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HomeMy WebLinkAboutThermal Energy Integrated Power Systems (TIPS) AK Coal 2008 append A$8 ThermoEnergyrpoiriOo Analysis of ThermoEnergy Integrated Power Systems in New Power Facilities Using Alaska Coals Interim Report Appendix A:Usibelli and CTL Modeling Flow Sheets and Stream Tables August 2008 Submitted by Alex Fassbender,Robert Henry,and Li Tao ThermoEnergy Corporation )Kane Industrial Drive Hudson,MA 01749 This work was sponsored by The Alaska Energy Authority Interim Draft Report Federal Grant Number FE M-833233301-0 August 22,2008 Appendix A:Usibelli and CTL Modeling Flowsheets and Stream Tables AIA:Usibelli Coal Power Plant,No Slurry,Dry Ash Flowsheet %%WCO2PMP W,''W,y :QCONV ;CHX y |;CO2PRODE.4 |FLUEL_y ¢y FLUE?FLUES FLUE6 |FLUE7_a LIQUI CONV CHX WATEROUT CONDNSR CO2PUMP }<-_________« W-O2NET Poe lS COMBUST FLUERECB FLUERECA ee SP SPE 02K ML fr War saa!a al -4 |02)WETW3W9|COoL4mayplorQ”Spb opn noergnal ong02G O2H eS O2I | COOLI COOL2 COOL2A COOL3 HPI TTT PL Ke > AWMIXSTAGEISTAGE2STAGE3STAGE4WH,|%-ee "|! BFW4 STM?STG TyenaLASTS STM|STM6 STM7-, :SH HP RHI :QSH 9%, W, |WPUMP BEW3 ox BEW2 <BFW 'CHX2 'OCHX2 PUMP % 59 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 AIB:Usibelli Coal Power Plant,No Slurry,Dry Ash Material Stream Table BFW1 Temperature F 79.6 Pressure psia 0.5 Vapor Frac 0 Mole Flow 21259.73 lobmol/hr ] Mass Flow.|b/hr 383000 Volume Flow 6155.754 cuft/hr Enthalpy - MMBtu/hr 2613.095 Density |b/cuft 62.218 Mass Flow.|b/hr H2O 383000 N2 0 O2 0 S 0 $O2 0 H2 0 Cc ¢) CO2 ¢) ARGON 0 FUEL 0 ASH 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 BFW2 BFW3 83.7 700 4000.14 4000.14 0 0 21259.73 21259.73 l l 383000 383000 6086.666 10996.01 3 -2607.4 =-2338.94 62.924 34.83] 383000 383000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 BFW4 CO2PROD COAL 700 107.7 4000.14 2200 1160.3 0 0 21259.73 =4922.285 0 1 383000 213485.38 118500 7 10996.01 7302.763 0 3 -2338.94 -804.091 34.83]29.234 89.087 383000 294.314 0 0 4055.163 0 0 60.159 0 0 0 0 0 341.364 0 0 0 0 0 0 0 0 2039.40.57 0 5 0 4793.812 0 0 0 118500 0 0 0 60 DECOM 59 1160.3 0.584 4124.92 9 118500 12375.7 4 -211.845 9.253 30810 711 19789.5 0 7939.5 FLUE1 2300 1160.3 l 31617.669 1.28E+06 819587.59 3 -4032.673 1.576 63836.42] 23203.122 344.235 0 1962.949 0 0 1.17E+06 27 430.626 0 7939.5 FLUE2 705 1160.3 l 31617.669 1.28E+06 336814.06 9 -4670.854 3.835 63836.421 23203.122 344.235 0 1962.949 0 0 1.17E+06 27430.626 0 7939.5 Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow.Ib/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density lb/cuft Mass Flow Ib/hr H20 N2 O2 SO2 CO2 ARGON ASH FLUES 120 1160.3 0.891 31617.6 1.29E+0 95087.7 4960.63 13.585 63836.4 23203.1 344.235 1962.94 1.17E+0 27430.6 7939.5 FLUES 120 1160.3 ] 28164.604 1.22E+06 94022.93 -4533.759 12.992 1684.024 23203.05 344.219 1953.235 1.17E+06 27429.5 0 FLUE7 120 1160.3 l 4922.285 213485.38 16432.245 -792.358 12.992 294.314 4055.163 60.159 341.364 2039 40.57 4793.812 0 FLUERECA 120 1160.3 1 23242.319 1.01E+06 77590.687 -3741.401 12.992 1389.71 19147.894 284.06 1611.871 962977.90 22635.688 0 61 FLUERECB 120 1160.3 ] 23234.632 1.01E+06 77523.887 -3743.73] 13.003 1256.514 18887.314 282.698 1489.445 96384 1.08 22290.07 0 O2A 59 14.7 1 5147.248 165215.83 1.95E+06 -0.666 0.085 0 3604.808 156470.4 0 0 5140.556 0 O2B O2C 233.9 80 35.5 35.5 1 1 9147.248 5147.248 165215.83 165215.83 1.08E+06 837882.81 5.638 0.057 0.153 0.197 0 0 3604.808 3604.808 156470.4 156470.4 0 0 0 0 5140.556 5140.556 0 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O2D 261.5 85.73 ] 5147.248 165215.83 464231 .36 3604.808 156470.4 0 0 5140.556 0 O2E O2F O2FB O2G O2H 02!O23)O2K PUMPIN Temperature 80 261.8 80 262.1]80 161 80 161 74 F Pressure 85.73 207.04 207.04 500 500 761.58 761.58 1160 1160.3 psia Vapor Frac ]1 ]]1 ]1 ]0 Mass Flow 165215.83 165215.83 165215.83 165215.83 165215.832 165215.832 165215.832 165215.832 213485.387 lb/hr Volume Flow 345899.74 192091.52 142214.64 80041.958 57963.285 44797.904 37586.094 29422.607 5824.599 cuft/hr Enthalpy -0.014 6.526 -0.183 6.402 -0.584 2.36 -0.93 2.043 -805.49| MMBtu/hr Density 0.478 0.86 1.162 2.064 2.85 3.688 4.396 5.615 36.652 lb/cuft Mass Flow lb/hr H20 0 0 0 0 0 0 0 0 294.314 N2 3604.808 3604.808 3604.808 3604.808 3604.808 3604.808 3604.808 3604.808 4055.163 O2 156470.46 156470.46 156470.46 156470.46 156470.46 156470.46 156470.46 156470.46 60.159 $O2 0 0 0 0 0 0 0 0 341.364 CO2 0 0 0 0 0 0 0 0 203940.5 ARGON 5140.556 5140.556 5140.556 5140.556 5140.556 5140.556 5140.556 5140.556 4793.812 62 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 STM2 STM3 STM4 STM5 STM6é STM7 WAT Temperature F 1350 700.1 1400 618.9 1400 375.6 120 Pressure psia 4000.14 437.72 437.72 27.12 27.12 0.5 1160.3 Vapor Frac ]]1 1 ]]0 Mass Flow |b/hr 383000 383000 383000 383000 383000 383000 70230.445 Volume Flow cuft/hr 96129.069 574969.129 962791.652 9.04E+06 1.56E+07 3.81E+08 1064.496 Enthalpy -1998.213 -2110.34 -1964.174 -2116.82 ---426.87] MMBtu/hr 1961.807 2160.117 Density |b/cuft 3.984 0.666 0.398 0.042 0.024 0.001 65.975 Mass Flow !b/hr H20 383000 383000 383000 383000 383000 383000 62152.397 N2 0 0 0 0 0 0 0.065 O2 0 0 0 0 ¢)0 0.016 SO2 0 0 0 0 0 0 9.714 CO2 0 0 0 0 0 0 127.627 ARGON 0 0 0 0 0 0 1.126 ASH 0 0 0 0 0 0 7939.5 63 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 AIC:Usibelli Coal Power Plant,No Slurry,Dry Ash Heat Stream Table QCHX QCHX2 QCONV QRH1 QRH2 QSEP QSH QCALC 288070035 268459894 641907877 146166336 155013816 74184731 340727725 Btu/hr TBEGIN F 704.986365 83.6865015 2300.00008 700.115047 618.887548 59 700 TEND F 120 700 704.986365 1400 1400 59 1350 AID:Usibelli Coal Power Plant,No Slurry,Dry Ash Work Stream Table W-HP W-IP W-LP W-NET W-O2NET Wl W2 W3 POWER -32861.307 -44736.323 -58118.982 -135716.61 9539.59309 1885.39499 1959.58879 1955.76238 kw Ww4 W5 W6é WCO2PMP WPUMP POWER 1969.177 880.430067 889.239861 410.529796 1669.06651 kw 64 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 AIE:Usibelli Coal Power Plant,No Slurry,Dry Ash Block Input STAGE 1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL! Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson 65 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 3 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL2B Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 4 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) 66 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL3 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL4 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HpP2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 67 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson W-O2MIX Model:Mixer Property Method =Peng -Robinson SEP Model:RYield Pressure =80 bar Temperature =59F Yield: Component Basis Yield H20 Mass 0.26 Cc Mass 0.468 O2 Mass 0.167 N2 Mass 0.006 H2 Mass 0.03 S Mass 0.002 Ash Mass 0.067 Property Method =Peng -Robinson COMBUST Model:RStoic Pressure =80 bar Combustion:Generate Combustion Reactions selected Property Method =Peng -Robinson 68 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONV Model:Heater Pressure Drop =0 bar Heat Duty =-926000000 Btu/hr (Initial Guess,Actual value nailed down in design spec) Property Method =Peng -Robinson CHX Model:Heater Temperature =120F Pressure Drop =0 bar Property Method =Peng -Robinson WATEROUT Model:FLASH2 Pressure Drop =0 bar Heat Duty =0 Btu/hr Property Method =Peng -Robinson FLUESPLT Model:FSplit FlueRecA SplitFraction =0.5 (Fraction of Inlet Stream going to this outlet stream)(Actual value determined by design spec) Property Method =Peng -Robinson CONDNSR Model:Heater Temperature =74F Pressure Drop =0 bar Property Method =Peng -Robinson CO2ZPUMP Model:Pump Discharge Pressure =2200 psia 69 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Pump Efficiency =0.8 Valid Phases =Liquid Only Property Method =Peng -Robinson SH2 Model:Heater Temperature =1350F Pressure Drop =0 bar Property Method =STEAMNBS HP Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Isentropic Efficiency =0.9 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH1 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS IP Model:Turbine Discharge Pressure =30.18 bar Isentropic Efficiency =0.9301 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS 70 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 RH2 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS LP Model:Turbine Discharge Pressure =0.5 psi Isentropic Efficiency =0.9414 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS WMIX Model:Mixer Pressure Drop =0 psi Property Method =STEAMNBS COND Model:Heater Vapor Fraction =0 (bubble point) Pressure Drop =0 bar Property Method =STEAMNBS PUMP Model:Pump Discharge Pressure =275.8 bar Pump Efficiency =0.8 Property Method =STEAMNBS CHX2 Model:Heater 71 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature =700F Pressure Drop =0 bar Property Method =STEAMNBS 72 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 AIF:Usibelli Coal Power Plant,No Slurry,Dry Ash Design Specs BFW4T Purpose:To set BF W3 Temp equal to BF W4T temp in the Rankine Cycle. Defined Variables: BFW4T:Stream-Var Stream=BFW4 Substream=MIXED Variable=TEMP Units=F WTR3T:Stream-Var Stream=BFW3 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:BFW4T Target:WIR3T Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:BFW4 Substream:Mixed Variable:Temp Units:F Manipulated Variable Limits Lower =300 Upper =1100 QCONV Purpose:To balance convective heat from combustion with superheat and reheats in Rankine Cycle. Defined Variables: QCONV:Heat-Duty Stream=QCONV Units=Btu/hr QSH:Heat-Duty Stream=QSH Units=Btu/hr QRH1:Heat-Duty Stream=QRH1 Units=Btu/hr QRH2?:Heat-Duty Stream=QRH2 Units=Btu/hr Design Specification Expressions Spec:QCONV 73 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Target:-QSH-QRH1-QRH2 Tolerance:.01 Manipulated Variable Type:Block-Var Stream:CONV Variable:Duty Units:Btu/hr Manipulated Variable Limits Lower =-1E9 Upper =-1 RECSPLT Purpose:To set recycle A and recycle B's flowrates equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=MASS-FLOW Units=lb/hr RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=MASS-FLOW Units=|b/hr Design Specification Expressions Spec:RECA Target:RECB Tolerance:.01 Manipulated Variable Type:Block-Var Stream:FLUESPLT Variable:FLOW/FRAC ID1:FLUERECA Manipulated Variable Limits Lower =0 Upper =1 RECYC Purpose:To set furnace outlet temperature to 2300 for dry ash combustion. Defined Variables: 74 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 FLUEIT:Stream-Var Stream=FLUE1 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:FLUEIT Target:2300 Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =1 Upper =2E6 RECYCT Purpose:To set recycle A and recycle B's temperatures equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=TEMP Units=F RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:RECB Target:RECA Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:TEMP Units:F Manipulated Variable Limits Lower =100 75 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Upper =400 XSO2 Purpose:To set excess oxygen in flue gas equal to 0.22%(Mass Fraction). Defined Variables: FLUEO?2:Mass-Flow Stream=FLUE1 Substream=MIXED Component=O2 Units=lb/hr O2IN:Mass-Flow Stream=O2A Substream=MIXED Component=O2 Units=lb/hr Design Specification Expressions Spec:FLUEO2 Target:0.0022*O2IN Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:O2A Substream:Mixed Variable:MASS-FLOW Units:lb/hr Manipulated Variable Limits Lower =100000 Upper =1E8 76 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 AIG:Usibelli Coal Power Plant,No Slurry,Dry Ash Block Results Summaries STAGE1 Compressor model:ASME polytropic Phase calculations:Vapor Phase Calculations Indicated horsepower:1847.68709 kW Brake horsepower:1885.39499 kW Net work required:1885.39499 kW Power loss:37.7078998 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:35.5001325 psia Outlet temperature:233.933136 F Isentropic outlet temperature:206.680466 F Vapor fraction:1 COOL! Outlet Temperature =80F Outlet Pressure =35.5001325 psia Vapor Fraction =1 Net Duty =-5580931.8 Btu/hr STAGE2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1920.39702 kW Brake horsepower:1959.58879 kW Net work required:1959.58879 kW Power loss:39.1917758 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:85.7319325 psia 77 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:261.515919 F Isentropic outlet temperature:233.409649 F Vapor fraction:1 COOL2 Outlet Temperature =80F Outlet Pressure =85.7319325 psia Vapor Fraction =1 Net Duty =-6623433.4 Btu/hr STAGE3 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1916.64713 kW Brake horsepower:1955.76238 kW Net work required:1955.76238 kW Power loss:39.1152475 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:207.040474 psia Outlet temperature:261.828378 F Isentropic outlet temperature:233.996708 F Vapor fraction:1 COOL2B Outlet Temperature =80F Outlet Pressure =207.040474 psia Vapor Fraction =1 Net Duty =-6709445.8 Btu/hr STAGE4 Compressor model:ASME polytropic 78 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Phase calculations:Vapor phase calculation Indicated horsepower:1929.79346 kW Brake horsepower:1969.177 kW Net work required:1969.177kW Power loss:39.38354 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:499.997568 psia Outlet temperature:262.088092 F Isentropic outlet temperature:234.572335 F Vapor fraction:1 COOL3 Outlet Temperature =80F Outlet Pressure =499.997568 psia Vapor Fraction =1 Net Duty =-6985635.6 Btu/hr HP1 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:862.821465 kW Brake horsepower:880.430067 kW Net work required:880.430067 kW Power loss:17.6086013 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:761.576295 psia Outlet temperature:160.978009 F Isentropic outlet temperature:149.664612 F Vapor fraction:1 79 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL4 Outlet Temperature =80F Outlet Pressure =761.576295 psia Vapor Fraction =1 Net Duty =-3290238.6 Btu/hr HpP2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:871.455064 kW Brake horsepower:889.239861 kW Net work required:889.239861 kW Power loss:17.7847972 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:1160.00255 psia Outlet temperature:160.970735 F Isentropic outlet temperature:149.91226 F Vapor fraction:1 SEP Outlet Temperature =59 F Outlet Pressure =1160.3019 psia Net Heat Duty =74184731.2 Btuw/hr Vapor Fraction =0.58372459 COMBUST Outlet Temperature =2300.00008 F Outlet Pressure =1160.3019 psia Net Heat Duty =-74184731.2 Btu/hr 80 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONV Outlet Temperature =704.986365 F Outlet Pressure =1160.3019 psia Heat Duty =-641907877 Btu/hr CHX Outlet Temperature =120 F Outlet Pressure =1160.3019 psia Heat Duty =-288070035 Btu/hr Vapor Fraction =0.8907869 WATEROUT Outlet Temperature =119.999495 F Outlet Pressure =1160.3019 psia Heat Duty =0 Btu/hr Vapor Fraction =0.8907869 FLUESPLT FLUE7 0.17476849 2 FLUERECA 0.82523152 1 CONDNSR Outlet Temperature =74 F Outlet Pressure =1160.3019 psia Heat Duty =-13133238 Btu/hr Vapor Fraction =0 CO2PUMP Fluid Power =328.423836 kW Brake Power =410.529796 kW 81 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Electricity =410.529796 kW Volumetric Flow Rate =5824.59926 cuft/hr Pressure Change =1039.6981 psi NPSH available =109.95886 ft-lbf/lb Head Developed =4084.7702 ft-lbf/lb Pump Efficiency Used =0.8 Net Work Required =410.529796 kW SH2 Outlet Temperature =1350 F Outlet Pressure =4000.1408 psia Heat Duty =340727725 Btu/hr Vapor Fraction =1 HP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-32861.307 kW Brake horsepower:-32861.307 kW Net work required:-32861.307 kW Power loss:0 kW Efficiency:0.9 Mechanical efficiency:1 Outlet pressure:437.723892 psia Outlet temperature:700.115047 F Isentropic outlet temperature:642.322373 F Vapor fraction:1 RH1 Outlet Temperature =1400 F Outlet Pressure =437.723892 psia Heat Duty =146166336 Btu/hr 82 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Vapor Fraction =1 IP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-44736.323 kW Brake horsepower:-44736.323 kW Net work required:-44736.323 kW Power loss:0 kW Efficiency:0.9301 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:618.887548 F Isentropic outlet temperature:557.072526 F Vapor fraction:1 RH2 Outlet Temperature =1400 F Outlet Pressure =27.1220569 psia Heat Duty =155013816 Btw/hr Vapor Fraction =1 LP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-58118.982 kW Brake horsepower:-58118.982 kW Net work required:-58118.982 kW Power loss:0 kW Efficiency:0.9414 Mechanical efficiency:1 Outlet pressure:0.5 psia 83 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:375.603099 F Isentropic outlet temperature:305.542816 F Vapor fraction:1 COND Outlet Temperature =79.556157 F Outlet Pressure =0.5 psia Heat Duty =-452978554 Btu/hr Vapor Fraction =0 PUMP Fluid Power =1335.25321 kW Brake Power =1669.06651 kW Electricity =1669.06651 kW Volumetric Flow Rate =6155.7542 cuft/hr Pressure Change =3999.6408 psi NPSH available =0 ft-lbf/lb Head Developed =9256.90844 ft-Ibf/lb Pump Efficiency Used =0.8 Net Work Required =1669.06651 kW CHX2 Outlet Temperature =700 F Outlet Pressure =4000.1408 psia Heat Duty =268459894 Btu/hr Vapor Fraction =0 84 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A2A:Usibelli Coal Power Plant,No Slurry,Slagging Flowsheet WCO2PMPy CO2PRODFLUE6FLUE7LIQUI>Q CONDNSR-(CQ2PUMPWATEROUT| FLUERECAW,02MIX - JET |lg OOwlV-O2NET|' WAT mi |73 |W-NET y,|2)W3 |w4 (OMET 1 O2A 02B AS ro gS Oe 02G O2 O21 TTT TA erCOOLICOOL2COOL2ACOOL3HP1AWMIXSTAGE1STAGE2STAGE3STAGE4WHE%|%|W-LP QRHI WIP 'orn ||||| BFW4 >STM?sis iSTM4 STS STM6 STM7:SH HP RHI IP RH2 LP :QSH % ai |WPUMP BEW3 BEW2 l <BEWI |CHX2 'OCHX2 PUMP % 85 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A2B:Usibelli Coal Power Plant,No Slurry,Slagging Material Stream Table Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow Ib/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density |b/cuft Mass Flow {b/hr H20 N2 ARGON PROPANE CACO3 CASO3 FUEL BFW1 79.6 0.5 0 ] 383000 6155.754 6086.666 2613.095 62.218 383000 BFW2 BFW3 BFW4 83.7 700 700 4000.14 4000.14 4000.14 0 0 0 21259.73 21259.73 21259.73 21259.73 1 l | 383000 383000 383000 10996.01 10996.01 3 3 -2607.4 =-2338.94 -2338.94 62.924 34.831 34.83] 383000 383000 383000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 86 CO2PROD 108.1 2200 0 4840.065 209852.04 7185.076 -789.772 29.207 289.136 4106.209 59.259 0 341.345 0 0 0 200326.20 2 4729 89 0 0 0 0 COAL 1160.3 0 116500 1307.70 8 284.088 89.087 0 0 0 0 0 0 0 0 0 0 0 0 0 116500 DECOMP 59 1160.3 0.584 4055.31 116500 12590.88 ] -211.155 9.253 30290 699 19455.5 233 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 FLUE1 2700 1160.3 ] 26010.844 1.05E+06 770707.40 9 -3142.115 1.362 62484.658 19185.623 276.894 0 1604.604 0 0 0 936115.31 7 22100.71 0 0 0 0 FLUE2 7918 1160.3 | 26010.844 1.05E+06 299840.85 7 -3784.022 3.5 62484.658 19185.623 276.894 0 1604.604 0 0 0 936115.31 7 22100.71 0 0 0 0 ASH 0 0 0 0 0 0 7805.5 7805.5 7805.5 87 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lobmol/hr Mass Flow lb/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density _lb/cuft Mass Flow |b/hr H20 N2 O2 FLUES 120 1160.3 0.869 26010.84 4 1.05E+06 76648.3 4056.425 13.693 62484.6 19185.6 276.894 0 1604.604 0 0 0 936115.3 22100.71 FLUES 120 1160.3 1 226 14.37 5 980497.7 75600.89 7 3636.552 12.969 1350.94 19185.5 276.877 0 1594.876 0 0 0 935989.9 I 22099.6 FLUE7 120 1160.3 | 4840.06 x) 209852. 