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PSIT

NO~ 1171 Gasifier Process Design COST ELEMENTS Improvement Facility GRAND TOTAL HOURS 18 45 280 8 2OO 32 40 120

20-Sep-93

TITLE: Task

6: Detail

GRAND TOTAL 2,464 5,176 28,724 701 19,567 2,673 2,423 5,433

Principal Research Scie~tis~ 1 Principal Research Scientist 3 Principal Research Scientist 4 Principal Research Scientist 5 Senior Instrumentation Specialist Principal Scientist/Engineer 1 Senior' Scientist/Engineer 1 Scientist/Engineer A) BURDENED io 2. 3¯ 4. 5. 6. 7. COSTS LABOR LAB CHARGE TRAVEL ~ ~ MATERIALS COMPUTER SUBCONTRACTS/CONSULTANTS FACILITIESCAPITALCOST TOTAL FEE/PROFIT TOTAL COST ESTIMATED COSTS: i0.0%

743

OF

MONEY

67,161 0 0 0 0 0 116 $67,277 $6,682 $'73,959 $0

(eMcludes PLUS FIXED

FCCOM) FEE

ID)

COST SHARE (via PSI Environmental TOTAL COST TO SPONSOR year

Corporation) $"73,959 1 July throuah 30 Jun

C)

PSI

fiscal

is from

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 2 of 28

PSIT

NO. i171 Gasifier Pr+ocess Improvement Facility GRAND TOTAL HOURS 0 0 62 0 0 0 0

20-Sep-93

TITLE: Task

7: site

Preparation/C0nstruction COST ELEMENTS

GRAND TOTAL 0 0 6,5!6 0 0 0 0 2,875

Principal Research Scientist 1 Principal Research Scientist 3 Principal Research Scientist 4 Principal Research Scientist 5 Senior Instrumentation Specialist Principal.Scientist/Engineerl Senior' Sclentist/Engineer 1 Scientist/Engineer A) BURDENED 2. 3. 4. COSTS

LABOR LAB CHARGE TRAVEL MATERIALS COMPUTER 6. SUBCONTRACTS/CONSULTANTS 7. FACILITIES CAPITAL COST TOTAL B) FEE/PROFIT C) TOTAL COST ESTIMATED FCCOM) FEE COSTS:

124

0 OF MONEY

9,391 0 7,953 0 0 0 17 $17,361

(excludes PLUS FIXED

10.0%

I

$1,725 $19,086 $0

D)

COST SHARE (via PSI Environmental TOTAL COST TO SPONSOR year

Corporation) $19,086

C)

PSI fiscal

is from

1 July

th~Dugh

30 Jun

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 3 of 28

PSIT NOo 1171 TITLE: Task Gasifier Process Test Plan COST ELEMENTS Improvement Facility GRAND TOTAL HOURS 18 45 8O 8O 80 32 80 120

20-Sep-93

8: Pre-Op

GRAND TOTAL

$$$$$
2,525 5,288 8,407 7,177 8,018 2,737 4,966 5,566

P'rin6ipal ResearCh Scientist 1 Principal Research Scientist 3 Principal Research Scientist 4 Principal Research Scientist 5 Senior Instrumentation Specialist Pri~cipal.Scigntist/~ngineer 1 Senior Sclentist/Englneer 1 Scientist/Engineer BURDENED COSTS LABOR LAB CHARGE TRAVEL _ MATERIALS COMP~UTER SUBCONTRACTS~CONSULTANTS FACILITIES CAPITAL COST TOTAL B) C) FEE/PROFIT TOTAL COST ESTIMATED COSTS:

A)

535

3o 4. 5. 6. 7.

0 OF MONEY

44,684 0 3,159 0 0 0 81 $'~7,924

(excludes PLUS FIXED

FCCOM) FEE

I0.o%

$4,760 $52,684 $0

D)
C)

COST SHARE (via PSI Environmental TOTAL COST TO SPONSOR year

Corporation) ¯ $52,6S I July through 30 Jun

PSI

fiscal

is from

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 4 of 28

PSIT NO. 1171 TITLE: Task Gasifier Process Testing COST ELEMENTS Improvement Facility GRAND TOTAL HOURS 0 0 60 0 6O 0 0 60

20-Sep-93

9: Pre-Op

GRAND TOTAL

$$$$$
0 0 6,305 0 6,013 0 0 2,783

Principa~ Research Sckentist 1 Principal Research Scientist 3 Principal Research Scientist 4 Principal Research Scientist 5 Senior Instrumentation Specialist Principal Scientist/Engineer 1 Senior Scientist~Engineer 1 Scientist/Engineer A) BURDENED 2. 3. 4. 5o 6. 7o COSTS

180 LAB CHARGE TRAVEL MATERIALS COMPUTER SUBCONTRACTS/CONSULTANTS FACILITIES CAPITAL COST TOTAL B) C) FEE/PROFIT TOTAL COST ESTIMATED COSTS:

0 OF MONEY

15,101 0 2,746 0 0 0 27 $17,874

(excludes PLUS FIXED

FCCOM) FEE

~.o.o%!

