Aerojet Rocketdyne (AR) has developed an innovative gasifier concept incorporating advanced technologies in ultra-dense phase dry feed system, rapid mix injector, and advanced component cooling to significantly improve gasifier performance, life, and cost compared to commercially available state-of-the-art systems. Design, fabrication and initial testing of the pilot plant compact gasifier was completed in 2011 by a development team led by AR. Findings from this initial test program, as well as subsequent gasifier design and pilot plant testing by AR, identified a number of technical aspects to address prior to advancing into a demonstration-scale gasifier design. Key among these were an evaluation of gasifier ability to handle thermal environments with highly reactive coals
ability to handle high ash content, high ash fusion temperature coals with reliable slag discharge
and to develop an understanding of residual properties pertaining to gasification kinetics as carbon conversion approaches 99%. The gasifier did demonstrate the ability to withstand the thermal environments of highly reactive Powder River Basin coal, while achieving high carbon conversion in <
0.15 seconds residence time. Continuous operation with the high ash fusion temperature Xinyuan coal was demonstrated in long duration testing, validating suitability of outlet design as well as downstream slag discharge systems. Surface area and porosity data were obtained for the Xinyuan and Xinjing coals for carbon conversion ranging from 85% to 97%, and showed a pronounced downward trend in surface area per unit mass carbon as conversion increased. Injector faceplate measurements showed no incremental loss of material over the course of these experiments, validating the commercially traceable design approach and supportive of long injector life goals. Hybrid testing of PRB and natural gas was successfully completed over a wide range of natural gas feed content, providing test data to anchor predictions for commercial operation of hybrid coal/natural gas gasification plants.