16180.5 6 -778.317 12.969 289.136 4106.20 9 59.259 0 341.345 0 0 0 200326. 2 4729 89 FLUEREC A 120 1160.3 1 17774.31 710645.7 59 420.33 8 2858.235 12.969 1061.804 15079 .34 9 217.618 0 1253.53] 0 0 0 735663.7 17369.7] 88 FLUEREC B 120 1160.3 1 17769.28 6 770645.7 59382.82 2860.036 12.978 960.952 14942.65 | 216.2 0 1139.092 0 0 0 736339.9 17046.90 8 O2A 59 14.7 1 5060.381 162427.5 1.91E+06 -0.655 0.085 0 3543.972 153829.8 oooo00+5053.802 O2B 233.9 35.5 l 5060.381 162427.5 1.06E+06 5.543 0.153 0 3543.972 153829.8 oooo0o0-5053.802 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O02C 80 35.5 l 5060.381 162427.58 4 8237 42.3 0.056 0.197 0 3543.972 153829.81 oOo0Co0005053.802 02D 261.5 85.73 1 5060.381 162427.58 4 456396.8 6.498 0.356 0 3543.972 153829.81 OOO0005053.802 PROPANE CACO3 CASO3 FUEL ASH 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 7805.5 0 0 0 0 0 0 89 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ooo0cooOo0o0O0Oo Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow Ib/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density -lb/cuft Mass Flow.Ib/hr H20 N2 O2 ARGON PROPANE O2E 80 85.73 1 5060.381 162427.5 340062.2 -0.013 0.478 0 3543.972 153829.8 oooo0o0o0-5053.802 0 O2F 261.8 207.04 1 5060.381 162427.5 188849.7 1 6.416 0.86 0 3543.972 153829.8 ooo000--5053.802 0 O2FB 80 207.04 1 5060.381 162427.5 139814.5 7 -0.18 1.162 0 3543.972 153829 .8 Oemeeweek.5053.802 0 O2G 262.1 500 l 5060.38] 162427.5 78691.13 8 6.294 2.064 0 3543.972 153829.8 oOooo0oo-5053.802 0 90 O2H 80 500 1 5060.381 162427.5 56985.07 4 -0.574 2.85 0 3543.972 153829.8 ooooo0>5053.802 0 02! 161 761.58 ] 5060.381 162427.5 44041.87 6 2.32 3.688 0 3543.972 153829.8 ooo0o0c00O->5053.802 0 O02) 80 761.58 | 5060.381 162427.5 36951.77 6 -0.914 4.396 0 3543.972 153829.8 oooo00>5053.802 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O2K 16] 1160 1 5060.381 162427.5 28926.06 2.009 5.615 0 3543.972 153829.8 ooooo0o--5053.802 0 PUMPIN 74 1160.3 0 4840.06 5 209852. 0 5754.05 -791.156 36.47 289.136 4106.20 9 59.259 0 341.345 0 0 0 200326. 2 4729.89 0 CACO3 CASO3 FUEL ASH 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 91 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 oOo00oooOo STM2 STM3 STM4 STM5 STM6 STM7 WAT Temperature F 1350 700.1 1400 618.9 1400 375.6 120 Pressure psia 4000.14 437.72 437.72 27.12 27.12 0.5 1160.3 Vapor Frac ]l 1 ]1 ]0 Mole Flow lomol/hr 21259.731 21259.731 =21259.731 =21259.731 21259.731 21259.731 3396.469 Mass Flow |b/hr 383000 383000 383000 383000 383000 383000 69075.544 Volume Flow cuft/hr 96129.069 574969.129 962791.652 9.04E+06 1.56E+07 3.81E+08 1047.03] Enthalpy -1998.213 -2110.34 -1964.174 -2116.82 -1961.807 -2160.117 -419.873 MMBtu/hr Density |b/cuft 3.984 0.666 0.398 0.042 0.024 0.001 65.973 Mass Flow,|b/hr H20 383000 383000 383000 383000 383000 383000 3=61133.718 N2 0 0 0 0 0 0 0.065 O2 0 0 0 0 0 0 0.016 S 0 0 0 0 0 0 0 SO2 0 0 0 0 0 0 9.727 H2 0 0 0 0 0 0 0 CL2 0 0 0 0 6)0 0 Cc 0 0 0 0 0 0 0 CO2 0 0 0 0 0 0 125.407 ARGON 0 0 0 0 0 0 1.1] PROPANE 0 0 0 0 0 0 0 CACO3 0 0 0.0 0 0 0 CASO3 0 0 ¢)0 0 0 0 FUEL 0 0 0 0 0 0 0 ASH 0 0 0 0 6)0 7805.5 92 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A2C:Usibelli Coal Power Plant,No Slurry,Slagging Heat Stream Table QCHX QCHX2 QCONV QRH1 QRH2 QSEP QSH QCALC 272402435 268459894 641907877 146166336 155013816 72932668 340727725 Btu/hr TBEGIN F 791.840289 83.6865015 2700 700.115047 618.887548 59 700 TEND F 120 700 79 |840289 1400 1400 59 1350 A2D:Usibelli Coal Power Plant,No Slurry,Slagging Work Stream Table W-HP W-IP W-LP W-NET W-O2NET WI W2 W3 POWER --32861.307 -44736.323 -58118.982 -135716.61 9378.5991 1853.5763 1926.51 1922.7561 kW 6 2 8 6 W5 W6é WCO2PMP WPUMP POWER 865.57158 874.23269 405.55734 1669.0665 kW 2 9 6 1 93 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 W4 1935.944 4 A2E:Usibelli Coal Power Plant,No Slurry,Slagging Block Input STAGE 1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOLI Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson 94 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 3 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL2B Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 4 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) 95 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL3 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL4 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HpP2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 96 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson W-O2MIX Model:Mixer Property Method =Peng -Robinson SEP Model:RYield Pressure =80 bar Temperature =59F Yield: Component Basis Yield H20 Mass 0.26 C Mass 0.468 O2 Mass 0.167 N2 Mass 0.006 H2 Mass 0.03 S Mass 0.002 Ash Mass 0.067 Property Method =Peng -Robinson COMBUST Model:RStoic Pressure =80 bar Combustion:Generate Combustion Reactions selected 97 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =Peng -Robinson CONV Model:Heater Pressure Drop =0 bar Heat Duty =-926000000 Btu/hr (Initial Guess,Actual value nailed down in design spec) Property Method =Peng -Robinson CHX Model:Heater Temperature =120F Pressure Drop =0 bar Property Method =Peng -Robinson WATEROUT Model:FLASH2 Pressure Drop =0 bar Heat Duty =0 Btu/hr Property Method =Peng -Robinson FLUESPLT Model:FSplit FlueRecA SplitFraction =0.5 (Fraction of Inlet Stream going to this outlet stream)(Actual value determined by design spec) Property Method =Peng -Robinson CONDNSR Model:Heater Temperature =74F Pressure Drop =0 bar Property Method =Peng -Robinson 98 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CO2PUMP Model:Pump Discharge Pressure =2200 psia Pump Efficiency =0.8 Valid Phases =Liquid Only Property Method =Peng -Robinson SH2 Model:Heater Temperature =1350F Pressure Drop =0 bar Property Method =STEAMNBS HP Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Isentropic Efficiency =0.9 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH1 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS IP Model:Turbine Discharge Pressure =30.18 bar Isentropic Efficiency =0.9301 99 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH2 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS LP Model:Turbine Discharge Pressure =0.5 psi Isentropic Efficiency =0.9414 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS WMIX Model:Mixer Pressure Drop =0 psi Property Method =STEAMNBS COND Model:Heater Vapor Fraction =0 (bubble point) Pressure Drop =0 bar Property Method =STEAMNBS PUMP Model:Pump Discharge Pressure =275.8 bar Pump Efficiency =0.8 Property Method =STEAMNBS 100 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CHX2 Model:Heater Temperature =700F Pressure Drop =0 bar Property Method =STEAMNBS 101 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A2F:;Usibelli Coal Power Plant,No Slurry,Slagging Design Specs BFW4T Purpose:To set BFW3 Temp equal to BFW4T temp in the Rankine Cycle. Defined Variables: BFW4T:Stream-Var Stream=BFW4 Substream=MIXED Variable=TEMP Units=F WTR3T:Stream-Var Stream=BFW3 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:BFW4T Target:WTR3T Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:BFW4 Substream:Mixed Variable:Temp Units:F Manipulated Variable Limits Lower =300 Upper =1100 QCONV Purpose:To balance convective heat from combustion with superheat and reheats in Rankine Cycle. Defined Variables: QCONV:Heat-Duty Stream=QCONV Units=Btu/hr QSH:Heat-Duty Stream=QSH Units=Btu/hr QRH1:Heat-Duty Stream=QRH1 Units=Btu/hr QRH2:Heat-Duty Stream=QRH2 Units=Btu/hr Design Specification Expressions Spec:QCONV Target:-QSH-QRH1-QRH2 Tolerance:.01 102 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Manipulated Variable Type:Block-Var Stream:CONV Variable:Duty Units:Btu/hr Manipulated Variable Limits Lower =-1E9 Upper =-1 RECSPLT Purpose:To set recycle A and recycle B's flowrates equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=MASS-FLOW Units=lb/hr RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=MASS-FLOW Units=Ib/hr Design Specification Expressions Spec:RECA Target:RECB Tolerance:.01 Manipulated Variable Type:Block-Var Stream:FLUESPLT Variable:FLOW/FRAC ID1:FLUERECA Manipulated Variable Limits Lower =0 Upper =1 RECYC Purpose:To set furnace outlet temperature to 2700 for slagging combustion. Defined Variables: FLUEIT:Stream-Var Stream=FLUE1 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions 103 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Spec:FLUE1T Target:2700 Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =1 Upper =2E6 RECYCT Purpose:To set recycle A and recycle B's temperatures equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=TEMP Units=F RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:RECB Target:RECA Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:TEMP Units:F Manipulated Variable Limits Lower =100 Upper =400 104 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 XSO2 Purpose:To set excess oxygen in flue gas equal to 0.18%(Mass Fraction). Defined Variables: FLUEO?:Mass-Flow Stream=FLUE1 Substream=MIXED Component=O2 Units=lb/hr O2IN:Mass-Flow Stream=O2A Substream=MIXED Component=O2 Units=lb/hr Design Specification Expressions Spec:FLUEO2 Target:0.0018*O2IN Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:O2A Substream:Mixed Variable:MASS-FLOW Units:lb/hr Manipulated Variable Limits Lower =100000 Upper =1E8 105 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A2G:Usibelli Coal Power Plant,No Slurry,Slagging Block Results Summaries STAGE1 Compressor model:ASME polytropic Phase calculations:Vapor Phase Calculations Indicated horsepower:1816.5048 kW Brake horsepower:1853.57632 kW Net work required:1853.57632 kW Power loss:37.0715265 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:35.5001325 psia Outlet temperature:233.933136 F Isentropic outlet temperature:206.680466 F Vapor fraction:1 COOLI Outlet Temperature =80F Outlet Pressure =35.5001325 psia Vapor Fraction =1 Net Duty =-5486745.8 Btu/hr STAGE2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1887.98764 kW Brake horsepower:1926.518 kW Net work required:1926.518 kW Power loss:38.53036 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:85.7319325 psia 106 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:261.515919 F Isentropic outlet temperature:233.409649 F Vapor fraction:1 COOL2 Outlet Temperature =80F Outlet Pressure =85.7319325 psia Vapor Fraction =1 Net Duty =-6511653.8 Btu/hr STAGE3 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1884.30104 kW Brake horsepower:1922.75616kW Net work required:1922.75616kW Power loss:38.4551232 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:207.040474 psia Outlet temperature:261.828378 F Isentropic outlet temperature:233.996708 F Vapor fraction:1 COOL2B Outlet Temperature =80F Outlet Pressure =207.040474 psia Vapor Fraction =1 Net Duty =-6596214.5 Btu/hr STAGE4 Compressor model:ASME polytropic 107 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Phase calculations:Vapor phase calculation Indicated horsepower:=1897.22551 kW Brake horsepower:1935.9444 kW Net work required:1935.9444 kW Power loss:38.7188879 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:499.997568 psia Outlet temperature:262.088092 F Isentropic outlet temperature:234.572335 F Vapor fraction:1 COOL3 Outlet Temperature =80F Outlet Pressure =499.997568 psia Vapor Fraction =1 Net Duty =-6867743.2 Btu/hr HP1 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:848.260151 kW Brake horsepower:865.571582 kW Net work required:865.571582 kW Power loss:17.3114316 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:761.576295 psia Outlet temperature:160.978009 F Isentropic outlet temperature:149.664612 F Vapor fraction:1 108 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL4 Outlet Temperature =80F Outlet Pressure =761.576295 psia Vapor Fraction =1 Net Duty =-3234711.3 Btu/hr HpP2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:856.748045 kW Brake horsepower:874.232699 kW Net work required:874.232699 kW Power loss:17.484654 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:1160.00255 psia Outlet temperature:160.970735 F Isentropic outlet temperature:149.91226 F Vapor fraction:1 SEP Outlet Temperature =59 F Outlet Pressure =1160.3019 psia Net Heat Duty =72932668.3 Btu/hr Vapor Fraction =0.58372459 COMBUST Outlet'Temperature =2700 F Outlet Pressure =1160.3019 psia Net Heat Duty =-72932668 Btu/hr 109 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONV Outlet Temperature =791.840289 F Outlet Pressure =1160.3019 psia Heat Duty =-641907877 Btu/hr CHX Outlet Temperature =120 F Outlet Pressure =1160.3019 psia Heat Duty =-272402435 Btu/hr Vapor Fraction =0.86942104 WATEROUT Outlet Temperature =119.999252 F Outlet Pressure =1160.3019 psia Heat Duty =0 Btu/hr Vapor Fraction =0.86942104 FLUESPLT FLUE7 0.21402603 2 FLUERECA 0.78597397 1 CONDNSR Outlet Temperature =74 F Outlet Pressure =1160.3019 psia Heat Duty =-12839022 Btu/hr Vapor Fraction =0 CO2PUMP Fluid Power =324.445877 kW Brake Power =405.557346 kW Electricity =405.557346 kW 110 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Volumetric Flow Rate =5754.05012 cuft/hr Pressure Change =1039.6981 psi NPSH available =93.6035259 ft-lbf/lb Head Developed =4105.16083 ft-lbf/lb Pump Efficiency Used =0.8 Net Work Required =405.557346 kW SH2 Outlet Temperature =1350 F Outlet Pressure =4000.1408 psia Heat Duty =340727725 Btu/hr Vapor Fraction =1 HP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-32861.307 kW Brake horsepower:-32861.307 kW Net work required:-32861.307 kW Power loss:0 kW Efficiency:0.9 Mechanical efficiency:1 Outlet pressure:437.723892 psia Outlet temperature:700.115047 F Isentropic outlet temperature:642.322373 F Vapor fraction:1 RHi1 Outlet Temperature =1400 F Outlet Pressure =437.723892 psia Heat Duty =146166336 Btu/hr Vapor Fraction =1 111 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 IP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-44736.323 kW Brake horsepower:-44736.323 kW Net work required:-44736.323 kW Power loss:0 kW Efficiency:0.9301 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:618.887548 F Isentropic outlet temperature:557.072526 F Vapor fraction:1 RH2 Outlet Temperature =1400 F Outlet Pressure =27.1220569 psia Heat Duty =155013816 Btu/hr Vapor Fraction =1 LP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-58118.982 kW Brake horsepower:-58118.982 kW Net work required:-58118.982 kW Power loss:0 kW Efficiency:0.9414 Mechanical efficiency:1 Outlet pressure:0.5 psia Outlet temperature:375.603099 F 112 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Isentropic outlet temperature:305.542816 F Vapor fraction:1 COND Outlet Temperature =79.556157 F Outlet Pressure =0.5 psia Heat Duty =-452978554 Btu/hr Vapor Fraction =0 PUMP Fluid Power =1335.25321 kW Brake Power =1669.06651 kW Electricity =1669.06651 kW Volumetric Flow Rate =6155.7542 cuft/hr Pressure Change =3999.6408 psi NPSH available =0 ft-Ibf/lb Head Developed =9256.90844 ft-lbf/lb Pump Efficiency Used =0.8 Net Work Required =1669.06651 kW CHX2 Outlet Temperature =700 F Outlet Pressure =4000.1408 psia Heat Duty =268459894 Btu/hr Vapor Fraction =0 113 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A3A:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Dry Ash Flowsheet W-H2OPMP %%WCO2PMP i QCONY =QCHX * FLUE].gy FLUE2.gv FLUES FLUE6 ©FLUE7.py LIQUIQ J.CO2PRODH20.4 OIN woruemP>WATEROUT CONDNSR =CQ2PUMP W,02 MIX COAL res :yV-O2NET |SEP QSEP FLUERECA wom ss Hata at W6bias HP2 wii H H 1 i 2)W-NETBOMNET %We W3 4 WS;COOLs ODA <preeO2B 02 O2FA Q2RRi__02G - COOLI Ccool2 COOL2A COOoL3 HPI ce }AWMIX t WLPSTAGE1STAGE2STAGE3STAGE4W-HP »*:{QRH 1 W-IP BFW4 >8 STM2 gSTM3 2 STM4LU STMS |STM6 det STM7 SH HP RHI IP RH2 LP :QSH A * {WPUMP BEW3 BEW2 BFW1 'CHX2 :QCHX2 PUMP % 114 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A3B:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Dry Ash Material Stream Table Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow lb/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density lb/cuft Mass Flow |b/hr H20 N2 O02 CO2 ARGON PROPANE 383000 BFW1 BFW2 79.6 83.7 0.5 4000.14 0 0 21259.73 21259.73 1 ] 6155.754 6086.666 --2607.4 2613.095 62.218 383000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 383000 62.924 383000 BFW3 700 4000.14 0 21259.73 ] 383000 10996.01 3 -2338.94 34.831 383000 0 ©BFW4 700 4000.14 0 21259.73 1 383000 10996.01 3 -2338.94 34.83] 383000 0 fo)ooo0o0o115 107.8 2200 0 5266.862 228413.50 ) 7814.75 -860.223 29.229 314.85 4347.09 73.309 0 341.575 0 0 0 218194.50 3 5142.178 0 CO2PROD COAL 1160.3 0 127055 1426.18 8 309.826 89.087 DECOMP 38.5 1160.3 0.329 7781 .287 18804] 14054.01 5 -652.943 13.38 94020.5 752.164 21248.63 3 188.041 0 3760.82 0 59420.95 6 0 0 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 FLUE1 2300 1160.3 1 32284.776 1.23E+06 836163.23 7 -3936.745 1.47] 128708.20 5 208 14.034 351.041 0 1654.06 0 0 0 1.04E+06 24623.1 0 FLUE2 706.4 1160.3 I 32284.776 1.23E+06 34099 1.99 7 -4578.653 3.606 128708.20 5 2081 4.034 351.041 0 1654.06 0 0 0 1.04E+06 24623.1 0 CACO3 0 0 0 0 0 0 0 0 0 CASO3 0 0 0 0 0 0 0 0 0 FUEL 0 0 0 0 0 127055 0 0 0 ASH 0 0 0 0 0 0 8649.886 8649.886 8649.886 116 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow.I|b/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density _Ib/cuft Mass Flow lb/hr H20 N2 O02 ARGON PROPANE FLUES 120 1160.3 0.781 32284.776 1.23E+06 86356.594 -4929.797 14.24] 128708.20 5 2081 4.034 351.041 0 1654.06 0 0 0 1.04E+06 24623.1 0 FLUE6 120 1160.3 1 25217.77 1.09E+06 84212.61 4058.733 12.987 1507.505 20813.90 2 351.002 0 1635.465 0 0 0 1.04E+06 24620.79 ] 0 FLUE7 120 1160.3 ] 5266.862 228413.50 17588.235 -847.687 12.987 314.85 4347.09 73.309 0 341.575 0 0 0 218194.50 3 5142.178 0 FLUERECA 120 1160.3 1 19950.915 865232.23 66624.379 -3211.046 12.987 1192.655 16466.812 277.694 0 1293.89 0 0 0 826522.56 9 19478.613 0 117 FLUERECB 120 1160.3 1 19943.184 865232.23 66551.242 -3213.19 13.001 1078.45 16210.739 280.947 0 1278.372 0 0 0 827252.44 3 19131.281 0 OOO000H2OIN 60 1160.3 0 3385.2 60986 974.28 1 417.08 62.596 60986 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 LIQUID 74 1160.3 0 9266.862 228413.50 6237.955 -861.723 36.617 314.85 4347.09 73.309 0 341.575 0 218194.50 3 5142.178 0 O2A 59 14.7 1 5498.968 176505.32 2.08E+06 -0.712 0.085 0 3851.13] 167162.37 1 0 0 0 0 0 0 5491.82 0 CACO3 CASO3 FUEL ASH 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8649 .886 0 0 0 0 0 0 118 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 OOO0oooOo Temperature F Pressure psia Vapor Frac Mole Flow lbmol/hr Mass Flow.