$!, 783 $19,657 $0

COST SHARE (via PSI Environmental c) TOTAL COST TO SPONSOR year

Corporation) $419, 657 1 July through 30 Jun

PSI

fiscal

is from

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 5 of 28

PSIT

NO. 1171 Process Improvement Facility GRAND TOTAL HOURS

20-Sep-93

TITLE: ' Gasifier PSI Environmental

Instruments COST

Corporation

GRAND TOTAL

ELEMENTS

Principal Research S~ientist 1 Principal Research Scientist 3 Principal Research Scientist 4 Principal Research Scientist 5 Senior Instz~mentation ~pecialist Principal Scientist/Englneerl Senior' Scientist/Engineer Scientist/Engineer ~A) BURDENED 1. 2. 3o 4. 5o 6o 7o COSTS LABOR LAB CHARGE TRAVEL " MATERIALS COMPUTER SUBCONTRACTS/CONSULTA/~TS FACILITIE.S CAPITAL COST OF MONEY TOTAL ESTIMATED FEE/PROFIT TOTAL COST (excludes PLUS FIXED COSTS :

~l II [I II II II II II

o 0 o o o o o

o 0 o o o o o

0

0

0 0 0 0 0 372,400 53 $"372,453

I l l

FCCOM) FEE

2.0% I

$7,537 $3'79,990 ($187,601)

D)

COST SHARE (via PSI Environmental TOTAL COST TO SPONSOR year

Corporation) $192,389 i July through 30 Jun

C)

PSI fiscal

is from

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 6 of 28

PSI

Environmental Gasifier to PSI

instruments Process

Corporation Facility GRAND TOTAL HOURS 0 890 1,270 1,270 120 743

20-Sep-93

TITLE: Total

Improvement Company

Technology

GRAND TOTAL

COST ELEMENTS President Director, Product Development Lead Product D~velopment Engineer Mechanical Englneer or Something or other Manufacturing Engineer Product Development Engineer

$$$$$
0 79,5'79 84,2'73 76,171 6.,150 37,554

A)

BURDENED 1. 2. 3o 4. 5o 6. 7.

COSTS LABOR LAB CHARGE TRAVEL MATERIALS COMPUTER SUBCONTRACTS/CONSULTANTS FACILITIES CAPITAL COST TOTAL ESTIMATED COSTS: 4,293 283,727 0 3,422 35,000 0 0 0 $322,149

0 OF MONEY

B) C)

FEE/PROFIT TOTAL COST

(excludes PLUS FIXED

FCCOM) FEE

o.o%11 11

$0 $322,149 ($161,075)

D) COST
TOTAL COST TO SPONSOR year is from I July through 30 Jun

$161,074

fiscal

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 7 of 28

EXHIBIT "E" TASK 4 UPDATE - I0 AUGUST,

1993

Case 1:02-cv-01500-GWM

Document 78-6

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I~rpose of Repo~ The role of' PowerServe the GPIFdesign involves four GPIFsubsy~tems: in Alkali and Trace Metal Control Clinker' Control Tars and NH Control 3 Monitoring Instlumentationfor the gasifier.. and Theactivities of Power'Serve Tasks4 to 6 ate~ in Task Provide subsystemfunctional descriptions and cost estimates Assist Riley and CRSS with control philosophy and conceptual design Provideinput int~ gasifier design Def'me design deficiencies and plan of action Task 5 Conduct technical concept studies to address the GPIFdesign and opetational issues for the PowexSetve subsystems Develop test in-situ monitorsand extlactive systems and Task 6 Provide procurement installation specifications for subsystemsbased on and Task 5 results Assist with gasifier and conttoI systemdetailed design Contributeto quality assuranceplan This report summat~,es workperformedin Task 4 relevant to the gasifier cost the estimate. In the case of the first three subsystems (Alkali/I'mceMetals, Clinker, Tat-s and NH Control), the infbrmationin this repor~ def'mesthe constraints the control subsystems 3 will have on the overall design., Asignificant amount informationis required in these of developmental areas before the design is finalized.. Therequired informationincludes data from Task 5 studies whichcannot be planned umil we receive the preliminary design of the gasifier subsystem.,Theseinformationdeficiencies are pointed out in each section, and pIans to acquire and use the infolmationgiven,.

