Dry Solids Pump Program Status Library/Research/Coal/energy systems... · Dry Solids Pump Program...

A GenCorp Company

Dry Solids Pump Program Status

Alan DarbyAerojet Rocketdyne

Pittsburgh Coal ConferenceBeijing, China

September 16-19, 2013

This document does not contain ITAR or EAR Technical Information

50 Years of Aerojet Rocketdyne Engines1,748 Launches

ACTIVE

AR #1 i Li id R k t P l i

AtlasAtlas SaturnSaturn SaturnSaturn TitanTitan PKPK SpaceSpace THAADTHAAD DeltaDelta AtlasAtlas Delta Delta RedstoneRedstone NavahoNavaho JupiterJupiter ThorThor I/III/II I/1BI/1B VV CentaurCentaur--T T ShuttleShuttle I/II/IIII/II/III IIIIII/V/V IVIV

85 11 46 380 568 19 13 17 51 135 22 350 34 17

AR #1 in Liquid Rocket Propulsion


Compact Gasification System

• Next generation Gasification System that is environmentally friendly and lower cost than existing systems

Testing Initiated March 2012

EERC – North Dakota

Successful TestingCompleted April 2011

Gas Technology Institute - IllinoisReduces customer capital and operating cost by 20%


Pump – Major Components

Weight: 50 T

FLOW

Weight: 50 T

Microwave sensorsCase side mount

5.3 m

Hydraulic Motor

Fines Bin

Outlet Pressure VesselOutlet Valve

Make up spool


Pump Mode of Operation

Belt Direction• Operation based on “solids lock-

up” physics that has achieved

Normal LoadsTractiveForce

Beltup physics that has achieved 1,000 psi solids injection in prior DOE-funded tests

• Design uses “solids plug” gas

Normal LoadsNormal Loads

LoadsForce

Drive Shaft

• Design uses solids plug gas seal also proven in prior DOE-funded research

• “Linear” concept advantages: LoadsLoads

Normal Shear

Drive Shaft Direction

CoalCoal

• Linear concept advantages:

– Higher efficiency

– Scalable to large capacitiesLoadsLoadCoal

Plug Load + Friction

Coal Plug Gas Load + Friction

– Feed material flexibility


Feed System and Pump DevelopmentFeed System (Completed)• Capacity – 400 - 600 TPD • Operating Pressure – 1000 psiOperating Pressure 1000 psi• Ultra Dense Flow – No plugging• Flow Splitter – Even distribution

Solids pump (Underway)• Discharge 400 TPD at 1200 psi• 500 hours of operation• Standard “Utility” grind feedstock• Multiple feedstocks to be tested • Validate computer modelsValidate computer models• Refine operating procedures• Twice efficiency of Lock Hoppers• Reduced feed system capital cost• Reduced feed system capital cost


Pump Manufacturing

Castings Machining

Page 6This document does not contain ITAR or EAR Technical Information

Precision Boring Assembly

Pump Installation

Page 7This document does not contain ITAR or EAR Technical Information

Dry Solids Pump Test Profile

400

450

Sys‐05d ‐ Plug Generation1 scfm Sparge Gas, 3.5 RPM/min ‐Target 40,000 ft‐lbf, 80 psig C/V

Pump start-up shows reduced t l f t l

200

250

300

350

Scrape

r Strain (uin/in)

Scraper Strain

East Torque/100

torque as new plug forms at low discharge tank pressures

50

100

150

200

Torque

(ft‐lbf), S East Torque/100

West Torque/100

30

35

1400

1600

Sys‐05d ‐50 PSIG Coal Upset 1 SCFM Sparge Gas, 1 RPM/0.092 ft/sec ‐cut on case pressure

Test

00 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Tile #

20

25

800

1000

1200

nsity

(lb/ft^3)

Scrape

r Strain uin/in

Scraper Strain

East Torque/100

WestTorque/100

5

10

15

200

400

600

Inlet D

en

Torque

(ft‐lbf), West Torque/100

East Tensioner Pres

Inlet DensityPlug evidenced by increasingmotor torque and scraper strain at zero coal flow conditions

Re-formed Plug

8

000 2 4 6 8 10 12 14 16 18 20

Tile #


Pump Testing Status

Shake-down testing started March 2012• Confirmed fundamental and mechanical operating concept;

l k d h i l d li• lock up and mechanical delivery • seal plug generation - gas seal at low pressure

• Stand-down to modify components for improved performanceB lt d li k t li k l• Belt and link-to-link clearances

• Adding sensors for enhanced monitoring of internal pump operationsNext testing series will include:

S S• Short-term testing at pressures up to 300 PSI• Performance mapping tests to understand and control upset

conditions• Long duration testing at pressures up to 1200 PSI• Long duration testing at pressures up to 1200 PSI• Alternate feedstock testing to validate pump operation for range of

fuelsTarget is 500 hours of operationg p


Gasification Plant Study to Produce Synthetic Natural Gas

Synthetic Natural Gas Plant

Aerojet Rocketdyne

yBased in Xinjiang Province

2.1 Nm3/day

Collaboration withE Chi E i i

Commercial Gasifier and Dry Solids Pump

East China Engineering Science and Technology Co.