{b/hr Volume Flow cuft/hr Enthalpy MMBitu/hr Density _Ib/cuft Mass Flow.|b/hr H2©O N2 O2 S SO2 H2 CL2 Cc CO2 ARGON PROPANE CACO3 CASO3 FUEL O2B 233.9 35.5 l 5498.968 176505.3 2 1.15E+06 6.023 0.153 0 3851.13] 167162.3 0 OnS=--O0000©NOoOOoO00O2C 80 35.5 1 5498.968 176505.3 2 895136.8 2 0.061 0.197 0 3851.13] 167162.3 0 NnS=--O0000[oe]NOoOo0002D 261.5 85.73 1 5498.968 176505.3 2 495953.1 ] 7.062 0.356 0 3851.13] 167162.3 0 wn6--O0000[ee]NoooooOO2E 80 85.73 ] 5498.968 176505.3 2 369535.6 8 -0.014 0.478 0 3851.13] 167162.3 O2F 261.8 207.04 1 5498.968 176505.3 2 205217.4 7 6.972 0.86 0 3851.13] 167162.3 Nn6--O00000©ONe]o0o0OoO2FB 80 207.04 1 5498.968 176505.3 2 151932.4 2 -0.196 1.162 0 3851.13] 167162.3 0 nn4--oOoO0000CoNooOO000O2G 262.1 500 ] 5498.968 176505.3 2 85511.36 7 6.839 2.064 0 3851.13] 167162.3 0 nS--O0000foe)NOooo0Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O2H 80 500 l 5498.968 176505.3 2 61924.01 9 -0.624 2.85 0 3851.13] 167162.3 0 NnS--O0000©NOoo0OoO21 16] 761.58 1 5498.968 176505.3 2 47859 .02 4 2.521 3.688 0 3851.13] 167162.3 nnS-- O0O00000©NOooo°o ASH 0 0 0 0 0 0 0 120 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow lb/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density !b/cuft Mass Flow lb/hr H20 N2 O2 S $O2 H2 CL2 Cc CO2 ARGON PROPANE CACO3 CASO3 O2J 80 761.58 1 5498.968 176505.3 40154.41 -0.994 4.396 0 3851.13] 167162.3 OOOOOONnnaw<OcoNOoO°O2K 16] 1160 1 5498.968 176505.3 31433.10 2.183 5.615 0 3851.13] 167162.3 OOOOOONNn&Se)OoNooOOoSTM2 1350 4000.14 1 21259.73 1 383000 96129.06 1998.213 3.984 383000 0 0 oOocoo000000STM3 700.1 437.72 1 STM4 1400 437.72 1 21259.73 =21259.73]1 1 383000 574969.1 2 -2110.34 0.666 383000 0 0 OROReeeemeReem)121 383000 96279 1.65 2 -1964.174 0.398 383000 oooOo0o00000STM5 618.9 27.12 ] 21259.73 =21259.73 =21259.73 ] 383000 9.04E+06 -2116.82 0.042 383000 oOoCoo000000STM6 1400 27.12 l I 383000 1.56E+07 3.81E+08 1961.807 2160.117 0.024 383000 0 0 ooo0000000Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 STM7 375.6 0.5 1 1 383000 0.001 383000 ooooo0o00000WAT 120 1160.3 0 7067 136132.81 6 2143.666 871.064 63.505 127200.7 0.132 0.038 261.155 2.3] 0 0 0 FUEL 0 0 0 0 0 0 0 0 0 ASH 0 0 0 0 0 0 0 0 8649.886 122 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A3C:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Dry Ash Heat Stream Table QCHX QCHX2 QCONV QRH]QRH2 QSEP QSH QCALC 351144160 -641907877 ---72794838 - Btu/hr 268459894 146166336 155013816 340727725 TBEGIN F 706.407556 83.6865015 2300.00054 700.115047 618.887548 81.9393748 700 TEND F 120 700 706.407556 1400 1400 38.5 1350 A3D:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Dry Ash Work Stream Table W-W-HP W-IP W-LP W-NET W-O2NET Wi W2 H2OPMP POWER 75.933116 32861.30 4473632 58118.98 1357166 10191.450 2014.2273 2093.4909 kW 4 7 3 2 1 4 7 6 123 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 W3 2089 .4030 8 A3E:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Dry Ash Block Input STAGE 1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOLI Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson 124 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 3 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL2B Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 4 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) 125 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL3 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL4 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 126 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson W-O2MIX Model:Mixer Property Method =Peng -Robinson H2O0PUMP Model:Pump Discharge Pressure =80 bar Pump Efficiency =0.8 Property Method =STEAMNBS SEP Model:R Yield Pressure =80 bar Temperature =38.5F Yield: Component Basis Yield H20 Mass 0.5 C Mass 0.316 O02 Mass 0.113 N2 Mass 0.004 H2 Mass 0.02 S Mass 0.001 Ash Mass 0.046 127 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =Peng -Robinson COMBUST Model:RStoic Pressure =80 bar Combustion:Generate Combustion Reactions selected Property Method =Peng -Robinson CONV Model:Heater Pressure Drop =0 bar Heat Duty =-926000000 Btu/hr (Initial Guess,Actual value nailed down in design spec) Property Method =Peng -Robinson CHX Model:Heater Temperature =120F Pressure Drop =0 bar Property Method =Peng -Robinson WATEROUT Model:FLASH2 Pressure Drop =0 bar Heat Duty =0 Btu/hr Property Method =Peng -Robinson FLUESPLT Model:FSplit FlueRecA SplitFraction =0.5 (Fraction of Inlet Stream going to this outlet stream)(Actual value determined by design spec) Property Method =Peng -Robinson 128 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONDNSR Model:Heater Temperature =74F Pressure Drop =0 bar Property Method =Peng -Robinson CO2PUMP Model:Pump Discharge Pressure =2200 psia Pump Efficiency =0.8 Valid Phases =Liquid Only Property Method =Peng -Robinson SH2 Model:Heater Temperature =1350F Pressure Drop =0 bar Property Method =STEAMNBS HP Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Isentropic Efficiency =0.9 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH1 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS 129 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 IP Model:Turbine Discharge Pressure =30.18 bar Isentropic Efficiency =0.9301 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH2 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS LP Model:Turbine Discharge Pressure =0.5 psi Isentropic Efficiency =0.9414 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS WMIX Model:Mixer Pressure Drop =0 psi Property Method =STEAMNBS COND Model:Heater Vapor Fraction =0 (bubble point) Pressure Drop =0 bar Property Method =STEAMNBS 130 | Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 PUMP Model:Pump Discharge Pressure =275.8 bar Pump Efficiency =0.8 Property Method =STEAMNBS CHX2 Model:Heater Temperature =700F Pressure Drop =0 bar Property Method =STEAMNBS 131 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A3F:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Dry Ash Design Specs BFW4T Purpose:To set BFW3 Temp equal to BF W4T temp in the Rankine Cycle. Defined Variables: BFW4T:Stream-Var Stream=BFW4 Substream=MIXED Variable=TEMP Units=F WTR3T:Stream-Var Stream=BFW3 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:BFW4T Target:WTR3T Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:BF W4 Substream:Mixed Variable:Temp Units:F Manipulated Variable Limits Lower =300 Upper =1100 QCONV Purpose:To balance convective heat from combustion with superheat and reheats in Rankine Cycle. Defined Variables: QCONV:Heat-Duty Stream=QCONV Units=Btu/hr QSH:Heat-Duty Stream=QSH Units=Btu/hr QRH1:Heat-Duty Stream=QRH1 Units=Btwhr QRH2:Heat-Duty Stream=QRH2 Units=Btwhr Design Specification Expressions Spec:QCONV Target:-QSH-QRH1-QRH2 Tolerance:.01 132 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Manipulated Variable Type:Block-Var Stream:CONV Variable:Duty Units:Btu/hr Manipulated Variable Limits Lower =-1E9 Upper =-1 RECSPLT Purpose:To set recycle A and recycle B's flowrates equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=MASS-FLOW Units=lb/hr RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=MASS-FLOW Units=Ib/hr Design Specification Expressions Spec:RECA Target:RECB Tolerance:.01 Manipulated Variable Type:Block-Var Stream:FLUESPLT Variable:FLOW/FRAC ID1:FLUERECA Manipulated Variable Limits Lower =0 Upper =1 RECYC Purpose:To set furnace outlet temperature to 2300 for dry ash combustion. Defined Variables: FLUEIT:Stream-Var Stream=FLUE1 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions 133 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Spec:FLUEIT Target:2300 Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:Mass-Flow Units:Ib/hr Manipulated Variable Limits Lower =1 Upper =2E6 RECYCT Purpose:To set recycle A and recycle B's temperatures equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=TEMP Units=F RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:RECB Target:RECA Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:TEMP Units:F Manipulated Variable Limits Lower =100 Upper =400 134 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 XSO2 Purpose:To set excess oxygen in flue gas equal to 0.21%(Mass Fraction). Defined Variables: FLUEO2:Mass-Flow Stream=FLUE1 Substream=MIXED Component=O2 Units=lb/hr O2IN:Mass-Flow Stream=O2A Substream=MIXED Component=O2 Units=lb/hr Design Specification Expressions Spec:FLUEO2 Target:0.0021*O2IN Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:O2A Substream:Mixed Variable:MASS-FLOW Units:lb/hr Manipulated Variable Limits Lower =100000 Upper =1E8 135 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A3G:Usibelli Coal Power Plant,50/50 Coal Water Slurry Block Results STAGE1 Compressor model:ASME polytropic Phase calculations:Vapor Phase Calculations Indicated horsepower:1973.94282 kW Brake horsepower:2014.22737 kW Net work required:2014.22737 kW Power loss:40.2845473 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:35.5001325 psia Outlet temperature:233.933136 F Isentropic outlet temperature:206.680466 F Vapor fraction:1 COOL!1 Outlet Temperature =80F Outlet Pressure =35.5001325 psia Vapor Fraction =1 Net Duty =-5962286.7 Btu/hr STAGE2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:2051.62114 kW Brake horsepower:2093.49096 kW Net work required:2093.49096 kW Power loss:41.8698192 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:85.7319325 psia 136 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:261.515919 F Isentropic outlet temperature:233.409649 F Vapor fraction:1 COOL2 Outlet Temperature =80F Outlet Pressure =85.7319325 psia Vapor Fraction =1 Net Duty =-7076024.3 Btu/hr STAGE3 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:2047.61502 kW Brake horsepower:2089.40308 kW Net work required:2089.40308 kW Power loss:41.7880616 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:207.040474 psia Outlet temperature:261.828378 F Isentropic outlet temperature:233.996708 F Vapor fraction:1 COOL2A Outlet Temperature =80F Outlet Pressure =207.040474 psia Vapor Fraction =1 Net Duty =-7167914.1 Btu/hr STAGE4 Compressor model:ASME polytropic 137 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Phase calculations:Vapor phase calculation Indicated horsepower:2061.65966 kW Brake horsepower:2103.73435 kW Net work required:2103.73435 kW Power loss:42.074687 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:499.997568 psia Outlet temperature:262.088092 F Isentropic outlet temperature:234.572335 F Vapor fraction:1 COOL3 Outlet Temperature =80F Outlet Pressure =499.997568 psia Vapor Fraction =1 Net Duty =-7462976.4 Btu/hr HP1 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:921.779583 kW Brake horsepower:940.591411 kW Net work required:940.591411 kW Power loss:18.8118282 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:761.576295 psia Outlet temperature:160.978009 F Isentropic outlet temperature:149.664612 F Vapor fraction:1 138 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL4 Outlet Temperature =80F Outlet Pressure =761.576295 psia Vapor Fraction =1 Net Duty =-3515066.5 Btu/hr HpP2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:931.00313 kW Brake horsepower:950.003194 kW Net work required:950.003194 kW Power loss:19.0000639 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:1160.00255 psia Outlet temperature:160.970735 F Isentropic outlet temperature:149.91226 F Vapor fraction:1 H2OPUMP Fluid Power =60.7464931 kW Brake Power =75.9331164 kW Electricity =75.9331164 kW Volumetric Flow Rate =977.746154 cuft/hr Pressure Change =1145.6019 psi NPSH available =33.367581 ft-lbf/lb Head Developed =2644.79597 ft-lbf/lb Net Work Required =75.9331164 kW 139 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 SEP Outlet Temperature =38.5 F Outlet Pressure =1160.3019 psia Net Heat Duty =72794837.9 Btu/hr Vapor Fraction =0.32855968 COMBUST Outlet Temperature =2300.00054 F Outlet Pressure =1160.3019 psia Net Heat Duty =-72794838 Btu/hr CONV Outlet Temperature =706.407556 F Outlet Pressure =1160.3019 psia Heat Duty =-641907877 Btu/hr CHX Outlet Temperature =120 F Outlet Pressure =1160.3019 psia Heat Duty =-351144160 Btu/hr Vapor Fraction =0.78110424 WATEROUT Outlet Temperature =119.999499 F Outlet Pressure =1160.3019 psia Heat Duty =0 Btu/hr Vapor Fraction =0.78110426 FLUESPLT FLUE7 0.20885511 2 FLUERECA 0.79114489 1 140 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONDNSR Outlet Temperature =74 F Outlet Pressure =1160.3019 psia Heat Duty =-14035682 Btu/hr Vapor Fraction =0 CO2PUMP Fluid Power =351.731148 kW Brake Power =439.663935 kW Electricity =439.663935 kW Volumetric Flow Rate =6237.9546 cuft/hr Pressure Change =1039.6981 psi NPSH available =107.5263 ft-Ibf/lb Head Developed =4088.74629 ft-Ibf/lb Pump Efficiency Used =0.8 Net Work Required =439.663935 kW SH2 Outlet Temperature =1350 F Outlet Pressure =4000.1408 psia Heat Duty =340727725 Btu/hr Vapor Fraction =1 HP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-32861.307 kW Brake horsepower:-32861.307kW Net work required:-32861.307 kW Power loss:0 kW Efficiency:0.9 141 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Mechanical efficiency:1 Outlet pressure:437.723892 psia Outlet temperature:700.115047 F Isentropic outlet temperature:642.322373 F Vapor fraction:1 RH1 Outlet Temperature =1400 F Outlet Pressure =437.723892 psia Heat Duty =146166336 Btu/hr Vapor Fraction =1 IP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-44736.323 kW Brake horsepower:-44736.323 kW Net work required:-44736.323 kW Power loss:0 kW Efficiency:0.9301 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:618.887548 F Isentropic outlet temperature:557.072526 F Vapor fraction:1 RH2 Outlet Temperature =1400 F Outlet Pressure =27.1220569 psia Heat Duty =155013816 Btu/hr Vapor Fraction =1 142 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 LP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-58118.982 kW Brake horsepower:-58118.982 kW Net work required:-58118.982 kW Power loss:0 kW Efficiency:0.9414 Mechanical efficiency:1 Outlet pressure:0.5 psia Outlet temperature:375.603099 F Isentropic outlet temperature:305.542816 F Vapor fraction:1 COND Outlet Temperature =79.556157 F Outlet Pressure =0.5 psia Heat Duty =-452978554 Btu/hr Vapor Fraction =0 PUMP Fluid Power =1335.25321 kW Brake Power =1669.06651 kW Electricity =1669.06651 kW Volumetric Flow Rate =6155.7542 cuft/hr Pressure Change =3999.6408 psi NPSH available =0 ft-lbf/lb Head Developed =9256.90844 ft-Ibf/Ib Pump Efficiency Used =0.8 Net Work Required =1669.06651 kW 143 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CHX2 Outlet Temperature =700 F Outlet Pressure =4000.1408 psia Heat Duty =268459894 Btu/hr Vapor Fraction =0 144 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A4A:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Slagging Flowsheet W-H2OP MP %%WCO2PMP y FQCONV =OCHX + ©O2PROD po.