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Eachsection begins with a description of the design problemto be addressed and a general description of the approachtaken in Task 4. Theri there is a descript.i~n of how the subsystem designwill affbct the overall gasifier cost,. Design Input of Alkali and Trace Metal Control Theobjective of' the alkali and trace metal workis to design the GPIFfacility with the ability to measure alkali and trace metal eoncentxations to ensure that the flexibility and exists to test alkali control schemesdevelopedby PowerSet'ce,METC, CRSS,, or ThePyGas design is uniquein its ability to captuie alkali and trace metals. Most gasification systemswill cool the gas to condense alkali and remove resulting particulate the with candle or cross flow filters,, In the GPIF faeility, the majorityof' the alkali ate released in the pyrolyzer and upper'.gasifier., In the downward flowing bed, the temperatureis ideal for capture of these species due to contact and reaction with aluminosilicates in the ash or with limestone,, Thepossibility exists to increase this capture by recycling ash or' adding sorbents to the coal feed s~eam,, Thus; the control systemenvisagedinvolves injecting sorbent into the bed via the coal feed or the limestone feed system. The maindesign features that will aff~t the amountof alkalis and trace metals capturedare, the amountof sorbent the sorbent surface a~ea and adsorptionactivity the contact time available in the upper bed region the concentration of water vapor and HCIin the gases temperattaeprofile in upper bed. Previous reseateh has shown ability of clays and other minerals foundin coal to the captttre alkali and trace metals,, However', enough not workexists at. conditions similar to those expectedto be fbundin the GPIFfacility,, Therefore, there is a significant amount of workrequired in Task5 to gather, data on this system, including: Determination the alkali and trace metal emissionsduring gasification of' Determination the effect of operating conditions on emissionsand capture of Determination the rate and capacity of" char, ash, recycled bottomash, and of clay as sorbents for emissionscontrol Useof the rate and capacity data to define the temperature, residence time, and sorbent concenuation requirementsto control alkalis and trace metals in the co-flowingbed region

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Theoverall control approach relies on a definition of gasifier' design and operating conditions required to minimize emissions, combined the addition of sor._bents, if with necessary,, The gasifier design objectives ad&essed Task 4 were: in Determinethe amountof sorbent to be added Determine effect of sorbent addition on the solids handling equipment the Develop strategy to utilize the data generatedin the Task5 studies a Make preliminary estimates of' the design constraints on the co-flow region with respect to alkali and trace metalcontrol.. Sot'bent Feed Rate: Becausethe tests in Task 5 are designedto define the kinetics of the reaction of alkalis and trace metals under GPIF conditions, it is not possible to set a design specification of the maximum amountof sorbent required with absolute certainty., However'. preliminaryestimates suggest that sorbent addition rate of' 1,200 Ib/~" or I0%of the coal feed ~ate shouldbe adequ@,te,.Thedetails of these estimates will be presentedin the ConceptualDesign report° This estimate of' 1,200 Ib/lar is based on preliminaryealculations of the amount of adsorption in the co-flow bed using kinetic data from Westinghouse,Werecommend designing a maximum rate of li200 lb/hr and testing at 0, 600, and 1,200 lb/hr. Data feed gainedf~'om these tests combined the results of' Task5 will showthe feasibility of alkali with adsorptionin the gasifier and lendto further improvements the gasifi.er design and in operation, Given the infomaadonPowerSetvehas about the solids handling equipment, the addition of 10%mass flow should be acceptable. This flow tare is well below the maximum of the limestonef~..eding systemwhichwill be used periodic.ally and shouldbe within dae excess capacity in this design. However, moredetailed information about the solids handling system design and capacity limits a~e necessary to determine the maximum dmountof sorbent feedingpossible., Sorbent FeedingMethod:The second a~ea of' interest is the methodfor feeding the extra sorbent.. Thefeeding methodwill dependon the sorbent chosen, but pt~visions should be made for' recycling bottomash as well., If' bottomash fi-omthe gasifier is used, the ash mustbe recoveredf/omthe filter cake on the drumf'tltero This filter cake could be transported with a front end loader and mixed with the coal before it is loaded onto the charge hopper and introduced into the GPIF facility,, A systemto meter and mixthe sorbent and coal will be required,, Also, the design of the crusher and drier systemmust be reviewedto determineif' this systemcan handle the addedcapacity of' solids and moistureand if the size and hardnessof' the recycledash will presentpr'oblems,,

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Sorbents such as clay wouldbe addedinto the limestone feeding system, If' the sorbent is addedby itself, it wouldbe fed in the samemanner' the limestone, through a as pneumatic transport line to the limestonestorage hopper'.. If the sorbent is addedwith limestone, the mixturewill be preparedoff:-site, and transported pneumatically into the systemas a mixture. In this case the design of- the limestone feeding Systemmust be reviewed assure that it has the capacity and the ability to handlematerials of different to density and particle size than the limestone. Upper Gasifier Design: The ~c0nd area of impact is in the design of the downward flowing char bed in the upper gasifier. Whilethere are many constraints on the design of this bed, one critical comtmint be the capture of alkali and uace metal species., The may release of these species will occurmainlyin the pyrolyzer., Vaporphasealkali species react, with silicates or aluminosLlicates reactions such by 2NaC1+ AhO -2SiO2 ÷ H20 --, 3
7

Na20"A1203-2SiO2 + HC1

Other metal species can react with the aluminosilicates (clays) and limestone similar' ways,, Thecapture of these elementsis controlled by the followingparameters: Sorbcnt loading, activity and surface area Uppergasifier bed residence time Water vapor concentration Chlorine content of the coal Tempelature,. Thegoal of' the Task:5 activities is to deffmethe conditionsrequired for alkali and trace metal control. Therefore, the design requirementsfbr the upper bed cannot be set at this time,. In the preliminary design repot%a methodology utilizing the data generatedin for Task5 will be given, along with the data deficiencies at present,. Theconclusion, at present, is that the capture of alkali and trace metalswill increase as the residencetime in this portion of the bed increases. Therefbre, the bed height should be maximized the gas velocity and minimized increase capture,. to In the absenceof conclusive rote information, the approachtaken for the preliminary design is to ensure adequatecapacity for up to 10% additional feed material and ensme that residence time in the upper gasifier bed is maximized respect to other design with constraints., This approach will ensure the flexibility of' the systemto study control of alkali and trace metal emissionswhile minimizing restrictions on the design until the necessary the datais created,.

