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DEVELOPMENT AND TESTING OF A WATER-GAS SHIFT REACTION CATALYTIC FILTER ELEMENT IN GASIFICATION PROCESS

A catalytic filter element has been developed at the Power Systems Development Facility combining a water-gas-shift reaction process with particulate removal within a filter element. A prototype of such catalytic filter element has been evaluated in a proof-of-concept test in a recent gasification test run. The catalytic filter element was tested under a wide range of operating conditions in a particulate free syngas. The preliminary test showed promising results. A CO conversion rate of 14%-84% was achieved at 533-728 K (500-850°F) temperature range. This paper serves as a progress report for the development and initial testing. Further modifications have been made and more detailed testing is underway. INTRODUCTION The Power Systems Development Facility (PSDF) is an engineering scale test facility of advanced coal-fired power systems, high-temperature and high pressure gas filtration systems, and gas cleanup systems. The PSDF was designed at sufficient scale so that advanced power systems and components can be tested in an integrated fashion to provide representative data for commercial scale-up. The PSDF is funded by the U.S. Department of Energy, the Electric Power Research Institute, Southern Company, Kellogg Brown & Root, Inc. (KBR), Siemens Power Generation, Peabody Energy, Burlington Northern and Santa Fe Railroad, and the Lignite Energy Council. The transport reactor has been operated successfully on sub-bituminous, bituminous, and lignite coals as a pressurized combustor and as a gasifier in both oxygenand air-blown modes and has exceeded its primary purpose of generating gases for downstream testing. Latest test results are summarized in References [1], [2], and [3]. Test run reports and published papers can be found on the PSDF website [4]. With a continuous interest in coal utilization and growing sense of urgency in carbon dioxide (CO2) control, the PSDF has shifted its focus to CO2 capture technology. The primary objective is to develop, evaluate, and facilitate the commercialization of emerging carbon control technologies. The PSDF has set up a flexible and cost-effective process system to test gas cleanup and CO2 capture technologies. One of the newly-developed technologies at the PSDF incorporates a water-gas shift (WGS) reaction catalyst into a particulate filter element to form a catalytic filter element. In a carbon constrained scenario, coal gasification for power generation will be achieved by a process that incorporates WGS. In the scenario, after syngas is generated in the gasifier and filtered to remove particulate matter, the syngas undergoes WGS reaction whereby carbon monoxide (CO) in the syngas reacts with steam to produce hydrogen (H2) and CO2 as follows: 2 2 2 H CO O H CO + ⇔ + (1) The CO2 would be separated from the main gas stream and pressurized for storage or sequestration. The main gas stream, rich in H2, would then be sent to the gas turbine for power production. In our catalytic filter element arrangement, particulate filtration and the WGS process are combined to eliminate or reduce capital and operation and maintenance (O&M) costs. The catalytic filter elements can be used as a stand alone or polishing process for the WGS reaction. The main benefit, however, is to fully utilize the significantly large surface area of the filter elements in a filter system. With a properly installed catalyst layer inside the filter element, the syngas is uniformly distributed through the catalyst layer with a slow face velocity. This arrangement