Pilot Plant Gasification – Fixed Bed and Entrained Flowas final step in RD&D activities
A. Laugwitz, O. Schulze, F. Mehlhose
Origin
2DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4558
Excellence inRessources and Education
since 250 Years
Institute of Energy ProcessEngineering & Chemical Engineering
Chair EVT
Excellence inThermo-Chemical Conversion
since 100 Years
Excellence inHigh Temperature Processes
since 2014
Source: TU Freiberg
Overview of technical and laboratory equipment
3DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Pilot plants (5-10 MWth)• GSP gasifier• Fixed-bed slagging gasifier• HP-POX• STF – Syngas-to-fuel
Larger test facilities• COORVED gasifier• Reaction kinetics
pressurized drop tube reactorspressurized TGA
• Pyrolysis:pressurized drop tubespressurized fixed beds
• Large sample furnace
High perfomance laboratory equipment• (T)-XRF• XRD• SEM and FIB-SEM• ICP OES / MS for fluids• Laser- or ETV-ICP OES / MS for solids• Thermo-optical measurement
TOMAC/TOMMI • Thermal analysis
TG, DSC, DTA, EGA• Py-GC-MS/FID• GC*GC TOF MS• FT ICR MS• NMR• IR
Routine analysis systems
Fixed-bed slagging gasifier
4DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Feedstock testing
• Fluxing agents screening/ slag discharge
• Crude gas yield
• Measuring and controlling yield of tars and oils
Operated by since 2014
Projects on gasification of:
Petcoke, lignite, RDF, biomass
40 bar
10 MWth
12x12 m
22 m heigh
Fixed bed with liquid slag discharge and slag quench
GSP entrained-flow gasifier
5DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Feedstock testing• Fluxing agents screening/ slag discharge• Crude gas yield• Burner design• Dense flow feeding properties
Operated by since 2018
Equipment:
• Gasifier with cooling screen and spray quench• Pulverized fuel dosing & feeding system (or Slurry feeding) • Gas treatment
• Desulphurization unit (Sulferox)• COS/HCN hydrolysis
• Waste water treatment• Gas and water sampling system
25 bar
5 MWth
Gasifier with cooling screen and spray quench
Permission for waste gasification
Feasibility Study
Pre-Basic Design
Experimental Substantiation
Detail Engin. Manufactur.
Process Optimization
Stages of RD&D Activities
6DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
scrubber
mill and feeding system
gasifier
quenchroom
make upwater
CO-shiftstage 1
CO-shift stage 2
coolingwater
acid gasremoval
clean gassaturator
clean dry gas
saturated clean gas to CC
H2S to Claus-plant
HP-steam to CCB
P-471
Air Separation Unit
N2 to CC
A
Diluent N2 from ASU
G
G
ambient air to MAC
O2 to CC(preheating)
A
B
I
I
condensate
feedstock
coal
raw gas
slag waterdischarge
saturated, diluted, preheated fuel gas
water discharge
CO2
excess N2 to environment
IP-steamfrom CC
waterdischarge
O2
make upwater
condensate
make up water
pureGAN
Project Examples – 1st Stage: Feasibility StudiesCoal-to-X for 2 Russian coals
7DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Feasibility of CtX routes in Russia
• Coal ash/slag properties
• Comparison of different gasification & synthesis technologies
• Thermodynamic and economic evaluationscrubber
mill and feeding system
gasifier
quenchroom
make upwater
CO-shiftstage 1
CO-shift stage 2
coolingwater
acid gasremoval
clean gassaturator
clean dry gas
saturated clean gas to CC
H2S to Claus-plant
HP-steam to CCB
P-471
Air Separation Unit
N2 to CC
A
Diluent N2 from ASU
G
G
ambient air to MAC
O2 to CC(preheating)
A
B
I
I
condensate
feedstock
coal
raw gas
slag waterdischarge
saturated, diluted, preheated fuel gas
