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Institute of Energy Process Engineering andChemical Engineering
Development and Modelling of 3rd Generation Gasification Concepts for Low Grade Coals
Martin Gräbner, Alexander Laugwitz, Bernd Meyer
International Freiberg Conference on IGCC & XtL Technologies
May 3rd – May 5th 2010 – Dresden, Germany
Paper # 06-1
2
Outline
1. The 3rd generation of gasifiers
2. Low grade coal in the sense of this study
3. Introduction of research approach
4. Development of ternary gasification diagram for standard coal
• Process conditions
• Performance parameters
5. Overview of proposed gasifier concepts
• Introduction of the INCI-concept
6. Application of the ternary diagram for high-ash coal
7. Conclusion & Outlook
3
1. The 3rd generation of gasifiers
1st generation 2nd generation 3rd generation
Since 1920s 1970s ~1990
etc.
GE
ConocoPhillips
BGL
HTW
Shell
SFGT
KBR
MHI
Lurgi dry ash
WinklerKoppers- Totzek
etc.
PWR
INCI
[1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle – Technologien und Projekte 1970-2000 in Deutschland, DGMK, Hamburg, 2008[2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002[3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993[4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005[5] Lynch, T. A.: Conoco Phillips – Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005[6] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology – Today’s Solutions and Developments, 2nd IFC, Freiberg, 2007[7] Smith, P. et al.: KBR Transport Gasifier, GTC, San Francisco, 2005[8] Ota, K.: PRB Coal Gasification Test Results with Air-Blown IGCC, GTC, Washington DC, 2006[9] Hartung, J.: PWR Compact Gasification System, GTC, Washington DC, 2006[10] IEC Material
[1]
[2][3] [10]
[4][5]
[6]
[8]
[9]
[7]
[10]
[10][10]+ newconcepts for2nd generation
4
2. Low grade coal in the sense of this study
South Africa USA Coal (typical) Pittsburgh #8
[11]Coal rank (ASTM [11]) HV C Bit. HV A Bit.Moisture wt% 6.0 2.4Proximate analysis (dry basis)
Ash wt% 25.0 10.2Volatiles wt% 23.0 36.1Fixed carbon wt% 52.0 53.7
Ultimate analysis (dry & ash free basis)Carbon wt% 80.0 83.3Hydrogen wt% 4.0 5.7Oxygen wt% 13.0 8.3Nitrogen wt% 2.0 1.4Sulphur wt% 1.0 1.3
Calorific Value (dry basis)Lower Heating Value MJ/kg 21.9 31.5
[11] Miller, B. G.; Tillman, D. A.: Combustion Engineering Issues For Solid Fuel Systems, Academic Press, New York, 2008
Technical limitations e.g.:
- Carbon conversion (encapsulated C)
- Efficiency due to physicalheating/cooling and melting of ash
- Coal preparation (grinding, de-ashing,drying, slurry energy density)
- Vast amounts of fines available
Ash property issues:
- Flux material addition
- Oxygen consumption by mineral matter(e.g. Fe3 O4 , FeS2 )
- CO2 emission by heating of carbonates(e.g. calcination of CaCO3 )
- Increased fouling in HRSG due toincreasing amounts of vaporized ashcompounds
High-ash coals in gasification processes
5
3. Introduction of research approach
Pathway to systematic and unified concept evaluation
Basis: Public domain data of 2nd generation gasifiers
Thermodynamic modeling and validation of gasifiers and gas cooling (Aspen Plus)
Standardi- zation of boundary conditions
Development of ternary diagram for Pittsburgh #8 coal
Incorporation and evaluation of proposed concepts
Diagram extension to high-ash coals and systematic concept evaluation
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4. Development of ternary gasification diagram
- Contacting various massflows of Pittsburgh #8coal with gasifyingagents H2 O and O2
- Definition of processtemperature byequilibrium calculation
- Definition of residualcarbon iso-lines,indicating conversion
domain of combustion (O2 excess, oxyfuel)
domain of gasifier operation
domain of kinetic limitation
4.1 Process conditions
7
4. Development of ternary gasification diagram
Lurgi FB
[1]
GE
[2]
ConocoPhillips[5]
SFGT
[6]
Shell
[4]
Prenflo
[1]
HTW
[3]
- Incorporation of gasifieroperation domains
- Location of existinggasification systems
4.1 Process conditions
[1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle – Technologien und Projekte 1970-2000 in Deutschland, DGMK, Hamburg, 2008[2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002[3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993[4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005[5] Lynch, T. A.: Conoco Phillips – Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005[6] Schingnitz, M et al.: Siemens IGCC and Gasification Technology – Today’s Solution and Developments, 2nd IFC, Freiberg, Germany, 2007[12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen 27.8.2009
8
4. Development of ternary gasification diagram
domain of ηCGE > 80 %
- Calculation of cold gasefficiency on LHV basis
- Maximum cold gasefficiency identical to100 % carbonconversion line
- Definition of methaneyields in product gas
4.2 Performance parameters
9
4. Development of ternary gasification diagram
4.2 Performance parameters
- Incorporation of gasifieroperation domains andlocation of existinggasification systems
Lurgi FB
[1]
GE
[2]
ConocoPhillips[5]
SFGT
[6]
Shell
[4]
Prenflo
[1]
HTW
[3]
