CFBC Boiler Island

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GREENHOUSE GAS EMISSIONS CONTROL VOLUMES I & IIBY OXYGEN FIRING IN CIRCULATING FLUIDIZED BED BOILERS

ALSTOM Power Inc. May 15, 2003i

GREENHOUSE GAS EMISSIONS CONTROLBY OXYGEN FIRING IN CIRCULATING FLUIDIZED BED BOILERS:

PHASE 1 A PRELIMINARY SYSTEMS EVALUATION

FINAL REPORT

VOLUME IEVALUATION OF ADVANCED COAL COMBUSTION & GASIFICATION

POWER PLANTS WITH GREENHOUSE GAS EMISSION CONTROL

VOLUME IIBENCH-SCALE FLUIDIZED BED COMBUSTION TESTING

SUBMITTED BY

ALSTOM POWER INC.POWER PLANT LABORATORIES

2000 DAY HILL ROADWINDSOR, CT 06095

(860) 688-1911

PREPARED FOR

NETL AAD DOCUMENT CONTROL BLDG. 921US DEPARTMENT OF ENERGY

NATIONAL ENERGY TECHNOLOGY LABORATORYP.O. BOX 10940

PITTSBURGH, PENNSYLVANIA 15236-0940(COOPERATIVE AGREEMENTT NO. DE-FC26-01NT41146)

PHASE I REPORT SUBMITTAL DATE: MAY 15, 2003

PHASE I PERFORMANCE PERIOD: SEPTEMBER 28, 2001 MAY 15, 2003

PPL REPORT NO. PPL-03-CT-09


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ALSTOM Power Inc. May 15, 2003ii

VOLUME I


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ALSTOM Power Inc. May 15, 2003iii

GREENHOUSE GAS EMISSIONS CONTROLBY OXYGEN FIRING IN CIRCULATING FLUIDIZED BED BOILERS:PHASE 1 A PRELIMINARY SYSTEMS EVALUATION

FINAL REPORT

VOLUME I

EVALUATION OF ADVANCED COAL COMBUSTION & GASIFICATIONPOWER PLANTS WITH GREENHOUSE GAS EMISSION CONTROL

SUBMITTED BY

ALSTOM POWER INC.POWER PLANT LABORATORIES

2000 DAY HILL ROADWINDSOR, CT 06095

(860) 688-1911

Project Manager: John L. MarionProject Adviser: Carl R. Bozzuto

Principal Investigators:Nsakala ya NsakalaGregory N. Liljedahl

Project Technical Expert: Herbert E. Andrus

Project Economics Expert: Ray P. Chamberland

PREPARED FOR

NETL AAD DOCUMENT CONTROL BLDG. 921US DEPARTMENT OF ENERGY

NATIONAL ENERGY TECHNOLOGY LABORATORYP.O. BOX 10940

PITTSBURGH, PENNSYLVANIA 15236-0940(COOPERATIVE AGREEMENTT NO. DE-FC26-01NT41146)

PHASE I REPORT SUBMITTAL DATE: MAY 15, 2003

PHASE I PERFORMANCE PERIOD: SEPTEMBER 28, 2001 MAY 15, 2003

PPL REPORT NO. PPL-03-CT-09


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ALSTOM Power Inc. May 15, 2003iv

DISCLAIMER

This report was prepared as an account of work sponsored by an agency of the UnitedSates Government. Neither the United States Government nor any agency thereof, norany of their employees makes any warranty, express or implied, or assumes any legal

liability or responsibility for the accuracy, completeness, or usefulness of any information,apparatus, product, or process disclosed, or represents that its use would not infringeprivately owned rights. Reference herein to any specific commercial product, process, orservice by trade name, trademark, manufacturer, or otherwise does not necessarilyconstitute or imply its endorsement, recommendation, or favoring by the United StatesGovernment or any agency thereof. The views and opinions of authors expressed hereindo not necessarily state or reflect those of the United States Government or any agencythereof.


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ALSTOM Power Inc. May 15, 2003v

ACKNOWLEDGMENTS

The authors appreciatively acknowledge the following people for their contributions to thesuccessful performance of the work presented herein:q John Ferguson, Roland Tetreault, Richard Waryasz, John Chiu, Pat Storey, Glen

Jukkola, and Larry Cellilli of ALSTOM Power Inc. for their contributions as follows: John Ferguson: For proving design guidance and cost calculations of Boiler andGasifier Islands for all combustion-based and chemical looping-based cases.

Roland Tetreault: For providing design graphics services for combustion-basedand chemical looping-based cases.

Richard Waryasz: For providing design and performance information on externaland moving bed heat exchangers.

John Chiu: For providing cyclone and particulate removal system design andperformance information.

Pat Storey: For providing guidance on construction costs of Boiler and GasifierIslands for combustion-based and chemical looping-based cases.

Glen Jukkola: For providing general consultation on Circulating Moving BedBoilers and more specifically on heat transfer in moving bed heat exchangers.

Larry Cellilli: For providing contract administration.

q Michael Rutkowski, Ronald Schoff, and Thomas Buchanan of Parsons Energy andChemical Group, Inc., of Wyomissing, Pennsylvania: For providing design and costinformation on the balance of plant (BOP) equipment for seven combustion-basedcases; for providing design, performance, and cost information for BOP equipmentfor two advanced Chemical Looping cases; and for providing complete design,performance, and cost information on four Texaco based IGCC cases.

q David Vogel and J.C. Gupta of ABB Lummus Global Inc. of Houston, Texas: Forproviding design, performance and cost information on the Gas Processing Systems(CO2capture, purification, compression, and liquefaction) of the combustion-basedcases and advanced Chemical Looping-based case, and gas compression systemdesign, performance and cost information for the IGCC cases.

q David Thompson, Abbey Harbert, and Ravi Prasad of Praxair Inc., of Tonawanda,New York: For providing design, performance, and cost information on bothcryogenic-based and oxygen transport membrane-based oxygen production systemsfor four of the combustion-based cases.

q Richard Schuller of Plasma Inc. of Butte, Montana: For providing consultationservices and contacts with CO2users and information on CO2use for EOR,particularly with respect to the Belridge, CA, project. Plasma, Inc. is a projectdeveloper with expertise in oil/gas production projects.

The financial support of this project by DOE National Energy Technology Laboratory(Contract No DE-FC26-01NT41146), and ALSTOM Power Inc. is also appreciativelyacknowledged.


