Aspen Plus IGCC Model

Contents

1 Introduction..............................................................................1 2 Components..............................................................................1 3 Process Description...................................................................4 4 Physical Properties....................................................................5 5 Chemical Reactions....................................................................6 5.1 Coal Gasification .................................................................................................................6 5.2 Desulfuration........................................................................................................................7 5.3 Power Generation................................................................................................................7 5.4 WGS.....................................................................................................................................7 5.5 Methanation.........................................................................................................................7 6 Simulation Approaches............................................................... ! Simulation Results...................................................................1" Conclusions.............................................................................11

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1 Introduction
Global warming and global politics are driving the US and other countries towards the development of new energy technologies which avoid the use of petroleum and which allow for carbon capture and sequestration. This model simulates an Integrated Coal Gasification Combined-Cycle ower !IGCC" process with different sections of the plant modeled as hierarchy bloc#s !model templates". The model includes the following sections$ Si%ing of the coal Gasification unit &ir Separation !&SU" Gas cleaning unit 'ater-gas shift unit &mmonia unit (ethani%er Combined cycle power generation

2 Components
The table below lists the components modeled in the simulation.

Components

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Component ID )* +* &C+&1 2I+(&SS 3*+ C+ C+* C C+&1&S3 S C+S 36) 3*S +*S +6S 3* C37 C1* 3C1 S-S )378 36+8 3C1+ )37C1!S" C1+C1+3)37C1 &((+)!S" )373S!S" S&1T9 S&1T* 3S+63SS+6-S-S* S6 S7 S; S< S= S> (.+3

Type C+), C+), C+), )C )C C+), C+), C+), S+1I4 )C C+), C+), C+), C+), C+), C+), C+), C+), C+), C+), S+1I4 C+), C+), C+), S+1I4 C+), C+), C+), C+), S+1I4 S+1I4 S+1I4 S+1I4 C+), C+), C+), C+), C+), C+), C+), C+), C+), C+), C+), C+),

Component name )IT-+G.) +/0G.) &-G+)

Formula )* +* &-

'&T.C&-2+)-(+)+/I4. C&-2+)-4I+/I4. C&-2+)-G-& 3IT. SU15UC&-2+)01-SU15I4. &((+)I& 304-+G.)-SU15I4. SU15U--4I+/I4. SU15U--T-I+/I4. 304-+G.) (.T3&). C31+-I). 304-+G.)-C31+-I4. SU15U)378 36+8 30 +C31+-+US-&CI4 &((+)IU(-C31+-I4. C1+C1+3&((+)IU(-C31+-I4. &((+)IU(-304-+G.)SU15IT. &((+)IU(-304-+G.)SU15I4. &((+)IU(-SU15IT.-304-&T. &((+)IU(-SU15IT. 3S+63SS+6-S-SU15U--4I&T+(IC-G&S SU15U--T-I&T+(IC-G&S SU15U--7-&T+(IC-G&S SU15U--;-&T+(IC-G&S SU15U--<-&T+(IC-G&S SU15U--=-&T+(IC-G&S SU15U-->-&T+(IC-G&S (.T3&)+1

3*+ C+ C+* C S C+S 36) 3*S +*S +6S 3* C37 C1* 3C1 S )378 36+8 3C1+ )37C1 C1+C1+3)37C1 )373S+6 )373S !)37"*S+6:' !)37"*S+6 3S+63SS+6-* S-* S* S6 S7 S; S< S= S> C37+

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+f the 7; components specified? C+&1? 2I+(&SS and C+&1&S3 are nonconventional solid components. The only properties calculated for nonconventional components are enthalpy and density. &spen lus includes special models for estimating these properties for coal and coal-derived materials. See item 7 Physical Properties for more details.

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3 Process Description
,i-ure 1 shows the rocess flowsheet of 'GCC rocess.

