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Institute of Energy Process Engineering and Chemical Engineering

Chair of Energy Process Engineering and Thermal Waste Treatment

n Efficient and sustainable use of fossil and renewable energy raw materials

n Leading in research for large-scale gasification processes based on com-prehensive knowledge of thermo-chemical conversion processes

n Educating students in bachelor, masters and diploma courses in process engineering, enviromental engineering, industrial engineering and energy technology

n Internationally linked and promoting knowledge exchange and collabora-tion between science, industry and public bodies

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Content

History of the IEC 4

Introduction of the IEC 5

Energy Process Engineering and Thermal Waste Treatment (EVT) 6

Research Groups 7

Thermo-Chemical Conversion 8

Mineral Matter 9

Low Carbon Technologies 10

Process Chain Development 11

CFD-Modeling of High-Temperature Processes 12

Technologies for Solid Fuels Gasification 13

Syngas Technologies 14

Plant Operation 15

Equipment 16

Pilot Plants 16

Bench-Scale Test Facilities 19

Laboratory Equipment 20

Software Tools 21

Training Courses 22

Networking 23

International Freiberg Conference 23

ERN - Energy Raw Materials Network 24

Service Offers 25

Contact Details 26

The history of the Institute of Energy Process Engineering and Chemical Engineering (IEC) dates back to 1918, when the Lignite Foundation of the State of Saxony was founded to support and develop the upcoming Saxon lignite indus-try. Since then, significant milestones and developments have been achieved. Building up on that tradition, the IEC is the largest institute of the TU Bergakademie Freiberg today, both with respect to the number of staff and funding for research.

Although topics in research and education and the focu-ses of the institutes chairs have seen changes in the recent decades, the IEC has maintained its close collaboration with the industry and broadened its research areas and competences in particular during the last years. The drive for excellence in theoretic and experimental research in the fields of energy process engineering, reaction engineering and numerical thermofluid dynamics remains the key focus of IEC‘s activities today.

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1918 Establishment of the “Lignite Foundation“ at the TU Bergakademie Freiberg financed by the Saxon Ministry of Finance and numerous industrial companies

1919 Foundation of the “Lignite Research Institute“ with a heat-economical lab at the TU Bergakademie Freiberg which can be seen as the precursor of the IEC

1921 Construction start of the technical test plant for the Heat-Economical Department of the Lignite Research Institute at the “Reiche Zeche“ site

1945 Transfer of the technical test facilities to the Institute for Technical Fuel Utilization, an independent institute from the Faculty of Mining at the university

1953 Foundation of the department “Processing“ with the study focus on coal and oil; later subdivision of the de-partment into the sections “Mechanical Processing“ and “Fuel Processing“

1954 Start of the wide expansion of the institute at the “Reiche Zeche“ site

1968 Assignment of the institute to the scientific field of “Reaction and Fuel Engineering“ within the section “Che-mical and Silicate Engineering“; Establishment of the teaching area “Reaction Engineering“; Further speciali-zation of the department “Coal Upgrading“ in the field of “Fuel Engineering“

1991 Scientific reorganization of the IEC after the German reunification

1994 Assignment of the institute to the “Faculty of Mechanical, Process and Energy Engineering“

2003 Start-up of the plant for the gasification of gaseous and liquid hydrocarbons by high-pressure partial oxidati-on (HP-POX)

2009 Kick-off of the first research group of the “Center for Innovation Competence Virtuhcon“ (Virtual High Temperature Conversion)

2010 Establishment of the chair of “Numerical Thermo-Fluid Dynamics“ (NTFD)

2010 First run of the Syngas-to-Fuel plant (STF)

2011 Inauguration of the new laboratory building at the IEC

2014 Commissioning of the pilot-scale fixed-bed slagging gasifier (SBV)

History of the IEC

Reiche Zeche, 2014(c) TU Bergakademie Freiberg / (Luftbildservice Dresden)

The Institute of Energy Process Engineering and Chemical Engineering (IEC) focuses on the comprehensive experi-mental investigation, theoretic description, modeling and simulation of material and energy conversion processes, e.g. syngas generation for the production of base chemi-cals or fuels, the beneficiation of carbonaceous feedstock for metallurgical and environmental applications or cata-lytic and non-catalytic flue gas treatment or syntheses.

The three chairs are responsible for fundamental lectu-res and multiple major subjects in the bachelor, master and diploma courses for “Process Engineering”. Additio-nally, the IEC is involved in the study courses of “Environ-mental Engineering”, “Energy Technology”, “Mechanical Engineering“ and “Industrial Engineering”. Since the winter semester of 2014/15, the chair NTFD offers the new mas-ter course “Computational Science and Engineering” which is jointly organized together with the TU Dresden.

