International Freiberg Conference on IGCC and XTL Technologies

May 21-24, 2012

DRY SOLIDS PUMP DEVELOPMENT

AND COMMERCIAL-SCALE TESTING

Tim Saunders

Pratt & Whitney Rocketdyne

Program Background and Opportunity

• Department of Energy (DOE) Funded PWR in 2006 to develop:

- “A commercial solids pump as soon as possible”

• Gasifiers need commercial solids pump capable of 500-1000 PSI injection

– Will reduce capital cost of IGCC, Coal-to-Chemical and Coal-to-Liquid gasification based plants

• Electric utilities in EPRI “Coal Fleet” identified by vote solids feeding as # 1 priority for successful commercialization of gasification plants

• GTC analysis shows global gasification growth of 35,000 MW thermal by 2014

– Equivalent to 100 to 200 solids pumps

– Market growth expected to continue to 2030 and beyond

• Target date for commercial pumps available around 2015

Program Objectives

Overall:

• Develop a solids pump that meets PWR gasifier requirements

• Develop a solids pump that meets gasification industry requirements

Current:

• Design, develop, manufacture and test a prototype solids pump capable of

“Commercial scale” feed rate

• Deliver prototype pump to test site, year-end 2011

• Test prototype to allow design optimization of commercial solids pump

Future:

• Manufacture and supply a solids pump for commercial validation

• Commence production of solids pumps for commercial sale

Technical Approach

• Concurrent risk reduction testing and design program

• Design prototype with component flexibility

• Utilize commercial components to maximum extent possible

• Utilize manufacturing integrator for produceability

• Extended testing at “commercial” defined scale

• Evaluate and test commercially defined and supplied feed-stocks:

- Initially Illinois #6 and PRB coals,

- then lignite, Pet Coke and coal/biomass blends

• Approach Provides:

- Thorough understanding of pump concept operating dynamics

- Thorough understanding of feed materials impact on pump performance

- Matures design performance and identifies maximum pump feed capacity

- Mitigated risks for final commercial manufacturing design criteria

- Data for analysis of economic benefits

- Integration of customer feed-stock requirements during program

Pump – Major Components

Inlet Valve

5.3 m

Weight: 50 MT

Microwave sensors

Hydraulic Motor

Fines Bin

Outlet Pressure Vessel

Outlet Valve

Make up spool

Case side mount

FLOW

Pump Internal Assemblies

Wear Tiles

Tensioner System

Internal Strongback

Track Link Assemblies (2)

Drive Sprocket

Coal Duct

Proprietary Outlet Comprising :

- Gas Seal Duct

- Deconsolidation Zone

- Gas Check Valve

Pump Mode of Operation

Normal

Loads

Normal

Loads

Normal

Loads

Shear

Load

Normal

Loads

Tractive

Force

Belt

Direction

Belt

Drive Shaft

Drive Shaft

Direction

Coal

Plug

Load +

Friction

Coal

Plug Gas

Load +

Friction

• Operation based on “solids lock-up” physics that has achieved 1000 PSI solids injection 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 efficiency

– Scalable to large capacities

– Feed material flexibility

• Linear moving belt based on well-proven “track” concept

• Design allowing commercial components and materials to be used in moving belt for supporting “lock-up” forces

• Track wear handled by novel replaceable tile with simple retention system

• Static coal deconsolidation uses no moving parts and minimal power

• Patent pending inlet hopper to promote flow of “hard-to-handle” materials and consolidating powders

• Internal solids duct designed for pressure containment allowing pump case lower pressure rating and reduced cost

• Internal fines handling system with no moving parts

Pump Design Innovation

Page 9

Pump Manufacturing

Making very large and very heavy material blocks into large and heavy components

Page 10

Pump Manufacturing

Machining at the limit of mill capacity with heavy component assemblies

Pump Manufacturing & Assembly

Assembling the track onto the strong-back

Pump Manufacturing & Assembly

Putting it all together

Pump Manufacturing & Assembly

The BIG lift!

One 280 Ton Crane

One 90 Ton Crane

Page 14

Pump Installation at Test Facility (EERC)

A

TIG

HT

Squ

eez

e

!

Pump Installation

1000 HP

Hydraulic

Motors

Installed

Scraper installed

Pump Installation

Lifting the Pressure

Vessel into place

Pump In Place, attached to

Isolation Valve and Fines

Bins Installed

Pump Installation

Happy Customers - DOE NETL

Program Managers with their

Newly Named “BABE”

Pump in the

Test Stand

Objective is to obtain data for commercial

scale demo plant

• Feed System (Completed)

• Initial Capability - 400 TPD (2007)

• Capability increased - 600 TPD (2010)

Testing Program at EERC

Solids pump (Underway)

- Discharge 400 TPD at 1200 psi

- Standard “Utility” grind feedstock

- Multiple feedstock to be tested

- Validate computer models

- Refine operating procedures

Ultra-dense flow

(no plugging)

Flow splitters

(uniform distribution)

Page 19

Pump Testing

• Shake-down testing started end March

- Validated controls system

- Verified system mechanical operation and characterization

- Confirmed fundamental operating criteria

• Currently modifying some components for improved performance

• Next testing will include

- Short-term testing at pressures up to 300 PSI

- Performance mapping tests to understand and control upset conditions

- Long duration testing at pressures up to 1200 PSI

- Alternate feedstock testing to validate pump operation with a range of fuels

• Target is 1000 hours of operation

• Testing expected to be complete by end of 2012

Acknowledgement

• Development of the Dry Solids Pump is supported by the U.S.

Department of Energy.

• Energy and Environment Solutions is the strategic energy technology

arm of the Alberta Government in the Ministry of Advanced Education

and Technology. Its mission is to enhance the development of Alberta's

energy resources through investment in research, technology and

innovation in partnership with industry.

• However, the opinions, findings and conclusions expressed herein are

those of the authors

THANK YOU