_____________________________________________________________________ Figure 1: IGCC Process Flo s!eet

a" The coal feed is mi@ed with water in the Si%ing section and undergoes crushing and screening. The S4 of 2ITU(+US feed stream and the resulting coal slurry 5U.1+UT product stream in the Si%ing section is shown in Table 9. Table 9 Inter"al 9 * 6 7 ; < = > B 9A #o er limit A *A 7A <A >A 9AA 9*A 97A 9<A 9>A $pper limit *A 7A <A >A 9AA 9*A 97A 9<A 9>A *AA %eig!t &raction in 'IT$M($) A.996*6<9> A.A7*9B<>; A.A;BB9*6B A.AB<>*B66 A.97;B*;; A.9A=B9BB A.A;*6A;< A.A7;><;=9 A.A;>7B6= A.*==697>7 %eig!t &raction in F$*#($T A.9BB9=6;7 A.ABA67;A* A.9A6<7=6 A.967A;<= A.9=77=B*9 A.9*<*AAA> A.A<;;=<;9 A.A76>=99 A.A*>=9>=6 A.A66B69=B

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b" The air separation unit !&SU" uses air to reach nearly pure +@ygen and )itrogen. Using -adfracrigorous method to separate the air after pretreatment. The resulting )itrogen product is BB.>6 mole C pure? and the +@ygen product is B; mole C pure. c" The coal-water slurry is mi@ed with B;C + * separated from air in the coal gasification section and converted into middle-low heating value syngas. d" Corrosive components such as sulfide? nitride and dust are removed from the raw syngas in the cleaning section. The 3*S-rich regeneration gas from the acid gas removal system is then fed into the Claus plant? producing elemental sulfur. e" The 4esulfuration section converts the hydrogen sulfide into sulfur. f" To capture the carbon dio@ide? a 'GS reactor containing a two sections in series with intercooling converts a nominal B<C of the carbon mono@ide to carbon dio@ide.

g" The plant will operate at e@tremely low emissions of regulated air pollutants and will isolate carbon dio@ide so that it can be captured. &mmonia is produced from 3ydrogen and )itrogen. h" The carbon mono@ide and 3ydrogen are synthesi%ed here into methane !by-product" in the (ethanation section. i" 5ollowing the cleaning section? the syngas is fed into the Combined Cycle ower Generation section? where the combustion energy is converted in electric energy at high efficiency.

+ P!ysical Properties
The global property option used in this model is eng--ob. This option set is used for the gasification and downstream unit operations. The S+1I4S property option is used for the coal crushing and screening section. The I4.&1 property option is used in the C1&US 3ierarchy !4esulfuration section". The 2'-S property option is used in the )36 3ierarchy !the previous step of (ethanation". The --2( property option is used in the ower Generation section. The enthalpy model for C+&1? 2I+(&SS and C+&1&S3 is 3C+&1G.) and the density model for all components is 4C+&1IGT. The 3C+&1G.) model includes a number of empirical correlations for heat of combustion? heat of formation and heat capacity. 0ou can select one of these correlations by specifying an option code in the roperties D &dvanced D )C rops form The table below lists the specifications for this model$

C(A# Model Parameter 3eat of Combustio n Code -alue 9 Correlation 2oie correlation 9 Code -alue

'I(MA)) Correlation The same as Code -alue 9

C(A#A), Correlation The same as

.nthalpy

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Standard 3eat of 5ormation 3eat Capacity .nthalpy 2asis

9 9

3eat-ofcombustionbased correlation Eirov correlation .lements in their standard states at *B>.9;E and 9 atm

9 9 those for C+&1

9 9

those for C+&1

The density method 4C+&1IGT is specified on the roperties D &dvanced D )C rops form. This model is based on equations from IGT !Institute of Gas Technology". The Aspen Properties User Guide, Chapter 6 gives more details on this.

. C!emical /eactions
The chemical reactions in this process are very comple@. This model uses a relatively simple approach to represent the reactions. There are some reactions of by-products in this model. The reactors are modeled with the built-in models -Stoic? -.quil and -Gibbs. -eactions in each reactor and their specifications in the &spen lus model are listed as follows$

5.1

Coal Gasification 'ase Component

.eactions in the C/M0 1.Stoic2 %loc3 /0n )peci&ication 1o2 type )toic!iometry
C+&1--F 3*+8+ *8)*8C!Cisolid"8 9 * 5rac. Conversion 5rac. Conversion C+&1&S38S-S!Cisolid"8C1 *83* 2I+(&SS --F3*8+ *8)*8C!Cisolid"8 C+&1&S38S-S!Cisolid"8C1 *83*