The IEC is equiped with a wide range of experimental facilities ranging from laboratory to pilot scale as well as comprehensive software packages for modeling and simulation of single processes and complete process chains. Because of its strong research background, the IEC is the institute with the highest third-party funding and the largest number of employees at the TU Bergakademie Freiberg. It is Germany’s leading research institute in the field of large-scale gasification processes.

Research activities of the chairs are focused on:

Energy Process Engineering and Thermal Waste Treatment (EVT): efficient and sustain-able use of fossil and renewable energy raw materials such as coal, petroleum, natural gas, biomass and waste materials by thermo-chemi-cal conversion processes (gasification, pyrolysis, coking, etc.).

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Introduction of the IEC

Numerical Thermo-Fluid Dynamics (NTFD): modeling and numerical simula-tion of reactive flows and high-tempera-ture processes using sophisticated models combined with 3D Computational Fluid Dynamics (CFD), combining basic and ap-plied research of detailed flame structu-res for the simulation of industrial reactors.

Reaction Engineering (RT): heterogeneous catalysis and chemical reaction enginee-ring, the removal of pollutants from flue and exhaust gases, CO2 abatement, petrochemis-try, optimization of existing and development of new processing methods for petroleum and petrochemicals, biofuels and synthetic fuels.

Prof. Dr.-Ing. Bernd Meyer(Director of institute)

Phone: +49 (0) 3731 39-4511Web: evt.tu-freiberg.de

Prof. Dr.-Ing. Christian Hasse

Phone: +49 (0) 3731 39-4830Web: ntfd.tu-freiberg.de

Prof. Dr. rer. nat. habil.Sven Kureti

Phone: +49 (0) 3731 39-4551Web: rt.tu-freiberg.de

The educational and research profile of the chair of Energy Process Engineering and Thermal Waste Treatment (EVT) is focused on the efficient and sustainable use of fossil and re-newable energy raw materials by thermo-chemical conver-sion processes. A wide variety of products can be obtained from these processes such as electricity, heat, synthetic pro-ducts for the chemical industry or transportation fuels as well as metallurgical coke or adsorbents for environmental applications.

Numerous facilities and sophisticated equipment, ran-ging from lab analysis equipment to pilot-scale test plants, are applied to investigate and develop related processes and products. In addition, manifold experimental work, mathematical and scientific modeling and simulation of conversion processes, e.g. by means of conventional or high-performance computing, are of high importance to EVT‘s research. Hence, not only single processes but whole process chains are being addressed. In this way, not only is it possible to evaluate, optimize and improve existing technologies, it furthermore supports the development of new approaches with reduced experimental efforts and in a shorter time.

The fields of research are reflected in the educational pro-file as well. The chair is responsible for student education in the study course “Process Engineering“ with its specia-lization in “Energy Process Engineering“. Besides that, a large number of lectures and seminars related to energy and fuel conversion processes are being offered to other study courses. In this context, practical relevance of the lec-ture content is of high importance. In addition to student

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Energy Process Engineering and Thermal Waste Treatment

education, EVT offers qualification courses to companies. These are held in English and focus on synthesis gas gene-ration and thermo-chemical conversion processes.

In terms of research, the chair EVT belongs to the strongest in Germany with respect to third-party funds for research. A large number of small and large research projects in the fields of fundamental and applied research are often being initiated and performed in collaboration with part-ners from scientific institutions and industry. Besides that, the chair actively fosters a network involving its scientific and industrial partners, e.g. ERN or DBI:bergakademie. One of the highlights is the “International Freiberg Con-ference on IGCC & XtL Technologies“, an internationally renowned conference organized biennially and attracting a well-mixed international audience from science and industry.

The chair is structured into eight research groups. Each group focuses on a distinct field related to fuel conversi-on, placing emphasis on syngas generation technologies.

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Research Groups

Thermo-Chemical ConversionDr.-Ing. Steffen Krzack

Chair EVT Prof. Dr.-Ing. Bernd Meyer Deputy Chair EVT Dr.-Ing. Robert Pardemann

Research Groups EVT

Mineral MatterDr.-Ing. Stefan Guhl

Low Carbon TechnologiesDr.-Ing. habil. Heiner Gutte

Process Chain DevelopmentDr.-Ing. Robert Pardemann

CFD-Modeling of High-Temperature ProcessesDr.-Ing. Andreas Richter

Technologies for Solid Fuels GasificationDipl.-Wi.-Ing. Alexander Laugwitz

Syngas TechnologiesDr.-Ing. Peter Seifert

Plant OperationDipl.-Ing. Olaf Schulze

They cover a wide range of activities ranging from theo-retic mainly modeling-based research, experimental work, process demonstration to operations up to pilot scale.