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Design Impacts of Clinker Control Clinker fbrrnation results fi'omsintering of ash'patxicles at temperatur~ fbundin the gasifier fixed bed combustion zone.. Thesintering can result in two problems.First, lalge agglomerates ash particles can form whichaxe difficult to pass tluough the ash grate., A of moredifficult problem the formationof large agglomerates the gasifier wails.. In the is on GPIF reactor, the agglomerates could bind either' to the outer gasifier surface or' the pyrolyzertube,. Themain waysto control this problemare : control the maximum temperature (add steam to the blast bed control the distribution of air and steamflow throughthe bed limit the coal choice due to ash properties minimizelimestone and sorbent addition select gasifiei' shell and pyrolyzertube materials that do not react with ash provide mechanical meansto dislodg~ eiinkers,, Theapproachto designing the clinker control subsysteminvolves experimefital work to understandclinker' formationand adhesionas a function of: temperature ash particle properties and interaction between particles ash limestone and sorbent addition gasifier materials of construction, Theresults of this study will be combined with a sintedng modelto predict the effect of coal choice, additives, gasifier design, and operation on the tendencyfor clinker formation and adhesion.. Theoverall control approachis to define gasifier design and operating conditions required to minimizeclinker formationand adhesionwith respect to the coal and additives beingutilized.. TheTask5 studies are necessaryto state the adjustmentsnecessa, ty to the lower' bed designto preventclinker' formation.. Design Impacts of Tar and NH Control 3 Previousf'Lxed-bedgasification experienceindicates that tars and NH emissionscould 3 pose significant problems the success of GPIF..If tars are emitted fromthe gasifier in to

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significant quantities, restrictions in flow can occur' wherethe ta~s condense; this condensationcan occur throughoutthe gas handling equipment resulting in gasifier downtime..NH is producedduring gasification wheresignificant amountso[ Steamare 3 added.. It is expected that high concentrations of NH will emergefrom the pyrolyzer 3 section, and if left untreated could result in high concentrationsof NO when gas is the x combusted.. Thecontrol of tars and N-H will be accomplished the upper dome the gasifier in of 3 by injection air through a "rebumer",, Theconceptualdesign allow fbr the addition of enoughair to increase the gas temperature from I600*Fat the pyrolyzer exit to 2300"F at the top of the fixed bed. Thereare two mainmechanisms tax' destruction, .cracking and oxidation.. Both of' for these reactions can be accomplished air" injection.. Some by fraction of the mrs will be oxidized and the test will be crackedby the high temperaturesresulting fi'om the oxidation of the tars and other gases.. In order to ensure total tar destruction, all the tats emerging from the pyrolyzer must be mixedwith the ah' and hot combustionproducts and given enoughtime to react.. Thus, complete!mixing maintainingsufficient residence time are the maingoals and of the reburnerluppergasifier dome design; the mainconsuaints are rebumerreliability, ease of opeTztion, safety, and cost.. Thesecondarea addressedby the reburner is the reduction of NI-I3 generatedin the pyrolyzeroUnderthe average conditions present in the gasifier, NH is a relatively stable 3 compound.. However, addition of aii" can be optimizedto minimizeNH leaving the gasifier.. 3 Injection of air' in the upper' gasifier will reduce NH to N by two mainreaction paths.. The 3 2 fur-st step in the process is the formationof NO;whilethe secondstep is the reaction of' NO with NH to form N While there are a large numberof actual reactions occurring on the 3 2, atomiclevel, the overall reaction path can be listed as.. 4NH + 502 .~ 4NO + 6H20 3 4NH + 6NO --, 3 5N + 6H20 2

Thereforethe uppergasifier air injection results in the creation of sufficient NO react with to the NH present and then allow the reduction reaction to occur'.. 3 Whilethe overall approachto tar and NH reduction is clear, a significant amount " of 3 infomaationis necessaryto fmalize the design.. Theoverall-approachincludes workin Task 4 and 5. In Task 4, the desired conditions in the upper gasifier have been considered, resulting in number conceptualdesigns.. In l'ask 5, the different designs will be of consideredin detail regarding the different mixingpatterns created.. Also, workwill be performed better understandthe effect of temperature, pressure, and residence time on the to extent and rate of both NH and tat' destruction in the upper dome 3

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"Ihe workin Task-4 has resulted in three design alternatives whichare shown schematicallyin Figures1 to 3.. Thedesign details of these alternatives will be presentedin the Concepma71 DesignReport.. Option1 is the mixing the pyrolysis gases with the air fight at the pyrolyzerexit, of whichinvolves designingan air-cooled annuluswithin the pyrolyzer robe to convey air'., the Option2 is injection of the air' tlu'oughoneport locateddirectly abovethe pyrolyzerexit.. Option3 involvesinjection of the air tluoughtllree or four' locations on the gasifier roof to create a vortex in the uppergasifier, Thechoice of' the best injection systemwill require considerationofa number' of' conflicting requirements: tar emissions NH emissions 3 simpIe,reli.able design structural i~,'tegri~ impacton flexibility of gasifier operation cost impact. " "'----Top Air

~--Air Annulus

Figure1., GPIF pyrolyzer exit design - Option! - annular injection..

