Performance of an IGCC Plant with Carbon Capture and Coal-CO2-Slurry Feed: Impact of Coal Rank, Slurry Loading, and Syngas Cooling Technology

The high heat capacity and latent enthalpy of vaporization of water lead to a low gasification efficiency in gasifiers fed with coal-water slurry. Liquid carbon dioxide, CO2(1), has been suggested as an alternative slurrying medium to improve the efficiency of low-rank coal gasification in integrated gasification combined cycle power plants with carbon capture. Steady-state process simulation is used in this work to confirm published findings and present a comprehensive assessment of the impact of the coal rank, gasifier cooling technology, and CO2 slurry loading uncertainty on the performance advantage of CO2 slurry-fed plants. A power generation efficiency improvement of up to 25% (5%-points) is predicted, which is shown to increase with decreasing coal rank and to be highest for full-quench gasifier cooling technology; the latter is a significant source of capital cost savings :and is especially attractive when combined with CO2 slurry feed. Using CO2(1) instead of water slurry reduces the performance penalty of low-rank coal gasification by half, thus substantially improving the feedstock flexibility of the plant. With a single exception, the performance benefit of coal-CO2 slurry was found to be outside the uncertainty range of the slurry loading, which is still one of the key unknowns of this alternative feed system.