Left to right: Dipl.-Ing. oec. U. Böhning, Dr.-Ing. S. Krzack, Dr.-Ing. habil. H. Gutte, Dr.-Ing. S. Guhl, Dr.-Ing. R. Pardemann, Dipl.-Wi.-Ing. A. Laugwitz, Prof. Dr.-Ing. B. Meyer, Dr.-Ing. A. Richter, Dr. rer. nat. M. Schreiner, Dr.-Ing. P. Seifert, Dr.-Ing. S. Bauersfeld, N. Klemm, Dipl.-Ing. O. Schulze

Laboratory Dr. rer. nat. Marcus SchreinerMechanical Workshop Werner Göhler/Tom Mader

Conversion processes at elevated or high temperatures can be applied to produce higher-value products from fossil and renewable energy raw materials, e.g. coke, hydrocarbons or combustible gases which are then further processed for energetic or non-energetic use. Typical pro-cess routes include the efficient and clean generation of electricity, heat, transportation fuels, base chemicals or the production of coke for metallurgical processes or as adsor-bent for environmental applications. The focus is placed on beneficiation and conversion of biomass, coal and fuel surrogates by pyrolysis, gasification and related processes. The “Thermo-Chemical Conversion“ research group aims for a better understanding and optimization of conversion processes as well as for the development and realization of new applications and variants of conversion processes to new feedstock and products.

Research tasks:n Fuel technological evaluation of energy raw materialsn Characterization of pyrolysis and gasification behavior

for a wide range of feedstockn Investigation of mechanisms, kinetics, energy and ma-

terial balances of pyrolysis processes

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Thermo-Chemical Conversion

n Investigation of reactivity of fuels and kinetics of gasifi-cation reactions

n Production and characterization of coke and chars for various applications including the development and optimization of carbon-based adsorbents

n Investigation of the influence of feed properties and operating conditions on the product quality of conver-sion processes

Current projects and references:n Demonstration of the gasification of high-ash coals

applying internal-circulating fluidized-bed gasification (COORVED, BMWi-funded)

n Investigation of co-conversion of coal and biomass n Investigation of suitability of various feedstock for the

production of adsorbents for flue gas and waste water treatment

n Investigation of the influence of ash-forming compo-nents and additives on pyrolysis product distribution and kinetics of gasification

n Evaluation of conversion routes for Mongolian coals

Dr.-Ing. Steffen Krzack

Phone: +49 (0) 3731 39-4524Email: [email protected]

The mineral matter behavior observed in high-temperature conversion processes such as gasification and combustion is of special interest as process disturbances and wear of plant components are often linked to the ash/slag proper-ties of the feedstock. The objectives of the “Mineral Matter“ research group are the chemical and physical characteri-zation of these mineral components. Based on this infor-mation, the understanding of the process and the influence of the ash/slag behavior is extended to the development of new approaches. Besides analytical and experimental investigations, chemical equilibrium calculations are used to estimate the behavior of mineral components in high- temperature processes.

Research tasks:n Chemical characterization of feedstock and process

samples (slags, agglomerates, fouling layers)n Determination of viscosity, density, surface tension and

wetting behavior of slagsn Experimental investigation of slag formation and the

interactions between solid, liquid and gaseous phases at high temperatures and under different gas atmo-spheres

n Modeling of the ash/slag behavior on the basis of chemical equilibrium considering experimental data (slag formation and solidification, mobilizing of trace elements and extraneous materials (sulfur and alkalis), deposit formation/fouling, refractory corrosion)

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Mineral Matter

Current projects and references:n Further development of the slagging fixed-bed

gasification process (BMWi-funded)n General investigations on selected process steps (ki-

netics, slag formation) inside gasifiers (HotVeGas I & II, BMWi-funded)

n Investigations on flux dosing and slag discharge (SBV, SMWA-funded)

n Support of property data acquisition for ash-slag-systems (CIC Virtuhcon, Group Multiphase Systems, BMBF-funded)

n Development of a heat recovery system for the Siemens gasification process (TEIMAB, BMWi-funded)

n Fouling and slagging models for coal-fired boilers ba-sed on experimental investigations and thermochemi-cal calculations (SIMEX, RWE Power AG-funded)

n Fouling inside a pressurized coal-fired boiler of the combined heat and power plant Cottbus

n Experimental investigation of single-particle reactions at high pressure and temperature in cooperation with Friedrich-Schiller-Universität Jena, Institute of Applied Physics (HITECOM I & II, BMBF-funded)