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1%-- Air

_ ~, ,~,{~.& ,~--~ ,~ Pyrolysis Products

.~ ~ Pyrolyzer

pyrolyzerexit design - Option - top injection. 2 Figure 2. GPIF

TopAir J '---- Pyrohrsis Products

i
~ Pyrolyzer

Figure

GPIF pyrolyzerexit design - Option3 - vortex injection,,

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Eachof the design options has advantagesand disadvantages.. Option 1 provides direct contact of the injected air with all of the pyrolysis gas.. Mixing rapid, since the is gases are contacted with the rebum right at the pyrolyzer exit.. Also, con'~eying air the rebum throughthe pyrolyzerannulus will preheat the air and will impro.vethe stability of air the rebuln flame.~ Extracting heat from the fixed bed side of the pyrolyzer mayeven be advantageous choice of materials of construction.. Aheat transfer analysis should be in performed estimate the cooling effect of the reburn air on the pyrolyzer tube,. Since the to tube will see temperatures as high as 2300°Fon the outside and 1600°Fon the inside, cooling will be required if the pyrolyzeris to be fabricated frommetal instead of a structural refractory.. A/so, injection of air through the pytolyzer wouldeliminate one or more penetrations through the pressure vessel. Eachpenetration is expectedto be expensiveto build and seal.. Themaindisadvantagesare the potential for pluggingthe air jets due to intimate contact with coal, the possibility of overheatingthe pyrolyzerexit due to the combustion gases by the reburner, and the general increase in complexityof the design. of Options2 and 3 .are really .variations on one design, injection throughthe upper dome..Thereason for ev..aluating twooptions is to determinewhichdesign creates the best and mostflexible mixingi~atter m. Theoptions differ in the number furnace intrusions, of injectors and flame detectors required, and the complexity the control system.. of At this stage, the impactof the reburner design on the gasifier cost es~...te depends on howmanyinjector concepts we want to test, However, enoughinformation exists to quantif~ this estimate., PowerServe proposes to design the GPIFwith two reburn systems, Consideringthe difficulty in accurately modellingthe behaviorof these rebumers,the best path to insure success is to create flexibility in the GPIF design,. Thexefore,the systemswill each be designedwith the ability to vary inputs such as jet velocity, swkl, and injection. angle° Theconcept is to allow for variations in the ~ate and degree of mixingwhichwill affect the conversion tars and NH3.,Additionally,the best path for this prototypefiacility of will be to allow for the testing of two burner conceptswith very different mixingpatterns,, Option 1 is the most complicateddesign task because of the interface betweenthe design of the py~olyzer,being performed Riley, and the design of the air reburner bei.v.g by performedby PowerSe~ve. This design option will affect the gasifier design in a number of ways: PyloIyzermaterials of' construction Injectortip(s) Distancebetween pyrolyzerexit and dome,i..e.., pyrolyzer length

Increase from one to two pyrolyzer tubes to conveythe rebum air.. Theexact impact of changein pyrolyzer materials cannot be madeuntil a detailed heat tlansfer analysis is performed,.Aninitial analysis has been performed will be and reported in the ConceptualDesignreport.. However, moteinformation about the gasifier

9

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conceptualdesign will be neededas a basis fi~r the final heat ttansf~r analysis to be made in Task6, detailed design., Theinjector tip designs will have minimum impact on the gasifier cost with each tip being in the $5,000to $I0,000 range,. Option 1 is the design whichaffected the length of the pyrotyzer least becausethe mixingis occunSng the pyrolyzer exit.. Other' designs may at involve Iengtheningthe pyrolyzer (or reducing the dome height) to ensure proper mixing.. It is easier to estimate the cost impacts of Options2 and 3. Themainissues are: Thenumber* size of furnace intrusions and Theinjectors themselves Distancebetweenpyrolyzerexit and dome,i..e., pyrolyzer length..