{ROI FLUE}FLUE7 LIQUID WATEROUT CONDNSRH20PUMP->£4 DECOMP CO2PUMP W.02MIX COAL ="yV-O2NET |SEP |FLUERECA aR Prep WAT hiige Wi "H W-NET W2i povcssssceeen ES Q2A i O2B 2. COOLI COOL2 COOL2A COOL3 HPI aeSTAGE1STAGE2STAGE3STAGE4W-HiP %%WLP BFW4 STD LgSTM3 /STM4 LOSTMS |STM6 oa sTM7 HP RH1sIP RH2 LP ' y {WPUMP BEW2 BEWI -_ PUMP 145 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A4B:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Slagging Material Stream Table Temperature F Pressure psia Vapor Frac Mole Flow lbmol/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Mass Flow |b/hr Density |b/cuft Mass Flow.lb/hr H20 N2 O2 S SO2 H2 CL2 Cc CO2 ARGON PROPANE CACO3 BFW1 BFW2 79.6 83.7 0.5 4000.14 0 0 21259.73 =21259.73 I l 6155.754 6086.666 --2607.4 2613.095 383000 383000 62.218 62.924 383000 383000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 BFW3 700 4000.14 0 21259.73 I 10996.01 3 -2338.94 383000 34.831 383000 ooO90000©}oooBFW4 700 4000.14 0 21259.73 l 10996.01 3 -2338.94 383000 34.83] 383000 ooooo0o00oOo©146 106 2200 0 4974.054 7368.646 -811.448 215649.33 2 29.266 296.961 4225.745 17.448 0 323.67 0 0 0 205759.10 4 5026.404 0 0 1160.3 0 0 12000 0 89.087 CO2PROD COAL DECOMP 60 1160.3 0.329 7349.23 13358.30 2 -611.014 177600 12.874 88800 710.4 20068.8 177.6 0 3552 0 6121.6 0 0 oO0 FLUE1 2700 1160.3 ] 2557 1.004 757090.76 9 -2925.875 947782.42 3 1.252 121295.88 5 16052.299 66.289 0 1247.166 0 0 0 781855.32 7 19095.857 0 0 FLUE2 705.3 1160.3 1 2557 1.004 268598.65 l -3562.732 947782.42 3 3.528 121295.88 5 16052.299 66.289 0 1247.166 0 0 0 781855.32 7 19095.857 0 0 CASO3 0 0 0 0 0 0 0 0 0 FUEL 0 0 0 0 0 12000 0 0 0 0 ASH 0 0 0 0 0 0 8169.6 8169.6 8169.6 147 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Mass Flow |b/hr Density |b/cuft Mass Flow |b/hr H20 N2 O2 S SO2 H2 CL2 C CO2 ARGON PROPANE CACO3 FLUES 120 1160.3 0.739 25571.004 65209.906 -3856.654 947782.42 14.526 121295.88 16052.299 66.289 0 1247.166 0 0 0 781855.32 7 19095.857 0 0 FLUES 120 1160.3 | 18894.741 63222.432 -3036.51 FLUE7 120 1160.3 1 4974.054 16643.349 -799 363 819178.58 215649.33 12.957 12.957 1128.053 296.961 1052.17 4225.745 66.28 17.448 0 0 1229.514 323.67 0 0 0 0 0 0 781608.97 205759.10 4 19093602 5026.404 0 0 0 0 FLUERECA 120 1160.3 l 13920.688 46579 .083 -2237.146 603529.25 12.957 831.092 11826.425 48.832 0 905.843 0 0 0 575849 .86 7 14067.198 0 0 148 FLUERECB 120 1160.3 1 13916.29 46547.935 -2238.094 603529.25 12.966 752.788 11705.73 49.027 0 892.339 0 0 0 §76218.79 4 13910.579 0 0 H20 59 14.7 0 3197.2 923.46 394.16 57600 62.374 57600 H2OIN 60 1160.3 0 3197.2 920.18 393.92 57600 62.596 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 LIQUID 73 1160.3 0 4974.054 5846.53] -812.854 215649 .33 36.885 296.96] 4225.745 17.448 205759.10 4 5026.404 0 0 O2A 59 14.7 ] 5192.028 1.96E+06 -0.672 166653.1 6 0.085 0 3636.169 157831.7 oOooo00>5185.278 0 0 149 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 oo Temperature F Pressure psia Vapor Frac Mole Flow lobmol/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Mass Flow.lb/hr Density -_|b/cuft Mass Flow,Ib/hr H20 N2 O2 CO2 ARGON PROPANE CACO3 CASO3 FUEL O2B 233.9 35.5 l 5192.028 1.09E+06 5.687 166653.1 6 0.153 0 3636.169 157831.7 O2C 80 35.5 od 5192.028 845172.1 7 0.058 166653.1 6 0.197 0 3636.169 157831.7 02D 261.5 85.73 l 5192.028 468270.0 5 6.667 166653.1 6 0.356 0 3636.169 157831.7 O2E 80 85.73 1 5192.028 348908.9 8 -0.014 166653.1 6 0.478 0 3636.169 157831.7 150 O2F 261.8 207.04 I 5192.028 193762.6 6 6.583 166653.1 6 0.86 0 3636.169 157831.7 O2FB 80 207.04 l 5192.028 143451.8 7 -0.185 166653.1 6 1.162 0 3636.169 157831.7 O2G 5192.028 80738.30 2 6.457 166653.1 6 2.064 0 3636.169 157831.7 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O2H 5192.028 58467.55 -0.589 166653.1 6 2.85 0 3636.169 157831.7 O2l 16] 761.58 1 5192.028 45187.63 4 2.381 166653.] 6 3.688 0 3636.169 157831.7 ASH 0 0 0 0 0 0 151 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lbmol/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Mass Flow lb/hr Density H2O N2 O02 CO2 ARGON PROPANE CACO3 lb/cuft Mass Flow Ib/hr O25 80 761.58 ] 5192.028 379 13.083 -0.938 166653.16 6 4.396 0 3636.169 157831.71 9185.278 0 0 O2K 161 1160 l 192.028 29678.576 2.061 166653.16 6 5.615 0 3636.169 157831.71 5185.278 0 0 STM2 1350 4000.14 l 21259.7 3 96129.0 6 1998.21 3 383000 3.984 383000 Oooooo0o0000STM3 700.1 437.72 I 21259.731 57496912 9 -2110.34 383000 0.666 383000 ome)oeeeeReemen®)-wwNSTM4 1400 437.72 | 21259.73) 96279 1.65 2 -1964.174 383000 0.398 383000 oOooooo00000STM5 618.9 27.12 1 21259.7 9.04E+0 6 2116.82 383000 0.042 383000 oOooO90O00000STMé 1400 27.12 1 21259.7 1.56E+0 7 1961.80 7 383000 0.024 383000 ooCocO000000Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 STM7 375.6 0.5 ] 21259.7 3.81E+0 8 2160.11 7 383000 0.001 383000 ooCoO000OOOOWAT 120 1160.3 0 6676.263 1987.602 -820.144 128603.83 4 63.504 120167.83 2 0.128 0.009 17.653 0 6 0 0 0 246.356 2.256 0 0 CASO3 FUEL ASH oOooOoOooo°ome)oooOoO153 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A4C;:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Slagging Heat Stream Table QCHX QCHX2 QCONV QRH1 QRH2 QSEP QSH QCALC 294923947 268459894 641907877 146166336 155013816 -72525802 340727725 Btu/hr TBEGIN F 705.296026 83.6865015 2700.0001 700.115047 618.887548 81.9394404 700 TEND F 120 700 705.296026 1400 1400 60 1350 A4D:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Slagging Work Stream Table W-H2OPMP W-HP W-IP W-LP W-NET W-O2NET wi W2 W3 POWER 71.7172385 32861.307 44736.323 58118.982 135716.61 9622.58507 1901.79744 1976.6367 1972.777 kw W4 W5 Wé WCO2PMP WPUMP POWER kW 1986.30833 888.089579 896.976017 412.075587 1669.06651 154 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A4E:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Slagging Block Input STAGE 1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOLI1 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson 155 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 3 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL2B Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 4 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) 156 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL3 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL4 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HpP2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 157 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson W-O2MIX Model:Mixer Property Method =Peng -Robinson H2O0PUMP Model:Pump Discharge Pressure =80 bar Pump Efficiency =0.8 Property Method =STEAMNBS SEP Model:R Yield Pressure =80 bar Temperature =60F Yield: Component Basis Yield H20 Mass 0.5 C Mass 0.316 O2 Mass 0.113 N2 Mass 0.004 H2 Mass 0.02 S Mass 0.001 Ash Mass 0.046 Property Method =Peng -Robinson 158 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COMBUST Model:RStoic Pressure =80 bar Combustion:Generate Combustion Reactions selected Property Method =Peng -Robinson CONV Model:Heater Pressure Drop =0 bar Heat Duty =-926000000 Btu/hr (Initial Guess,Actual value nailed down in design spec) Property Method =Peng Robinson CHX Model:Heater Temperature =120F Pressure Drop =0 bar Property Method =Peng -Robinson WATEROUT Model:FLASH2 Pressure Drop =0 bar Heat Duty =0 Btu/hr Property Method =Peng -Robinson FLUESPLT Model:FSplit FlueRecA SplitFraction =0.5 (Fraction of Inlet Stream going to this outlet stream)(Actual value determined by design spec) Property Method =Peng -Robinson CONDNSR Model:Heater Temperature =74F 159 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Pressure Drop =0 bar Property Method =Peng -Robinson CO2PUMP Model:Pump Discharge Pressure =2200 psia Pump Efficiency =0.8 Valid Phases =Liquid Only Property Method =Peng -Robinson SH2 Model:Heater Temperature =1350F Pressure Drop =0 bar Property Method =STEAMNBS HP Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Isentropic Efficiency =0.9 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RHI Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS IP Model:Turbine 160 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Discharge Pressure =30.18 bar Isentropic Efficiency =0.9301 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH2 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS LP Model:Turbine Discharge Pressure =0.5 psi Isentropic Efficiency =0.9414 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS WMIX Model:Mixer Pressure Drop =0 psi Property Method =STEAMNBS COND Model:Heater Vapor Fraction =0 (bubble point) Pressure Drop =0 bar Property Method =STEAMNBS PUMP Model:Pump Discharge Pressure =275.8 bar 161 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Pump Efficiency =0.8 Property Method =STEAMNBS CHX2 Model:Heater Temperature =700F Pressure Drop =0 bar Property Method =STEAMNBS 162 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A4F:Usibelli Coal Power Plant,50/50 Coal Water Slurry Feed,Slagging Design Specs BFW4T Purpose:To set BFW3 Temp equal to BF W4T temp in the Rankine Cycle. Defined Variables: BFW4T:Stream-Var Stream=BFW4 Substream=MIXED Variable=TEMP Units=F WTR3T:Stream-Var Stream=BFW3 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:BFW4T Target:WTR3T Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:BF W4 Substream:Mixed Variable:Temp Units:F Manipulated Variable Limits Lower =300 Upper =1100 QCONV Purpose:To balance convective heat from combustion with superheat and reheats in Rankine Cycle. Defined Variables: QCONV:Heat-Duty Stream=QCONV Units=Btu/hr QSH:Heat-Duty Stream=QSH Units=Btu/hr QRH1:Heat-Duty Stream=QRH1 Units=Btu/hr QRH2:Heat-Duty Stream=QRH2 Units=Btu/hr Design Specification Expressions Spec:QCONV Target:-QSH-QRH1-QRH2 163 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Tolerance:.01 Manipulated Variable Type:Block-Var Stream:CONV Variable:Duty Units:Btu/hr Manipulated Variable Limits Lower =-1E9 Upper =-1 RECSPLT Purpose:To set recycle A and recycle B's flowrates equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=MASS-FLOW Units=lb/hr RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=+MASS-FLOW Units=Ib/hr Design Specification Expressions Spec:RECA Target:RECB Tolerance:.01 Manipulated Variable Type:Block-Var Stream:FLUESPLT Variable:FLOW/FRAC ID1:FLUERECA Manipulated Variable Limits Lower =0 Upper =1 RECYC Purpose:To set furnace outlet temperature to 2700 for slagging combustion. Defined Variables: FLUEIT:Stream-Var Stream=FLUE1 Substream=MIXED Variable=TEMP Units=F 164 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Design Specification Expressions Spec:FLUEIT Target:2700 Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =1 Upper =2E6 RECYCT Purpose:To set recycle A and recycle B's temperatures equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=TEMP Units=F RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:RECB Target:RECA Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:TEMP Units:F Manipulated Variable Limits Lower =100 Upper =400 165 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 XSO2 Purpose:To set excess oxygen in flue gas equal to 0.042%(Mass Fraction). Defined Variables: FLUEO2:Mass-Flow Stream=FLUE1 Substream=MIXED Component=O2 Units=|b/hr O2IN:Mass-Flow Stream=O2A Substream=MIXED Component=O2 Units=lb/hr Design Specification Expressions Spec:FLUEO2 Target:0.00042*O2IN Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:O2A Substream:Mixed Variable:MASS-FLOW Units:lb/hr Manipulated Variable Limits Lower =100000 Upper =1E8 166 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 AAG:Usibelli Coal Power Plant,50/50 Coal Water Slurry,Slagging Block Results STAGE1 Compressor model:ASME polytropic Phase calculations:Vapor Phase Calculations Indicated horsepower:1863.76149 kW Brake horsepower:1901.79744 kW Net work required:1901.79744 kW Power loss:38.0359487 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:35.5001325 psia Outlet temperature:233.933136 F Isentropic outlet temperature:206.680466 F Vapor fraction:1 COOLI1 Outlet Temperature =80F Outlet Pressure =35.5001325 psia Vapor Fraction =1 Net Duty =-5629484.4 Btu/hr STAGE2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1937.10397 kW Brake horsepower:1976.6367 kW Net work required:1976.6367 kW Power loss:39.5327341 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:85.7319325 psia 167 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:261.515919 F Isentropic outlet temperature:233.409649 F Vapor fraction:] COOL2 Outlet Temperature =80F Outlet Pressure =85.7319325 psia Vapor Fraction =1 Net Duty =-6681055.6 Btu/hr STAGE3 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1933.32146 kW Brake horsepower:1972.777 kW Net work required:1972.777 kW Power loss:39.45554 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:207.040474 psia Outlet temperature:261.828378 F Isentropic outlet temperature:233.996708 F Vapor fraction:I COOL2A Outlet Temperature =80F Outlet Pressure =207.040474 psia Vapor Fraction =1 Net Duty =-6767816.2 Btu/hr STAGE4 Compressor model:ASME polytropic 168 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Phase calculations:Vapor phase calculation Indicated horsepower: 1946.58216kW Brake horsepower:1986.30833 kW Net work required:1986.30833 kW Power loss:39.7261666 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:499.997568 psia Outlet temperature:262.088092 F Isentropic outlet temperature:234.572335 F Vapor fraction:1 COOL3 Outlet Temperature =80F Outlet Pressure =499.997568 psia Vapor Fraction =1 Net Duty =-7046408.8 Btu/hr HPI Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:870.327788 kW Brake horsepower:888.089579 kW Net work required:888.089579 kW Power loss:17.7617916 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:761.576295 psia Outlet temperature:160.978009 F Isentropic outlet temperature:149.664612 F Vapor fraction:1 169 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL4 Outlet Temperature =80F Outlet Pressure =761.576295 psia Vapor Fraction =1 Net Duty =-3318862.8 Btu/hr HpP2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:879.036496 kW Brake horsepower:896.976017 kW Net work required:896.976017 kW Power loss:17.9395203 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:1160.00255 psia Outlet temperature:160.970735 F Isentropic outlet temperature:149.91226 F Vapor fraction:1 H2OPUMP Fluid Power =57.3737908 kW Brake Power =71.7172385 kW Electricity =71.7172385 kW Volumetric Flow Rate =923.460769 cuft/hr Pressure Change =1145.6019 psi NPSH available =33.367581 ft-lbf/lb Head Developed =2644.79597 ft-lbf/lb Net Work Required =71.7172385 kW SEP 170 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet Temperature =60 F Outlet Pressure =1160.3019 psia Net Heat Duty =72525802.3 Btu/hr Vapor Fraction =0.3285955 COMBUST Outlet Temperature =2700.0001 F Outlet Pressure =1160.3019 psia Net Heat Duty =-72525802 Btu/hr CONV Outlet Temperature =705.296026 F Outlet Pressure =1160.3019 psia Heat Duty =-641907877 Btu/hr CHX Outlet Temperature =120 F Outlet Pressure =1160.3019 psia Heat Duty =-294923947 Btu/hr Vapor Fraction =0.73891278 WATEROUT Outlet Temperature =120.000272 F Outlet Pressure =1160.3019 psia Heat Duty =0 Btu/hr Vapor Fraction =0.73891276 FLUESPLT FLUE7 0.26325069 2 FLUERECA 0.73674931 1 CONDNSR 171 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet Temperature =74 F Outlet Pressure =1160.3019 psia Heat Duty =-13491184 Btu/hr Vapor Fraction =0 CO2PUMP Fluid Power =329.660469 kW Brake Power =412.075587 kW Electricity =412.075587 kW Volumetric Flow Rate =5846.53095 cuft/hr Pressure Change =1039.6981 psi NPSH available =115.791047 ft-lbf/Ib Head Developed =4059.00763 ft-Ibf/lb Pump Efficiency Used =0.8 Net Work Required =412.075587 kW SH2 Outlet Temperature =1350 F Outlet Pressure =4000.1408 psia Heat Duty =340727725 Btu/hr Vapor Fraction =1 HP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-32861.307 kW Brake horsepower:-32861.307 kW Net work required:-32861.307 kW Power loss:0 kW Efficiency:0.9 Mechanical efficiency:1 Outlet pressure:437.723892 psia 172 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:700.115047 F Isentropic outlet temperature:642.322373 F Vapor fraction:1 RH1 Outlet Temperature =1400 F Outlet Pressure =437.723892 psia Heat Duty =146166336 Btu/hr Vapor Fraction =1 IP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-44736.323 kW Brake horsepower:-44736.323 kW Net work required:-44736.323 kW Power loss:0 kW Efficiency:0.9301 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:618.887548 F Isentropic outlet temperature:557.072526 F Vapor fraction:1 RH2 Outlet Temperature =1400 F Outlet Pressure =27.1220569 psia Heat Duty =155013816 Btu/hr Vapor Fraction =1 LP Compressor model:Isentropic Turbine 173 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Phase calculations:Vapor Phase Calculation Indicated horsepower:-58118.982 kW Brake horsepower:-58118.982 kW Net work required:-58118.982 kW Power loss:0 kW Efficiency:0.9414 Mechanical efficiency:1 Outlet pressure:0.5 psia Outlet temperature:375.603099 F Isentropic outlet temperature:305.542816 F Vapor fraction:1 COND Outlet Temperature =79.556157 F Outlet Pressure =0.5 psia Heat Duty =-452978554 Btu/hr Vapor Fraction =0 PUMP Fluid Power =1335.25321 kW Brake Power =1669.06651 kW Electricity =1669.06651 kW Volumetric Flow Rate =6155.7542 cuft/hr Pressure Change =3999.6408 psi NPSH available =0 ft-lbf/lb Head Developed =9256.90844 ft-lbf/Ib Pump Efficiency Used =0.8 Net Work Required =1669.06651 kW CHX2 Outlet Temperature =700 F Outlet Pressure =4000.1408 psia 174 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Heat Duty =268459894 Btu/hr Vapor Fraction =0 175 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ASA:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Dry Ash Flowsheet W,02MIX yl-O2NET| H20 COAL ow :TEANIN ¢ W-H2OP MP i EROIN H20PUMP2 FLUE]! CONV CHX FLUE6 WATEROUT FLUERECA WAT ODA O2B 525 = COOLI STAGE1 STAGE2 cool2 COOL2A Ccool3 i wo } i AWMIX lw.STAGE3 STAGE W-HPA %%pW-LP i QRHE|OUI WIP on | BEW4 -STM?L,STM3 {STM41 STMS |STM6 bacPY>oT og oy:SH HP RH IP RH2 LP 'QSH % ¥ i WPUMP £K BFW2 !<BFWI 'CHX2 OCHX2 PUMP % 176 FLUE7 WCO2PMP Liouin CO2PROD CONDNSR =CO2PUMP Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ASB:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Dry Ash Material Stream Table BFW1 BFW2 BFW3 BFW4 Temperature F 79.6 83.7 700 700 Pressure psia 0.5 4000.14 4000.14 4000.14 Vapor Frac 0 0 0 0 Mole Flow 21259.73 21259.73 21259.73 21259.73 lobmol/nr l 1 1 1 Mass Flow Ib/hr 383000 383000 383000 383000 Volume Flow 6155.754 6086.666 10996.01 10996.01 cuft/hr 3 3 Enthalpy --2607.4 -2338.94 -2338.94 MMBtu/hr 2613.095 Density lb/cuft 62.218 62.924 34.831 34.83] Mass Flow.