Dr.-Ing. Stefan Guhl


Fossil and renewable carbon resources are currently predo-minantly used for the generation of power, heat and fuels. Global carbon dioxide emissions from utilization of carbon resources have increased to approximately 31 billion tons per year in 2014. As a result, there is an increasing de-mand for the development of sustainable and competitive low carbon technologies which could facilitate the transfor-mation from the current carbon-intensive economy towards a sustainable low carbon economy. Integrated approaches are required to ensure an aligned integration of producti-on, refining and utilization of carbon resources.

Research tasks:n Reduction in the consumption of carbon resources and

primary energy for the generation of power and heat as well as reduced usage in transportation

n Enhancement of energy and materials efficiency (resource efficiency) in energy-intensive industries

n Transition from fossil to renewable energy sources (energy transition)

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Low Carbon Technologies

n Transition from primary to secondary or renewable substances (material transition)

n Transition from a currently energetic use of primary and secondary resources to a future non-energetic application through an innovative integration of rene-wable energies (resource transition)

n Closing of carbon cycles and related carbon-intensive metallurgical cycles

n Technology assessment for low carbon technologies

Current projects and references:n DER – German Center for Energy Resources

(BMBF-funded, co-financed by industry partners)n Technology assessment of innovative low carbon tech-

nologies n Strategy development for a low carbon economy

(Zwanzig20, BMBF-funded)

Dr.-Ing. habil. Heiner Gutte


n Investigation of dynamic process behavior, e.g. load change processes

n Scaling of plants and processes n Evaluation of economics (identification of advanta-

geous routes)

Current projects and references:n Study to evaluate concepts integrating small-scale CtL

and large-scale conventional coal power plants aiming for a process demonstration (Polygeneration-Annex, BMWi-funded)

n Fundamental studies to develop future high-tempera-ture gasification and gas treatment processes for dyna-mic power generation and storage technologies (Hot-VeGas I & II, BMWi-funded)

n Investigation of pyroelectric materials for waste heat recovery (PYROCONVERT, SMWK-funded)

n Study investigation of IGCC concepts with and without CCS (COORIVA, BMWi-funded)

n Study evaluating load-flexible polygeneration concepts (BMWi-funded)

n Industry-funded process and concept evaluation, e.g.: - Options for CO2 utilization with integrated

renewable H2 production - Dynamic IGCC modeling

Today’s technologies to use fossil and biogenic energy raw materials need continuous development and adaptation to meet the requirements of improved efficiency, minimal en-vironmental impact and optimal economic performance.

The “Process Chain Development“ research group focuses on developing and investigating process chains for:n Energetic fuel utilization (e.g. in IGCC plants with and

without CO2 capture)n Production of chemicals from fuels (XtY routes)n Polygeneration concepts for combined energetic and

non-energetic fuel conversionn CO2 utilization n New concepts integrating renewable and fossil power

generation

All relevant processes of the process chain are modeled in detail for comprehensive simulation (including fuel treat-ment, gasification, air separation, gas treatment, synthe-ses, power block etc.). Based on the extensive experience in this research field, a large number of validated process models are readily available at the chair EVT.

Research tasks:n Concept development and modeling using suitable

software tools (stationary and dynamic)n Detailed material and energy balancing and optimiza-

tion of processesn Technological and ecological evaluation of process

chains

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Process Chain Development

Dr.-Ing. Robert Pardemann


© Siemens

The tasks of the “CFD-Modeling of High-Temperature Pro-cesses“ research group cover the modeling of high-tempe-rature processes on all length scales, from the chemically reacting particles to the complete reactor. The develop-ment of models and strategies for the simulation of high- temperature reactors (fixed bed, fluidized bed, entrained flow) and the numerical simulation of chemically reacting particles or clusters of particles are part of the research fo-cus. Based on the achieved results, new sub-models e.g. for the prediction of fuel conversion are developed, allowing for an improved simulation of fluid-solid systems.