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ALSTOM Power Inc. May 15, 2003vi

Table of Contents

1. Introduction....................................................................................................................................................1

2. Case Studies: Design Basis, Process Descriptions, Equipment, and Plant Performance .........................42.1. CASE-1: AIR FIRED CFB WITHOUT CO2CAPTURE (BASE CASE FOR COMPARISON TO COMBUSTIONCASES) ..............................................................................................................................................................12

2.1.1. Case-1 Boiler Island Process Description and Equipment.......................................................132.1.1.1. Process Description and Process Flow Diagrams.............................................................13

2.1.1.2. Material and Energy Balance.............................................................................................142.1.1.3. Boiler Island Equipment ....................................................................................................15

2.1.2. Case-1 Balance of Plant Equipment and Performance.............................................................212.1.2.1. Steam Cycle Performance..................................................................................................212.1.2.2. Steam Cycle Equipment.....................................................................................................232.1.2.3. Other Balance of Plant Equipment ....................................................................................23

2.1.3. Case-1 Overall Plant Performance and CO2Emissions...........................................................312.2. CASE2: OXYGEN FIRED CFB WITH MOVING BED HEAT EXCHANGER AND CO2CAPTURE...........33

2.2.1. Case 2 Boiler Island Process Description and Equipment .......................................................382.2.1.1. Process Description and Process Flow Diagrams.............................................................382.2.1.2. Material and Energy Balance.............................................................................................392.2.1.3. Boiler Island Equipment ....................................................................................................41

2.2.2. Case-2 Gas Processing System Process Description and Equipment......................................472.2.2.1. Process Description............................................................................................................482.2.2.2. Process Flow Diagrams......................................................................................................512.2.2.3. Material and Energy Balance.............................................................................................552.2.2.4. Gas Processing System Utilities........................................................................................562.2.2.5. Gas Processing System Equipment ...................................................................................57

2.2.3. Case-2 Air Separation Unit Process Description and Equipment............................................572.2.3.1. Process Description and Process Flow Diagrams.............................................................572.2.3.2. Material and Energy Balance.............................................................................................602.2.3.3. Air Separation Unit Utility Summary...............................................................................62

2.2.3.4. Air Separation Unit Equipment .........................................................................................622.2.3.5. Air Separation Unit Miscellaneous Items.........................................................................62

2.2.4. Case-2 Balance of Plant Equipment and Performance.............................................................642.2.4.1. Steam Cycle Performance..................................................................................................642.2.4.2. Steam Cycle Equipment.....................................................................................................652.2.4.3. Other Balance of Plant Equipment ....................................................................................66

2.2.5. Case-2 Overall Plant Performance and CO2Emissions...........................................................732.3. CASE-3: OXYGEN FIRED CFB WITH CO2CAPTURE (SEQUESTRATION ONLY OPTION).....................76

2.3.1. Case-3 Boiler Island Process Description and Equipment.......................................................762.3.1.1. Process Description and Process Flow Diagrams.............................................................762.3.1.2. Material and Energy Balance.............................................................................................762.3.1.3. Boiler Island Equipment ....................................................................................................76

2.3.2. Case-3 Gas Processing System Process Description and Equipment......................................76

2.3.2.1. Process Description............................................................................................................772.3.2.2. Process Flow Diagrams......................................................................................................792.3.2.3. Material and Energy Balance.............................................................................................832.3.2.4. Gas Processing System Utilities........................................................................................852.3.2.5. Gas Processing System Equipment ...................................................................................86

2.3.3. Case-3 Air Separation Unit Process Description and Equipment............................................862.3.3.1. Process Description and Process Flow Diagrams.............................................................86

2.3.3.2. Material and Energy Balance.............................................................................................862.3.3.3. Air Separation Unit Utility Summary...............................................................................86


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2.3.3.4. Air Separation Unit Equipment .........................................................................................862.3.4. Case-3 Balance of Plant Equipment and Performance.............................................................86

2.3.4.1. Steam Cycle Performance..................................................................................................86

2.3.4.2. Other Balance of Plant Equipment ....................................................................................862.3.5. Case-3 Overall Plant Performance and CO2Emissions...........................................................86

2.4. CASE-4: OXYGEN FIRED CIRCULATING MOVING BED WITH CO2CAPTURE ....................................892.4.1. Case-4 Boiler Island Process Description and Equipment.......................................................89

2.4.1.1. Process Description and Process Flow Diagrams.............................................................892.4.1.2. Material and Energy Balance.............................................................................................92

2.4.1.3. Boiler Island Equipment ....................................................................................................942.4.2. Case-4 Gas Processing System Process Description and Equipment....................................101

2.4.2.1. Process Description..........................................................................................................1012.4.2.2. Process Flow Diagrams....................................................................................................1052.4.2.3. Material and Energy Balance...........................................................................................1082.4.2.4. Gas Processing System Utilities......................................................................................109

2.4.2.5. Gas Processing System Equipment .................................................................................1102.4.3. Case-4 Air Separation Unit Process Description and Equipment..........................................110

2.4.3.1. Process Description and Process Flow Diagrams...........................................................1102.4.3.2. Material and Energy Balance...........................................................................................1102.4.3.3. Air Separation Unit Utility Summary.............................................................................110

2.4.3.4. Air Separation Unit Equipment .......................................................................................1102.4.4. Case-4 Balance of Plant Equipment and Performance...........................................................111

2.4.4.1. Steam Cycle Performance................................................................................................1112.4.4.2. Steam Cycle Equipment...................................................................................................1122.4.4.3. Other Balance of Plant Equipment ..................................................................................113

2.4.5. Case-4 Overall Plant Performance and CO2Emissions.........................................................1202.5. CASE-5: AIR FIRED CMB WITH CO2CAPTURE UTILIZING REGENERATIVE CARBONATE PROCESS ....

............................................................................................................................................................1222.5.1. Case-5 Boiler Island Process Description and Equipment.....................................................122

2.5.1.1. Process Description and Process Flow Diagrams...........................................................1222.5.1.2. Material and Energy Balance...........................................................................................1252.5.1.3. Boiler Island Equipment ..................................................................................................126

2.5.2. Case-5 Gas Processing System Process Description and Equipment....................................132

2.5.2.1. Process Description..........................................................................................................1322.5.2.2. Process Flow Diagrams....................................................................................................1342.5.2.3. Material and Energy Balance...........................................................................................1362.5.2.4. Gas Processing System Utilities......................................................................................1382.5.2.5. Gas Processing System Equipment .................................................................................138

2.5.3. Case-5 Balance of Plant Equipment and Performance...........................................................139


2.5.4. Case-5 Overall Plant Performance and CO2Emissions.........................................................1472.6. CASE-6: OXYGEN FIRED CMB WITH OXYGEN TRANSPORT MEMBRANE AND CO2CAPTURE ......149

2.6.1. Case-6 Boiler Island Process Description and Equipment.....................................................149

2.6.1.1. Process Description and Process Flow Diagrams...........................................................149

2.6.1.2. Material and Energy Balance...........................................................................................1532.6.1.3. Boiler Island Equipment ..................................................................................................1552.6.2. Case-6 Gas Processing System Process Description and Equipment....................................163

2.6.2.1. Process Description..........................................................................................................1632.6.2.2. Process Flow Diagrams....................................................................................................167

2.6.2.3. Material and Energy Balance...........................................................................................1712.6.2.4. Gas Processing System Utilities......................................................................................1722.6.2.5. Gas Processing System Equipment .................................................................................173

2.6.3. Case-6 Oxygen Transport Membrane System Process Description and Equipment............1732.6.3.1. Process Description..........................................................................................................173


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2.6.4. Case-6 Balance of Plant Equipment and Performance...........................................................1742.6.4.1. Steam Cycle Performance................................................................................................1752.6.4.2. Steam Cycle Equipment...................................................................................................176