|b/hr H2O 383000 383000 383000 383000 N2 0 0 0 0 O2 0 0 0 0 S 0 0 0 0 $O2 0 0 0 0 H2 0 0 0 0 CL2 0 0 0 0 Cc 0 0 0 0 CO2 0 0 0 0 ARGON 0 0 0 0 PROPANE 0 0 0 0 CACO3 0 0 0 0 177 CO2PROD 107.8 2200 0 5067.153 219761.71 7 7518.163 -827.639 29.231 302.949 4181.603 67.164 0 351.514 0 0 0 2099 15.43 3 49 43.054 0 0 COAL 1160.3 0 122000 1369.44 rs) -297.5 89.087 DECOMP 59 1160.3 0.427 5847.554 150467 13743.44 7 -417.049 10.948 60186.8 737.288 20373.23 2 240.747 0 3701.488 0 $7102.22 6 0 0 0 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 FLUE1 FLUE2 2300 706.4 1160.3 1160.3 ]1 31951.94 31951.94 1.26E+06 =1.26E+06 827947.26 339337.01 7 7 -3988.749 -4630.656 1.526 3.723 94440.35 94440.35 22111.516 22111.516 355.175 355.175 0 0 1873.246 1873.246 0 0 0 0 0 0 1.11E+06 =1.11E+06 26139.492 26139.492 0 0 0 0 CASO3 0 0 0 0 0 0 0 0 0 FUEL 0 0 0 0 0 122000 0 0 0 ASH 0 0 0 0 0 0 8125.218 8125.218 8125.218 178 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lbmol/hr Mass Flow Ib/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density lb/cuft Mass Flow lb/hr H20 N2 O2 S $O2 H2 CL2 Cc CO2 ARGON PROPANE FLUES 120 1160.3 0.839 31951.94 1.26E+06 91035.65 9 49 48.931 13.876 94440.35 22111.5] 6 355.175 0 1873.246 0 0 0 1.11E+06 26139.49 2 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 FLUE6 120 1160.3 1 2679 4.02 1.16E+06 89462.70 6 4312.564 12.989 1601.929 22111.42 355.149 0 1858.73 0 0 0 1.11E+06 26137.80 7 0 FLUE7 120 1160.3 ] 5067.153 219761.71 7 16918.747 -815.571 12.989 302.949 4181.603 67.164 0 351.514 0 0 0 209915.43 3 4943.054 0 FLUERECA 120 1160.3 1 21726.867 942291.12 2 72543.959 -3496.993 12.989 1298.98 17929.817 287.985 0 1507.216 0 0 0 900072.37 1 21194.754 FLUERECB 120 1160.3 1 21719.183 942291.12 2 72475.25) -3499.44 13.002 1174.524 17654.883 285.113 0 1392.257 0 0 0 9009 48.74 2 20835.603 0 H20IN 60 1160.3 0 1580.1 5 28467 454.77 4 194.68 5 62.596 LIQUID 74 1160.3 0 5067.153 219761.7) 7 5999 .006 829.082 36.633 302.949 4181.603 67.164 0 351.514 0 0 0 2099 15.43 3 4943.054 0 O2A 59 14.7 1 5310.793 170465.28 8 2.01E+06 -0.688 0.085 0 3719.345 161442.05 oOOoOOOOOF5303.889 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 8125.218 0 0 0 0 0 0 180 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ooo0oO0o00 Temperature F Pressure psia Vapor Frac Mole Flow lbmol/hr Mass Flow !b/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density lb/cuft Mass Flow |b/hr H20 N2 O2 S $O2 H2 CL2 Cc CO2 ARGON PROPANE CACO3 CASO3 FUEL O2B 233.9 35.5 1 5310.793 170465.2 8 1.11E+06 5.817 0.153 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 O2C 80 35.5 1 5310.793 170465.2 8 864505.1 3 0.059 0.197 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 O2D 261.5 85.73 1 5310.793 170465.2 8 478981.5 4 6.82 0.356 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 O2E 80 85.73 1 5310.793 170465.2 8 356890.1 2 -0.014 0.478 0 3719.345 161442. 0 0 0 0 0 0 5303.889 0 0 O2F 261.8 207.04 1 5310.793 170465.2 8 1981949 0 6.734 0.86 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 O2FB 80 207.04 1 5310.793 170465.2 8 146733.2 7 -0.189 1.162 0 3719.345 161442.0 0 0 0 0 0 0 303.889 0 0 0 0 O2G 262.1 500 l 5310.793 170465.2 8 82585.15 7 6.605 2.064 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O2H 80 500 1 5310.793 170465.2 8 59804.97 ] -0.603 2.85 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 O2I 161 761.58 1 5310.793 170465.2 8 4622].28 2 2.435 3.688 0 3719.345 161442.0 0 0 0 0 0 0 5303.889 0 0 0 0 ASH 0 0 0 0 0 0 0 182 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mole Flow lomol/hr Mass Flow.lb/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density Mass Flow lb/hr H20 N2 ARGON PROPANE CACO3 02) 80 761.58 5310.793 170465.28 38780.329 -0.96 4.396 0 3719.345 161442.05 5303.889 0 0 O2K 161 1160 5310.793 170465.28 30357.461 2.108 9.615 0 3719.345 161442.05 STM2 1350 4000.14 1 21259.73 383000 96129.06 9 1998.213 3.984 383000 0 oOooO0000000STM3 700.1 437.72 1 21259.73 383000 574969.12 9 -2110.34 0.666 383000 0 oooo0o0o0000183 STM4 1400 437.72 1 21259.73 383000 962791.65 2 -1964.174 0.398 383000 0 oooOo0000000STM5 618.9 27.12 ] 21259.7 383000 9.04E+0 6 2116.82 0.042 383000 0 oooOo000000STM6 1400 27.12 ] 21259.7 383000 1.56E+0 7 1961.80 7 0.024 383000 0 oooO0000000Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 STM7 375.6 0.5 1 21259.7 3 383000 3.81E+0 8 2160.11 7 0.001 383000 0 ooo0000000WAT 120 1160.3 0 5157.92 101170.5 7 1572.907 -636.366 64.32] 92838.42 2 0.097 0.027 0 14.516 0 0 0 190.608 1.685 0 0 CASO3 0 0 0 0 0 0 0 0 0 FUEL 0 0 0 0 0 0 0 0 0 ASH 0 0 0 0 0 0 0 O 8125.218 184 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ASC:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Dry Ash Heat Stream Table QCHX QCHX2 QCONV QRHI1 QRH2 QSEP QSH QCALC 318274283 268459894 641907877 146166336 155013816 74367867 340727725 Btu/hr TBEGIN F 706.441712 83.6865015 2300 700.115047 618.887548 74.715052 700 TEND F 120 700 706.441712 1400 1400 59 1350 ASD:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Dry Ash Work Stream Table W-H2OPMP W-HP W-IP W-LP W-NET W-O2NET Wi W2 POWER kW 35.4440039 32861.307 44736323 58118.982 135716.61 9842.69768 1945.30026 2021.85144 W4 W5 Wé WCO2PMP WPUMP POWER =.2031.74 908.40425 917.49396 422.82236 1669.0665 kW 185 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 W3 2017.90345 ASE:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Dry Ash Block Input STAGE 1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOLI1 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson 186 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 3 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL2B Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 4 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) 187 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL3 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL4 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HpP2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 188 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson W-O2MIX Model:Mixer Property Method =Peng -Robinson H2O0PUMP Model:Pump Discharge Pressure =80 bar Pump Efficiency =0.8 Property Method =STEAMNBS SEP Model:R Yield Pressure =80 bar Temperature =59F Yield: Component Basis Yield H20 Mass 0.4 Cc Mass 0.3795 O02 Mass 0.1354 N2 Mass 0.0049 H2 Mass 0.0246 S Mass 0.0016 Ash Mass 0.054 189 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =Peng -Robinson COMBUST Model:RStoic Pressure =80 bar Combustion:Generate Combustion Reactions selected Property Method =Peng -Robinson CONV Model:Heater Pressure Drop =0 bar Heat Duty =-926000000 Btu/hr (Initial Guess,Actual value nailed down in design spec) Property Method =Peng -Robinson CHX Model:Heater Temperature =120F Pressure Drop =0 bar Property Method =Peng -Robinson WATEROUT Model:FLASH2 Pressure Drop =0 bar Heat Duty =0 Btu/hr Property Method =Peng -Robinson FLUESPLT Model:FSplit FlueRecA SplitFraction =0.5 (Fraction of Inlet Stream going to this outlet stream)(Actual value determined by design spec) Property Method =Peng -Robinson 190 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONDNSR Model:Heater Temperature =74F Pressure Drop =0 bar Property Method =Peng -Robinson CO2ZPUMP Model:Pump Discharge Pressure =2200 psia Pump Efficiency =0.8 Valid Phases =Liquid Only Property Method =Peng -Robinson SH2 Model:Heater Temperature =1350F Pressure Drop =0 bar Property Method =STEAMNBS HP Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Isentropic Efficiency =0.9 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH1 Model:Heater Temperature =1400F Pressure Drop =0 bar 191 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =STEAMNBS IP Model:Turbine Discharge Pressure =30.18 bar Isentropic Efficiency =0.9301 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH2 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS LP Model:Turbine Discharge Pressure =0.5 psi Isentropic Efficiency =0.9414 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS WMIX Model:Mixer Pressure Drop =0 psi Property Method =STEAMNBS COND Model:Heater Vapor Fraction =0 (bubble point) Pressure Drop =0 bar 192 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =STEAMNBS PUMP Model:Pump Discharge Pressure =275.8 bar Pump Efficiency =0.8 Property Method =STEAMNBS | CHX2 Model:Heater Temperature =700F Pressure Drop =0 bar Property Method =STEAMNBS 193 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ASF:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Dry Ash Design Specs BFW4T Purpose:To set BFW3 Temp equal to BFW4T temp in the Rankine Cycle. Defined Variables: BFW4T:Stream-Var Stream=BFW4 Substream=MIXED Variable=TEMP Units=F WTR3T:Stream-Var Stream=BFW3 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:BFW4T Target:WTR3T Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:BF W4 Substream:Mixed Variable:Temp Units:F Manipulated Variable Limits Lower =300 Upper =1100 QCONV Purpose:To balance convective heat from combustion with superheat and reheats in Rankine Cycle. Defined Variables: QCONV:Heat-Duty Stream=QCONV Units=Btu/hr QSH:Heat-Duty Stream=QSH Units=Btu/hr QRHI:Heat-Duty Stream=QRH1 Units=Btu/hr QRH2:Heat-Duty Stream=QRH2 Units=Btu/hr Design Specification Expressions Spec:QCONV Target:-QSH-QRH1-QRH2 Tolerance:.01 194 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Manipulated Variable Type:Block-Var Stream:CONV Variable:Duty Units:Btu/hr Manipulated Variable Limits Lower =-1E9 Upper =-1 RECSPLT Purpose:To set recycle A and recycle B's flowrates equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=MASS-FLOW Units=lb/hr RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=MASS-FLOW Units=lb/hr Design Specification Expressions Spec:RECA Target:RECB Tolerance:.01 Manipulated Variable Type:Block-Var Stream:FLUESPLT Variable:FLOW/FRAC IDi:FLUERECA Manipulated Variable Limits Lower =0 Upper =1 RECYC Purpose:To set furnace outlet temperature to 2300 for dry ash combustion. Defined Variables: FLUEIT:Stream-Var Stream=FLUE1 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions 195 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Spec:FLUEIT Target:2300 Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =1 Upper =2E6 RECYCT Purpose:To set recycle A and recycle B's temperatures equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=TEMP Units=F RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:RECB Target:RECA Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:TEMP Units:F Manipulated Variable Limits Lower =100 Upper =400 196 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 XSO2 Purpose:To set excess oxygen in flue gas equal to 0.042%(Mass Fraction). Defined Variables: FLUEO2:Mass-Flow Streaam=FLUE1 Substream=MIXED Component=O2 Units=Ib/hr O2IN:Mass-Flow Stream=O2A Substream=MIXED Component=O2 Units=Ib/hr Design Specification Expressions Spec:FLUEO2 Target:0.00042*O2IN Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:O2A Substream:Mixed Variable:MASS-FLOW Units:lb/hr Manipulated Variable Limits Lower =100000 Upper =1E8 197 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ASG:Usibelli Coal Power Plant,60/40 Coal Water Slurry,Dry Ash Block Results STAGE1 Compressor model:ASME polytropic Phase calculations:Vapor Phase Calculations Indicated horsepower:1906.39425 kW Brake horsepower:1945.30026 kW Net work required:1945.30026 kW Power loss:38.9060052 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:35.5001325 psia Outlet temperature:233.933136 F Isentropic outlet temperature:206.680466 F Vapor fraction:1 COOL! Outlet Temperature =80F Outlet Pressure =35.5001325 psia Vapor Fraction =1 Net Duty =-5758256.5 Btu/hr STAGE2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1981.41441 kW Brake horsepower:2021.85144 kW Net work required:2021.85144 kW Power loss:40.4370289 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:85.7319325 psia 198 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet temperature:261.515919 F Isentropic outlet temperature:233.409649 F Vapor fraction:1 COOL2 Outlet Temperature =80F Outlet Pressure =85.7319325 psia Vapor Fraction =1 Net Duty =-6833881.9 Btu/hr STAGE3 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1977.54538 kW Brake horsepower:2017.90345 kW Net work required:2017.90345 kW Power loss:40.358069 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:207.040474 psia Outlet temperature:261.828378 F Isentropic outlet temperature:233.996708 F Vapor fraction:1 COOL2B Outlet Temperature =80F Outlet Pressure =207.040474 psia Vapor Fraction =1 Net Duty =-6922627.2 Btu/hr STAGE4 Compressor model:ASME polytropic 199 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Phase calculations:Vapor phase calculation Indicated horsepower: 1991.10942 kW Brake horsepower:2031.7443 kW Net work required:2031.7443 kW Power loss:40.634886 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:499.997568 psia Outlet temperature:262.088092 F Isentropic outlet temperature:234.572335 F Vapor fraction:1 COOL3 Outlet Temperature =80F Outlet Pressure =499.997568 psia Vapor Fraction =1 Net Duty =-7207592.4 Btu/hr HP1 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:890.236172 kW Brake horsepower:908.404257 kW Net work required:908.404257 kW Power loss:18.1680851 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:761.576295 psia Outlet temperature:160.978009 F Isentropic outlet temperature:149.664612 F Vapor fraction:1 200 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL4 Outlet Temperature =80F Outlet Pressure =761.576295 psia Vapor Fraction =1 Net Duty =-3394780.5 Btu/hr HpP2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:899.144089 kW Brake horsepower:917.493968 kW Net work required:917.493968 kW Power loss:18.3498794 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:1160.00255 psia Outlet temperature:160.970735 F Isentropic outlet temperature:149.91226 F Vapor fraction:1 H2OPUMP Fluid Power =28.3552032 kW Brake Power =35.4440039 kW Electricity =35.4440039 kW Volumetric Flow Rate =456.391627 cuft/hr Pressure Change =1145.6019 psi NPSH available =33.367581 ft-lbf/Ib Head Developed =2644.79597 ft-lbf/lb Net Work Required =35.4440039 kW 201 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 SEP Outlet Temperature =59 F Outlet Pressure =1160.3019 psia Net Heat Duty =74367867.4 Btu/hr Vapor Fraction =0.42746487 COMBUST Outlet Temperature =2300 F Outlet Pressure =1160.3019 psia Net Heat Duty =-74367867 Btu/hr CONV Outlet Temperature =706.441712 F Outlet Pressure =1160.3019 psia Heat Duty =-641907877 Btu/hr CHX Outlet Temperature =120 F Outlet Pressure =1160.3019 psia Heat Duty =-318274283 Btu/hr Vapor Fraction =0.83857254 WATEROUT Outlet Temperature =119.999932 F Outlet Pressure =1160.3019 psia Heat Duty =0 Btu/hr Vapor Fraction =0.83857257 FLUESPLT FLUE7 0.18911508 2 FLUERECA 0.81088492 1 202 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CONDNSR Outlet Temperature =74 F Outlet Pressure =1160.3019 psia Heat Duty =-13511003 Btu/hr Vapor Fraction =0 CO2PUMP Fluid Power =338.257888 kW Brake Power =422.82236 kW Electricity =422.82236 kW Volumetric Flow Rate =5999.00624 cuft/hr Pressure Change =1039.6981 psi NPSH available =108.194633 ft-Ibf/lb Head Developed =4086.92818 ft-lbf/lb Pump Efficiency Used =0.8 Net Work Required =422.82236 kW SH2 Outlet Temperature =1350 F Outlet Pressure =4000.1408 psia Heat Duty =340727725 Btu/hr Vapor Fraction =1 HP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-32861.307 kW Brake horsepower:-32861.307 kW Net work required:-32861.307 kW Power loss:0 kW Efficiency:0.9 203 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Mechanical efficiency:1 Outlet pressure:437.723892 psia Outlet temperature:700.115047 F Isentropic outlet temperature:642.322373 F Vapor fraction:1 RH1 Outlet Temperature =1400 F Outlet Pressure =437.723892 psia Heat Duty =146166336 Btu/hr Vapor Fraction =1 IP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-44736.323 kW Brake horsepower:-44736.323 kW Net work required:-44736.323 kW' Power loss:0 kW Efficiency:0.9301 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:618.887548 F Isentropic outlet temperature:557.072526 F Vapor fraction:1 RH2 Outlet Temperature =1400 F Outlet Pressure =27.1220569 psia Heat Duty =155013816 Btu/hr Vapor Fraction =1 204 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 LP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-58118.982 kW Brake horsepower:-58118.982 kW Net work required:-58118.982 kW Power loss:0 kW Efficiency:0.9414 Mechanical efficiency:1 Outlet pressure:0.5 psia Outlet temperature:375.603099 F Isentropic outlet temperature:305.542816 F Vapor fraction:1 COND Outlet Temperature =79.556157 F Outlet Pressure =0.5 psia Heat Duty =-452978554 Btu/hr Vapor Fraction =0 PUMP Fluid Power =1335.25321 kW Brake Power =1669.06651 kW Electricity =1669.06651 kW Volumetric Flow Rate =6155.7542 cuft/hr Pressure Change =3999.6408 psi NPSH available =0 ft-lbf/lb Head Developed =9256.90844 ft-lbf/lb Pump Efficiency Used =0.8 Net Work Required =1669.06651 kW 205 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CHX2 Outlet Temperature =700 F Outlet Pressure =4000.1408 psia Heat Duty =268459894 Btu/hr Vapor Fraction =0 206 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A6A:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Slagging Flowsheet W-H2OP MP %WCO2PMP i :OCONV * D0 LOIN FLUE].,FLUE6 |FLUET7 LiQUIn j CO2PROD WATEROUT CONDNSRH2O0PUM>A CO2PUMP W,02MIX COAL FLUERECAlaceLOSERweIE MARA |WAT tis Whi |W-NETW2iW834WAWSRgreene % Q2A L.O2B 2C pond we COOLI Coo12 COOL2A =COOLS py aadxSTAGE1STAGE2STAGE3STAGE4W-HPI %4 pW-LPORULWIPorp| BFW4 re STM?iaSIM3 i STM4 LOSTMS §STM6 bee STMT ad|SH HP RHI IP RH2 LP 'QSH % % i WPUMP BEW3 ex BEW2 -,BEWI !CHX2 "OCHX2 PUMPjor 207 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A6B:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Slagging Material Stream Table Temperature F Pressure psia Vapor Frac Mass Flow |b/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density {b/cuft Mass Flow_|b/hr H20 N2 O2 ARGON PROPANE CACO3 BFW1 79.6 0.5 0 383000 6155.75 4 2613.09 5 62.218 383000 oOo0oO0c0OoInterim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 BFW2 83.7 4000.14 0 383000 6086.66 6 -2607.4 62.924 383000 oO000BFW3 700 4000.14 0 383000 10996.01 3 -2338.94 34.831 383000 BFW4 70 0 4000.14 0 383000 10996.01 3 -2338.94 34.83] 383000 oOoo00208 CO2PROD COAL 106 2200 1160.3 0 208869.08 116000 |; 7136.438 1302.09 6 -785.897 -282.869 29.268 89.087 287.648 0 4094.54]0 15.113 0 0 0 340.349 0 0 0 0 0 0 0 199264.34 0 | 4867.089 0 0 0 0 0 DECOMP 38.5 1160.3 0.427 143067 12583.32 l -398.369 11.37 57226.8 701.028 19371.27 2 228.907 0 3519.448 0 54293.92 7 0 0 0 0 FLUE1 2700 1160.3 1 986851.34 ) 753777 .87 -2994.187 1.309 89529361 17459.378 64.449 0 1465.344 0 0 0 849852.07 6 20755.118 0 0 FLUE2 720.6 1160.3 1 986851 .34 5 273258.30 6 -3636.095 3.611 89529 361 17459.378 64.449 0 1465.344 0 0 0 849852.07 6 20755.118 0 0 CASO3 0 0 0 0 0 0 0 0 0 FUEL 0 116000 0 0 0 ASH 0 0 0 0 0 0 7725.618 7725.618 7725.618OooOlo)lo)209 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mass Flow |b/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density |b/cuft Mass Flow.lb/hr H20 N2 O2 ARGON PROPANE CACO3 CASO3 FUEL FLUES 120 1160.3 0.807 986851 .34 70221.613 3906.441 14.053 8952936] 17459.378 64.449 0 1465.344 0 0 0 849852.07 6 20755.118 0 oOo0FLUES 120 1160.3 l 890626.04 68725.59 -3301.166 12.959 1226.544 17459.283 64.443 0 1451.261 0 0 0 849671.04 ? 