Research tasks:n CFD-modeling of single particles in high-temperature

environments (heat and mass transfer, pyrolysis, gasifi-cation, particle structure)

n Model development (0D and 1D) of sub-processes for solid-matter conversion

n Software development for the analysis of chemically re-acting particles

n Computation and modeling of the wall slag film in ga-sification processes

n CFD-simulation of gasifiers for solid feedstockn HP-POX reactor simulationsn Design and modeling of test reactorsn CFD-simulation of different sub-processes in technical

systems

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CFD-Modeling of High-Temperature Processes

Current projects and references:n CFD-simulation of chemically reacting coal particles

under oxidizing and gasification conditions (CIC Virtuh-con, Group Interface Phenomena, SMWK-funded)

n CFD-simulation of pore growth (CIC Virtuhcon, Group Interface Phenomena, SMWK-funded)

n Direct numerical simulation of macro-pore develop-ment (CIC Virtuhcon, Group Interface Phenomena, SMWK-funded)

n Model development for heating, drying, pyrolysis, and char conversion of coal particles (CIC Virtuhcon, Group Interface Phenomena, SMWK-funded)

n Slag-film modeling for high-temperature systems (CIC Virtuhcon, Group Interface Phenomena, SMWK- funded)

n Software development for single-particle analysis (CIC Virtuhcon, Group Interface Phenomena, SMWK- funded)

n Simulation of heat and mass transfer in porous me-dia (CIC Virtuhcon, Group Interface Phenomena, SMWK-funded)

n CFD-modeling of fixed-bed slagging gasifier (SBV, SMWA-funded)

n Numerical simulations of a hybrid reactor with novel feed system (internal project)

n Numerical simulation of autothermic reforming (inter-nal project)

Dr.-Ing. Andreas Richter


The evaluation and comparison of commercial coal gasi-fiers of the so-called second generation as well as their suggested improvements and own gasifier developments are conducted by the “Technologies for Solid Fuels Ga-sification“ research group. Accordingly, the influence of type and quality of the feedstock or process parameters such as temperature and pressure on the operation suc-cess is analyzed. Addressed processes are investigated by applying various computer-based simulation tools as well as empirical non-dimensional correlations. Calcula-tion results are represented with thermodynamic indices, exergy analyses and multidimensional maps (ternary diagrams). An additional topic is the gasification of low-quality (low-grade and/or high-ash) coals and the development of suitable gasification concepts as well as optimization of established commercial gasifiers.

Research tasks: n Evaluation and comparison of commercial coal

gasifiers: - Thermodynamic efficiency under different

operation conditions - Investment and operational costs

n Development of advanced gasifiers and raw gas cooling concepts: - Reactor design

- Gas-solid flow pattern - Fuel blending - Water quench chambers

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Technologies for Solid Fuels Gasification

Current projects and references:n Concept studies on production routes applying a slag-

ging fixed-bed gasifier: market analyses, technologi-cal & economic evaluation as well as operation of a 10 MW(th), 40 bar gasifier and its simulation in flow sheets

n Development of full water quench and partial water quench designs for entrained-flow gasifiers using cou-pled flow sheet and CFD-simulations in ASPEN Plus and ANSYS Fluent

n Numerical simulation of an entrained-flow gasifier in OpenFOAM

n Developement of the patented INCI gasifier including CFD-simulation of the reactive fast fluidized bed in a 100 kW(th) input reactor, balancing various loads and feedstock

n Flow sheet simulation of a process chain for a material based production of various products from Central German lignite, development of a reactor network model for fuel blend gasification kinetics

n Detailed numerical simulation of the slag flow behavior under changing material properties using VOF method in OpenFOAM

n Slag behavior simulation of different operating condi-tions including slag tapping under varying process pa-rameters of the pilot-scale slagging fixed-bed gasifier test unit at “Reiche Zeche“

n Improvement of gasifier components using optimizati-on algorithms via coupling of modeFRONTIER, ICEM-CFD and ANSYS Fluent

Dipl.-Wi.-Ing. Alexander Laugwitz


The generation of synthesis gas by high-pressure partial oxidation and the synthesis of high-quality fuels are import-ant process steps of modern XtL routes. The IEC operates a high-pressure synthesis gas plant for the gasification of liquid and gaseous feedstock (HP-POX – High Pressure Par-tial Oxidation) connected to a gasoline synthesis plant for the generation of high-octane gasoline out of synthesis gas (Syngas-To-Fuel – STF). The “Syngas Technologies“ research group focusses on pre-calculation, planning, evaluation and tests jointly carried out with the plant operation group.

