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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

6

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

15

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?

Martin.Graebner@iec.tu-freiberg.de

Freiberg, Germany