The University of Missouri-Rolla will identify materials that will permit the safe, reliable and economical operation of combined cycle gasifiers by the pulp and paper industry. The primary emphasis of this project will be to resolve the material problems encountered during the operation of low-pressure high-temperature (LPHT) and low-pressure low-temperature (LPLT) gasifiers while simultaneously understanding the materials barriers to the successful demonstration of high-pressure high-temperature (HPHT) black liquor gasifiers. This study will define the chemical, thermal and physical conditions in current and proposed gasifier designs and then modify existing materials and develop new materials to successfully meet the formidable material challenges. Resolving the material challenges of black liquor gasification combined cycle technology will provide energy, environmental, and economic benefits that include higher thermal efficiencies, up to three times greater electrical output per unit of fuel, and lower emissions. In the near term, adoption of this technology will allow the pulp and paper industry greater capital effectiveness and flexibility, as gasifiers are added to increase mill capacity. In the long term, combined-cycle gasification will lessen the industry's environmental impact while increasing its potential for energy production, allowing the production of all the mill's heat and power needs along with surplus electricity being returned to the grid. An added benefit will be the potential elimination of the possibility of smelt-water explosions, which constitute an important safety concern wherever conventional Tomlinson recovery boilers are operated. Developing cost-effective materials with improved performance in gasifier environments may be the best answer to the material challenges presented by black liquor gasification. Refractory materials may be selected/developed that either react with the gasifier environment to form protective surfaces in-situ; are functionally-graded to give the best combination of thermal, mechanical, and physical properties and chemical stability; or are relatively inexpensive, reliable repair materials. This report covers Task 1.4, Industrial Trial of candidate materials developed by refractory producers and in the laboratory based on the results of Task 1.1, 1.2 and 1.3. Refractories provided by in-kind sponsors to industrial installations tested by cup testing, density/porosity determinations, chemical analysis and microscopy. None of the materials produced in this program have been tried in high temperature gasifiers, but the mortar developed Morcocoat SP-P is outperforming other mortars tested at ORNL. MORCO PhosGun M-90-O has shown in laboratory testing to be an acceptable candidate for hot and cold repairs of existing high temperature gasifiers. It may prove to be an acceptable lining material.