2.6.4.3. Other Balance of Plant Equipment ..................................................................................1782.6.5. Case-6 Overall Plant Performance and CO2Emissions.........................................................186

2.7. CASE-7: INDIRECT COMBUSTION OF COAL VIA CHEMICAL LOOPING AND CO2CAPTURE.............1892.7.1. Case-7 Boiler Island Process Description and Equipment.....................................................189

2.7.1.1. Process Description and Process Flow Diagrams...........................................................1892.7.1.2. Material and Energy Balance...........................................................................................192

2.7.1.3. Boiler Island Equipment ..................................................................................................1932.7.2. Case-7 Gas Processing System Process Description and Equipment....................................198

2.7.2.1. Process Description..........................................................................................................1992.7.2.2. Process Flow Diagrams....................................................................................................2012.7.2.3. Material and Energy Balance...........................................................................................2052.7.2.4. Gas Processing System Utilities......................................................................................206

2.7.2.5. Gas Processing System Equipment .................................................................................2072.7.3. Case-7 Balance of Plant Equipment and Performance...........................................................207


2.7.4. Case-7 Overall Plant Performance and CO2Emissions.........................................................2152.8. CASE-8: BUILT AND OPERATING IGCC PLANT WITHOUT CO2CAPTURE (BASE CASE FORCOMPARISON WITH CASE-9)..........................................................................................................................218

2.8.1. Case-8 IGCC Plant Process Description.................................................................................2192.8.1.1. Block Flow Diagram........................................................................................................2202.8.1.2. Material and Energy Balance...........................................................................................2222.8.1.3. Gasifier Island...................................................................................................................224

2.8.1.4. Power Generation System................................................................................................2272.8.1.5. Other Balance of Plant Equipment ..................................................................................229

2.8.2. Case-8 Overall Plant Performance and Emissions .................................................................2332.9. CASE-9: BUILT AND OPERATING IGCC WITH SHIFT REACTOR AND CO2CAPTURE......................236

2.9.1. Case-9 IGCC Plant Process Description.................................................................................2362.9.1.1. Block Flow Diagram:.......................................................................................................237

2.9.1.2. Material and Energy Balance...........................................................................................2392.9.1.3. Gasifier Island...................................................................................................................2412.9.1.4. Power Generation System................................................................................................2442.9.1.5. Other Balance of Plant Equipment ..................................................................................246

2.9.2. Case-9 Overall Plant Performance and CO2Emissions.........................................................2502.10. CASE-10: COMMERCIALLY OFFERED FUTURE IGCC WITHOUT CO2CAPTURE (BASE CASE FOR

COMPARISON WITH CASE-11) .......................................................................................................................2532.10.1. Case-10 IGCC Plant Process Description...............................................................................254

2.10.1.1. Block Flow Diagram ........................................................................................................2542.10.1.2. Material and Energy Balance...........................................................................................2572.10.1.3. Gasifier Island...................................................................................................................2592.10.1.4. Power Generation System................................................................................................262

2.10.1.5. Other Balance of Plant Equipment..................................................................................264

2.10.2. Case-10 Overall Plant Performance and Emissions ...............................................................2672.11. CASE-11: COMMERCIALLY OFFERED FUTURE IGCC WITH SHIFT REACTOR AND CO2CAPTURE...........................................................................................................................................................270

2.11.1. Case-11 IGCC Plant Process Description...............................................................................2712.11.1.1. Block Flow Diagram ........................................................................................................271

2.11.1.2. Material and Energy Balance...........................................................................................2742.11.1.3. Gasifier Island...................................................................................................................2762.11.1.4. Power Generation System................................................................................................2792.11.1.5. Other Balance of Plant Equipment..................................................................................281

2.11.2. Case-11 Overall Plant Performance and Emissions ...............................................................285


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2.12. CASE12: INDIRECT GASIFICATION OF COAL VIA CHEMICAL LOOPING.....................................2872.12.1. Case 12 Gasifier Island Process Description and Equipment ................................................288

2.12.1.1. Gasification Process Description and Process Flow Diagrams .....................................288

2.12.1.2. Material and Energy Balance...........................................................................................2902.12.1.3. Gasifier Island Equipment ...............................................................................................291

2.12.2. Case-12 Balance of Plant Performance and Equipment.........................................................2962.12.2.1. Power Generation System Performance and Equipment ...............................................2962.12.2.2. Other Balance of Plant Equipment..................................................................................299

2.12.3. Case-12 Overall Plant Performance and CO2Emissions .......................................................305

2.13. CASE13: INDIRECT GASIFICATION OF COAL AND CO2CAPTURE VIA CHEMICAL LOOPING.....3072.13.1. Case 13 Gasifier Island Process Description and Equipment ................................................308

2.13.1.1. Process Description and Process Flow Diagrams...........................................................3092.13.1.2. Material and Energy Balance...........................................................................................3122.13.1.3. Gasifier Island Equipment ...............................................................................................312

2.13.2. Case 13 Gas Processing System Process Description and Equipment ..................................318

2.13.2.1. Process Description..........................................................................................................3182.13.2.2. Process Flow Diagrams....................................................................................................3212.13.2.3. Material and Energy Balance...........................................................................................3252.13.2.4. Gas Processing System Utilities......................................................................................3262.13.2.5. Gas Processing System Equipment .................................................................................327

2.13.3. Case 13 Balance of Plant Performance and Equipment .........................................................3272.13.3.1. Power Generation System Performance and Equipment ...............................................3272.13.3.2. Other Balance of Plant Equipment..................................................................................331

2.13.4. Case-13 Overall Plant Performance and CO2Emissions .......................................................3353. Cost Analysis .............................................................................................................................................338

3.1. CASE-1 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3433.2. CASE-2 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COST.....................................345

3.3. CASE-3 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3473.4. CASE-4 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3493.5. CASE-5 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3513.6. CASE-6 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3533.7. CASE-7 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3553.8. CASE-8 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................357

3.9. CASE-9 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS ...................................3593.10. CASE-10 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS.............................3613.11. CASE-11 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS.............................3633.12. CASE-12 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS.............................3653.13. CASE-13 INVESTMENT COSTS AND OPERATING AND MAINTENANCE COSTS.............................367

4. Economic Analysis....................................................................................................................................369

4.1. ECONOMIC ANALYSIS ASSUMPTIONS ...............................................................................................3694.2. COST OF ELECTRICITY CALCULATION ..............................................................................................3704.3. ECONOMIC ANALYSIS RESULTS ........................................................................................................371

4.3.1. Combustion Cases ....................................................................................................................3714.3.2. Gasification Cases ....................................................................................................................3724.3.3. Sensitivity Study Results .........................................................................................................373

4.3.3.1. Case 2 - Oxygen-Fired CFB with Air Separation Unit and CO2 Capture....................373

4.3.3.2. Case 9 - Built and Operating Texaco IGCC with CO2Capture ....................................3744.3.3.3. Case 13 - ALSTOM Advanced Chemical Looping with CO2Capture .......................3744.4. ECONOMIC STUDY SUMMARY AND CONCLUSIONS..........................................................................375