HP-POX related research tasks:n Generation and evaluation of experimental data sets

obtained from HP-POX plantn Material and enthalpy balances, thermodynamical

pre- and recalculation, and modeling of synthesis gas production

n Studies on formation of trace components relevant for gas cleaning and utilization, e.g. HCN, NH3, COS and organic acids

n Optimization of the gasification process for different feedstock

n Flame visualization by an optical probe system and in-vestigation of flame geometries

n Development and testing of advanced burners

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Syngas Technologies

Gasoline synthesis related research tasks:n Generation and evaluation of experimental data sets

obtained from the STF plantn Material and enthalpy balances, thermodynamical

modeling of gasoline synthesisn Optimization of operating parametersn Overall system analysis in terms of process efficiency

and economy

Current projects and references:n Gasification tests for the generation of reference data

sets for the CFD-modeling of the non-catalytic gas re-forming and for practical tests of new burner concepts

n Gasification of hydrocarbons and slurries by high- pressure partial oxidation (HP-POX, funded by BMWi/ SMWK and mg engineering (third-party funding) as well as Lurgi AG (sub-contractor))

n Further development of IGCC power plant technology with CO2 capture (COORAMENT, funded by BMWi and SMWK (EFRE) and Air Liquide Group)

n Oxygen reforming (R&D, funded by Air Liquide Group)n Development of a new technology for the production

of high-octane gasoline from synthesis gas (funded by SMWK (EFRE) and Chemieanlagenbau Chemnitz GmbH)

n Test campaigns at the STF plant (funded by Chemie- anlagenbau Chemnitz GmbH)

Dr.-Ing. Peter Seifert


The “Plant Operation“ group is involved in the design, construction and operation of bench-scale and pilot-scale research plants. These plants enable investigation, process development, equipment performance assessment and optimization under realistic operating conditions. Diverse experimental activities are contributing to the realization of innovative process concepts and process chains.

Research tasks:n Designing, planning, construction and operation of

bench-scale and pilot-scale research plantsn Assessment of process design parameters for

industrial-scale plant designn Optimization of process design and equipmentn Sampling under process conditions (high pressure and

temperature)n Development, implementation and operation of com-

plex measurement equipment n Provision of synthesis gas products for external

analyses

Plants operated by the group “Plant Operation“ include:n HP-POX plant: (5 MW(th), 100 bar, up to 1500 °C):

pilot-scale high pressure partial gasification plant for liquid and gaseous hydrocarbon feeds

n STF gasoline plant: (Input: 700 m³(STP)/h syngas): pilot-scale plant for the production of gasoline from methanol or syngas

n SBV plant: (10 MW(th), 40 bar, up to 2000 °C): pilot-scale moving-bed gasification plant for analysis of “difficult” feedstock

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Plant Operation

n KIVAN reactor (10 kW(th), 100 bar, up to 1600 °C): bench-scale drop tube reactor for kinetic analyses

n COORVED reactor (60 kW(th), 0.4 bar, up to 1600 °C): bench-scale gasifier for analysis of flame development in gasification systems

Current projects and references:n Further development of moving-bed slagging gasifier

to a polygeneration process, test of two technology routes (BMWi-funded)

n Construction and operation of a moving-bed slagging gasifier to obtain design specifications for “difficult” feedstock, development of measurement methods for slag behavior and gas flow in the moving bed under high-pressure conditions (SBV, SMWA-funded)

n Investigation of reaction kinetics up to 100 bar un-der different gas atmospheres (Virtuhcon, BMBF/ SMWK-funded)

n Commissioning, operation and optimization of a fluidized-bed gasifier including the optical measure-ment of the particle flow under operating conditions (COORVED, BMWi-funded)

n Investigation of syngas production from gaseous and liquid hydrocarbons for different operation modes applying the HP-POX plant (industrial R&D, Air Liqui-de Group-funded and COORAMENT, BMWi/SMWK (EFRE) and Air Liquide Group-funded)

n Demonstration and performance of test programs to prove and optimize a new gasoline synthesis technology (Syngas-to-Fuel)

Dipl.-Ing. Olaf Schulze


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Equipment – Pilot Plants

Pilot plant for the gasification of gaseous and liquid hydrocarbons by high-pressure parti-al oxidation – HP-POX (operated for research since summer 2004)

Process applications: n Autothermic catalytic reforming (ATR) of gaseous

feedstock at pressures up to 70 bar(g)n Autothermic non-catalytic partial oxidation of gaseous

feedstock (Gas POX) at pressures up to 100 bar(g)n Autothermic non-catalytic gasification of liquid

hydrocarbons (Oil POX) at pressures up to 100 bar(g)

Feedstock:n Natural gasn Light and heavy oilsn Heavy residues from crude oil processing

