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347 way while producing nonhazardous waste that offers the possibility of constructive use. It should be understood that the Cool Water plant was built as a demonstration plant to prove a technology on a large but not a full scale. Engineering studies based on the Cool Water operating experience (ref. 4) have indicated that a 360- MW full-scale IGCC plant using Illinois #6 coal could be built with a net heat rate of 9000 Btu/kW-hr at a capital cost of $1530/kW and with operating and maintenance costs of 2.3 cents/kW-hr (or 5.2 cents/kW-hr, which includes all fixed charges) (ref. 3). These costs are competitive with those for conventional new coal-burning power plants using flue gas desulfurization. An important feature of the IGCC plant concept is the attractiveness of phased construction. A conventional coal-burning steam power plant must be constructed as a unit and takes a relatively long time to erect. On the other hand, one or more gas turbines of a planned IGCC plant may be quickly put into service using natural gas as a fuel. Additional gas and steam turbines may be added later to transform the plant into a combined-cycle plant, with coal gasifiers and an oxygen plant added still later at a third stage. Because the units may be paid for as they are built, phased construction offers significant financial benefits as well as ordely growth. Significant materials problems have been overcome in the Texaco and Cool Water plant technology. The inside of the gasifier requires refractory materials to withstand the severely corrosive high-temperature environment. Cool Water experience (ref . 5) indicates that 10,000–14,000 hours of refractory life is attainable. This implies that gasifier overhaul will be required at least every two years. Additional problems with cooler tube-wall materials, coal slurry pumps, and piping; and other severe material operating environments offer challenges for materials research to improve IGCC operation. Several of the references expand on the idea of cogeneration–polygeneration– by pointing out that, based on the Cool Water technology today, a single facility whose only major requirements are air, water, and coal can simultaneously produce electricity, steam, sulfur, inert slag for road construction, oxygen, nitrogen, hydrogen, carbon monoxide, carbon dioxide, argon, methanol, other chemical products, and even syngas. The Dow Gasification Process Another coal gasification process combined-cycle system (CGCC), developed by Dow Chemical Co., operates in Plaquemine, Louisiana. Like the IGCC system, the Dow process reacts a coal slurry with oxygen to produce syngas, from which most of the sulfur is removed for by-product use. The raw syngas from the gasifier produces steam in an HRSG, is cooled, passes through pollutant removal equipment, and is burned in gas turbines. Reference 47 indicates that “of the new coal-based technologies, the CGCC system has the highest efficiency and the lowest emission of environmental pollutants.” The 161-MW plant, built in the remarkable time of twenty-one months, was completed in 1987. The reference indicates for CGCC plants a net heat rate based on lower heating value of 8670PDF Image | Advanced Systems Steam Power Plant
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