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Title: An update on field test results for an engineered refractory for slagging gasifiers

Abstract

The widespread commercial adaptation of slagging gasifier technology to produce power, fuel, and/or chemicals from coal will depend in large measure on the technology’s ability to prove itself both economic and reliable. Improvements in gasifier reliability, availability, and maintainability will in part depend on the development of improved performance structural materials with longer service life in this application. Current generation refractory materials used to line the air-cooled, slagging gasifier vessel, and contain the gasification reaction, often last no more than three to 18 months in commercial applications. The downtime required for tear-out and replacement of these critical materials contributes to gasifier on-line availabilities that fall short of targeted goals. In this talk we will discuss the development of an improved refractory material engineered by the NETL for longer service life in this application, and provide an update on recent field test results.

Authors:
; ; ;
Publication Date:
Research Org.:
National Energy Technology Laboratory (NETL), Pittsburgh, PA, and Morgantown, WV
Sponsoring Org.:
USDOE - Office of Fossil Energy (FE)
OSTI Identifier:
922945
Report Number(s):
DOE/NETL-IR-2006-101
TRN: US200804%%932
DOE Contract Number:
None cited
Resource Type:
Conference
Resource Relation:
Conference: 31st International Technical Conference on Coal Utilization & Fuel Systems, Clearwater, FL, May 21-25, 2006
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 20 FOSSIL-FUELED POWER PLANTS; 01 COAL, LIGNITE, AND PEAT; AVAILABILITY; BUILDING MATERIALS; COAL; ECONOMICS; FIELD TESTS; FUEL SYSTEMS; GASIFICATION; PERFORMANCE; RELIABILITY; SERVICE LIFE; refractories; slagging gasifiers; improved service life; field trials

Citation Formats

Dogan, O.N., Alman, D.E., Jablonski, P.D., and Hawk, J.A. An update on field test results for an engineered refractory for slagging gasifiers. United States: N. p., 2006. Web.
Dogan, O.N., Alman, D.E., Jablonski, P.D., & Hawk, J.A. An update on field test results for an engineered refractory for slagging gasifiers. United States.
Dogan, O.N., Alman, D.E., Jablonski, P.D., and Hawk, J.A. Mon . "An update on field test results for an engineered refractory for slagging gasifiers". United States. doi:. https://www.osti.gov/servlets/purl/922945.
@article{osti_922945,
title = {An update on field test results for an engineered refractory for slagging gasifiers},
author = {Dogan, O.N. and Alman, D.E. and Jablonski, P.D. and Hawk, J.A.},
abstractNote = {The widespread commercial adaptation of slagging gasifier technology to produce power, fuel, and/or chemicals from coal will depend in large measure on the technology’s ability to prove itself both economic and reliable. Improvements in gasifier reliability, availability, and maintainability will in part depend on the development of improved performance structural materials with longer service life in this application. Current generation refractory materials used to line the air-cooled, slagging gasifier vessel, and contain the gasification reaction, often last no more than three to 18 months in commercial applications. The downtime required for tear-out and replacement of these critical materials contributes to gasifier on-line availabilities that fall short of targeted goals. In this talk we will discuss the development of an improved refractory material engineered by the NETL for longer service life in this application, and provide an update on recent field test results.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Mon May 01 00:00:00 EDT 2006},
month = {Mon May 01 00:00:00 EDT 2006}
}