5. Comparative Analysis ...............................................................................................................................3795.1. COMBUSTION CASES ..........................................................................................................................379

5.1.1. Combustion Cases: Performance and CO2Emissions Comparison......................................3795.1.2. Combustion Cases: Costs and Economics Comparison.........................................................386

5.2. GASIFICATION CASES ........................................................................................................................3905.2.1. Gasification Cases: Performance and CO2Emissions Comparison......................................3905.2.2. Gasification Cases: Costs and Economics Comparison.........................................................396


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5.3. COMPARISON OF COMBUSTION CASES AND GASIFICATION CASES.................................................3995.4. COMPARISONS WITH OTHER WORK.................................................................................................404

6. COMMERCIAL APPLICATION OF O2-FIRED CIRCULATING FLUIDIZED BED BOILER (CFB)

TECHNOLOGY................................................................................................................................................4106.1. BACKGROUND ....................................................................................................................................4106.2. POTENTIAL EARLY EOR SIT E...........................................................................................................4116.3. PERFORMANCE AND ECONOMIC ANALYSES .....................................................................................412

6.3.1. Performance Analysis...............................................................................................................4126.3.2. Economic Analysis...................................................................................................................413

6.4. VISION OF COMMERCIAL DEVELOPMENT PATHWAY.......................................................................4156.5. CONCLUDING REMARKS ....................................................................................................................416

7. Summary, Conclusions & Recommendations for Future Work.............................................................4177.1. SUMMARY...........................................................................................................................................4177.2. CONCLUSIONS....................................................................................................................................4197.3. R ECOMMENDATIONS FOR FUTURE WORK........................................................................................422

8. Bibliography ..............................................................................................................................................4239. Appendices ................................................................................................................................................425

9.1. APPENDIX I - EQUIPMENT LISTS........................................................................................................4269.1.1. Case-1 Equipment List.............................................................................................................427

9.1.1.1. Boiler Island Equipment ..................................................................................................427

9.1.1.2. Case-1 Balance of Plant Equipment................................................................................4309.1.2. Case-2 Equipment List.............................................................................................................436

9.1.2.1. Case-2 Boiler Island Equipment......................................................................................4369.1.2.2. Case-2 Gas Processing System Equipment ....................................................................4399.1.2.3. Case-2 Air Separation Unit Equipment ..........................................................................4409.1.2.4. Case-2 Balance of Plant Equipment................................................................................443

9.1.3. Case-3 Equipment List.............................................................................................................449

9.1.3.1. Case-3 Boiler Island Equipment......................................................................................4499.1.3.2. Case-3 Gas Processing System Equipment ....................................................................4499.1.3.3. Case-3 Air Separation Unit Equipment ..........................................................................4509.1.3.4. Case-3 Balance of Plant Equipment................................................................................451

9.1.4. Case-4 Equipment List.............................................................................................................4579.1.4.1. Case-4 Boiler Island Equipment......................................................................................457

9.1.4.2. Case-4 Gas Processing System Equipment ....................................................................4609.1.4.3. Case-4 Air Separation Unit Equipment ..........................................................................4619.1.4.4. Case-4 Balance of Plant Equipment................................................................................462

9.1.5. Case-5 Equipment List.............................................................................................................4689.1.5.1. Case-5 Boiler Island Equipment......................................................................................4689.1.5.2. Case-5 Gas Processing System Equipment ....................................................................470

9.1.5.3. Case-5 Balance of Plant Equipment................................................................................4719.1.6. Case-6 Equipment List.............................................................................................................477

9.1.6.1. Case-6 Boiler Island Equipment......................................................................................4779.1.6.2. Case-6 Gas Processing System Equipment ....................................................................4809.1.6.3. Case-6 Oxygen Tr ansport Membrane System Equipment ............................................4819.1.6.4. Case-6 Balance of Plant Equipment................................................................................482

9.1.7. Case-7 Equipment List.............................................................................................................488

9.1.7.1. Case-7 Boiler Island Equipment......................................................................................4889.1.7.2. Case-7 Gas Processing System Equipment ....................................................................4909.1.7.3. Case-7 Balance of Plant Equipment................................................................................491

9.1.8. Case-8 Equipment List.............................................................................................................4979.1.9. Case-9 Equipment List.............................................................................................................507

9.1.10. Case-10 Equipment List...........................................................................................................5189.1.11. Case-11 Equipment List...........................................................................................................5289.1.12. Case-12 Equipment List...........................................................................................................540

9.1.12.1. Case-12 Gasifier Island Equipment.................................................................................5409.1.12.2. Case-12 Balance of Plant Equipment..............................................................................542


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9.1.13. Case-13 Equipment List...........................................................................................................5499.1.13.1. Case-13 Gasifier Island Equipment .................................................................................5499.1.13.2. Case-13 Gas Processing System Equipment ..................................................................551

9.1.13.3. Case-13 Balance of Plant Equipment..............................................................................5529.2. APPENDIX II DRAWINGS.................................................................................................................559

9.2.1. Case-1 Drawings.......................................................................................................................5609.2.1.1. Case-1 Boiler Island Equipment......................................................................................5609.2.1.2. Case-1 Site Plan................................................................................................................563

9.2.2. Case-2 Drawings.......................................................................................................................564

9.2.2.1. Case-2 Boiler Island Equipment......................................................................................5649.2.2.2. Case-2 Gas Processing System Equipment ....................................................................5709.2.2.3. Case-2 Air Separation Unit Equipment ..........................................................................5719.2.2.4. Case-2 Site Plan................................................................................................................572

9.2.3. Case-3 Drawings.......................................................................................................................5739.2.3.1. Case-3 Boiler Island Equipment......................................................................................573

9.2.3.2. Case-3 Gas Processing System Equipment ....................................................................5749.2.3.3. Case-3 Air Separation Unit Equipment ..........................................................................5759.2.3.4. Case-3 Site Plan................................................................................................................576

9.2.4. Case-4 Drawings.......................................................................................................................5779.2.4.1. Case-4 Boiler Island Equipment......................................................................................577

9.2.4.2. Case-4 Gas Processing System Equipment ....................................................................5819.2.4.3. Case-4 Air Separation Unit Equipment ..........................................................................5829.2.4.4. Case-4 Site Plan................................................................................................................583

9.2.5. Case-5 Drawings.......................................................................................................................5849.2.5.1. Case-5 Boiler Island Equipment......................................................................................5849.2.5.2. Case-5 Gas Processing System Equipment ....................................................................5879.2.5.3. Case-5 Site Plan................................................................................................................588

9.2.6. Case-6 Drawings.......................................................................................................................5899.2.6.1. Case-6 Boiler Island Equipment......................................................................................5899.2.6.2. Case-6 Gas Processing System Equipment ....................................................................5949.2.6.3. Case-6 Oxygen Transport Membrane System Equipment ............................................5959.2.6.4. Case-6 Site Plan................................................................................................................596

9.2.7. Case-7 Drawings.......................................................................................................................597

9.2.7.1. Case-7 Boiler Island Equipment......................................................................................5979.2.7.2. Case-7 Gas Processing System Equipment ....................................................................6019.2.7.3. Case-7 Site Plan................................................................................................................602