In the case of Option2, one furnace intrusion will be necessary; Option 3 requires three or fbm'intrusions.. ~'he injectors will be simple, with watercooledinjector' tubes and nozzle tips being the mainiitems.,.. Thecost of these injectors is estimatedat $10,000 each. The effect on the pyrolyzer length will be determinedin the Task 4 mixingstudies, Desi_maImpact of GI'IF Instrumentation Accurateand reliable process monitoringand control of the GPIF facility is of critical importance,Thetest gasifier facility will be equipped with a state-of-the-axt control and instrumentation system which will include advancedmeasmement techniques to monitor temperatureprofiles, gas composition,and other parametersof the process° PSI PowerServe (formerly PSI Technology)is responsible for the instrumentation neededto assess gasifier performance., PSI PowerServe will design and develop, or select and specify, all specialized instrumentation for monitoringthe PyGAS reactor', Ourgoal is to provide all the measurements requLredfor' successful commercial development the of PyGas system.. A list of the all the instrumentationaroundthe gasifier is containedin Table I,. Figure 4 presents these monitoringdevices,. Mostare standard pressure, temperature and flow instruments on inlet and outlet streams whichshould require no developmentwork.. However,there are a numberof measurement tasks which will be more difficult,. Thesetasks are related to the fact that GPIF a pilot-scale facility, and one of the is tasks is to fully evaluatethe perfi~rmance this first version of the PYGAS of' process.. It is expectedthat latter' units will not have the samelevel of monitoring equipment necessary., This document contains a functional description and cost estimate of the above instrumentation subsystems,, The discussion in this report concernsthe non-standardand difficult tasks,. Bothlevels of instrumentsare shown Figure 4.. in

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Table 1., GPIF Instrument List rag No. AI'-001 AT-002 ATq303 ATq?04 AT-05 Extractionprobes Particle impactor for PSD Alkali and trace metal trap Gas conditioning system CO, H CH4, H2S 2, analyzers Data acquisition system and cabinet HI-IV monitor Vertical tern .perature probe Horizontal,!e ,mperatureprobe Optical pyrometer Miscellaneous thermocouples Pressurizedoptical pyrometer port Datalogger for temperature data Upper dome pressure Miscellaneouspressure transducers Gasifier bed level - microwave technology Flowtransducer ,, Description NH3/HCNanalyzer . ' Quantity 1 3 1 2 1 Cost/" Instrument *Included $I0,000 $I0,000 $15,000 $150,000 Total Cost *Included $30,000 $10,000 $30,000 $150,000

.

AT-006 "rr-ool TT-002 Ti'-003 "IT-004 TP-O01 TR-O01 PT-001 PT-002 LT001 FT-O01

1 10 i2 2 1 5 1 1 14 1 13

$20,000 $2,000

$20,000 $20,000 $12,000

*Included Various $2,000 $30,000 $2,000 $1,000 $5,000 Various

*Included $5,000 $10,000 $30,000 $2,000 $14,000 $5,000 $21,3~

*Part of PSIproposalsubcontract; all other costs are responsibility of CRSS..

The issues to be discussed in detail are: Gas and pan:iculate sample exuaction system Optical sampling port Gas analysis system Alkali and l~ace metal analysis system Continuous gas temperature monitoring in the upper gasifier Reactor bed temperature profile monitoring

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HHV H2S CO NH H2 3 HCN CH4 CO 2

Pressure Reducing

Water

Hot Gas

Speed Control

Coal

Ash Removal Ash Monitodng

C-3185C

Figure 4.,

Monitoring and control

devices around GPIF,,

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Gasifier pressure measurement Gasifier bed Ievel measurement.. Gasand Solids will be sampledat two points: after' the cyclone located downstream of the gasifier and in the upper' gasifier region.. Theexpectedconditions after the cyclone and pressure let down are: Maximum temperature of 1100*F Gas pressure of 20 to 30 psi Verylow particle and tar Ioadings under normalconditions.. Sampling will also be performedin the upper dome;this will give information about the operation of the various stages of the gasifier: the pyrolyzer, the upper dome,and the fixed bed; Theexpected conditions in the dome muchmoredifficult: are Maximum t~mperature of 2500°F ¯ Opera'dng p,~essmeof 200 to 600 psi gas Moderately l~igh particle and tar Ioadingso Both systems will utilize the same-sampling probe design. Tl~s extraction pto~ will transfer the gas and particles to either' a samplecollection device, a ~emote monitorsetup, or analysis equipment located adjacent to the gasifier. Sampling will occur continuouslyfor somespecies and on an intermediate basis for others.. In addition to withstandingthe temperaturesand pressures cited, the extraction system mustnot allow depositionof' ta~s or particles inside-the sampleline or react with anythingin the gas stream.. Theextraction probe conceptual design is similzr to designs PSI PowerServe has used for other" experimentaldevices, and PowerServe provide the design for' these will probes. Eachprobe is water-cooled, madeof 316-stairdess steel and lined with a porous metal tube tl~'ough whichnitrogen passes into the gas sueam, The purge wouldreduce the samplegas temperature but maintain the high pressure and prevent deposition on the probe walls.. Care must be taken to use minimum dilution of the gases so that the concentrations do not fall belowmirtimum detection limits for each gas.. Different lengths of probes will be made alter the samplinglocation within the gasifier.. Thedifferences in temperaturefound to at the two samplelocations will be compensated by the amount nitrogen addition in the for' of exu'actionprobe, so that the gas temperature exiting the probe is constant.. After the extraction probe, thele wouldbe a number samplinglines fbr gas of conditioning prior to the gas analysis systems. The design will dependon the sampling location~ and the specifics of these systemswill be discussedlater in this report when the analysis technique addressed.. is