Conference:
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  • Slag attack of refractory materials used to line the hot face of slagging gasifiers limits their service life to between 3 and 24 months. These gasifiers use coal, petroleum coke, or combinations of them as raw materials to produce chemicals, liquid fuel, and/or electricity; with future consideration being given to the use of other abundant, low cost feedstock such as biomass. The ash from these materials generate liquid slags during gasification at temperature between 1300 - 1575 C and pressures up to 1000 psi, leading to severe slag attack of a vessel lining and causing unacceptable gasifier reliability and on-linemore » availability. To maximize refractory life and provide protection of the gasifier metal shell, the best liners have contained a minimum of 60-70 pct chromia in combination with alumina, alumina/zirconia, or magnesia. The Albany Research Center of DOE has developed a phosphate containing high chrome oxide refractory liner that indicates potential for increased service life over currently used materials. This new liner has been produced commercially by a refractory company and installed in a gasifier for performance evaluation. Refractory issues in slagging gasifiers, the development and properties of the phosphate containing high chrome oxide material, and the preliminary results from the plant trial of this material will be presented.« less
  • Gasifiers are used commercially to react a carbon feedstock with water and oxygen under reducing conditions; producing chemicals used as feedstock for other processes, fuel for power plants, and/or steam used in other processes. A gasifier acts as a high temperature, high pressure reaction chamber, typically operating between 1250-1575°C, and with pressures between 300-1000 psi. Ash that originates from mineral impurities in the carbon feedstock becomes a by-product of gasification. In a slagging gasifier it melts, forming a liquid which flows down the gasifier sidewall; penetrating and wearing away the refractory liner by corrosive dissolution, abrasive wear, or by othermore » processes such as spalling. The refractory liner must withstand the severe service environment, protecting the steel shell against corrosive gases, temperature, and material wear. Users have identified refractory service life as the most important limitation to sustained on-line availability of gasifiers, limiting gasifier acceptance and use by industry. The National Energy Technology Laboratory in Albany, OR, has developed and patented (US Patent # 6,815,386) a phosphate containing high chrome oxide refractory for use in slagging gasifiers. In cooperation with ANH Refractories Company, this refractory material has been commercially produced and is undergoing field tests in commercial gasifiers. An analysis of data from these field tests indicates that the phosphate containing refractory results in an improved service life over other refractory materials currently used as gasifier liners. Results from the post-mortem analysis of the field trial in relation to the failure mechanisms in a slagging gasifier will be presented.« less
  • Severe slag attack of high temperature materials that line coal gasifiers used in the production of chemicals, liquid fuels, and/or electricity result in their unacceptably short lifetimes, lasting anywhere from 3 months to 24 months. Lengthening of this short service life to increase gasifier reliability and increase on-line availability of a gasifier is viewed as critical for greater technology acceptance and utilization. A phosphate containing high chrome oxide refractory has been developed by the Albany Research Center of DOE and scaled up by an industrial producer of refractories for plant trials. An update of this material and its properties willmore » be presented.« less
  • Slagging coal gasifiers suffer from significant attack by the coal slag on the refractory liner. To better understand the corrosive attack on the refractory the interactions were thermochemically simulated. The slag is observed to penetrate the refractory, which complicates modeling the phase behavior of the slag-penetrated interior of the refractory. To address this issue a simple strategy was adopted such that step-wise changes in composition with decreasing slag content were assumed to account for the compositional changes as slag penetrates the refractory, at least partially through its thickness. The thermochemical equilibrium calculations following this strategy typically yielded three solution phasesmore » as well as the stoichiometric crystalline phases AlPO4, Ca3(PO4)2, and (MgO)(Cr2O3), depending on composition/penetration. In addition, under some conditions a slag liquid miscibility gap exists such that two slag liquids co-exist.« less
  • The widespread commercial adaptation of slagging gasifier technology to produce power, fuel, and/or chemicals from coal will depend in large measure on the technology's ability to prove itself both economic and reliable. Improvements in gasifier reliability, availability, and maintainability will in part depend on the development of improved structural materials with longer service life in this application. Current generation refractory materials used to line the gasifier vessel, and contain the gasification reaction, often last no more than three to 18 months in commercial applications. The downtime required for tear-out and replacement of these critical materials results in gasifier on-line availabilitiesmore » that fall short of targeted goals. In this talk we will discuss the development of improved refractory materials engineered specifically for longer service life in this application, with emphasis on the design of new refractories that contain little or no chrome.« less