Gasification Technology Development under Changing ConstraintsProf. Dr.-Ing. Bernd Meyer

1

Fuel Research at Institute IEC in Freiberg, Germany

DBI-GTI

Institute of Energy Process Engineering and Chemical Engineering IEC

Appointment Erich Rammler BHT Coke

Saxony State Lignite Research Foundation

Institute of Fuel Utilisation

1918

2013

SIEMENS FGT

Deutsches Brennstoffinstitut DBIGerman Fuel Institute

HP POX- Plant

STF Pilot Plant

1990

19491956

1947

1921

2008

2009

2011

2010

Lignite ResearchInstitute

2003

Fixed-Bed Slagging Gasifier2014

2016

DBI-Virtuhcon GmbH

1965 10 bar Oil Gasification

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CTO Plant in Baotou, Inner Mongolia; Xia, 2011

Impacts on Gasification Technology Development

1990th 2005 2010

Political support forclean coal to power

IGCC power plants Maximize ηel R&D on HRSG Optimize ASU integration and

O2 purity (or air gasific.) …

Strong increase inoil and gas prices

Coal to Chemicals Demands on syngas-

quality Pressures up to 60 bar …

Shale gas boomGas to Power and Heat

Gas to power and heat Excess coal pushes into

chemicals market Fluctuating coal qualities …

Annual Energy Outlook, US EIA, 2013IGCC Bugegnum; Kanaar, 20023

Impacts on Gasification Technology Development

2013 2015 ???

Fluctuating power production from renewables (esp. in EU)

Flexibility Energy storage (Power to

SNG or MeOH) Polygeneration Partial load operation …

Environmental concerns eps. in China

Improve ecological footprint Water consumption Higher standards on

emissions and waste water disposal

…

- Optimize value added chain- Renewables to Chemicals

Horizontally integrated production routes From mining to refining (ibi) With staged conversionRenewables to H2 to Chemicals Annex concepts (Add CtL to PCC)

Fast changing constraintsCost reduction is a key issueUtilization of low-quality and high-ash coals 4

Cost Reduction

Efficiency

• Reduced O2 consumption(e.g. mild gasification)

• Reduced steam consumption

Availability

• Robustness• Design simplification • Gravimetric feeding

Space-Time-Yield

• Higher pressure (up to 100 bar)• Plug flow instead of STR

• Quench conversion (partial quench)• HRSG• Feed pumps

• Compact gasifiers• Increase thermal input per unit

• Lower degree of integration (e.g. ASU)• Knowledge about coal and ash

properties

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Gasifier Development Timeline

Theory Bench-Scale Pilot Demo Commercial

Reduce development periods for evolution/adaption of existing technology and new approaches

Past:25 yearse.g. BGL, HTW, AFB, E-Gas, Shell

Today:15 yearse.g. OMB

Still too long

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Demands on R&D towards reduced development periodsGoal: 1) Less scale-up steps

2) Direct application of new components in existing large-scale unitsMethod: Process VirtualizationNeeds: New insights in underlying physical and chemical processes

at HP/HT and reducing atmosphere

Advanced ModelingCFD

Optimization

Process Chain Modeling

1D Tools

Thermo-dynamics

Predictive SimulationFrom empirically driven process

adaptation towards thermo-dynamically and fluid-dynamically optimized solutions

Advanced Experimental Procedures

Fuel properties and kinetics Material and corrosion testing Property database and interpolation In situ measurements

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Demands on R&D towards reduced development periodsAdvanced Experimental

Procedures Fuel properties and kinetics Material and corrosion testing Property database and interpolation In situ measurements

Determination of chemical & physical material properties

Reflect conditions of large-scale gasifiers

Scope: particle level High resolution

Comprehensive property databases

and models

Measurement of selected supporting points only

Interpolation

CFD assisted Experiments & In-situ

measurements

Flow conditions inside experimental equipment

Measurements in large units

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Advanced Experiments – Material Properties

Chemical and physical property data at condition valid for real processes Fuel characterization (standard, no R&D needs)

Pyrolysis and gasification kinetics valid for HP/HT and high heating rates by drop tube reactors in

lab/pilot-plant scale PEFR (CSIRO), PITER (TU Munich), KIVAN and PYMEQ (TU-Freiberg)

