s for lower than expected loads
• Commencing pressure testing (150 PSI max) shortly
DOE C & CBTL Workshop 20
Turning Raw Technology
into Practical Solutions
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