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_Optical AccessPorts Thegasifier will also contain 5ptical access ports to utilize the twooptical temperature monitors (GASTEMP~ provided by PSI Environmental Instruments. being Thedesign of each port should be such that the end of the port containing the window and associated elementscan be connectedto the gas samplingports.. In this way, wecan obtain maximum flexibility with minimum pressure vessel intrusions,. Aboutten furnace intrusions ~' and will be necessary to accommodate locations for GA_STEMP gas sampling, five in the the upper' gasifier dome five in gasifier outer shell (before the gas exits).. Endpieces and will be designedfor these ports including optical access windows, extraction probes, and blank end caps to block off the por~; not being used at any particular time. Theoptical access assembly provides a 2 in.. diamcleat' openingand bolts to standard ANSI flanges...Standard sizes up to 8 in.. diamare available fromvendorsfor' other' applications.. It can be equippedwith an optional "spray ring" whichis used to keep the window clean.. This ring can be steam, air', or nitrogen fed for' use in the gasifier., (Morgantown EnergyTeqhnology Center personnel will give advice based on their patented process for' window cleaning:) Mateiials of construction should be 316-stainless steel for' corrosion resistance witheither quartz or sapphire windows high temperature and for pressure.. Theports should also be water-cooledin order to maintainthe high pressure rating ~' rail-type moia..nting system of the steel at elevated temperatures. Thestandard GASTEMP can be used with a clamping ring attached to the optical port flange to stabilize the instrument's sight tube if necessary. Additionally, valves maybe attached to the ports to allowcleaningwhilethe gasifier is on line.. G.as,, Patti.tie., Tar', ~ali, and TraceMetalSample Conditioning, Capture,an.d ..Analysis Thegas, particulate, tat', alkali and trace metal analysis systemsall have interdependent requirements, and therefore mustbe discussed to~ether.. Gasand particle samplingwill occur' at two points, the upper dome after' the cyclone.. Theextraction and system will be very similar at both locations, and a conceptualdesign waspresented previously.. Thenext step after the temperaturereduction will be the reduction of pressure to the level necessaryfor the sampleconditioningand analysis system.. At present, a conceptualdesign for the systemexists whichis detailed enoughto give an overall view of the systemrequirementsand cost.. However, this area represents the largest cost component the instrumentation under the PowerServe of scope.. Vendors at'e still being contacted, and consideration is being given to a number' majorissues, including of pro'chasing components from one or morevendors or purchasing the whole system from one vendor, completewith instrument housing, data acquisition, control system, and a manual.. Theoverall systemapproach preferred if the price, reliability, accuracy, and precision is necessary can be guaranteed. Aschematicof the overall systemwhichwill be applied to samplingand analysis at both locations is shownin Figure 5. Themostimportant dif-f~rence in the two locations

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J
} "I Exlraetion0~ Probe C~.e Impinger System Alkalis, Trace Metals

impactor| System GasConditioning CO,H;z,CH4~-i2 (~ NH3,H H Analyzer DataAcqu~sition System Alkalis, Trace Medals .

I
C-4673

Figure 5. Gonceprualgas and particle samplingand analysis uain. froma sampleanalysis stkudpointwill be the concentrationo£ pardcula.te and tar in the upper' dome.Two s'a'ategies arc being considered for dewingwith tars so that clean g~ses can be analyzed fbr CO, H CH H2S, HCN,and NH3: 2, 4, immediatelyquenchand removethe tars and particulate befoze gas analysis capture the patticu, late in a cycloneand filter systemand keepthe gas temperature above600°Fto keep the tars from condensinguntil after gas analysis Thelatter systemhas been offered by a vendorexperiencedin instmmeiatationfor gasifiers, and, if it can be provento woxk,shouldbe a very attractive alternative. As stated, the alkali and trace metals will be measuredin a batch mode.Two systemsare being consideredfor capturing tars, particulate and vapor species close to the gasifier.. Thefirst option is a modification of EPA Method to be capable of running 29 under the reactor pressure.. The second is a modification of a novel HazardousElement SamplingTrain (HEST)being developed by Chester" EnvironmentalCompaniesfor the EPA and EPRI.. Onceagain, we have to adapt the system to the temperatures and pressures of GPIF,but the systemconsists of a cyclonefollowedby cat'bon impregnated f'flters to capture the timer material.. TheHEST systemis ptefezred fbr a number' reasons, including ease of of operation, accuracy, cost, and the f~ct that the systemcan be morereadily adapted to ° measuringNH3.TheNH monitor will requi~e a clean sample that is at 450 to 500°t=, and 3 bubbling the samplettu'ough impingerswill temovethe NH3.. "Ihe informationgeneratedfrom the on-site gas analysis equipment should be sent to a cenual data acquisition systemfbr monitoring, manipulating, and storing experimentaldata output.. This systemshould be capable of' providing updatedreports on the gas composition,

