Integrated Sensing & Controls for Coal Gasification – Development of Model-Based Controls for GE‟s Gasifier & Syngas Cooler

This technical report presents the development of an integrated sensing and control solution for gasification processes at GE's facilities. The objective is to enhance operational efficiency through advanced model-based controls, particularly focusing on the gasifier and syngas cooler sections. A comprehensive methodology involving modeling, sensor implementation, and control system design was employed. Key tasks included modeling the gasification section, implementing fiber optic sensors for temperature and strain at the TECO Integrated Gasification Combined Cycle (IGCC) plant, and designing an extended Kalman filter (EKF) for real-time monitoring. Results demonstrated successful integration of model-based methods with sensor data, enabling improved monitoring and performance estimation of plant operations. The model predictive control (MPC) was tested in advisory mode, providing operators with enhanced decision-support capabilities, while suggesting pathways for future implementations in closed-loop operations. This overall approach aims to optimize not only the gasification section but also potentially integrates across the entire IGCC plant, promoting advanced control solutions for improved operational outcomes.