Fraction

A.B; 9

C+&1 2I+(&SS

.eactions in C/S45D. 1.Stoic2 %loc3 /0n )peci&ication 1o2 type )toic!iometry

9 5rac. Conversion C+S 8 3*+ --F C+* 8 3*S

Fraction
A.B

'ase Component
C+S

Coal gasification is modeled using the Gibbs free energy minimi%ation method in the -Gibbs model named G&SI5I.-. The option G-Gibbs considers all components as products in roducts sheetH is selected so the model can determine the phase of each of the products as fluid or solid based on their properties. )ote$ The component yield of the coal decomposition product depends on the coal U1T&)&1 attributes? not on the yield specification. Calculator bloc#s 2C+),-T and CC+),-T set up the appropriate coefficients to establish the yield. Pro rietar& 'nfor#ation of As en(ech )nauthori*e+ +u lication or +istri%ution rohi%ite+ without rior written er#ission

5.2

Desulfuration 'ase Component

+* +*

.eactions in 0).6!. 1.Stoic2 %loc3 /0n )peci&ication 1o2 type )toic!iometry

Fraction
A.<; 9

9 5rac. Conversion 3*S 8 A.; +* --F 3*+ 8 S * 5rac. Conversion 3*S 8 9.; + * --F +*S 8 3*+ In this model? 3*S are converted to S and S+ *? and finally S will become Sulfur.

5.3

Power Generation 'ase Component

9 9 C+ 3*

.eactions in the C/M07A 1.Stoic2 %loc3 /0n )peci&ication 1o2 type )toic!iometry
9 * 5rac. Conversion 5rac. Conversion C+ 8 A.; + * --F C+* 3* 8 A.; +* --F 3*+

Fraction

.eactions in the 0).6!. 1.Stoic2 %loc3 /0n )peci&ication 1o2 type )toic!iometry
9 5rac. Conversion C37 8 * +* --F C+* 8 * 3*+

Fraction
9

'ase Component
C37

&t very high temperature? it is assumed that components 3 *? C+ and C37 burn completely.

5.4

WGS

.eactions in S4,( 1.!8uil2 an+ S4,(2 1.!8uil2 %loc3s /0n 1o2 )peci&ication type )toic!iometry
9 Temp. approach C+ 8 3*+ I--F C+* 8 3*

(he water -as shift 1WGS2 reactor con9erts #ost of the C/ containe+ in the s&n-as into C/2 an+ 42 5.5 Methanation

.eactions in the M!(4A6:. 1.!8uil2 %loc3 /0n 1o2 )peci&ication type )toic!iometry
9 Temp. approach C+ 8 6 3* I--F 3*+ 8 C37

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3 )imulation Approac!es
Unit Operations J The maKor unit operations are represented by &spen lus models as shown in the following table !e@cludes reactor units"$

Aspen Plus $nit (peration Models $sed in t!e Model $nit (peration
Coal Si%ing &ir Separation Coal Gasification Syngas Clean-up 4esulfuration ower Generation (ethanation 'GS )36

Aspen Plus Model

Crusher? Screen? (i@er 5lash*? Sep? Compr? 3eat/? (3eat/? -ad5rac? 3eater -Stoic? -Gibbs? 3eat/? Sep? (i@er? 5lash*? 3eater -ad5rac? 5lash*? 3eat/? Sep? Compr? 3eater -Stoic? -Gibbs? 5lash* Compr? (i@er? 3eater? 5lash*? 3eat/? ump (i@er? -.quil -.quil? 5lash*? 3eat/? -ad5rac -Gibbs? 3eat/? Sep? (i@er? 3eater? 5lash*

Comments 4 )peci&ications
-educe coal particle si%e Separate &ir into +@ygen and )itrogen 4ecompose coal to produce coal gas

-emove the corrosive components from the raw syngas -emoval of the Sulfur Generate electrical power by utili%ing the coal gas roduce (ethane Convert the carbon mono@ide to carbon dio@ide? and then capture carbon dio@ide. roduce ammonia

Streams - Streams represent the material and energy flows in and out of the process. 5or the nonconventional solid components in the coal feed stream 5..4C+&1? the specification of S4 and component attributes is required. The values used are$ S4 Specification$

Inter"al 1 2 3 4 5 6 7 < = 1; ; 2; 4; 6; <; 1;; 12; 14; 16; 1<;

