UKERC EDC: Publications

DTICC110_file20066.pdf

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Abstract:

The objectives of this project are:

To assess the potential corrosive effects of deposits formed on coal-fired and coal/waste co-fired gasifier fuel-gas/syngas heat exchangers in Air Blown Gasification Cycle (ABGC) and Integrated Gasification Combined Cycle (IGCC) systems.

To determine the composition ranges of deposits in ABGC and IGCC fuel-gas/syngas heat exchangers.

To quantitatively assess the rates at which these deposits cause downtime corrosion and the effectiveness of proposed preventative measures.

To assess the potential for the deposits to cause synergistic degradation (at high and low temperatures), and to measure the resulting increase in material damage rates.

To identify exposure/operating conditions/materials which could lead to rapid heat exchanger failures.

A wide variety of gasification systems are continuing to be developed around the world, including Integrated Gasification Combined Cycle (IGCC) and the UK developed Air Blown Gasification Cycle (ABGC) systems. Originally, these systems were developed to be fired on various grades of coal, but there is now interest in using a more diverse range of solid fuels (e.g. co-firing coal with waste or biomass, using low grade coals and heavy fuel oils) in order to reduce environmental impact and fuel costs.

All gasification technologies require a heat exchanger (often called either a syngas cooler or fuel gas cooler) between the gasifier and the gas cleaning system. The duty required from this heat exchanger varies depending on the type of gasifier, gas-cleaning requirements (e.g. hot dry cleaning or wet scrubbing) and steam cycle needs.

The data generated has been used to identify safe operating windows where factors do not combine to produce rapid heat exchanger failures. Aspects such as candidate heat exchanger materials, gasifier type, fuel and fuel gas compositions, deposit compositions and heat exchanger operating conditions have been investigated.

This summary provides information on:

Objectives

Summary

Background

Deposit Formation on Gasifier Hot Gas Path Components

Downtime Corrosion Testing

Downtime Corrosion Testing and Preventative Measures

Synergistic Testing

Conclusions

Potential for Future Development

Cost

Duration