20753.461 0 0 0 0 FLUE7 120 1160.3 1 208869 .08 16117.484 -774.187 12.959 287.648 4094.541 15.113 0 340.349 0 0 0 199264.34 ] 4867 .089 0 0 0 0 FLUERECA 120 1160.3 l 681756.96 52608.106 -2526.978 12.959 938.895 13364.743 49.33 0 1110.912 0 0 0 650406.70 8 15886.371 0 0 0 0 210 FLUERECB 120 1160.3 l 681756.96 52580.413 -2528.212 12.966 850.369 13223.109 49.34] 0 1008.01 0 0 0 6509 12.36 7 15713.768 0 0 0 0 H2OIN 60 1160.3 0 27067 432.40 185.11 62.596 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 LIQUID 73 1160.3 0 208869 .08 5660.825 -787.259 36.897 287.648 4094.54] 15.113 0 340.349 0 199264.34 I 4867 .089 0 0 0 0 O2A 59 14.7 ] 162027.3 8 1.91TE+06 -0.654 0.085 0 3535.24 153450.7 ooooOo0085041.35 0 0 0 0 ASH 7725.618 0 0 0 0 0 0 211 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mass Flow Ib/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density H20 N2 ARGON PROPANE CACO3 CASO3 FUEL ASH Ib/cuft Mass Flow lb/hr O2B 233.9 35.5 l 162027.3 8 1.06E+06 5.529 0.153 0 3535.24 153450.7 0 unR--O0000WwOnooo00O2C 80 35.5 l 162027.3 8 821712.7 6 0.056 0.197 0 3535.24 153450.7 0 inoOFooc0o0now[Calooo0o0oOO2D 261.5 85.73 l 162027.3 8 455272.3 0 6.482 0.356 0 3535.24 153450.7 wnOoFoaooacnotoonoOoo00OCO2E 80 85.73 ] 162027.3 8 339224.3 2 -0.013 0.478 0 3535.24 153450.7 0 nng=O0000WwOnooo0cOo212 O2F 261.8 207.04 l 162027.3 8 188384.4 0 6.4 0 3535.24 153450.7 0 ong--O0000WonoO000O2FB 80 207.04 l 162027.3 8 139470.0 8 -0.18 1.162 0 3535.24 153450.7 0 iwoOFooccnowwonooo00O2G 262.1 500 l 162027.3 8 78497 .25 2 6.278 2.064 0 3535.24 153450.7 0 ealg--oO0000WwOnooo00Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 O2H 80 500 1 162027.3 8 56844.66 9 -0.573 2.85 0 3535.24 153450.7 0 [CalOoRococowe(oa)oooo002! 16] 761.58 l 162027.3 8 43933.36 2 2.315 3.688 0 3535.24 153450.7 0 [aloOFooo0o0cowe[SaoO0O000 213 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature F Pressure psia Vapor Frac Mass Flow |b/hr Volume Flow cuft/hr Enthalpy MMBtu/hr Density Ib/cuft Mass Flow |b/hr H20 N2 O02 S SO2 H2 CL2 C CO2 ARGON PROPANE CACO3 CASO3 FUEL 02)02K 80 161 761.58 1160 162027.38 162027.38 36860.731 28854.789 0.912 2.004 4.396 5.615 0 0 3535.24 3535.24 153450.79 153450.79 0 0 0 0 0 0 0 0 0 0 0 0 5041.35 5041.35 0 0 0 0 0 0 0 0 STM2 STM3 STM4 1350 700.1 1400 4000.14 437.72 437.72 l ]l 383000 383000 383000 96129.06 574969.12 962791.65 9 9 2 --2110.34 -1964.174 1998.213 3.984 0.666 0.398 383000 383000 383000 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 214 STM5 618.9 27.12 1 383000 9.04E+0 6 2116.82 0.042 383000 oooo000000000STM6 1400 27.12 | 383000 1.56E+0 7 1961.80 7 0.024 383000 oe@)OROOOROeReReemene)Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 STM7 375.6 0.5 1 383000 3.81E+0 8 2160.11 7 0.001 383000 ome)oooO00000000WAT 120 1160.3 0 96225.30 4 1496.05 -605.275 64.32 88302.81 8 0.094 0.006 181.027 1.657 0 0 0 0 ASH 0 0 0 0 0 0 0 0 7725.618 215 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A6C:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Slagging Heat Stream Table QCHX QCHX2 QCONV QRH]QRH2 QSEP QSH QCALC 270346699 268459894 641907877 146166336 155013816 -69609191 340727725 Btu/hr TBEGIN F 720.608241 83.6865015 2700.0001 700.115047 618.887548 74.7150579 700 TEND F 120 700 720.60824 1 1400 1400 38.5 1350 A6D:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Slagging Work Stream Table W-W-HP W-IP W-LP W-NET W-O2NET Wi Ww2 H2OPMP POWER 33.700876 32861.30 4473632 5811898 1357166 9355.4913 1849.0093 1921.7712 kw 6 7 3 2 ]6 2 8 Ww4 W5 Wé WCO2PMP WPUMP POWER -1931.17445 863.438913 872.07869 398.986614 1669.06651 kw 216 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 W3 1918.0187 I AGE:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Slagging Block Input STAGE 1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL! Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson 217 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 3 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL2B Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson STAGE 4 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =2.414975 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) 218 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL3 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HP1 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson COOL4 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson HpP2 Model:Compressor Type:Polytropic Using ASME Method Pressure Ratio =1.52316 219 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiencies: Polytropic =0.86,Mechanical =0.98 Convergence: Valid Phases =Vapor Only (Perform VL Check) Maximum Iterations =30 Tolerance =0.0001 Property Method =Peng -Robinson W-O2MIX Model:Mixer Property Method =Peng -Robinson H2O0PUMP Model:Pump Discharge Pressure =80 bar Pump Efficiency =0.8 Property Method =STEAMNBS SEP Model:R Yield Pressure =80 bar Temperature =38.5F Yield: Component Basis Yield H20 Mass 0.4 Cc Mass 0.3795 O2 Mass 0.1354 N2 Mass 0.0049 H2 Mass 0.0246 S Mass 0.0016 Ash Mass 0.054 Property Method =Peng -Robinson 220 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COMBUST Model:RStoic Pressure =80 bar Combustion:Generate Combustion Reactions selected Property Method =Peng -Robinson CONV Model:Heater Pressure Drop =0 bar Heat Duty =-926000000 Btu/hr (Initial Guess,Actual value nailed down in design spec) Property Method =Peng -Robinson CHX Model:Heater Temperature =120F Pressure Drop =0 bar Property Method =Peng -Robinson WATEROUT Model:FLASH2 Pressure Drop =0 bar Heat Duty =0 Btu/hr Property Method =Peng -Robinson FLUESPLT Model:FSplit FlueRecA SplitFraction =0.5 (Fraction of Inlet Stream going to this outlet stream)(Actual value determined by design spec) Property Method =Peng -Robinson CONDNSR Model:Heater Temperature =74F 221 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Pressure Drop =0 bar Property Method =Peng -Robinson CO2PUMP Model:Pump Discharge Pressure =2200 psia Pump Efficiency =0.8 Valid Phases =Liquid Only Property Method =Peng -Robinson SH2 Model:Heater Temperature =1350F Pressure Drop =0 bar Property Method =STEAMNBS HP Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Isentropic Efficiency =0.9 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH1 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS 222 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 IP Model:Turbine Discharge Pressure =30.18 bar Isentropic Efficiency =0.9301 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS RH2 Model:Heater Temperature =1400F Pressure Drop =0 bar Property Method =STEAMNBS LP Model:Turbine Discharge Pressure =0.5 psi Isentropic Efficiency =0.9414 Valid Phases =Vapor-Only (Perform VL Check) Property Method =STEAMNBS WMIX Model:Mixer Pressure Drop =0 psi Property Method =STEAMNBS COND Model:Heater Vapor Fraction =0 (bubble point) Pressure Drop =0 bar Property Method =STEAMNBS 223 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 PUMP Model:Pump Discharge Pressure =275.8 bar Pump Efficiency =0.8 Property Method =STEAMNBS CHX2 Model:Heater Temperature =700F Pressure Drop =0 bar Property Method =STEAMNBS 224 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A6F:Usibelli Coal Power Plant,60/40 Coal Water Slurry Feed,Slagging Design Specs BFW4T Purpose:To set BFW3 Temp equal to BFW4T temp in the Rankine Cycle. Defined Variables: BFW4T:Stream-Var Stream=BFW4 Substream=MIXED Variable=TEMP Units=F WTR3T:Stream-Var Stream=BFW3 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:BFW4T Target:WTR3T Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:BF W4 Substream:Mixed Variable:Temp Units:F Manipulated Variable Limits Lower =300 Upper =1100 QCONV Purpose:To balance convective heat from combustion with superheat and reheats in Rankine Cycle. Defined Variables: QCONV:Heat-Duty Stream=QCONV Units=Btu/hr QSH:Heat-Duty Stream=QSH Units=Btu/hr QRH1:Heat-Duty Stream=QRH1 Units=Btu/hr QRH2:Heat-Duty Stream=QRH2 Units=Btu/hr Design Specification Expressions Spec:QCONV Target:-QSH-QRH1-QRH2 Tolerance:.01 225 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Manipulated Variable Type:Block-Var Stream:CONV Variable:Duty Units:Btu/hr Manipulated Variable Limits Lower =-1E9 Upper =-1 RECSPLT Purpose:To set recycle A and recycle B's flowrates equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=MASS-FLOW Units=lb/hr RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=MASS-FLOW Units=lb/hr Design Specification Expressions Spec:RECA Target:RECB Tolerance:.01 Manipulated Variable Type:Block-Var Stream:FLUESPLT Variable:FLOW/FRAC ID1:FLUERECA Manipulated Variable Limits Lower =0 Upper =1 RECYC Purpose:To set furnace outlet temperature to 2700 for dry ash combustion. Defined Variables: FLUEIT:Stream-Var Stream=FLUE1 Substream=MIXED Variable=TEMP Units=F Design Specification Expressions 226 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Spec:FLUEIT Target:2700 Tolerance:.001 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =1 Upper =2E6 RECYCT Purpose:To set recycle A and recycle B's temperatures equal to each other. Defined Variables: RECA:Stream-Var Stream=FLUERECA Substream=MIXED Variable=TEMP Units=F RECB:Stream-Var Stream=FLUERECB Substream=MIXED Variable=TEMP Units=F Design Specification Expressions Spec:RECB Target:RECA Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:FLUERECB Substream:Mixed Variable:TEMP Units:F Manipulated Variable Limits Lower =100 Upper =400 227 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 XSO2 Purpose:To set excess oxygen in flue gas equal to 0.042%(Mass Fraction). Defined Variables: FLUEO?2:Mass-Flow Stream=FLUE1 Substream=MIXED Component=O2 Units=|b/hr O2IN:Mass-Flow Stream=O2A Substream=MIXED Component=O2 Units=lb/hr Design Specification Expressions Spec:FLUEO2 Target:0.00042*O2IN Tolerance:.01 Manipulated Variable Type:Stream-Var Stream:O2A Substream:Mixed Variable:MASS-FLOW Units:lb/hr Manipulated Variable Limits Lower =100000 Upper =1E8 228 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A6G:Usibelli Coal Power Plant,60/40 Coal Water Slurry,Slagging Block Results STAGE1 Compressor model:ASME polytropic Phase calculations:Vapor Phase Calculations Indicated horsepower:1812.02914 kW Brake horsepower:1849.00932 kW Net work required:1849.00932 kW Power loss:36.9801865 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:35.5001325 psia Outlet temperature:233.933136 F Isentropic outlet temperature:206.680466 F Vapor fraction: COOLI Outlet Temperature =80F 1 Outlet Pressure =35.5001325 psia Vapor Fraction =1 Net Duty =-5473227.1 Btu/hr STAGE2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1883.33585 kW Brake horsepower:1921.77128 kW Net work required:1921.77128 kW Power loss:38.4354256 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:85.7319325 psia Outlet temperature:261.515919 F 229 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Isentropic outlet temperature:233.409649 F Vapor fraction:1 COOL2 Outlet Temperature =80F Outlet Pressure =85.7319325 psia Vapor Fraction =1 Net Duty =-6495609.8 Btu/hr STAGE3 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:1879.65833 kW Brake horsepower:1918.01871 kW Net work required:1918.01871 kW Power loss:38.3603742 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:207.040474 psia Outlet temperature:261.828378 F Isentropic outlet temperature:233.996708 F Vapor fraction:1 COOL2B Outlet Temperature =80F Outlet Pressure =207.040474 psia Vapor Fraction =1 Net Duty =-6579962.2 Btu/hr STAGE4 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation 230 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Indicated horsepower:1892.55096 kW Brake horsepower:1931.17445 kW Net work required:1931.17445 kW Power loss:38.623489 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:499.997568 psia Outlet temperature:262.088092 F Isentropic outlet temperature:234.572335 F Vapor fraction:1 COOL3 Outlet Temperature =80F Outlet Pressure =499.997568 psia Vapor Fraction =1 Net Duty =-6850821.9 Btu/hr HP1 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:846.170134 kW Brake horsepower:863.438913 kW Net work required:863.438913 kW Power loss:17.2687783 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:761.576295 psia Outlet temperature:160.978009 F Isentropic outlet temperature:149.664612 F Vapor fraction:1 231 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COOL4 Outlet Temperature =80F Outlet Pressure =761.576295 psia Vapor Fraction =1 Net Duty =-3226741.3 Btu/hr HP2 Compressor model:ASME polytropic Phase calculations:Vapor phase calculation Indicated horsepower:854.637116kW Brake horsepower:872.07869 kW Net work required:872.07869 kW Power loss:17.4415738 kW Efficiency:0.86 Mechanical efficiency:0.98 Outlet pressure:1160.00255 psia Outlet temperature:160.970735 F Isentropic outlet temperature:149.91226 F Vapor fraction:1 H2O0PUMP Fluid Power =26.9607013 kW Brake Power =33.7008766 kW Electricity =33.7008766 kW Volumetric Flow Rate =433.9464 cuft/hr Pressure Change =1145.6019 psi NPSH available =33.367581 ft-lbf/lb Head Developed =2644.79597 ft-lbf/lb Net Work Required =33.7008766 kW SEP Outlet Temperature =38.5 F 232 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet Pressure =1160.3019 psia Net Heat Duty =69609190.8 Btu/hr Vapor Fraction =0.42741767 COMBUST Outlet Temperature =2700.0001 F Outlet Pressure =1160.3019 psia Net Heat Duty =-69609191 Btu/hr CONV Outlet Temperature =720.608241 F Outlet Pressure =1160.3019 psia Heat Duty =-641907877 Btu/hr CHX Outlet Temperature =120 F Outlet Pressure =1160.3019 psia Heat Duty =-270346699 Btu/hr Vapor Fraction =0.8072163 WATEROUT Outlet Temperature =120.000053 F Outlet Pressure =1160.3019 psia Heat Duty =0 Btu/hr Vapor Fraction =0.8072163 FLUESPLT FLUE7 0.2345194 2 FLUERECA 0.7654806 1 CONDNSR Outlet Temperature =73 F 233 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet Pressure =1160.3019 psia Heat Duty =-13071384 Btu/hr Vapor Fraction =0 CO2PUMP Fluid Power =319.189291 kW Brake Power =398.986614 kW Electricity =398.986614 kW Volumetric Flow Rate =5660.82452 cuft/hr Pressure Change =1039.6981 psi NPSH available =115.826283 ft-lbf/lb Head Developed =4057.6564 ft-lbf/lb Pump Efficiency Used =0.8 Net Work Required =398.986614 kW SH2 Outlet Temperature =1350 F Outlet Pressure =4000.1408 psia Heat Duty =340727725 Btu/hr Vapor Fraction =1 HP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-32861.307 kW Brake horsepower:-32861.307 kW Net work required:-32861.307 kW Power loss:0 kW Efficiency:0.9 Mechanical efficiency:I Outlet pressure:437.723892 psia Outlet temperature:700.115047 F 234 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Isentropic outlet temperature:642.322373 F Vapor fraction:1 RH1 Outlet Temperature =1400 F Outlet Pressure =437.723892 psia Heat Duty =146166336 Btu/hr Vapor Fraction =1 IP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation Indicated horsepower:-44736.323 kW Brake horsepower:-44736.323 kW Net work required:-44736.323 kW Power loss:0 kW Efficiency:0.9301 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:618.887548 F Isentropic outlet temperature:557.072526 F Vapor fraction:1 RH2 Outlet Temperature =1400 F Outlet Pressure =27.1220569 psia Heat Duty =155013816 Btu/hr Vapor Fraction =1 LP Compressor model:Isentropic Turbine Phase calculations:Vapor Phase Calculation 235 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Indicated horsepower:-58118.982 kW Brake horsepower:-58118.982 kW Net work required:-58118.982 kW Power loss:0 kW Efficiency:0.9414 Mechanical efficiency:1 Outlet pressure:0.5 psia Outlet temperature:375.603099 F Isentropic outlet temperature:305.542816 F Vapor fraction:1 COND Outlet Temperature =79.556157 F Outlet Pressure =0.5 psia Heat Duty =-452978554 Btu/hr Vapor Fraction =0 PUMP Fluid Power =1335.25321 kW Brake Power =1669.06651 kW Electricity =1669.06651 kW Volumetric Flow Rate =6155.7542 cuft/hr Pressure Change =3999.6408 psi NPSH available =0 ft-lbf/Ib Head Developed =9256.90844 ft-Ibf/lb Pump Efficiency Used =0.8 Net Work Required =1669.06651 kW CHX2 Outlet Temperature =700 F Outlet Pressure =4000.1408 psia Heat Duty =268459894 Btu/hr 236 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Vapor Fraction =0 237 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7A:CTL with TIPS Flowsheet 238 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 SCRBWTR F Q-SGCL3 WGSH20:30x,SP-1 i SGCOOI3 18 ou ae RE-CMPR O-WGSHT HYDROLYS WGSCOOL -WeCO2CMES 34 RECTCOOL 35 FILTER w. "Cc + COOL Q-CO2CM P ° Cco2 CO2ZAiRRECTSEPIfLoQ-SGCI2 TAILGAS co2zCooLt CO2COMP CO2COOI2 Co2Cc LOXHT1 ff LOXHTTOT FICOOL 6 H .Q-ASU.Ppoxmp fn Gove tttttceee"e W-O2PRMP }Q-FTCL2 i Al PRO DREC W-PRPUMP2:;Q-TCOOTM H v ;H PROD @COOLER :HAIR-CMPR 2 H :'TPROD4 1W-TGCOMP upscnp >PSCCOL -pRODPUMPWTR1owimpPOXHT2COMBUSTHripdoaswOOUrRTIPSCND2TIPSLIQ2 FIPSCND1CONVIHX: 45 CONRHX1 TIPSLI Q-ET W-HPTURB aA W-STM W-IPTURB ,------------|serHHSTMWORK i tye.. Q-CNDHX1 :SHIRHMIX "RH i W-LPTURB -SH Q-RH1 i ; BEWT7A ¢y j iq STM7 RH2 IPTURB °STMCOND Q-CNDI OT W-BE-W PMP BFWI1 BEWZ BEW4_x BFW3¢i a7 CONDHX2 SGHT3 ASUHT BFWPUMP 239 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7B:CTL with TIPS Material Stream Table (Note:Model results were scaled to compare with NETL paper which used 4,891 TPD of Coal.Since the model used 3,171 TPD (From NETL Gasifier Model),a factor of 1.54 was used to scale flows, heat and work streams.) Mass Flow.