Operating parameters:n Temperature: up to 1450 °Cn Pressure: up to 100 bar(g)n Input: up to 500 m³(STP)/h natural gas or 500 kg/h

liquid feedsn Syngas output: up to 1500 m³(STP)/h

Objectives:n Variation of steam-to-feed ration Investigation of influence of pressure and temperaturen Analysis of product streams including trace

componentsn Energy, exergy and material balancing

Scientific topics:n Gasification process design and modeling (auto-

thermic non-catalytic partial oxidation at up to 100 bar, autothermic catalytic partial reforming of natural gas at up to 70 bar)

n Reactor and burner design and modeling (gasification of liquid hydrocarbons)

n Modeling and understanding of trace component behavior (mechanisms of formation and distribution of technologically relevant trace components)

Accomplished projects and funding:n Federal Ministry of Economic Affairs and Energy

(BMWi) and Saxon State Ministry of Science and Fine Arts (SMWK) with funds provided by the European Fund of Regional Development (EFRE) in the frame of the re-search projects HP-POX and COORAMENT (till 30 June 2010)

n Saxon State Ministry of Science and Fine Arts (SMWK) with funds provided by the European Fund of Regional Development (EFRE) in the frame of the research pro-ject ”Development of a new technology for producing high-octane gasoline from syngas” (till 31 December 2012)

n Plant operation in the frame of industrial-funded research projects

Plant construction funded by:

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Syngas-to-Fuel (STF) – Pilot plant for the synthesis of high-octane gasoline from syngas (start-up in 2010)

STF plant characteristics:n Pilot-scale synthesis plant for demonstration of the

production of high-octane gasoline from synthesis gasn Input: 700 m3(STP)/h of syngas (provided by the

HP-POX)n Two-stage reactor concept: 1st stage: methanol synthe-

sis at 50 bar, 2nd stage: gasoline synthesisn Output: 120 l/h of stabilized gasoline

STF process innovations:n New heat exchanger concept and reactor design

allowing for isothermic operation of the gasoline synthesis reactor

n Application of a newly developed catalyst for the selec-tive yield of isomeric hydrocarbons instead of aromats during gasoline synthesis

n New catalytic waste water treatment for minimization of process waste water production

STF gasoline quality:n Gasoline quality meeting DIN standard and achieving

an octane number higher than 93n Substitution of aromats by isomers (Aromatic content

<35 %)

Accomplished projects and funding:n Demonstration and performance of test programs

proving and optimizing a new gasoline synthesis technology (Syngas-to-Fuel)

n Funded by the European Fund for Regional Develop-ment (EFRE) and the State of Saxony (Saxon Develop-ment Bank) and co-financed by Chemieanlagenbau Chemnitz GmbH and partners

STF project partners during the first funding period (1 May 2008 till 30 June 2013):n Chemieanlagenbau Chemnitz GmbH jointly with

- SAPR Neftechim - Techno Trading Ltd

n TU Bergakademie Freiberg with - Institute of Energy Process Engineering and

Chemical Engineering (IEC) - Institute of Technical Chemistry (ITC)


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Slagging Gasifier – fixed-bed slag-ging gasifier for difficult solid feedstock (commissioned in 2013)

Characteristics of the slagging gasifier:n Pilot-scale gasifier for solid feedstockn Operating pressure: 40 bar(g)n Input:

- 1.38 t/h hard coal (equivalent to 10 MW(th))- Up to 430 m³(STP)/h of oxygen and up to

450 kg/h of steamn Output: ca. 2300 m³(STP)/h raw gas

Plant infrastructure: n Coal hoppern Lock hopper system for coal feeding and slag

extractionn Gasification reactor with slag tap and quenchn Gas cooling and gas water storage n Gasifier steel structure (12 x 12 x 22 m)

Research topics:n Investigation of fuel influence and fluxing agents on

ash/slag behaviorn Generation of material property data for application

oriented modelingn Characterization of ash/slag systems under real

process conditions

Accomplished and current projects:n Further development of moving-bed slagging gasifier

to a polygeneration process, test of two technology routes (BMWi-funded)

n Construction and operation of a moving-bed slagging gasifier to obtain design specifications for “difficult” feedstock, development of measurement methods for slag behavior and gas flow in the moving bed under high-pressure conditions (SBV, SMWA-funded)


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Equipment – Bench-Scale Test Facilities

List of bench-scale and larger test facilities:n COORVED gasification reactor for low-rank high-ash

coalsn High-temperature drop tube reactor: HTRn Pressurized gasification measurement equipment

