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Title: Power Systems Development Facility

Abstract

This report discusses Test Campaign TC15 of the Kellogg Brown & Root, Inc. (KBR) Transport Gasifier train with a Siemens Power Generation, Inc. (SPG) particle filter system at the Power Systems Development Facility (PSDF) located in Wilsonville, Alabama. The Transport Gasifier is an advanced circulating fluidized-bed reactor designed to operate as either a combustor or gasifier using a particulate control device (PCD). While operating as a gasifier, either air or oxygen can be used as the oxidant. Test run TC15 began on April 19, 2004, with the startup of the main air compressor and the lighting of the gasifier startup burner. The Transport Gasifier was shutdown on April 29, 2004, accumulating 200 hours of operation using Powder River Basin (PRB) subbituminous coal. About 91 hours of the test run occurred during oxygen-blown operations. Another 6 hours of the test run was in enriched-air mode. The remainder of the test run, approximately 103 hours, took place during air-blown operations. The highest operating temperature in the gasifier mixing zone mostly varied from 1,800 to 1,850 F. The gasifier exit pressure ran between 200 and 230 psig during air-blown operations and between 110 and 150 psig in oxygen-enhanced air operations.

Authors:
Publication Date:
Research Org.:
Southern Company Services, Incorporated
Sponsoring Org.:
USDOE
OSTI Identifier:
914629
DOE Contract Number:
FC21-90MC25140
Resource Type:
Other
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; 24 POWER TRANSMISSION AND DISTRIBUTION; AIR; CIRCULATING SYSTEMS; FLUIDIZED BEDS; OXYGEN; POWDER RIVER BASIN; POWER GENERATION; POWER SYSTEMS; SUBBITUMINOUS COAL; TRANSPORT