|b/hr H2 CO CH4 H20 CO2 CL2 Cc COAL ASH Total Flow lb/hr Enthalpy Btu/hr Total Flow cuft/hr Vapor Frac Density |b/cuft Temperature F Pressure psia ooooo000000lo)2.64E+05 0 2.64E+05 2.41E+08 3052.032 86.5859| 59 14.7 0 7387 .027 536.0162 14920.73 8.79E+05 2.69E+05 0 0 0 1.17E+06 -4,.99E+07 1.55E+07 l 0.0755918 59 14.5736 3 4 0 0 0 0 0 0 0 7214 0 0 18589.2 0 0 0 381.799 0 0 0 0 0 0 0 0 0 0 0 1897]7214 59 180.58 - 4.00E+07 2533.536 3851.49 1 l 7.487955 1.873041 104 694 1100 1100 240 § 0 0 0 2234.83] 536.0141 14920.73 8.79E+05 2.69E+05 1.17E+06 1.91E+07 1.03E+06 ] 1.127295 203.7165 278 oO0O000 6613.235 0 2.07E+05 2.13E+05 2.47E+07 4648.232 0 45.8684] -182 1100 oo0Oo0 6613.235 0 2.07E+05 2.13E+05 2.87E+06 31713.67 l 6.722873 60 1100 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 8 11884.77 0 0 29386.05 0 0 3311.765 18202.96 6623.53 775.094 1.67E+05 0 26779 .26 2.64E+05 -2.26E+08 2.53E+06 0.8129682 0.1042819 59 14.7 11884.77 0 0 13211.97 0 0 3311.765 18202.96 6623.53 775.0939 1.67E+05 0 26779 .26 2.48E+05 1.14E+08 2.53E+06 0.912584 0.097911 59 14.7 Mass Flow.I|b/hr H2 CO CH4 H20 CO2 AR N2 O2 NH3 CL2 HCL H2S COS ASH Total Flow lb/hr Enthalpy B8tu/hr Total Flow cuft/hr Vapor Frac Density _Ib/cuft Temperature F Pressure psia 10 16174.08 oOoOo000000016174.08 1.11E+08 303.4765 0 53.29598 59 14.7 11 12040.18 3.73E+05 652.4359 13967.83 23962.14 25202.44 3301.25 1.84E-08 12.7855] 1.28E-06 797.1303 6407.179 1115.354 28188.7 4.89E+05 -4,06E+08 6.32E+05 1 0.7729817 2500 1100 12 12040.18 3.73E+05 652.4359 13967.83 23962.14 25202.44 3301.25 1.84E-08 12.7855] 1.28E-06 797.1303 6407.179 1115.354 1409.435 4.62E+05 -4,01E+08 6.32E+05 1 0.7308086 2500 1100 -_(¢X)oooooooooo00026779 .26 26779 .26 .A3E+06 144.954] 184.743] 2500 1100 241 14 17196.53 5.33E+05 931.5348 14163.06 3341 2.29 35958.56 4715.792 2.62E-08 12.80897 1.61E-06 797.3201 7797 898 1115.354 1409.435 6.51E+05 9.99E+08 3.42E+05 1 1.904403 640 1080 15 17196.53 5.33E+05 931.5348 14163.06 33412.29 35958.56 4715.792 2.62E-08 12.80897 1.61E-06 797.3201 7797 898 1115.354 0 6.49E+05 9.98E+08 3.42E+05 1 1.900321 640 1080 -Ooooooo0o000000001409.435 1409.435 1.08E+06 7.629162 184.743] 640 1080 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 7 17196.53 5.33E+05 931.5348 14163.06 33412.29 35958.56 4715.792 2.62E-08 12.80897 1.61E-06 797.3201 7797 898 1115.354 0 6.49E+05 1.04E+09 2.83E+05 1 2.292995 450 1077 18 17196.53 5.33E+05 931.5348 13828.59 34229 .35 35958.56 4715.792 2.62E-08 12.80897 1.61E-06 797.3201 8430.649 0 0 6.49E+05 1.04E+09 2.84E+05 ] 2.290202 451.0575 1077 19 Mass Flow |b/hr H2 17196.53 CO 5.33E+05 CH4 931.5348 H20 13828.58 CO2 34229.35 AR 35958.56 N2 4715.792 O2 2.62E-08 NH3 12.80897 CL2 1.61E-06 HCL 797.3201 H2S 8430.649 Total Flow lb/hr 6.49E+05 Enthalpy Btu/hr =-1.10E+09 Total Flow cuft/hr 2.09E+05 20 17196.53 9.33E+05 931.5348 9.47E+06 34229 .35 35958.56 4715.792 2.62E-08 12.80897 1.61E-06 797 3201 8430.649 1.01E+07 -6.61E+10 3.35E+05 21 17187.8 3 5.33E+0 5 930.329 8 650.917 6 31500.4 3 35853.7 4 4715.14 2 2.61 E-08 1.56444 1.11E-06 632.500 8 4635.86 5 6.29E+0 5 1.03E+0 9 1.67E+0 ) 22 8.699149 7724898 1.204997 9.47E+06 2728.926 104.8178 0.650197 2 0 11.24453 4.97E-07 164.8192 3794.783 9.48E+06 -6.48E+10 1.80E+05 242 23 17187.83 5.33E+05 930.3298 650.9176 31500.43 35853.74 4715.142 2.61E-08 0.078222 1.11E-06 0.632500 8 4635.865 6.29E+05 -1.03E+09 1.67E+05 0 0 1.48621 8 0 631.868 3 0 633.354 6 7.67E+0 5 15.3076 6 25 5156.35 1.60E+05 279.0989 195.2753 9450.128 10756.12 1414.543 7 84E-09 0.023466 6 3.33E-07 0.189750 3 1390.76 1.89E+05 -3.10E+08 50145.87 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 26 12031.48 3.73E+05 651.2309 455.6423 22050.3 25097 .62 3300.599 1.83E-08 0.054755 4 7.78E-07 0.442750 6 3245.106 4.40E+05 -7 .22E+08 1.17E+05 27 5156.35 1.60E+05 279.0989 195.2753 9450.128 10756.12 1414.543 7 .84E-09 0.023466 6 3.33E-07 0.189750 3 1390.76 1.89E+05 -3.09E+08 49182.39 Vapor Frac 0.994840 0.053246 |0 0.999998 0 0.999998 0.999998 l I 3 8 8 8 Density Ib/cuft 3.109686 30.20741 3.76241 52.56353 3.760442 41.375 3.760442 3.760442 3.834109 Temperature F 220 69 .58394 100 100 100 100 100 100 106.2922 Pressure psia 1075 1070 1065 1065 1065 1065 1065 1065 1100 243 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 28 Mass Flow.lb/hr H2 17196.53 CoO 5.33E+05 CH4 931.5348 H20 14163.06 CO?33412,29 AR 35958.56 N2 4715.792 O2 2.62E-08 NH3 12.80897 CL2 1.61E-06 HCL 797.320) H2S 7797 898 COS 1115.354 ASH 1409 .435 Total Flow lb/hr 6.51E+05 Enthalpy Btu/hr -7.10E+08 Total Flow cuft/hr 7.08E+05 Vapor Frac ] 29 0 126.8763 0.299566 2 0 3307.545 11.5449 0.759137 9 0 0 6677.625 30 12031.48 3.73E+05 650.9313 455.6423 18742.75 25086.07 3299.84 1.83E-08 0.054755 4 7.78E-07 0.442750 6 14.50562 0 0 4.33E+05 -1.46E+07 -7.09E+08 144.9823 0 1.16E+05 0.999981 31 12031.48 3.73E+05 650.9313 1.20E+05 18742.75 25086.07 3299.84 1.83E-08 0.054755 4 7.78E-07 0.442750 6 14.50562 0 0 5.53E+05 -1.53E+09 1.15E+05 0.754554 244 32 12031.48 3.73E+05 650.9313 1.20E+05 18742.75 25086.07 3299.84 1.83E-08 0.054755 4 7.78E-07 0.442750 6 14.50562 0 0 9.53E+05 -1.34E+09 2.33E+05 l 33 25455.1 1.87E+05 650.9313 493.0834 3.12E+05 25086.07 3299.84 1.83E-08 0.054755 4 7.78E-07 0.442750 6 14.50562 0 0 5.53E+05 -1.34E+09 3.78E+05 1 34 25455.1 1.87E+05 650.9313 493.0834 3.12E+05 25086.07 3299.84 1.83E-08 0.054755 4 7.78E-07 0.442750 6 14.50562 0 0 5.53E+05 -1.40E+09 3.08E+05 1 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 35 25455.1 1.87E+05 650.9313 493.0834 3.12E+05 25086.07 3299.84 1.83E-08 0.054755 4 7./8E-07 0.442750 6 14.50562 0 0 5.53E+05 -].42E+09 2.87E+05 1 36 25376.2 2 1.81E+0 5 0 0 0 2610.96 6 343.448 4 0 0 0 0 0 0 2.09E+0 5 2.42E+0 8 2.03E+0 5 | 4 9 Density Ib/cuft 0.919418 46.05822 3.728965 4.819581 2.371427 1.464433 1.793627 1.926117 1.03039 8 4 Temperature F 1850.555 100 100 82.08124 400 886.6912 640 565.2781 565.278 1 Pressure psia 1085 1065 1065 1060 1060 1060 1060 1060 1060 245 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Mass Flow lb/hr H2 CoO CH4 H20 CO2 AR N2 O2 C2H6 C3H8 N-BUT-01 N-PEN-O1 N-HEX-01 1-HEP-0O1 N-OCT-01 N-NON-O1 Total Flow lb/hr Enthalpy Btu/hr Total Flow cuft/hr Vapor Frac Density |b/cuft Temperature F Pressure psia 38 2643.98 2415.488 7377 03 97040.91 18344.65 2610.966 343.4484 0 1436.236 257.8697 166.4729 15357.48 15357.48 15357.48 15357.48 15357.48 2.09E+05 -2.42E+08 3.20E+05 1 0.6542943 3174.793 1060 39A 2643.98 2415.488 7377.03 97040.91 18344.65 2610.966 343.4484 0 1436.236 257.8697 166.4729 15357.48 15357.48 15357.48 15357.48 15357.48 2.09E+05 6.53E+08 86305.19 l 2.426557 640 1060 39B 2643.98 2415.488 7377.03 97040.91 18344.65 2610.966 343.4484 0 1436.236 257.8697 166.4729 15357.48 15357.48 15357.48 15357.48 15357.48 2.09E+05 -8.2]E+08 8438.496 0.3741677 24.81774 77 1060 40 2643.98 2415.488 7377.03 0 18344.65 2610.966 343.4484 0 1436.236 257.8697 166.4729 35596.14 9.21E+07 12582.06 | 2.829118 77 1060 246 4)42 43 44 2643.98 0 0 0 2415.488 0 0 0 7377.03 0 0 0 0 0 0 0 18344.65 0 0 0 2610.966 2011.514 2011.514 2011.514 343.4484 0 0 0 0 62838.59 62838.59 62838.59 1436.236 0 0 0 257.8697 0 0 0 166.4729 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 35596.14 64850.1 64850.1 64850.1 9.18E+O7 7.51E+06 7.49E+06 4.13E+05 11878.17 1413.829 1408.384 9810.293 1 0 0 ] 2.996768 45.86841 4604576 6.610415 92.56845 -182 -90 180.7063 1160 1100 1160 1160 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 44152.06 3.63E+05 2689 1.33 3272.709 478.0786 0 oOOCO0O000 4.37E+05 1.27E+09 3.58E+05 1 1.220634 2868.14] 1160 Mass Flow Ib/hr H2©0 CO2 AR N2 O02 Total Flow lb/hr Enthalpy Btu/hr Total Flow cuft/hr Vapor Frac Density Ib/cuft Temperature F Pressure psia 46 44152.06 3.63E+05 2689 1.33 3272.709 478.0786 4.37E+05 1.32E+09 3.31E+05 1 1.320486 2600.638 1155 47 44152.06 3.63E+05 2689 1.33 3272.709 478.0786 4.37E+05 -1.65E+09 66297.61 0.8957895 6.596021 325.2615 1155 BFW1 7.52E+05 0 0 0 0 7.92E+05 5.15E+09 14240.33 0 52.80775 84.59198 0.5 BFW2 7.52E+05 0 0 0 0 7.52E+05 5.15E+09 14227.48 0 92.85544 88.7035 2800 247 BFW3 7.52E+05 0 0 0 0 7.52E+05 5.06E+09 14896.26 0 50.48248 200 2800 BFW4 7.52E+05 0 0 0 0 7.52E+05 5.00E+09 15421.23 0 48.76396 267.2704 2800 BFW5 7.S2E+05 0 0 0 0 7.S2E+05 4.96E+09 15908.58 0 47.27009 318.672 2800 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 BFW7 7.52E+05 0 0 0 0 7.92E+05 4.62E+09 25021.99 0 30.05357 640 2795 BFW7A 7.92E+05 0 0 0 0 7.52E+05 4.62E+09 25014.77 0 30.06224 640 2800 Mass Flow Ib/hr H2 CO CH4 H2O CO2 AR N2 O2 NH3 CL2 HCL H2S N-PEN-O1 N-HEX-01 1-HEP-O1 N-OCT-01 C02 72.9819 4910.12 0 0 1.93E+05 89.64845 11.79242 0 0 0 CO2A 77.73594 5375.35 0 0 3.06E+05 22268.85 2929.261 0 0 0 ©CO2B 77.73594 5375.35 0 0 3.06E+05 22268.85 2929.26| 0 0 0 [o)CcoO2Cc 77.7359 4 5375.35 0 0 3.06E+0 fs) 22268.8 ) 2929.26 ] 0 0 0 0 0 248 H2S 1.137028 50.25001 650.9313 493.0834 5598.094 206.2564 27.13111 1.83E-08 0.054755 4 7.78E-07 0.442750 6 14.50562 0 0 0 0 PROD =SCRBWT STM2 R 0 0 0 0 0 0 0 0 0 97040.9 9.46E+06 7.52E+0 l 5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 15357.4 0 0 8 15357.4 0 0 8 15357.4 0 0 8 15357.4 0 0 8 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 STM3 0 0 0 7.52E+05 0 N-NON-O1 Total Flow !b/hr Enthalpy Btu/hr Total Flow cuft/hr Vapor Frac Density |b/cuft Temperature F Pressure psia 0 1.98E+05 -7.26E+08 1.93E+06 1 0.102262 7 565.2781 26.10679 0 3.37E+05 -1.17E+09 3.92E+06 1 0.086041 6 283 15.95415 0 3.37E+05 -1.19E+09 2.84E+06 l 0.118818 8 80 15.95415 0 3.37E+0 5 1.18E+0 9 42470.9 8 1 7.93139 7 228.670 6 1160 249 0 7041.887 -2.48E+07 61843.66 I 0.113865 9 565.2781 36.25943 15357.4 8 1.74E+0 5 7.O9E+0 8 3707.01 8 0 46.8916 8 77 1060 0 9.46E+06 6.50E+10 1.78E+05 0 53.2288 65 1100 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 0 7.S2E+0 S 4,06E+0 9 2.13E+0 5 ] 3.53490 8 1050 2795 0 7.52E+05 -4.20E+09 9.32E+05 1 0.806759 9 540.1624 437.7239 Mass Flow_|b/hr H2 CO H20 CO2 AR N2 O2 Total Flow lb/hr Enthalpy Btu/hr Total Flow cuft/hr Vapor Frac Density !b/cuft Temperature F Pressure psia STM4 0 0 7.52E+05 0 0 0 7 .52E+05 -3.98E+09 1.59E+06 l 0.473863 5 1100 432.7239 STM5 0 0 7 .S2E+05 0 0 0 7.S2E+05 -4.21E+09 1.51E+07 l 0.049812 7 460.5159 27.12206 STM6 0 0 7.52E+0 ) 0 0 0 0 7.92E+0 5 3.97E+0 9 3.16E+0 7 1 0.02383 2 1100 22.1220 6 STM7 0 0 7.52E+0 5 0 0 0 0 7.52E+0 5 4.26E+0 9 6.93E+0 8 I 1.09E-03 313.631 0.5 250 TAILGAS 4.754045 465.2299 0 1.14E+05 22179.2 29 17.468 0 1.39E+05 -4,.23E+08 2.25E+06 l 0.061939 7 565.278] 15.95415 TIPSGAS 1 0 0 22776.99 3.62E+05 26885.07 3272.57] 477.9694 4.15E+05 1.51 E+09 65833.33 1 6.310405 325.2615 1155 TIPSLIQI 0 0 21375.07 483.9109 6.261209 0.137992 3 0.109209 1 21865.49 -1.43E+08 464.284 0 47 .09508 325.2615 1155 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 TIPSLIQ2 0 0 22427 .85 189.1341 0.776312 4.44E-03 0.014682 x) 22617.78 -].54E+08 426.1686 0 53.07237 82.0006 1155 TPROD1 0 0 22776.99 3.62E+05 26885.07 3272.57] 477.9694 4.15E+05 -1.57E+09 21565.65 0.878654 8 19.26374 82 1155 TPROD2 TPROD3 TPROD4 WGSH20 WTR1 Mass Flow lb/hr H2O0 349.1348 349.1348 349.1348 1.20E+05 5152.196 CO2 3.62E+05 3.62E+05 3.62E+05 0 2.12E-03 AR 26884.29 26884.29 26884.29 0 1.41E-03 N2 3272.567 3272.567 3272.567 0 3.27E-03 O2 477.9547 477.9547 477.9547 0 0.0271145 Total Flow lb/hr 3.93E+05 3.93E+O05 3.93E+05 1.20E+05 5152.23 Enthalpy Btu/hr ---8.25E+08 -3.53E+07 1.41E+09 1.44E+09 1.44E+09 Total Flow cuft/nr 21139.77 6976.396 6784.785 2249.737 97.63063 Vapor Frac ]0 0 0 1.96E-06 Density |b/cuft 18.5819 56.30661 57.89678 53.33956 52.77268 Temperature F 82.0006 28.49854 43.60156 59 80.22935 Pressure psia 1155 1155 2200 1100 14.5736 251 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 QCALC Btu/hr TBEGIN F TEND F QCALC Btu/hr TBEGIN F TEND F QCALC Btu/nr TBEGIN F TEND F QCALC Btu/hr TBEGIN F TEND F Q-WGSHT LOXHT1 21819817 -182 60 Q-CNVTOT 1.12E-06 Q-FTCL2 168348254 640 77 Q-SGCL3 55198472.4 451.057527 220 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7C:CTL with TIPS Heat Stream Table LOXHT2 7077428.5 180.70629 90 Q-CO2CL 14542119.9 283 80 Q-FICOOL 411236111 3174.79338 640 Q-SGCOOL 332552108 REFCOO SGCOOLI LOXHTTOT -28897245 Q-CO2CL1 22302809.] 565.081 129 283 Q-GASIF 232812393 Q-SGHT2 -43100000 267.270412 318.672026 Q-ASU 137751070 Q- CO2CMP 42154185.7 Q-GFER 233000000 Q-SGHT3 -55200000 200 267.270412 WGSCOO 252 Q-ASUHT 89878642 88.703501 9 200 Q-CONV 40576252. 2868.410 260.688 Q-RH1 222902667 $40.16238 1 1100 Q-SH 561556825 640 1050 Q- CNDHX1 335819969 2600.6383 l 325.261 48 8 Q- COOLER 58047404. 7 325.2615] 1 82 Q-RH2 239416760 460.51586 6 1100 Q-STM -].02E+09 Q- CNDHX2 335819969 318.67202 6 640 Q- DECOMP -14990275 59 59 Q-SGCL1 289462170 1850.7954 x) 640 Q-TCOOL 28897245. | 82.000598 28.498535 7 Q-CNDTOT 2.03E-06 Q-FT 411000000 Q-SGCL2 43089937. 8 640 450 Q-WGSCL 56546501. 9 886.69 123 640 L L QCALC --28900000 Btu/hr 190468318 16900000 0 50300000 82.081243 TBEGIN F 9 TEND F 400 253 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7D:CTL with TIPS Work Stream Table W-BFWPMP W-CO2CMP W-HPTURB W-IPTURB W-LPTURB w- O2PUMP POWER 3624.16484 --18007.041 -90419.604 -113622.15 7.71179662 hp 56127.913 W-PRPUMP W-STM W- TGCOMP POWER 662.757598 260169.67 106.820061 hp 254 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7E:CTL with TIPS Block Input AIR-CMPR Model:Multicompressor Number of Stages =5 Compressor Model =Isentropic Discharge Pressure (Last Stage)=278 psia Stage 1-5 Isentropic Efficiency =0.83 Interstage Cooling T =80F Duty (Last Stage)=0 Btu/hr Property Method =Peng -Robinson with Boston Mathias Modifications LOXHT1 Temperature =60F Pressure =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications DECOMP Model:R Yield Pressure =14.7 bar Temperature =59F Yield:(Actual yields determined by calculator block) Component Basis Yield H20 Mass 0.2 Ash Mass 0.2 C Mass 0.1 H2 Mass 0.1 N2 Mass 0.1 CL2 Mass 0.1 S Mass 0.1 02 Mass 0.1 Property Method =Peng -Robinson with Boston Mathias Modifications 255 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 DRYER Model:Sep H20 Split Fraction to Stream 10 =0.5504 Property Method =Peng -Robinson with Boston Mathias Modifications GASIFIC Model:RGibbs Pressure =1100 psia Temperature =2500 F Calculate phase equilibrium and chemical equilibrium Products:Identify Possible Products,H20,N2,02,NH3,CH4,H2,CL2,HCL,C,S,CO,CO2,H2S,COS,AR Property Method =Peng -Robinson with Boston Mathias Modifications SOLIDSPL Model:SSplit Split Fraction of C to Stream 13 =0.95 Split Fraction of NC to Stream 13 =0.95 Property Method =Peng -Robinson with Boston Mathias Modifications MIX1 Model:Mixer Pressure Drop =15 psia Property Method =Peng -Robinson with Boston Mathias Modifications SGCOOLI1 Model:Heater Temperature =640F Pressure Drop =5 psia Property Method =Peng -Robinson with Boston Mathias Modifications FILTER Model:SSplit 256 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Split Fraction of C to Stream 16 =1 Split Fraction of NC to Stream 16 =1 Property Method =Peng - SGCOOL2 Model:Heater Temperature =450F Pressure Drop =3 psia Property Method =Peng - HYDROLYS Model:RStoic Pressure Drop =0 bar Heat Duty =0 Btu/hr FRAC CONVERSION Property Method =Peng - SGCOOL3 Model:Heater Temperature =220F Pressure Drop =2 psia Property Method =Peng - MIX1 Model:Mixer Pressure Drop =5 psia Property Method =Peng - SCRUBBER Model:Flash2 Temperature =100F Pressure Drop =5 psia Robinson with Boston Mathias Modifications Robinson with Boston Mathias Modifications COS +H20 -->H2S +CO2 Robinson with Boston Mathias Modifications Robinson with Boston Mathias Modifications Robinson with Boston Mathias Modifications 257 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =Peng -Robinson with Boston Mathias Modifications SEP Model:Sep Split Fraction of H2 to Stream 23 =1 Split Fraction of CO to Stream 23 =1 Split Fraction of CH4 to Stream 23 =1 Split Fraction of H2O to Stream 23 =1 Split Fraction of CO2 to Stream 23 =1 Split Fraction of AR to Stream 23 =1 Split Fraction of N2 to Stream 23 =1 Split Fraction of O2 to Stream 23 =] Split Fraction of NH3 to Stream 23 =0.05 Split Fraction of S to Stream 23 =1 Split Fraction of SO2 to Stream 23 =1 Split Fraction of CL2 to Stream 23 =1 Split Fraction of HCL to Stream 23 =0.001 Split Fraction of H2S to Stream 23 =1 Split Fraction of COS to Stream 23 =1 Split Fraction of C to Stream 23 =1 Property Method =Peng -Robinson with Boston Mathias Modifications SP-1 Model:FSplit Split Fraction of inlet stream to stream 25 =0.3 Property Method =Peng -Robinson with Boston Mathias Modifications RE-COMPR Model:Compr Type:Isentropic Discharge Pressure =1100 psia Efficiency =0.83 258 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Convergence =Vapor-Liquid Property Method =Peng -Robinson with Boston Mathias Modifications ABS-H2S Model:Sep Split Fraction of H2 to Stream 30 =1 Split Fraction of CO to Stream 30 =0.99966 Split Fraction of CH4 to Stream 30 =0.99954 Split Fraction of H20 to Stream 30 =1 Split Fraction of CO2 to Stream 30 =0.85 Split Fraction of AR to Stream 30 =0.99954 Split Fraction of N2 to Stream 30 =0.99977 Split Fraction of O2 