9.2.8. Case-8 Site Plan Drawing.........................................................................................................6039.2.9. Case-9 Site Plan Drawing.........................................................................................................6049.2.10. Case-10 Site Plan Drawing.......................................................................................................605

9.2.11. Case-11 Drawings.....................................................................................................................6069.2.12. Case-12 Drawings.....................................................................................................................607

9.2.12.1. Case-12 Gasifer Island Equipment ..................................................................................6079.2.12.2. Case-12 Site Plan..............................................................................................................610

9.2.13. Case-13 Drawings.....................................................................................................................6119.2.13.1. Case-13 Gasifer Island Equipment ..................................................................................611

9.2.13.2. Case-13 Gas Processing System Equipment ..................................................................614

9.2.13.3. Case-13 Site Plan..............................................................................................................6159.3. APPENDIX III DETAILED INVESTMENT COST BREAKDOWNS AND OPERATING AND MAINTENANCECOSTS ............................................................................................................................................................616

9.3.1. Case-1 Investment Costs and Operating and Maintenance Costs .........................................6179.3.2. Case-2 Investment Costs and Operating and Maintenance Costs .........................................622

9.3.3. Case-3 Investment Costs and Operating and Maintenance Costs .........................................6309.3.4. Case-4 Investment Costs and Operating and Maintenance Costs .........................................6389.3.5. Case-5 Investment Costs and Operating and Maintenance Costs .........................................6469.3.6. Case-6 Investment Costs and Operating and Maintenance Costs .........................................6539.3.7. Case-7 Investment Costs and Operating and Maintenance Costs .........................................660


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9.3.8. Case-8 Investment Costs and Operating and Maintenance Costs .........................................6679.3.9. Case-9 Investment Costs and Operating and Maintenance Costs .........................................6699.3.10. Case-10 Investment Costs and Operating and Maintenance Costs.......................................671

9.3.11. Case-11 Investment Costs and Operating and Maintenance Costs.......................................6739.3.12. Case-12 Investment Costs and Operating and Maintenance Costs.......................................6759.3.13. Case-13 Investment Costs and Operating and Maintenance Costs.......................................680

9.4. APPENDIX IV: ECONOMIC SENSITIVITY STUDIES............................................................................6879.4.1. Case 1 Air-Fired CFB without CO2Capture .......................................................................6879.4.2. Case 2 Oxygen-Fired CFB with ASU and CO2Capture.....................................................689

9.4.3. Case 3 Oxygen-Fired CFB with ASU and Flue Gas Sequestration...................................6919.4.4. Case 4 Oxygen-Fired CMB with ASU and CO2Capture ...................................................6939.4.5. Case 5 Air-Fired CFB with Carbonate Regeneration and CO2Capture ............................6959.4.6. Case 6 Oxygen-Fired CMB with OTM and CO2Capture ..................................................6979.4.7. Case 7 Chemical Looping Combustion with CO2Capture.................................................6999.4.8. Case 8 Texaco Built and Operating IGCC without CO2Capture.......................................701

9.4.9. Case 9 Texaco Built and Operating IGCC with CO2Capture............................................7039.4.10. Case 10 Texaco Commercially Offered IGCC with CO2Capture .....................................7059.4.11. Case 11 Texaco Commercially Offered IGCC with CO2Capture .....................................7079.4.12. Case 12 ALSTOM Chemical Looping Gasification without CO2Capture .......................7099.4.13. Case 13 ALSTOM Chemical Looping Gasification with CO2Capture.............................711


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List of Figures

Figure 2.1. 1: Case-1 Simplified Boiler Island Gas Side Process Flow Diagram (Base Case) ................14Figure 2.1. 2: Case-1 Boiler Island General Arrangement Drawing - Side Elevation of Nominal 210

MW-gross CFB Steam Generator ..............................................................................................................17

Figure 2.1. 3: Case-1 Boiler Island General Arrangement Drawing - Plan View of Nominal 210 MW-gross CFB Steam Generator .......................................................................................................................18

Figure 2.1. 4: Case-1 Steam Cycle Schematic and Performance................................................................22Figure 2.1. 5: Case-1 Steam Cycle Mollier Diagram ..................................................................................22Figure 2.2. 1: Case-2: Simplified Boiler Island Gas Side Process Flow Diagram.....................................39Figure 2.2. 2: CFB Boiler Heat Absorption Comparison (Air and O2Firing)...........................................41Figure 2.2. 3: Case-2 Boiler Island General Arrangement Drawing Side Elevation..............................42

Figure 2.2. 4: Case-2 Boiler Island General Arrangement Drawing - Plan View......................................43Figure 2.2. 5: Case-2 Parallel Feedwater Heater Arrangement ..................................................................47Figure 2.2. 6: Case-2 Flue Gas Cooling Process Flow Diagram.................................................................53Figure 2.2. 7: Case-2 CO2Compression and Liquefaction Process Flow Diagram ..................................54Figure 2.2. 8: Case-2 Air Separation Unit Process Flow Diagram.............................................................58Figure 2.2. 9: Case-2 Steam Cycle Schematic and Performance................................................................65

Figure 2.3. 1: Case-3 Flue Gas Cooling Process Flow Diagram.................................................................81Figure 2.3. 2: Case-3 CO2Compression and Liquefaction Process Flow Diagram ..................................82Figure 2.4. 1: Case-4 Simplified Boiler Island Gas Side Process Flow Diagram......................................90Figure 2.4. 2: Case-4 Boiler Island General Arrangement Drawing Side Elevation..............................95Figure 2.4. 3: Case-4 Boiler Island General Arrangement Drawing Plan View.....................................96Figure 2.4. 4: Case-4 Parallel Feedwater Heater Arrangement ................................................................100

Figure 2.4. 5: Case-4 Flue Gas Cooling Process Flow Diagram...............................................................106Figure 2.4. 6: Case-4 CO2Compression and Liquefaction Process Flow Diagram ................................107Figure 2.4. 7: Case-4 Steam Cycle Schematic and Performance..............................................................112Figure 2.5. 1: Case-5: Simplified Boiler Island Gas Side Process Flow Diagram...................................123Figure 2.5. 2: Case-5 Boiler Island General Arrangement Drawing Side Elevation............................127Figure 2.5. 3: Case-5 Boiler Island General Arrangement Drawing Plan View...................................128

Figure 2.5. 4: Case-5 CO2Compression and Liquefaction Process Flow Diagram ................................135

Figure 2.5. 5: Case-5 Steam Cycle Schematic and Performance..............................................................140Figure 2.6. 1: Case-6 Simplified Boiler Island Gas Side Process Flow Diagram....................................150Figure 2.6. 2: Case-6 Boiler Island General Arrangement Drawing Side Elevation............................156Figure 2.6. 3: Case-6 Boiler Island General Arrangement Drawing Plan View...................................157Figure 2.6. 4: Case-6 High Temperature Parallel Feedwater Heater Arrangement.................................162