water discharge
CO2
excess N2 to environment
IP-steamfrom CC
waterdischarge
O2
make upwater
condensate
make up water
pureGAN
Calculation case 1 2 3 4
CAPEX 40.31 31.73 44.84 34.17
Fuel costs 8.47 7.46 8.38 7.22OPEX including service 22.66 17.71 25.01 17.79
Annual costs 71.44 56.90 78.23 59.18Revenue for the by-products -13.15 -10.91 -13.38 -10.86
Product costs- in €/MWh product- in €/t product- in €/litre product
58.29697.17
0.54
45.99550.01
0.43
64.85775.63
0.60
48.32577.93
0.45
Data and graphics from Springer
Gasifier 1 Gasifier 1Gasifier 2 Gasifier 2
Gasifier 2 Gasifier 2Gasifier 1Gasifier 1
Project Examples – 2nd Stage: Pre-Basic EngineeringBGL gasifier in Allam Cycle IGCC
8DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
K. Uebel, 2015
Scope:• Gasification island
• PFD/Main equip. list
• General arrangement drawings
• Consumers and consumption
• Thermodynamic calculations (key performance indicators)
• Operational experiences from pilot
Project Examples – 3rd stage: Experimental SubstantiationPhosphor recovery from sewage sludge
9DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Feed characterization
• Ultimate, proximate, ash composition, fusibility, release of elements at different temperatures
• TGA gasification
Wan an wf an wf an wf an wf an wf an wf an wf an wf an wf
KS-01 (4065) 1.28 35.1 35.5 33.5 33.9 4.76 4.82 4.86 4.92 1.29 1.31 0.15 0.15 1.15 1.16 19.4 19.7 100 100KS-03 (4067) 0.91 39.4 39.8 30.6 30.9 4.37 4.41 4.34 4.38 1.23 1.24 0.34 0.35 0.89 0.9 19.5 19.7 100 100KS-06 (4070) 0.86 37.3 37.6 32 32.3 4.44 4.48 4.71 4.75 1.34 1.35 0.09 0.09 1.25 1.26 19.5 19.6 100 100KS-08 (4072) 0.93 36.8 37.2 32.6 32.9 4.57 4.61 4.66 4.7 1.75 1.77 0.39 0.39 1.36 1.37 19 19.2 100 100KS-10 (4074) 0.55 39.9 40.2 30.4 30.5 4.38 4.4 4.73 4.76 1.1 1.1 0.4 0.4 0.7 0.7 19.4 19.5 100 100KS-11 (4075) 0.76 39.3 39.6 30.7 30.9 4.5 4.54 4.56 4.6 0.99 1 0.27 0.28 0.72 0.72 19.4 19.6 100 100
ProbeN St SA SC O SummeA 815°C C H
Elementaranalyse - Klärschlamm [Ma-%]
0102030405060708090
100
0 100 200 300 400 500 600 700 800 900 1000
m/m
0 in
Ma.
-%
Temperatur in °C
TGA CO2
4065 4067 4070 4072 4074 4075
10DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Feed characterization
• Ultimate, proximate, ash composition, fusibility, release of elements at different temperatures
• TGA gasification
• Bench scale gasification trials
Project Examples – 3rd stage: Experimental SubstantiationPhosphor recovery from sewage sludge
Project Examples – 4th stage: Process DesignBiomass gasification
11DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Experimental investigation of pyrolyses of torrefied biomass
• Identifying optimal process conditions in a rotary kiln pyrolyzer
12DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Experimental investigation of pyrolyses of torrefied biomass
• Identifying optimal process conditions in a rotary kiln pyrolyzer
• Basic Design for a pilot
• Manufacturing and Delivery of rotary pyrolyzer (100 kg/h)
Project Examples – 4th stage: Process DesignBiomass gasification
13DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
Scope:• Testing feedstock and fluxing agents• Optimal process temperature
• PCI burners• Testing different burner configurations
Project Examples – 5th stage: Process OptimizationGSP gasifier operation
Thank you for your attention
14DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4192
From bench scale … From flowsheet …
… to pilot scale
Excellence in High Temperature Processes
RD&D Services
… to CFD