Technology qualification for IGCC power plant with CO2 Capture
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Summary:This thesis presents the technology qualification plan for the integrated gasification combined cycle power plant (IGCC) with carbon dioxide capture based on DNV recommendations. Objectives of the thesis work were development of a qualification plan, heat balance, material balance and performance characteristics for IGCC with CO2 capture. GT PRO software by thermoflow was used for the development of heat balance, material balance and performance characteristics of power plant.IGCC with pre-combustion capture is a process of generating power with very low CO2 emissions. The IGCC process gasifies coal to a syngas, converts the CO to CO2 in the shift reactors, separates the CO2 in the capture subsystem, and the resulting fuel is used for the gas turbine (GT) in a combined cycle setup. A comparison is also made between the enriched air blown gasification combined cycle power plant with CO2 capture and shell gasification combined cycle power plant with CO2 capture. For the case of this thesis, technology qualification steps obtained from DNV guidelines are implemented on the enriched air blown integrated gasification power plant with CO2 capture. First step of the technology qualification was to establish a qualification basis for the IGCC power plant with CO2 capture. In this step detailed process description of power plant is done in order to define what technology should do and what its functional requirements are?Next step of the technology qualification was technology assessment. The main purpose of this step was to divide the IGCC power plant with CO2 capture into manageable elements that involve the aspects of new technology and identify key challenges and uncertainties associated with those novel elements.Threat assessment was the third step in the technology qualification. Risks and failure modes associated with the commercialization of IGCC with CO2 capture are identified by applying risk assessment techniques like (Failure Mode Effect & Criticality Analysis (FMECA) and Hazard and Operability Analysis (Hazop). Analysis of variance was used in order to give priority to more critical failure modes.Faiure modes like surge problem of gas turbine,fouling,metal dusting and tube vibration for the heat exchanger, deactivation of catalyst for shift reactor, maldistribution of the solvent for the absorber, contaminated supply of steam to steam turbine have been identified.Qualification plans were developed for the identified failure modes of concern obtained from FMECA and Hazop analysis .The main objective of this step was to select qualification activities that adequately address the identified failure modes of concern with respect to its risk and determination of sufficient performance margins. Activities like integration of gas turbine to air separation unit, chemical treatment of water in order to avoid contaminated supply of water to HRSG and contaminated supply of steam to steam turbine, better understanding of distributor design and packing development for the absorber were suggested.After the selection of these qualification activities, execution of selected qualification activities was done in a systematic manner to document performance margins for the failure modes of concern.Last step of the technology qualification plan was concept improvement. The objective of the concept improvement step was to implement improvements that have been found necessary or beneficial during the failure mode identification and risk ranking or in the performance assessment.The focus of this work was to reduce uncertainties in these parameters in order to improve the confidence in the IGCC power plant with CO2 capture.