#o er limit 2; 4; 6; <; 1;; 12; 14; 16; 1<; 2;;

$pper limit

%eig!t &raction ;.1132361< ;.;421=6<5 ;.;5==123= ;.;=6<2=33 ;.145=255 ;.1;7=1== ;.;523;56 ;.;45<6571 ;.;5<4=37 ;.277314<4

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<

Component &ttributes$

P/(5A1A#
Element MOISTURE FC VM ASH ' ' ' Value 9.535 50.909191 4 39.451!#1 ! 9.6390&69 4 ' ' ' Element ASH CARBO

$#TA1A#
Value 9.66 !4.455 4.955 1.5&5 0.065 #.44 6.&4 ' ' ' '

)$#FA1A#
Element PYRITIC SU"FATE OR%A IC Value 100 0 0 ' ' ' '

HY$RO%E ITRO%E CH"ORI E SU"FUR O(Y%E

Design-Specs, Calculator Blocks and Con ergence - The simulation is augmented with a combination of flowsheeting capabilities such as Convergence? 4esign Specs and Calculator 2loc#s. The following tables outlines the #ey flowsheeting capabilities used in this model$ Design6)pecs $sed in t!e IGCC Model

)pec 1ame
&SU-4S-9 G&S5--CSC25' G&S5-- -SC25'

)pec 7Target8
Sets the 3eat-4uty of stream ).T-4UT0 to A 'att Sets the temperature of stream CSCS0)9 to =AA 5 Sets the temperature of stream 2 to 97AA 5

Manipulated -aria9les
3/-* hot temperature CSC925' mass flow -&4-25' mass flow

Calculators $sed in t!e IGCC Model

,iearac!y 1ame Purpose 7Calculator name8

SILI)G ! C-S149" &SU !C++1&)T" &SU !5-9" &SU !3U(I4IT0" G&S5!2C+),-T" G&S5!CC+),-T" C1&US !&I-5..4" 'GS !ST.&(" Sets the value of water stream to corresponding to solid stream Sets the temperature of streams with the same value of TC'9 Specify the pressure of TU-2-9? ,&1,.-9 and ,&1,.-6 Sets the water flow and temperature according to stream &I--&. (odify the stoichiometric coefficient of each component in reaction *. (odify the stoichiometric coefficient of each component in reaction 9. Sets the flow of stream 2U-)&I- to corresponding to flow of 3 *S Sets the flow of 3*+ in stream S0)G&S equal with the flow of C+ in stream ST.&(

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: )imulation /esults
The &spen lus simulation main flowsheet is shown in 5igure *.

Figure 22 IGCC Flo s!eet in Aspen Plus

)o errors occur in the simulation. 'arnings occur due to physical property parameters C and 5ree%e oint of carbon being outside the normal range. Eey simulation results are shown in the following table$ Eey Stream Simulation -esults$

Main Flo s!eet -aria9le

Coal 5eed 'ater for crushing +* for Gasification &ir for Separation &ir for Combustion -&4-25' 'ater for 'ater-gas-shift 'ater for (ethanation Sulfur (ethane &mmonia ower

-alue
*==769 97B6>< *76>7A 9A;6976 *BB69=; 79AAAA 6A6;* 9>A9; 9=7= 99>*= 6<*; 77=AA6

$nit
lbMhr lbMhr lbMhr lbMhr lbMhr lbMhr lbMhr lbMhr lbMhr lbMhr lbMhr hp

5eed

roduct

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1;

Eey rocess Simulation results$

Process -aria9le
Coal (oisture before entering into Gasification furnace Coal article Si%e Gasification 5urnace Temperature Combuster Temperature &irMfuelgas mole -atio in combustor

-alue
77.>C >AC of coal I 9*A 97;9 96B; <.>7

$nit

mu ) )

; Conclusions
The IGCC model provides a useful description of the process. The simulation ta#es advantage of &spen lusNs capabilities for modeling solid components. This includes trac#ing component attributes and particle si%e distribution? and estimating properties for coal. It also produces (ethane? Sulfur and &mmonia as by-products. The model may be used as a guide for understanding the process and the economics? and also as a starting point for more sophisticated models for plant design and specifying process equipment.

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11