to Stream 30 =1 Split Fraction of NH3 to Stream 30 =1 Split Fraction of S to Stream 30 =1 Split Fraction of SO2 to Stream 30 =1 Split Fraction of CL2 to Stream 30 =1 Split Fraction of HCL to Stream 30 =1 Split Fraction of H2S to Stream 30 =0.00447 Split Fraction of COS to Stream 30 =1 Split Fraction of C to Stream 30 =1 Property Method =Peng -Robinson with Boston Mathias Modifications MX-WGS Model:Mixer Pressure Drop =5 psia Property Method =Peng -Robinson with Boston Mathias Modifications WGSHTR Model:Heater Temperature =400F Pressure Drop =0 bar 259 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =Peng -Robinson with Boston Mathias Modifications WGS Model:RStoic Pressure Drop =0 bar Heat Duty =0 Btu/hr FRAC CONVERSION CO +H20-->CO2+H2 Property Method =Peng -Robinson with Boston Mathias Modifications WGSCOOL Model:Heater Temperature =640F Pressure Drop =0 bar Property Method =Peng -Robinson with Boston Mathias Modifications RECTCOOL Model:Heater Pressure Drop =0 bar Heat Input =-16900000 Btu/hr Property Method =Peng -Robinson with Boston Mathias Modifications RECTSEP Model:Sep Split Fraction of H2 to Stream 36 =0.99690149 Split Fraction of CO to Stream 36 =0.97091 134 Split Fraction of CH4 to Stream 36 =0 Split Fraction of H20 to Stream 36 =0 Split Fraction of CO2 to Stream 36 =0 Split Fraction of AR to Stream 36 =0.10408031 Split Fraction of N2 to Stream 36 =0.10408031 Split Fraction of O2 to Stream 36 =0 Property Method =Peng -Robinson with Boston Mathias Modifications 260 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CO2COOL1 Model:Heater Temperature =283F Pressure Drop =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications CO2COOL2 Model:Heater Temperature =80F Pressure Drop =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications CO2COMP Model:Multicompressor Number of Stages =5 Compressor Model =Isentropic Discharge Pressure (Last Stage)=1160 psia Efficiency (1-5)=0.83 Interstage Cooling T =80F Property Method =Peng -Robinson with Boston Mathias Modifications FTRXN Model:RYield Pressure Drop =0 psia Heat Duty =0 Btu/hr Yields Component Basis Yield H20 Mass 0.47 H2 Mass 0.01280563 CO Mass 0.01169897 CO2 Mass 0.08884896 CH4 Mass 0.03572930 261 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 C2H6 Mass 0.00695614 C3H8 Mass 0.00124894 N-BUT-01 Mass 0.00080628 N-PEN-O1 Mass 0.07438115 N-HEX-01 -Mass 0.07438115 1-HEP-01 Mass 0.07438115 N-OCT-01 =Mass 0.07438115 N-NON-O1 =Mass 0.07438115 Property Method =Peng -Robinson with Boston Mathias Modifications FTCOOL Model:Heater Temperature =640F Pressure Drop =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications FTCOOL2 Model:Heater Temperature =77F Pressure Drop =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications PRODREC Model:Sep Split Fraction of H2O to PROD Stream =1 Split Fraction of CSH12 (and above)to PROD Stream =1 Property Method =Peng -Robinson with Boston Mathias Modifications TGCOMP 'Model:Compr Type:Isentropic Discharge Pressure =1160 psia 262 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Isentropic Efficiency =0.83 Convergence =Vapor-Liquid Property Method =Peng -Robinson with Boston Mathias Modifications O2PUMP Model:Pump Discharge Pressure =1160 psia Pump Efficiency =0.8 Property Method =Peng -Robinson with Boston Mathias Modifications LOXHT2 Model:Heater Temperature =90F Pressure =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications COMBUST Model:RStoic Pressure Drop =0 psia Heat Duty =0 Btu/hr Generate combustion products selected Property Method =Peng -Robinson with Boston Mathias Modifications CONVHX Model:Heater Pressure Drop =0 psiaHeatDuty=-6.8 *10°Btwhr (Determined by Design Spec) Property Method =Peng -Robinson with Boston Mathias Modifications CONDHX!1 Model:Heater Pressure Drop =0 psia 263 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Heat Duty =-2 *10°Btu/hr (Determined by Design Spec) Property Method =Peng -Robinson with Boston Mathias Modifications TIPSCND1 Model:Flash2 Pressure Drop =0 psia Heat Duty =0 Btu/hr Property Method =Peng -Robinson with Boston Mathias Modifications COOLER Model:Heater Temperature =82F Pressure Drop =0 psia Property Method =Peng -Robinson with Boston Mathias Modifications TIPSCND2 Model:Flash2 Pressure Drop =0 psia Heat Duty =0 Btu/hr Property Method =Peng -Robinson with Boston Mathias Modifications TIPSCOOL Model:Heater Pressure Drop =0 psia Heat Duty =-38300000 Property Method =Peng -Robinson with Boston Mathias Modifications PRODPUMP Model:Pump Discharge Pressure =2200 psia Pump Efficiency =0.8 264 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Property Method =Peng -Robinson with Boston Mathias Modifications SH Model:Heater Temperature =1050F Pressure Drop =5 psia Property Method =Peng -Robinson with Boston Mathias Modifications HPTURB Model:Turbine Type:Isentropic Discharge Pressure =30.18 bar Efficiency =0.875 Convergence =Vapor-Liquid Property Method =Peng -Robinson with Boston Mathias Modifications RH1 Model:Heater Temperature =1100F Pressure Drop =5 psia Property Method =Peng -Robinson with Boston Mathias Modifications IPTURB Model:Turbine Type:Isentropic Discharge Pressure =1.87 bar Efficiency =0.875 Convergence =Vapor-Liquid Property Method =Peng -Robinson with Boston Mathias Modifications RH2 Model:Heater 265 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Temperature =1100F Pressure Drop =5 psia Property Method =Peng -Robinson with Boston Mathias Modifications LPTURB Model:Turbine Type:Isentropic Discharge Pressure =0.5 psi Efficiency =0.875 Convergence =Vapor-Liquid Property Method =Peng -Robinson with Boston Mathias Modifications STMCOND Model:Heater Pressure Drop =0 psia Vapor Fraction =0 Property Method =Peng -Robinson with Boston Mathias Modifications BFWPUMP Model:Pump Discharge Pressure =2800 psia Efficiency =0.8 Property Method =Peng -Robinson with Boston Mathias Modifications ASUHT Model:Heater Pressure Drop =0 psia Temperature =200F Property Method =Peng -Robinson with Boston Mathias Modifications SGHT3 Model:Heater 266 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Pressure Drop =0 psia Heat Duty =55200000 Btu/hr Property Method =Peng -Robinson with Boston Mathias Modifications SGHT2 Model:Heater Pressure Drop =0 psia Heat Duty =43100000 Btu/hr Property Method =Peng -Robinson with Boston Mathias Modifications CONDHX2 Model:Heater Pressure Drop =5 psia Temperature =640F Property Method =Peng -Robinson with Boston Mathias Modifications 267 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7F:CTL with TIPS Design Specs ASUO2 Purpose:To send the same amount of oxygen to the ASU as the sum to the gasifier and TIPS. Defined Variables: O2ASU:Mass-Flow Stream=2 Substream=MIXED Component=O2 Units=lb/hr O2GF:Mass-Flow Stream=6 Substream=MIXED Component=O2 Units=lb/hr O2TIPS:Mass-Flow Stream=42 Substream=MIXED Component=O2 Units=lb/hr Design Specification Expressions Spec:O2ASU Target:O2GF+O2TIPS Tolerance:.0001 Manipulated Variable Type:Stream-Var Stream:2 Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =1E5 Upper =1E8 0245 Purpose:To set oxygen mole fraction to 0.0013 in furnace outlet. Defined Variables: O2FRAC:Mole-Frac Stream=45 Substream=MIXED Component=O2 Design Specification Expressions Spec:O2FRAC Target:0.0013 Tolerance:.0001 Manipulated Variable Type:Stream-Var 268 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Stream:42 Substream:Mixed Variable:Mass-Flow Units:lb/hr Manipulated Variable Limits Lower =10000 Upper =90000 PRODCOOL Purpose:To balance LOX heat with Product cooling. Defined Variables: PRCOOL:Heat-Duty Stream=Q-TCOOL Units=Btu/hr O2HT Heat-Duty Stream=LOXHTTOT Units=Btu/hr Design Specification Expressions Spec:PRCOOL Target:-O2HT Tolerance:.0001 Manipulated Variable Type:Block-Var Block:TIPSCOOL Variable:DUTY Units:Btu/hr Manipulated Variable Limits Lower =-1E10 Upper =-1E7 Q-COND Purpose:To balance condensing heat exchanger. Defined Variables: CNDTOT Heat-Duty Stream=Q-CNDTOT Units=Btu/hrDesign Specification Expressions Spec:CNDTOT Target:0 269 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Tolerance:.0001 Manipulated Variable Type:Block-Var Block:CONDHX1 Variable:DUTY Units:Btu/hr Manipulated Variable Limits Lower =-1E10 Upper =-1E8 Q-CONV Purpose:To balance convective heat exchangers. Defined Variables: CNVTOT Heat-Duty Stream=Q-CNVTOT Units=Btu/hr Spec:CNVTOT Target:0 Tolerance:.0001 Manipulated Variable Type:Block-Var Block:CONVHX1 Variable:DUTY Units:Btu/hr Manipulated Variable Limits Lower =-1E11 Upper =1E11 270 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 A7G:CTL with TIPS Block Results AIR-CMPR Outlet Pressure =278 psia Total Work =67380.4246 hP Total cooling duty =-137751070 Btu/hr Net work required =67380.4246 hP Net cooling duty =-137751070 Btu/hr LOXHT1 Outlet Temperature =60F Outlet Pressure =1100 psia Vapor Frac =1 Net Duty =21819816.5 Btu/hr DECOMP Outlet Temperature =59F Outlet Pressure =14.7 psia Vapor Frac =0.8129682 Net Duty =14990275.2Btu/hr DRYER H20 0.4496 0.5504 GASIFIC Outlet Temperature =2500F Outlet Pressure =1100 psia Heat Duty =-247802669 Btu/hr Net Duty =-232812393 Btu/hr SOLIDSPL Stream MIXED CISOLID NC 13 0 0.95 0.95 271 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 12 1 0.05 0.05 MIX1 Outlet Temperature =1850.55524 F Outlet Pressure =1085 psia SGCOOLI Outlet Temperature =640F Outlet Pressure =1080 psia Net Duty =-289462170 Btu/hr FILTER Stream MIXED CISOLID NC 15 1 0 0 16 0 1 1 SGCOOL2 Outlet Temperature =450F Outlet Pressure =1077 psia Net Duty =-43089938 Btu/hr HYDROLYS Outlet Temperature =451.057527F Outlet Pressure =1077 psia Net Duty =0 Btu/hr SGCOOL3 Outlet Temperature =220F Outlet Pressure =1075 psia Vapor Frac =0.99484008 Net Duty =-55198472 Btu/hr 272 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 MIX1 Outlet Temperature =69.5839449F Outlet Pressure =1070 psia Vapor Frac =0.05324630 SCRUBBER Outlet Temperature =100F Outlet Pressure =1065 psia Vapor Frac =0.05326193 Net Duty =316864119 Btu/hr SEP Heat Duty =-68184.868 Btu/hr Component ID23 24 H2 CO CH4 H20 CO2 AR N2 O02 )\O'Oo\O7)\oFa)(eo)NCoooroOOORBRSeeeHee273 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 C2H6 0 C2H4 0 C3H8 0 C3H6 0 N-BUT-O1 1-BUT-01 CIS-2-01 1-PEN-01 N-PEN-O1 1-HEX-01 N-HEX-01 1-HEP-01 N-HEP-01 1-OCT-01 N-OCT-01 N-NON-O1 COAL ASH SP-1 ooooocoococooocoocoococeooooococoococnocoStream Split fraction Stream order 25 0.3 26 0.7 RE-COMPR 1 2 Compressor model:Isentropic Compressor Phase calculations:Two Phase Calculation Indicated horsepower:152.150952 hP Brake horsepower:152.150952 hP Net work required:152.150952 hP Power loss:0 hP Efficiency:0.83 274 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Mechanical efficiency:1 Outlet pressure:1100 psia Outlet temperature:106.292168 F Isentropic outlet temperature:105.316711 F Vapor fraction:1 ABS-H2S Heat Duty =-778016.77 Btu/hr Component ID29 30 H2 0 1 CO 0.00034 0.99966 CH4 0.00046 0.99954 H20 0 1 CO2 0.15 0.85 AR 0.00046 0.99954 N2 -_0.00023 0.99977 O02 «0 NH3 S SO2 CL2 HCL H2S 1 0 1 0 0 0 0 0 1 0 1 0. COS 0 0 0 0 0 0 0 99553 0.00447 C CH2 CH3 C2H6 C2H4 C3H8 C3H6 0 N-BUT-01 275 'Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 1-BUT-01 CIS-2-01 1-PEN-01 N-PEN-O1 1-HEX-01 N-HEX-01 1-HEP-01 N-HEP-01 1-OCT-01 N-OCT-01 N-NON-O1 COAL ASH MX-WGS oooooocooeococoeooqeeoeooocoococoocoOutlet Temperature =82.0812439F Outlet Pressure =1060 psia Vapor Frac =0.75455488 WGSHTR Outlet Temperature =400F Outlet Pressure =1060 psia Vapor Frac =1 Net Duty =190468318 Btu/hr WGS Outlet Temperature =886.69123F Outlet Pressure =1060 psia Vapor Frac =1 Net Duty =0 Btu/hr 276 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 WGSCOOL Outlet Temperature =640F Outlet Pressure =1060 psia Vapor Frac =1 Net Duty =-56546502 Btu/hr RECTCOOL Outlet Temperature =565.278132F Outlet Pressure =1060 psia Vapor Frac =1 Net Duty =-16900000 Btu/hr RECTSEP Heat Duty =1430793.92 Btu/hr Component ID36 CO2 TAILGAS H28 H2 =0.99690149 =0.00286708 0.00018676 4.4668e-05 CO 0.97091134 =0.02632498 0.00249427 0.00026940 CH4 0 0 0 1 H20 0 0 0 1 CO2 0 0.61753104 0.3645149 0.01795405 AR -0.10408031 0.00357363 0.88412411 0.00822194 N2 __0.10408031 0.00357363 0.88412411 0.00822194 02 OQontoagoocoococceoagoooccocococeeaoeoco0occococo2OOPHHOOH277 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CH3 0 C2H6 0 C2H4 0 C3H8 0 C3H6 0 N-BUT-O1 1-BUT-01 CIS-2-01 1-PEN-01 N-PEN-O1 1-HEX-01 N-HEX-01 1-HEP-01 N-HEP-01 1-OCT-01 N-OCT-O1 N-NON-O1 COAL ASH QoqQoeooeooeoeocoocoocoocqcoocooooocoocoooocoocooococjoooqoqooocoocoocooocooocceoooooqooocooocococoeCO2COOL1 Outlet Temperature =283F Outlet Pressure =15.9541511 psia Vapor Frac =1 Net Duty =-22302809 Btu/hr CO2COOL2 Outlet Temperature =80F Outlet Pressure =15.9541511 psia Vapor Frac =1 Net Duty =-14542120Btu/hr 278 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 CO2COMP Outlet Pressure =1160 psia Total Work =18007.041 hP Total Cooling Duty =-42154186 Btu/hr Net Work Required =18007.041 hP Net Cooling Duty =-42154186 Btu/hr FTRXN Outlet Temperature =3174.79338F Outlet Pressure =1060 psia Vapor Fraction =1 Net Heat Duty =0 Btu/hr FTCOOL Outlet Temperature =640F Outlet Pressure =1060 psia Vapor Fraction =1 Net Heat Duty =-411236111 Btu/hr FTCOOL2 Outlet Temperature =77F Outlet Pressure =1060 psia Vapor Fraction =0.37416772 Net Heat Duty =-168348254 Btu/hr PRODREC Heat Duty =20547512.9 Btu/hr Component IDPROD 40 H2 0 1 CO 0 1 CH4 0 1 279 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 H20 CO2 AR N2 02 NH3 S SO2 CL2 HCL H28 COS C CH2 CH3 C2H6 C2H4 C3H8 C3H6 N-BUT-01 1-BUT-01 CIS-2-01 1-PEN-01 N-PEN-O1 1-HEX-01 N-HEX-01 1-HEP-01 N-HEP-01 1-OCT-01 N-OCT-01 N-NON-O1 COAL 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 meOOrrOrcocoeorcocoroococococmlccocCcCCoOCoCcCclcCCCOCUcUOUrwRSLEhECOcoooococoococoo-=280 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 ASH TGCOMP Compressor Model =Isentropic Compressor Phase Calculations =Two phase calculation Indicated horsepower:106.820061 hP Brake horsepower:106.820061 hP Net work required:106.820061 hP Power loss:0 hP Efficiency:0.83 Mechanical efficiency:1 Outlet pressure:1160 psia Outlet temperature:92.5684511 F Isentropic outlet temperature:90.3087956 F Vapor fraction:1 O2PUMP Fluid Power =6.1694373 hP Brake Power =7.71179662 hP Electricity =5.75068574 kW Volumetric Flow Rate =1413.82938 cuft/hr Pressure Change =60 psi NPSH available =1789.25541 ft-lbf/Ib Head Developed =188.364937 ft-lbf/lb Pump Efficiency Used =0.8 Net work required =7.71179662 hP LOXHT2 Outlet Temperature =90F Outlet Pressure =1160 psia Vapor Fraction =1 Net Heat Duty =7077428.54 Btu/hr 281 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 COMBUST Outlet Temperature =2868.14101F Outlet Pressure =1160 psia Vapor Fraction =1 Net Heat Duty =0 Btu/hr CONVHX Outlet Temperature =2600.63831F Outlet Pressure =1155 psia Vapor Fraction =1 Heat Duty =0 Btu/hr CONDHX!1 Outlet Temperature =325.261488F Outlet Pressure =1155 psia Vapor Fraction =0.89578953 Heat Duty =-335819969 Btu/hr TIPSCND1 Outlet Temperature =325.261511F Outlet Pressure =1155 psia Vapor Fraction =0.89578956 Heat Duty =0 Btu/hr COOLER Outlet Temperature =82F Outlet Pressure =1155 psia Vapor Fraction =0.87865475 Heat Duty =-58047405 Btu/hr TIPSCND2 Outlet Temperature =82.000598F 282 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Outlet Pressure =1155 psia Vapor Fraction =0.87865472 Heat Duty =0 Btu/hr TIPSCOOL Outlet Temperature =28.4985357F Outlet Pressure =1155 psia Vapor Fraction =0 Heat Duty =-28897245 Btu/hr PRODPUMP Fluid Power =530.206078 hP Brake Power =662.757598 hP Electricity =494.218255 kW Volumetric Flow Rate =6976.39576 cuft/hr Pressure Change =1045 psi NPSH available =580.190778 ft-lbf/lb Head Developed =2672.51043 ft-lbf/lb Pump Efficiency Used =0.8 Net work required =662.757598 hP SH Outlet Temperature =1050F Outlet Pressure =2795 psia Vapor Fraction =1 Heat Duty =561556825 Btu/hr\ HPTURB Indicated horsepower:-56127.913 hP Brake horsepower:-56127.913 hP Net work required:-56127.913 hP Power loss:0 hP 283 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Efficiency:0.875 Mechanical efficiency:1 Outlet pressure:437.723892 psia Outlet temperature:540.162381F Isentropic outlet temperature:489.439476F RHI Outlet Temperature =1100F Outlet Pressure =432.723892 psia Vapor Fraction =1 Heat Duty =222902667 Btu/hr IPTURB Indicated horsepower:-90419.604 hP Brake horsepower:-90419.604 hP Net work required:-90419.604 hP Power loss:0 hP Efficiency:0.875 Mechanical efficiency:1 Outlet pressure:27.1220569 psia Outlet temperature:460.515866F Isentropic outlet temperature:367.290008F RH2 Outlet Temperature =1100F Outlet Pressure =22.1220569 psia Vapor Fraction =1 Heat Duty =239416760 Btu/hr LPTURB Indicated horsepower:-113622.15hP 284 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 Brake horsepower:-113622.15 hP Net work required:-113622.15 hP Power loss:0 hP Efficiency:0.875 Mechanical efficiency:1 Outlet pressure:0.5 psia Outlet temperature:313.631015F Isentropic outlet temperature:192.6029F STMCOND Outlet Temperature =84.5919809F Outlet Pressure =0.5 psia Vapor Fraction =0 Heat Duty =-895039587 Btu/hr BFWPUMP Fluid Power =2899.33187 hP Brake Power =3624.16484 hP Electricity =2702.53925 kW Volumetric Flow Rate =14240.3334 cuft/hr Pressure Change =2799.5 psi NPSH available =0 ft-lbf/Ib Head Developed =7633.87894 ft-lbf/lb Pump Efficiency Used =0.8 Net work required =3624.16484 hP ASUHT Outlet Temperature =200F Outlet Pressure =2800 psia Vapor Fraction =0 Heat Duty =89878641.7 Btu/hr 285 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008 SGHT3 Outlet Temperature =267.270412F Outlet Pressure =2800 psia Vapor Fraction =0 Heat Duty =55200000 Btu/hr SGHT2 Outlet Temperature =318.672026F Outlet Pressure =2800 psia Vapor Fraction =0 Heat Duty =43100000 Btu/hr CONDHX2 Outlet Temperature =640F Outlet Pressure =2795 psia Vapor Fraction =0 Heat Duty =335819969 Btu/hr 286 Interim Draft Report Fed Grant Number EM-833233301-0 August 22,2008