[1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle – Technologien und Projekte 1970-2000 in Deutschland, DGMK, Hamburg, 2008[2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002[3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993[4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005[5] Lynch, T. A.: Conoco Phillips – Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005[6] Schingnitz, M et al.: Siemens IGCC and Gasification Technology – Today’s Solution and Developments, 2nd IFC, Freiberg, Germany, 2007[12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen 27.8.2009
10
5. Overview of proposed gasifier concepts
Selction:
Siemens – partial water quench
Shell – partial water quench
[12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen 27.8.2009[13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology – Today’s Solutions and Developments, 2nd International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007[14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, 23.9.2008[15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, 18-21 May 2009[16] Zuiker, J.R.: Building on History…the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4 - 7 October 2009[17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October 2004[18] Gräbner, M.; Messig, D.; Uebel, K.; Meyer, B.: Development and Modelling of 3rd generation gasifiers for low-rank and high-ash coals, ICCST, Cape Town, South Africa 2009
Prenflo – full water quench
GE – posimetric feeding system
ConocoPhillips – Entrained slagging transport reactor
INCI – Internal Circulation gasifier concept
[13]
[14]
[15]
[16] [17]
[18]
[12]
11
Lessons learnt from analysis of established systems[1]:
- Water jacket, no brick lining+ fluidised bed gasifiers features- Slag-free tuyere nozzles[19]
- Ash particle agglomeration- Outlet temperature of ~1000 -1100 °C- Internal circulation (transport-principle, CFB)+ entrained flow gasifiers features- High central flame temperatures > 2,000 °C- Dust feeding+ new principle of post-gasification
(similar to fixed bed)- Enhanced carbon conversion by O2 /H2 O- or
O2 /CO2 -mixtures (5..13 %vol O2 )- Sensible and fusion heat recovery into
gasification process
cooling water
cooling water
primary gasification agent
coalgasification agent tuyres
Δp
Agglomerates © IEC
5.1 Introduction of Internal Circulation Gasifier - INCI
(H2 O/O2 )[1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle – Technologien und Projekte 1970-2000 in Deutschland,
DGMK, Hamburg, 2008.[19] Lambertz, J.: Process for gasifying carbonaceous solids, and fluidized –bed reactor for carrying out the procss, German Patent
DE 3439404, 1985
12
6. Application of the ternary diagram for high-ash coal
General comments to high-ash coal:
- Shifting towards lowertemperature (generallyfavorable for ηCGE )
- No moderatornecessary
- Smaller domain ofcarbon presence
Ash properties under reducing atmosphere:
- Softeningtemperature:1290 °C
- Flow temperature:1430 °C
Sticking zone (w/o flux): 1140-1580 °C
13
6. Application of the ternary diagram for high-ash coal
[17]T>1600 °C
Moremoderator
1
1
2
Slurry 66/34
2
3
3
Mixing lines
[16]
[13]
[14] [15]
[13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology – Today’s Solutions and Developments, 2nd International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007[14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, 23.9.2008[15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, 18-21 May 2009[16] Zuiker, J.R.: Building on History…the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4 - 7 October 2009[17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October 2004
14
6. Application of the ternary diagram for high-ash coal
[17]
[16]
[13]
[14] [15]
[18]
1
2
[13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology – Today’s Solutions and Developments, 2nd International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007[14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, 23.9.2008[15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, 18-21 May 2009[16] Zuiker, J.R.: Building on History…the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4 - 7 October 2009[17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October 2004[18] Gräbner, M.; Messig, D.; Uebel, K.; Meyer, B.: Development and Modelling of 3rd generation gasifiers for low-rank and high-ash coals, ICCST, Cape Town, South Africa 2009
900°C < T < 1100°C
25-13 %vol O2
1
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7. Conclusion & Outlook
Conclusion:
-Development of an unified ternary diagram for gasificationprocesses
-No focus of 3rd generation concepts on high-ash coals (fines)
-INCI gasification concept & ConocoPhillips ESTR conceptshow high potential for high ash coals
-Most of the technology providers favor
- Dry feeding systems (even look hopper-free)
- Flexible gas cooling concepts
-Development of INCI gasifier concept for low grade coals
Outlook:
-Construction 10 kg/h INCI lab scale plant (COORVED-projectID# 0327865)
-Finishing numerical modeling of the INCI process with FLUENT
-Extension of the diagram to low-rank coals (lignite)and other gasification agents
[20] Gräbner, M.; Uebel, K.; Messig, D.; Meyer, B.: Development and Numerical Simulation of 3rd Generation Gasifiers for High-ash Coals, ICCES Paper # ICCES1020091117059, Las Vegas, USA, 2010
[20]
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End of Presentation
Thank you for your attention – Questions?
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