Figure 2.6. 5: Case-6 Low Temperature Parallel Feedwater Heater Arrangement .................................162Figure 2.6. 6: Case-6 Flue Gas Cooling Process Flow Diagram...............................................................169Figure 2.6. 7: Case-6 CO2Compression and Liquefaction Process Flow Diagram ................................170Figure 2.6. 8: Schematic of the Dual Phase Oxygen Transport Membrane (from Prasad, et al., 2002) 174Figure 2.6. 9: Case-6 Steam Cycle Schematic and Performance..............................................................176Figure 2.7. 1: Case-7: Simplified Boiler Island Gas Side Process Flow Diagram...................................190

Figure 2.7. 2: Case-7 Boiler Island General Arrangement Drawing Side Elevation............................194Figure 2.7. 3: Case-7 Boiler Island General Arrangement Drawing Plan View...................................195Figure 2.7. 4: Case-7 Flue Gas Cooling Process Flow Diagram...............................................................203Figure 2.7. 5: Case-7 CO2Compression and Liquefaction Process Flow Diagram ................................204Figure 2.7. 6: Case-7 Steam Cycle Schematic and Performance..............................................................208Figure 2.8. 1: Schematic of Tampa Electric Integrated Gasification Combined Cycle Demonstration

Project (CCT Demonstration Program: Update 2001, USDOE, 2002) .................................................219Figure 2.8. 2: Case-8 - Oxygen Blown Integrated Gasification Combined Cycle Block Flow Diagram

....................................................................................................................................................................221Figure 2.9. 1: Case-9 IGCC with CO2Capture Block Flow Diagram...................................................238Figure 2.10. 1: Case-10 Overall Plant Block Flow Diagram.......................................................................256Figure 2.11. 1: Case-11 Overall Plant Block Flow Diagram.......................................................................273


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Figure 2.12. 1: Case-12: Simplified Block Flow Diagram..........................................................................287Figure 2.12. 2: Case-12: Simplified Gasifier Island Process Flow Diagram .............................................289Figure 2.12. 3: Case-12 Gasifier Island General Arrangement Drawing Side Elevation.......................292

Figure 2.12. 4: Case-12 Gasifier Island General Arrangement Drawing Plan View..............................293Figure 2.12. 5: Case-12 Simplified Steam Cycle Diagram.........................................................................297Figure 2.13. 1: Case-13: Simplified Block Flow Diagram..........................................................................307Figure 2.13. 2: Case-13: Simplified Gasifier Island Process Flow Diagram.............................................309Figure 2.13. 3: Case-13 Gasifier Island General Arrangement Drawing Side Elevation.......................314Figure 2.13. 4: Case-13 Gasifier Island General Arrangement Drawing Plan View..............................315

Figure 2.13. 5: Process Flow Diagram for Case-13: Flue Gas Cooling....................................................323Figure 2.13. 6: Process Flow Diagram for Case-13: CO2Compression and Liquefaction......................324Figure 2.13. 7: Case-13 Simplified Steam Cycle Diagram.........................................................................328Figure 3.0. 1: EPC Plant Costs Summary of all Cases...........................................................................340Figure 4.3. 1: Case 2 - Oxygen-Fired CFB with ASU and CO2Capture Economic Sensitivity Results374Figure 4.3. 2: Case 9 - Built and Operating Texaco IGCC with CO2Capture Economic Sensitivity

Results ..............................................................................................................................................374Figure 4.3. 3: Case 13 ALSTOM Advanced Chemical Looping with CO2Capture Economic

Sensitivity Results.....................................................................................................................................375Figure 4.4. 1: Levelized Cost of Electricity Comparison for all Cases....................................................376Figure 4.4. 2: Incremental COE of CO2Capture Technologies ...............................................................376

Figure 4.4. 3: Mitigation Costs of CO2Capture Technologies.................................................................377Figure 4.4. 4: Mitigation Cost versus NPHR of CO2Capture Technologies...........................................377Figure 5.1. 1: Combustion Cases Plant Boiler Efficiency Comparison...................................................381Figure 5.1. 2: Combustion Cases Coal Heat Input Comparison...............................................................381Figure 5.1. 3: Combustion Cases Plant Steam Cycle Efficiency Comparison........................................382Figure 5.1. 4: Combustion Cases Gas Processing System Normalized Auxiliary Power Comparison.383Figure 5.1. 5: Combustion Cases Total Plant Auxiliary Power Comparison...........................................384

Figure 5.1. 6: Combustion Cases Net Plant Output Comparison.............................................................384Figure 5.1. 7: Combustion Cases Plant Thermal Efficiency Comparison................................................385Figure 5.1. 8: Combustion Cases Plant CO2Emission Comparison ........................................................386Figure 5.1. 9: Combustion Cases Avoided CO2Emission Comparison (Relative to Case-1)................386Figure 5.1.10: Plant Investment Costs for Combustion Cases...................................................................387Figure 5.1.11: Cost of Electricity for Combustion Cases...........................................................................388

Figure 5.2. 1: Gasification Plants Gas Processing System Normalized Auxiliary Power Comparison.392Figure 5.2. 2: Gasification Plants Total Plant Auxiliary Power Comparison..........................................393Figure 5.2. 3: Gasification Plants Net Plant Output Comparison.............................................................394Figure 5.2. 4: Gasification Plants Thermal Efficiency Comparison.........................................................394Figure 5.2. 5: Gasification Plants CO2Emissions Comparison................................................................395Figure 5.2. 6: Gasification Plants Avoided CO2Emissions Comparison ................................................396

Figure 5.2. 7: Investment Costs for Gasification Cases ............................................................................396Figure 5.2. 8: Cost of Electricity for Gasification Cases...........................................................................397Figure 5.3. 1: Gas Processing Power Comparison between Combustion and Gasification Cases.........399Figure 5.3. 2: Net Plant Heat Rate (HHV) Comparison between Combustion and Gasification Cases400Figure 5.3. 3: CO2Emissions Comparison between Combustion and Gasification Cases.....................401Figure 5.3. 4: Avoided CO2Emissions Comparison between Combustion and Gasification Cases .....401

Figure 5.3. 5: Overall Plant EPC Cost Comparison between Combustion and Gasification Cases.......402

Figure 5.3. 6: Cost of Electricity Comparison between Combustion and Gasification Cases................403Figure 5.3. 7: CO2Mitigation Cost Comparison between Combustion and Gasification Cases............403Figure 5.4. 1: Net Plant Heat Rates (LHV basis) from This Work...........................................................407Figure 5.4. 2: Net Plant Heat Rates (LHV basis) from EPRI & Parsons (Holt, 2000) ...........................407Figure 5.4. 3: Energy Penalty Comparison with Other Work...................................................................408

Figure 5.4. 4: CO2Emissions Comparison with Other Work...................................................................408Figure 5.4. 5: IGCCs w/o CO2Capture - Comparison with Other Work...............................................409Figure 5.4. 6: IGCCs with CO2Capture - Comparison with Other Work..............................................409Figure 6.2. 1: Location Map of Major Oil Fields in Southern San Joaquin Valley, CA. Lost Hills is

Highlighted (from Walker and Perri, 2002) ............................................................................................411