Hefei, China

10This document does not contain ITAR or EAR Technical Information

China Commercial Plant Economic Study

• Study basis: 2.1 B Nm3/yr SNG product– Domestic China coal– Approximately 15 000 STPD coal input using PWR technologyApproximately 15,000 STPD coal input using PWR technology

• Comparison of AR to leading gasification technologies in China– Domestic Dry Feed Gasifier

W t D F d G ifi– Western Dry Feed Gasifier– Slurry Fed Gasifier

• Capital costs generated by ECEC for gasification island syngas output– Scaled to support SNG output target

• Operating costs generated by ECEC captures utilities consumption specific to each technology

– Coal feed– Power requirements– Oxygen, steam, process water, nitrogen, etc.O yge , stea , p ocess ate , t oge , etc


Economics Comparison of China Based 2.1B Nm3/day SNG Plant

Compact Gasifier System Offers Lowest Cost of Product

TECHNOLOGY

ParameterAerojet

RocketdyneDry Feed(Western)

Dry Feed (Domestic) Slurry Units

Capex 377689 500058 347291 426377 10,000 RMB

Annual Revenue 517106 513031 511404 511404 10,000 RMB/yr

Annual Cost 270280 372212 370093 319734 10,000 RMB/yr

Annual Profit 151438 83245 84540 115795 10,000 RMB/yr

Syngas Cost 318.3 445.5 437.7 373.3 RMB/kNm3

Payback 3 65 5 41 4 52 4 3 yrPayback 3.65 5.41 4.52 4.3 yr

FIRR 48.26 24.7 33.02 35.95 %

15%-25% Cost Of Syngas Advantage vs. Slurry Fed% % y g g y


Gasification Plant Studies Supports AR Cost Advantages

Power (IGCC)

Power (IGCC)

Hydrogen Hydrogen Hydrogen Syngas

Compared Versus GE Shell GE GE GE Siemens

Feedstock Coal Coal Coal Petcoke Petcoke Coal

Capex Benefit 10% 20% 24% 21% 23% 27%Capex Benefit 10% 20% 24% 21% 23% 27%

Cost of Product Benefit

15% 21% 27% 24% 27% 29%

Study Performed NETL NETL NETL Jacobs PWR ECECStudy Performed By

NETL (Worley Parsons)



Jacobs PWRPilot Plant (2011)

ECEC(China Location)

Overall Plant Cost Savings• 10% to 27% lower capital cost• 15% to 29% lower cost of product


DSP Reduces Feed System Capital Cost

DSP Reduces Feed System Infrastructure To Reduce Capital Cost by 60% (USGC Basis)


PWR Initiating Demonstration and Commercial Hardware Design

Primary Scaling Tools

• Gasifier: CFD (Computational Fluid Dynamics) model

• Pump: GSD (Granular Solid p (Dynamics) model

46’

20’

Pilot Plant

Demo Plant

Commercial Plant Demo Pump (400+ TPD)

18 TPD 400 TPD 3,000 TPD Commercial (1,000 TPD)


Summary

• The 400 tpd Dry Solids Pump testing verifies design approach and will continue performance testing andapproach and will continue performance testing and develop operating procedures.

• The 18 tpd pilot plant gasifier will resume testing this year to validate modifications for improved performance with low quality coals.

• PWR gasification technology is ready for demonstration• PWR gasification technology is ready for demonstration scale operation and is seeking commercial demonstration partners to provide a host site.

• For questions, please call Alan Darby, 818-586-0975 (USA).


Acknowledgement

• This Dry Solids Pump Program is supported by the y p g pp yU.S. Department of Energy, under Award No. DE-FC26-04NT42237. However, any opinions, findings, conclusions, or recommendations expressed herein are those of the author(s) and do not necessarily reflect the views of the DOE".

• The Illinois Department of Commerce and Economic• The Illinois Department of Commerce and Economic Opportunity provided funding in support of this effort under the Coal Competitiveness Program.

Questions?


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