Measurement of ash/slag properties at gasification atmosphere, HT (surface tension, viscosity,

heat conductivity, density)

Lab scale investigation of refractory corrosion at gasification atmosphere, HP and HT and

application of advanced analytical methods (HP/HT-XRD, SEM-EDX/WDX-EBSD)

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Validation, optimization and application of empirical/physical models for property data Pyrolysis models CPD, FG-DVC Models for heterogeneous gasification reactions CBK Property databases that allow for interpolation between measured supporting points Improved property data models/correlations for reduced analytical/experimental effort

CFD-based evaluation of experimental data Analysis of nonhomogeneous temperature and velocity distribution in

drop tube reactors (residence time, recirculation) Detailed heat and mass transfer in TGA CFD-based improved analysis of HT/HP experiments estimation of data that cannot be measured directly

Particle tracks in KIVAN reactor, IEC

Advanced Experiments – Databases and Models

CFD Assisted Experimentation

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In-situ measurement of process data at HP/HT High quality process data for validation Improved process understanding

Single particle reactionsOPTISOS, HP-POX® Slag flow

Advanced Experiments – In-Situ Measurement

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Demands on R&D towards reduced development periods

Advanced ModelingCFD

Optimization

Process Chain Modeling

1D Tools

Thermo-dynamics

Coupling CFD with e.g. Flow-Sheet

CFD results used as supporting point for faster 0D and 1D Tools

AdvancedCFD & Validation

Accurate reflection of physics and chemistry

More aspects of importance included Improved sub-models

Validation against large units Prove of Process Virtualization

ComputationalReactiveFlowOptimization

Significant speed-up in computation time

Automated case studies Grid generation Defining numerical set-up Result evaluation

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Advanced CFD Modeling & Validation

Integration of sophisticated sub-models for pyrolysis, char gasification, slag film

Physic-based sub models instead of empirical correlations

Implementation of material properties based on advanced experiments

Validation against large-scale experiments

Requirement forvirtual up and down-scaling without pilot-scale experiments

Successful Process Virtualization

2 mm anthracite; 1500K

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Process levelTypical tasks: Determination of material and heat

balance Kinetic and thermodynamic modelling Optimization of operating conditions Stationary and dynamic process modeling Estimation and scaling of equipment size Cost estimation

Identification of bottlenecks CFD investigation

Process chain levelTypical tasks: Determination of overall material and heat

balance (at different levels of detail) Overall process integration and optimization Stationary and dynamic process modeling Evaluation of overall efficiency, economics

and environmental performance

Investigation and optimization of overall process economics or efficiency

Fuel Raw Gas Syngas ProductGasification Gas Treatment Synthesis or Power Generation

Advanced Flow-Sheet Simulation

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Coupling CFD and e.g. Flow-Sheet

reaction rate H2 [kg/m2 s]

CFD simulation of WGS in quench chamber

Correlate dimensionless numbers, that are applicable to both simulations

CFD results

Correlation

Improved Flow-sheet model for quench conversion

Improved Flow-sheet for total plant

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

ambient air to MAC

O2 to CC(preheating)

I

condensate

feedstock

coal

raw gas

slag waterdischarge

water discharge

CO2

excess N2 to environment

IP-steamfrom CC

waterdischarge

O2

make upwater

condensate

make up water

pureGAN

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1000 CFD sim. in 7 daysOptimum

Computational Reactive Flow Optimization

Optimization for single componentse.g. reaction chambers, burners, experimental equipment,…

Sensitivity analyses of numerical or physical parameters

New Design

H2/CO ratioH2/CO ratio

Original Design(Quench Conversion)

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Summary

What we need:

Market compliant gasification technologies (new technologies, components and systems) at faster time to market by

- Recently obtained broad operating experiences- New fundamental process and feedstock understanding- Process Virtualization

• CFD assisted experiments

• Combining simulation tools

• Large-scale validation

• …

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Thank You

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Nuon Power Buggenum; Kanaar; GTC, 2002

China gasification market outlook; Xia; ASIACHEM 2011

Annual Energy Outlook 2013; US Energy Information Administration

Biomass fluidized bed gasification for fuel gas; Yongqi Zhang; ICC-CAS; 2014

E-Gas Technology Gasification for the Refining and Coal Chemical Industries; P. Amick; CoalGas 2014

Presentation Material, ECUST, 2015

Sources

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