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Figure 6.3. 1: Net Plant Heat Rate Comparison between Air-Fired and Oxy-fuel Fired CFB Plants....413Figure 6.3. 2: Total EPC Investment Costs of Air-Fired CFB and Retrofit of this CFB to O2Firing...414Figure 6.3. 3: Levelized Costs of Electricity for Base Case and EOR Application with Credits...........415

Figure 6.4. 1: Commercialization Pathway ................................................................................................415Figure 7.2. 1: Variation of Levelized Cost of Electricity with Capacity Factor for Various Plant

Technologies with CO2 Capture...............................................................................................................421Figure 9.4. 1: Case 1 - Air-Fired CFB without CO

2Capture Economic Sensitivity Results ..................687

Figure 9.4. 2: Case 2 - Oxygen-Fired CFB with ASU and CO2Capture Economic Sensitivity Results689Figure 9.4. 3: Case 3 - Oxygen-Fired CFB with ASU and Flue Gas Sequestration Economic Sensitivity

Results ........................................................................................................................................................691Figure 9.4. 4: Case 4 - Oxygen-Fired CFB with ASU and CO2Capture Economic Sensitivity Results693Figure 9.4. 5: Case 5 - Air-Fired CFB with Carbonate Regeneration and CO2Capture Economic

Sensitivity Results.....................................................................................................................................695Figure 9.4. 6: Case 6 - Oxygen-Fired CMB with OTM and CO2Capture Economic Sensitivity Results

....................................................................................................................................................................697

Figure 9.4. 7: Case 7 Chemical Looping Combustion with CO2Capture Economic Sensitivity Results....................................................................................................................................................................699

Figure 9.4. 8: Case 8 Texaco Built and Operating IGCC without CO2Capture Economic SensitivityResults ........................................................................................................................................................701

Figure 9.4. 9: Case 9 Texaco Built and Operating IGCC with CO2Capture Economic Sensitivity

Results ........................................................................................................................................................703Figure 9.4.10: Case 10 - Texaco Commercially Offered IGCC without CO2Capture Economic

Sensitivity Results.....................................................................................................................................705Figure 9.4.11: Case 11 - Texaco Commercially Offered IGCC with CO2Capture Economic Sensitivity

Results ........................................................................................................................................................707Figure 9.4.12: Case 12 ALSTOM Chemical Looping Gasification without CO2Capture Economic

Sensitivity Results.....................................................................................................................................709

Figure 9.4.13: Case 13 ALSTOM Chemical Looping Gasification with CO2Capture EconomicSensitivity Results.....................................................................................................................................711


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List of Tables

Table 2.0. 1: Dakota Gasification Projects CO2Specification for EOR....................................................7Table 2.0. 2: Site Characteristics...................................................................................................................9Table 2.0. 3: Design Coal Analysis (Medium Volatile Bituminous)........................................................10Table 2.0. 4: Design Limestone Analysis ...................................................................................................10

Table 2.1. 1: Case-1 Boiler Island Gas Side Material and Energy Balance .............................................15Table 2.1. 2: Primary Air Fan Specification...............................................................................................25Table 2.1. 3: Secondary Air Fan Specification...........................................................................................25Table 2.1. 4: Induced Draft Fan Specification............................................................................................26Table 2.1. 5: Fluidizing Air Blower Specification.....................................................................................26Table 2.1. 6: Stack Design Summary ..........................................................................................................27Table 2.1. 7: Coal Receiving Design Summary..........................................................................................28

Table 2.1. 8: Particle Size Distribution.......................................................................................................28Table 2.1. 9: Fly Ash Removal Design Summary......................................................................................29Table 2.1.10: Ash Handling System Design Summary...............................................................................29Table 2.1.11: Condenser Analysis................................................................................................................30Table 2.1.12: Case-1 Overall Plant Performance Summary (Base Case)..................................................32Table 2.2. 1: Range of Fuels Fired in Air Fired CFBs..............................................................................35

Table 2.2. 2: Test Matrix for Bench-Scale Fluidized Bed Combustion....................................................37Table 2.2. 3: Case-2 Boiler Island Gas Side Material and Energy Balance .............................................40Table 2.2. 4: Case-2 Gas Processing System Material & Energy Balance...............................................55Table 2.2. 5: Case-2 Gas Processing System Cooling Water and Fuel Gas Requirements .....................56Table 2.2. 6: Case-2 Gas Processing System Electrical Requirements ....................................................56Table 2.2. 7: Ambient Conditions ...............................................................................................................57

Table 2.2. 8: Production and Purity.............................................................................................................57Table 2.2. 9: Case-2 Air Separation Unit Energy and Material Balance ..................................................61Table 2.2. 10: Gas Recirculation Fan Specification.....................................................................................67Table 2.2. 11: Induced Draft Fan Specification............................................................................................68Table 2.2. 12 Fluidizing Gas Blower Specification....................................................................................68Table 2.2. 13: Coal Receiving Design Summary..........................................................................................69

Table 2.2. 14: Particle Size Distribution.......................................................................................................70

Table 2.2. 15: Fly Ash Removal Design Summary......................................................................................70Table 2.2.16: Ash Handling System Design Summary...............................................................................71Table 2.2.17: Condenser Analysis................................................................................................................72Table 2.2.18: Case-2 Overall Plant Performance and Emissions...............................................................75Table 2.3. 1: Gas Analysis Specification for Sequestration Only.............................................................77

Table 2.3. 2: Case-3 Gas Processing System Material & Energy Balance...............................................83Table 2.3. 3: Case-3 Gas Processing System Cooling Water and Fuel Gas Requirements.....................85Table 2.3. 4: Case-3 Gas Processing System Electrical Requirements ....................................................85Table 2.3. 5: Case-3 Overall Plant Performance and Emissions ...............................................................88Table 2.4. 1: Case-4 Boiler Island Gas Side Material and Energy Balance .............................................93Table 2.4. 2: Case-4 Gas Processing System Material & Energy Balance............................................108

Table 2.4. 3: Case-4 Gas Processing System Cooling Water and Fuel Gas Requirements...................109Table 2.4. 4: Case-4 Gas Processing System Electrical Requirements ..................................................110Table 2.4. 5: Gas Recirculation Fan Specification...................................................................................114Table 2.4. 6: Induced Draft Fan Specification..........................................................................................114Table 2.4. 7: Fluidizing Gas Blower Specification..................................................................................115Table 2.4. 8: Transport Air Blower Specification....................................................................................115

Table 2.2. 9: Coal Receiving Design Summary........................................................................................116Table 2.4.10: Particle Size Distribution.....................................................................................................117Table 2.4.11: Fly Ash Removal Design Summary....................................................................................117Table 2.4.12: Ash Handling System Design Summary.............................................................................118Table 2.4.13: Condenser Analysis..............................................................................................................118Table 2.4.14: Case-4 Overall Plant Performance and Emissions .............................................................121


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Table 2.5. 1: Case-5 Boiler Island Gas Side Material and Energy Balance ...........................................126Table 2.5. 2: Case-5 Gas Processing System Material & Energy Balance.............................................136Table 2.5. 3: Case-5 Gas Processing System Cooling Water and Fuel Gas Requirements...................138