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gas temperature, and bed temperature systems along with other key data points concerning gasifier operationso that this systemfunction can be manipulated independen.t,ly fromthe gasifier operation. Particulate will be sampled size-segregatedin a particle impactorsystemto create and sampleswhich will be analyzed to showthe dependence trace metals and alkali content on of particle size. This informationwill be used to understandthe behavior of these elementsand to predict the efficiency of emissioncontrol equipment removing for alkali and trace elements from the gas. Tern.pe.rature Measurement For gas temperature measurements, the PSI GASTEMP" be used., This will instrument is developedfor' high temperatureapplications in eoal-fn-ed eombustors., Fwo regions will be continuouslymonitored,the upper dome the outer shell/gasifier exit.. and Pyrolyzerand gas:ifier bed tempetatuieprofiles will be monitored using vertical and horizontal ceramic temperature probes (CTP)(Figure 6). In the conceptual design, we proposedten vertical ceramicprobes, inserted fi'om the gasifier top and extendingthrough the gasifier., Thehorizontal probeswill extend3 tO 6 in. into the bed; Ibur probes will ~ locatedon three levels to get a full picture of. the gasifier temperature profile,,

Figure6.. GPIFtemperature profil e monitoringsystem.,

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EXHIBIT LETTER

"F" 22, 1993

OF OCTOBER

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CRS Sirrine Eng!fieers,. Inc.. PowerDivisi.6n . ¯ 10.~1 Butler Road Greenville~ SC 29606-5456
,:

Attention:

M~.,.

L .a~.yS

Hou~e,

Pr0jee.t

Director

....

Subje.~t!.. C-3asifieafi0n Pr~odu.et. Lrnprov. emen~tFacility .(GPI~). PSITSubcontract No. I:I7i Dear ~., House: ~ confima the conclusion 0f negd~iations oe

: PS Technology ComP.any(ps./~ is pleascd..to ! its su.bcontract a~. follows: ¯ :. Total: Estimated; Cost and Fee: Cost Share: Total Co~ t o SPbnsor:

¯ $904,62.5i.

080,925)
$723,700

The .follow~ng.ehange~shall be mhdeto the resultant subcon.tract as discusse.d 21 O~tober 1993 a.tME"ICwith.M... M.0rgan (PSi, L.. Brandt and R-. Johns6n .~.-. TC),ha L, House (CRS) d and outline, d in '.METC letter (uns!gn~d) dated October 19, 1993: 1) " PSI agree~, to delete subtasks 5..1 .and .5..2, cqnc~m~ng bench s~le experiments 9n alk~i and trace mefalcapture,. ~ntire.ly and has reduced costs ~ppropfiately. 2) tt is understood that subt.~k. 5..4; coriceming mathe.~afical moddliingof the gasifier. ~ir injector, .shall remain uncha~, ged and shall continue to remain a i~art of PSrs work scope and subcontrh~t. .PSI has revi~ed the d.esc.riptio n of Task 5 in Exhibit A, to exclude ~e. statement "ev~u,afin~ work at

3)

In addition -to the ~bove, please rioie .that PSi had 6uflined in its 20 Septembe.r19.93 ~ubmission a reduCtion/revision to the work scope 9f subtasks 5..1 and 52 and th~ delefior~ of ¯ su.btask: 5, 3 (bench scal~ studies of clink6r formation) as well as a redu.cti0ia to tasks ;7 ~d 9 (on site acfiqifies) ofthe PSI "~ork ~cope. : " "

Teleph?ne:~.508) 689-000,.i

20"New England Busihe_ss Ce.nter, .~,ndo~;~r, CompuServe: [76000,

Facsimile: (508) 689-3232

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 26 of 28

Page 2 of 2

-.. Enclosure:. as stat.ed abo~/e

Contracts Administrator

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 27 of 28

A DI.V. ISION OFPHYSICAL $CIEt~(~:ES 'INC

CERTIF!c~T.'E CURREN.r OR COST pR~cINe DaTa
This is to certify .th.~t, to the best ofmy knowledge belief,, the and. cost or pdcingd~.ia (a#Acquisit section i.5,80J of " definedion in the. isederal ¯ Regulation (FAR-)a.nd required:unde~"FAR subsec!ig.n., i s.8(~4-2)-submi~e.d either actually OrBy sp#cific |~lentifica..t~gn in w~ffing,.to the .contracting officeror ~thec.~ntracting offi. ceres representatiye,suppo..rt PS~T in. of. Pr.~p~sa~ No. 1 !71 are accurate, :.c0mplefe~ ~ndeurrentas of 22 ¯october ~99&This cei-tific~tion includes cdst 5r pri.cin~ data ~Up~.orting ~aEl~nce th~ any ¯ agreements forwardpri.c.ing rate.. agreements and between thebfferor and the Government tl~at are part of the proposal. .

Date

Telephone: (50g) 6.8.9-0000

" " Co.m~uSe~e:[76300, 2!67]

"

Fac3imite: i.~08) 6.89.-3232.

Case 1:02-cv-01500-GWM

Document 78-6

Filed 10/02/2006

Page 28 of 28

CERTIFICATE I hereby foregoing certify that

OF

FILING 2, 2006, APPENDIX" a copy was this of the

on October

"DEFENDANT'S

SUPPLEMENTAL that

filed filing will be

electronically. sent to all

I understand

notice of the

of

parties may

by operation access this

Court's through

electronic the Court's

filing

system. system.

Parties

filing

S/

James

W.

Poirier