(212e) Development of a Plant-Wide Dynamic Model of An Integrated Gasification Combined Cycle (IGCC) Plant

Bhattacharyya, D., West Virginia University
Turton, R., West Virginia University
Zitney, S. E., National Energy Technology Laboratory, U.S. Department of Energy

In this presentation, development of a plant-wide dynamic model of an advanced Integrated Gasification Combined Cycle (IGCC) plant with CO2 capture will be discussed. The IGCC reference plant generates 640 MWe of net power using Illinois #6 coal as the feed. The plant includes an entrained, downflow, General Electric Energy (GEE) gasifier with a radiant syngas cooler (RSC), a two-stage water gas shift (WGS) conversion process, and two advanced ?F? class combustion turbines partially integrated with an elevated-pressure air separation unit (ASU). A subcritical steam cycle is considered for heat recovery steam generation. Syngas is selectively cleaned by a SELEXOL acid gas removal (AGR) process. Sulfur is recovered using a two-train Claus unit with tail gas recycle to the AGR. A multistage intercooled compressor is used for compressing CO2 to the pressure required for sequestration. Using Illinois #6 coal, the reference plant generates 640 MWe of net power.

The plant-wide steady-state and dynamic IGCC simulations have been generated using the Aspen Plus® and Aspen Plus Dynamics® process simulators, respectively. The model is generated based on the Case 2 IGCC configuration detailed in the study available in the NETL website1. The GEE gasifier is represented with a restricted equilibrium reactor model where the temperature approach to equilibrium for individual reactions can be modified based on the experimental data. In this radiant-only configuration, the syngas from the Radiant Syngas Cooler (RSC) is quenched in a scrubber. The blackwater from the scrubber bottom is further cleaned in the blackwater treatment plant. The cleaned water is returned back to the scrubber and also used for slurry preparation. The acid gas from the sour water stripper (SWS) is sent to the Claus plant. The syngas from the scrubber passes through a sour shift process. The WGS reactors are modeled as adiabatic plug flow reactors with rigorous kinetics based on the mid-life activity of the shift-catalyst. The SELEXOL unit consists of the H2S and CO2 absorbers that are designed to meet the stringent environmental limits and requirements of other associated units. The model also considers the stripper for recovering H2S that is sent as a feed to a split-flow Claus unit. The tail gas from the Claus unit is recycled to the SELEXOL unit. The cleaned syngas is sent to the GE 7FB gas turbine. This turbine is modeled as per published data in the literature. Diluent N2 is used from the elevated-pressure ASU for reducing the NOx formation. The heat recovery steam generator (HRSG) is modeled by considering generation of high-pressure, intermediate-pressure, and low-pressure steam. All of the vessels, reactors, heat exchangers, and the columns have been sized. The basic IGCC process control structure has been synthesized by standard guidelines and existing practices.

The steady-state simulation is solved in sequential-modular mode in Aspen Plus® and consists of more than 300 unit operations, 33 design specs, and 16 calculator blocks. The equation-oriented dynamic simulation consists of more than 100,000 equations solved using a multi-step Gear's integrator in Aspen Plus Dynamics®. The challenges faced in solving the dynamic model and key transient results from this dynamic model will also be discussed.

1 Cost and Performance Baseline for Fossil Energy Power Plants Study, Volume 1: Bituminous Coal and Natural Gas to Electricity,? National Energy Technology Laboratory, www.netl.doe.gov, August 2007