Table 2.5. 4: Case-5 Gas Processing System Electrical Requirements ..................................................138Table 2.5. 5: Primary Air Fan Specification.............................................................................................142Table 2.5. 6: Transport Air Blower Specification....................................................................................142Table 2.5. 7: Induced Draft Fan Specification..........................................................................................143Table 2.5. 8: Stack Design Summary ........................................................................................................143Table 2.5. 9: Coal Receiving Design Summary........................................................................................144

Table 2.5.10: Ash Handling System Design Summary.............................................................................145Table 2.5.11: Condenser Analysis..............................................................................................................145Table 2.5.12: Case-5 Overall Plant Performance and Emissions.............................................................148Table 2.6. 1: Case-6 Boiler Island Gas Side Material and Energy Balance ...........................................154Table 2.6. 2: Case-6 Gas Processing System Material & Energy Balance.............................................171Table 2.6. 3: Case-6 Gas Processing System Cooling Water and Fuel Gas Requirements...................172

Table 2.6. 4: Case-6 Gas Processing System Electrical Requirements ..................................................173Table 2.6. 5: OTM Heat Recovery Heat Exchanger Specification.........................................................177Table 2.6. 6: OTM Heat Recovery System Gas Analysis........................................................................178Table 2.6. 7: Sweep Gas Fan Specification ..............................................................................................179Table 2.6. 8: Induced Draft Fan Specification..........................................................................................179

Table 2.6. 9: Fluidizing Gas Blower Specification..................................................................................180Table 2.6.10: Transport Air Blower Specification....................................................................................180Table 2.6.11: OTM Air Compressor Specification...................................................................................181Table 2.6.12: OTM Gas Expander Specification......................................................................................181Table 2.6.13: Coal Receiving Design Summary........................................................................................182Table 2.6.14: Particle Size Distribution.....................................................................................................183Table 2.6.15: Fly Ash Removal Design Summary....................................................................................184

Table 2.6.16: Ash Handling System Design Summary.............................................................................184Table 2.6.17: Condenser Analysis..............................................................................................................185Table 2.6.18: Case-6 Overall Plant Performance and Emissions.............................................................188Table 2.7. 1: Case-7 Boiler Island Gas Side Material and Energy Balance ...........................................193Table 2.7. 2: Case-7 Gas Processing System Material & Energy Balance.............................................205Table 2.7. 3: Case-7 Gas Processing System Cooling Water and Fuel Gas Requirements...................206

Table 2.7. 4: Case-7 Gas Processing System Electrical Requirements...................................................206Table 2.7. 5: Primary Air Fan Specification.............................................................................................210Table 2.7. 6: Transport Air Blower Specification....................................................................................211Table 2.7. 7: Induced Draft Fan Specification..........................................................................................211Table 2.7. 8: Stack Design Summary ........................................................................................................212Table 2.7. 9: Coal Receiving Design Summary........................................................................................213

Table 2.7.10: Ash Handling System Design Summary.............................................................................213Table 2.7.11: Condenser Analysis..............................................................................................................214Table 2.7.12: Case-7 Overall Plant Performance and Emissions.............................................................217Table 2.8. 1: Case-8 Overall Material and Energy Balance ....................................................................223Table 2.8. 2: Coal Receiving Design Summary........................................................................................230Table 2.8. 3: Case-8 IGCC Plant Performance.........................................................................................234

Table 2.8. 4: Overall Plant Emissions .......................................................................................................235

Table 2.9. 1: Case-9 Overall Material and Energy Balance.....................................................................240Table 2.9. 2: Coal Receiving Design Summary........................................................................................247Table 2.9. 3: Case-9 Overall Plant Performance: Impact of CO2Recovery...........................................251Table 2.9. 4: Overall Plant Emissions.......................................................................................................252Table 2.10. 1: Case-10 Overall Plant Material and Energy Balance.........................................................258

Table 2.10. 2: Case-10 Coal Receiving Design Summary.........................................................................265Table 2.10. 3: Case-10 Overall Plant Performance ....................................................................................268Table 2.10. 4: Case-10 Overall Plant Emissions ........................................................................................269Table 2.11. 1: Case-11 Overall Plant Material and Energy Balance.........................................................275Table 2.11. 2: Case-11Coal Receiving Design Summary..........................................................................282


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Table 2.11. 3: Case-11 Overall Plant Performance ....................................................................................285Table 2.11. 4: Case-11 Overall Plant Emissions ........................................................................................286Table 2.12. 1: Case-12: Overall Plant Stream Report................................................................................288

Table 2.12. 2: Case-12 Gasifier Island Material and Energy Balance ......................................................291Table 2.12. 3: Coal Receiving Design Summary........................................................................................300Table 2.12. 4: Ash Handling Design Summary..........................................................................................301Table 2.12. 5: Primary Air Fan Specification.............................................................................................301Table 2.12. 6: Induced Draft Fan Specification..........................................................................................301Table 2.12. 7: Stack Design Summary........................................................................................................302

Table 2.12. 8: Case-12: Overall Plant Performance and Emissions..........................................................306Table 2.13. 1: Case-13: Overall Plant Stream Report................................................................................308Table 2.13. 2: Case-13 Gasifier Island Material and Energy Balance......................................................312Table 2.13. 3: Case-13 Gas Processing System Material & Energy Balance...........................................325Table 2.13. 4: Case-13 Gas Processing System Cooling Water and Fuel Gas Requirements.................326Table 2.13. 5: Case-13 Gas Processing System Electrical Requirements ................................................327

Table 2.13. 6: Coal Receiving Design Summary........................................................................................331Table 2.13. 7: Ash Handling Design Summary..........................................................................................332Table 2.13. 8: Primary Air Fan Specification.............................................................................................332Table 2.13. 9: CO2Induced Draft Fan Specification .................................................................................333Table 2.13.10: Induced Draft Fan Specification..........................................................................................333

Table 2.13.11: Stack Design Summary........................................................................................................334Table 2.13.12: Case-13: Overall Plant Performance and Emissions ..........................................................337Table 3.0. 1: EPC Plant Costs and O&M Costs Summary of all Cases ..............................................340Table 3.1. 1: Case-1 Total Plant Investment Cost Summary...................................................................343Table 3.1. 2: Case-1 Total Plant Operating and Maintenance Costs.......................................................344Table 3.2. 1: Case-2 Total Plant Investment Cost Summary...................................................................345Table 3.2. 2: Case-2 Total Plant Operating and Maintenance Costs.......................................................346

Table 3.3. 1: Case-3 Total Plant Investment Cost Summary...................................................................347Table 3.3. 2: Case-3 Total Plant Operating and Maintenance Costs.......................................................348Table 3.4. 1: Case-4 Total Plant Investment Cost Summary...................................................................349Table 3.4. 2: Case-4 Total Plant Operating and Maintenance Costs.......................................................350Table 3.5. 1: Case-5 Total Plant Investment Cost Summary...................................................................351Table 3.5. 2: Case-5 Total Plant Operating and Maintenance Costs.......................................................352

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CFBC Boiler Island