Citation Formats

Southern Company Services. Power Systems Development Facility. United States: N. p., 2004. Web.
Southern Company Services. Power Systems Development Facility. United States.
Southern Company Services. Fri . "Power Systems Development Facility". United States. doi:. https://www.osti.gov/servlets/purl/914629.
@article{osti_914629,
title = {Power Systems Development Facility},
author = {Southern Company Services},
abstractNote = {This report discusses Test Campaign TC15 of the Kellogg Brown & Root, Inc. (KBR) Transport Gasifier train with a Siemens Power Generation, Inc. (SPG) particle filter system at the Power Systems Development Facility (PSDF) located in Wilsonville, Alabama. The Transport Gasifier is an advanced circulating fluidized-bed reactor designed to operate as either a combustor or gasifier using a particulate control device (PCD). While operating as a gasifier, either air or oxygen can be used as the oxidant. Test run TC15 began on April 19, 2004, with the startup of the main air compressor and the lighting of the gasifier startup burner. The Transport Gasifier was shutdown on April 29, 2004, accumulating 200 hours of operation using Powder River Basin (PRB) subbituminous coal. About 91 hours of the test run occurred during oxygen-blown operations. Another 6 hours of the test run was in enriched-air mode. The remainder of the test run, approximately 103 hours, took place during air-blown operations. The highest operating temperature in the gasifier mixing zone mostly varied from 1,800 to 1,850 F. The gasifier exit pressure ran between 200 and 230 psig during air-blown operations and between 110 and 150 psig in oxygen-enhanced air operations.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Fri Apr 30 00:00:00 EDT 2004},
month = {Fri Apr 30 00:00:00 EDT 2004}
}
  • Testing and development of new components and integrated, advanced systems under long-term realistic conditions is critical to the future commercialization of cleaner, more efficient, coal-fired power generation. The Power Systems Development Facility (PSDF) is a joint Industry/DOE facility operated by Southern Company Services near Wilsonville, Alabama, about 25 miles southeast of Birmingham. The objective of the PSDF project is to test and gain operating experience with new process configurations and critical components for advanced coal-based power generating systems at a scale large enough to provide data for scaleup to demonstration or first commercial plants. Southern Company Services, Inc. is leadingmore » a team of equipment and process developers which is currently starting up and/or operating the PSDF technologies. The ability of advanced Particulate Control Devices (PCDs) to clean hot gas is critical since they are necessary for the advanced process configurations and more developmental effort is needed to improve their mechanical integrity and reliability. In addition, it is necessary to demonstrate reliable operation of many off-the-shelf equipment components and systems under the conditions of advanced coal conversion processes to reduce the risk of these new systems to levels where financing can be arranged for demonstration and early commercial plants. Combining test facilities for these technologies at the PSDF site saves more than $32 million compared with the cost of building stand-alone facilities. The PSDF is divided into two systems, a transport reactor system for parametric testing of components under typical Integrated Gasification Combined Cycle (IGCC) or Pressurized Fluidized Bed Combustion (PFBC) conditions, and an advanced PFBC system for longer term testing of components in an integrated power generation system.« less
  • Testing and development of new components and advanced systems under long-term, realistic integrated process conditions is critical to the future commercialization of cleaner, more efficient, fossil fuel-fired power generation. The Power Systems Development Facility (PSDF) is a joint Industry/DOE large scale pilot/demonstration plant operated by Southern Company Services near Wilsonville, Alabama, about 25 miles southeast of Birmingham. The objective of the PSDF project is to test and gain operating experience with new process configurations and critical components for advanced fossil fuel-based power generation systems at a scale large enough to provide data for scaleup to demonstration or first commercial plants.more » Southern Company Services, Inc. is leading a team of equipment and process developers which is currently starting up and/or operating the PSDF technologies. The ability of advanced Particulate Control Devices (PCDs) to clean hot gas is critical since they are necessary for the advanced process configurations and more developmental effort is needed to improve their design and reliability under typical gasification and combustion operating conditions. In addition, it is necessary to demonstrate reliable operation of many off-the-shelf equipment components and systems under the conditions of advanced power generation processes to reduce the risk of these new systems to levels where financing can be arranged for demonstration and early commercial plants. Several technologies have been located at the PSDF to save on the costs of balance-of-plant utilities and other infrastructure.« less
  • Air Products and Chemicals, along with development participants and in association with the U.S. Department of Energy, has made substantial progress in developing a novel air separation technology. Unlike conventional cryogenic processes, this method uses high-temperature ceramic membranes to produce high-purity oxygen. The membranes selectively transport oxygen ions with high flux and infinite theoretical selectivity. Reaction-driven ceramic membranes are fabricated from non-porous, multi-component metallic oxides, operate at temperatures typically over 700°C, and have exceptionally high oxygen flux and selectivity. Oxygen from low-pressure air permeates as oxygen ions through the ceramic membrane and is consumed through chemical reactions, thus creating amore » chemical driving force that pulls oxygen ions across the membrane at high rates. The oxygen reacts with a hydrocarbon fuel in a partial oxidation process to produce a hydrogen and carbon monoxide mixture – synthesis gas. This project expands the partial-oxidation scope of ITM technology beyond natural gas feed and investigates the potential for ITM reaction-driven technology to be used in conjunction with gasification and pyrolysis technologies to provide more economical routes for producing hydrogen and synthesis gas. This report presents an overview of the ITM reaction-driven development effort, including ceramic materials development, fabrication and testing of small-scale ceramic modules, ceramic modeling, and the investigation of gasifier integration schemes« less
  • The U.S. Department of Energy (DOE) has been developing advanced power systems which will have higher efficiencies, lower capital costs, and lower emissions. The most promising of these have been the integrated gasification combined cycle (IGCC) and pressurized fluidized bed combustion (PFBC) systems. Testing and development of new components and integrated IGCC and PFBC systems under long-term, realistic conditions is critical to the future commercialization of cleaner, more efficient, coal-fired power generating systems. In 1992, it was decided that a large pilot scale facility was needed to advance these systems from bench and small pilot-scale testing to demonstration and firstmore » commercial facilities. A planned project to test a particulate control device (PCD) using the M.W. Kellogg transport reactor technology to produce particulate-laden gases under gasification or combustion conditions was modified by adding a PFBC system, three more PCDs, and a fuel cell to create the Power Systems Development Facility (PSDF). Combining test facilities for these technologies at a single site is expected to save more than $32 million compared with the cost of building stand-alone facilities. The purpose of the PSDF project is to test and gain operating experience with new process configurations and critical components for advanced coal-based power generating systems at a scale large enough to provide data for scaleup to demonstration or first commercial plants.« less
  • The US Department of Energy (DOE) has been developing advanced power systems which will have higher efficiencies, lower capital costs, and lower emissions. The most promising of these have been the integrated gasification combined cycle (IGCC) and pressurized fluidized bed combustion (PFBC) systems. Testing and development of new components and integrated IGCC and PFBC systems under long-term, realistic conditions is critical to the future commercialization of cleaner, more efficient, coal-fired power generating systems. In 1992, it was decided that a large pilot scale facility was needed to advance these systems from bench and small pilot-scale testing to demonstration and firstmore » commercial facilities. A planned project to test a particulate control device (PCD) using the M.W.Kellogg transport reactor technology to produce particulate-laden gases under gasification or combustion conditions was modified by adding a PFBC system, three more PCDs, and a fuel cell to create the Power Systems Development Facility (PSDF). Combining test facilities for these technologies at a single site is expected to save more than $32 million compared with the cost of building stand-alone facilities. The purpose of the PSDF project is to test and gain operating experience with new process configurations and critical components for advanced coal-based power generating systems at a scale large enough to provide data for scaleup to demonstration or first commercial plants. This paper describes the facility and results from first tests.« less