(drop tube): GMEQn Kinetic test reactor (High-pressure high-temperature

drop tube reactor): KIVAN reactorn Laboratory pyrolysis facility: LPAn Advanced laboratory pyrolysis facility: ALPAn Pressurized pyrolysis reactor (fixed-bed and drop tube

mode): DPAn High-pressure pyrolysis measurement equipment

(drop tube reactor): PYMEQ

Furnaces available at the chair EVT: n Muffle furnaces (6) n High-pressure furnace n Large sample furnace n Ashing furnaces (2)

COORVED reactor

n Pyrolysis furnaces (3) n Rotary kiln furnaces (2) n Vertical tube furnaces (2)n QTF (quenching test facility, in-house development) n Horizontal tube furnace

Solid fuels characterization facilities: n Ruhr dilatometres (2) n Gieseler plastometer n Facility to determine the coke reactivity index (CRI) and

coke strength after reaction (CSR)n Facility to determine reactivity in fixed bed: RiFixn Quartz glass reactors to determine reactivity with

CO2 (7)n Camsizers (Determination of particle size

distribution) (2)n Simple particle disintegrator: SPaltorn Ambient pressure thermo-analysis (thermo-gravime-

try: TG, differential thermo-analysis: DTA, differenti-al-scanning calorimetry: DSC, all with optional mass spectrometer (MS) coupling)

n High-pressure thermo-analysis (TG, DTA, DSC)n High-pressure magnetic-coupling thermo-balance

Mechanical fuel preparation equipment:n Sieve analysisn Mills (cutting mill, impact mill, ultracentrifugal mill,

freezer mill)n Tablet/pellet presses (2)

PYMEQ

Large sample furnace

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Laboratory Equipment

Fuel technological laboratory: n Leitz heated microscope (LEM) for investigations of

ash melting behaviorn Elemental (ultimate) analyzers (3)n Combustion calorimeters (2)n Karl-Fischer titrations (2)n Mercury analyzern Microwave pressure pulpingn BET measurement (determination of weight-specific

surface area according to Brunauer-Emmett-Teller)n Mercury porosimetryn Helium pycnometry

Liquids and gas analysis: n Gas chromatography (various micro gas chromato-

graphs, gas chromatographs with different columns and detectors)

n Ion chromatography (3)n High-performance liquid chromatography: HPLCn Pyrolysis facility coupled with gas chromatograph and

mass spectrometer (Pyrolysis-GC-MS)n Viscometers for oil and watern Total-reflection X-ray fluorescence analysis (XRF)

Pyrolysis-GC-MS

SEM

FIB-SEM

Ash/slag analysis: n Plasma ashing devicen X-ray analysis (X-ray fluorescence analysis: XRF (2),

X-ray diffractometrical analysis (also under high tem-perature and pressure): XRD (2))

n Electron microscopy (SEM, FIB-SEM)n Thermo-optical measurement systems for surface ten-

sion and characteristic ash melting temperatures (with atmosphere control: TOM-AC, without atmosphere control: TOMMI)

n High-temperature viscometers (2)n Two-chamber double thermo-balancen Calorimeter AlexSys (drop-in melting calorimetry)

Dr. rer. nat. Marcus Schreiner


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Equipment – Software Tools

Various software tools are available for different research and development activities including in-house code (ih), commercial (c) and open source (os) codes.

CAD: n AutoCAD (c), AutoCAD P&ID (c)n Autodesk Inventor (c)

CFD:n ANSYS CFD (c)

- Fluent, CFX, ICEM, Workbench, etc. (c) - ANSYS Mechanical (c) - Fluent-UDFs (ih): for the coupling of stand-alone tools (drying, pyrolysis, gasification, slag layer) with Fluent

n OpenFOAM (os, ih): reactor and slag flow modelingn PBS – Perić Based Solver (ih): in-house solver (2D and

3D, reactive and non-reactive flows, flows in porous media)

DEM:n FB-DEM (ih): simulation of polydisperse packed beds

Flow sheet simulation:n Aspen Engineering Suite (c): Aspen Plus, Aspen

Dynamic, Aspen Custom Modeler, Aspen HYSYSn EBSILON® Professional (c)n SimuSage (c)

CFD/DEM

Mathematic tools:n Matlab (c), Origin 9 (c)

Optimization:n modeFRONTIER 4 (c)

Particle simulation:n Pyrolysis simulator (ih)n RPG – Resolved Pore Growth (ih): modeling of the

growth of macro-pores for different feedstockn Drying simulator (ih): particle drying n Gasification simulator (ih): analysis of single particle

gasification

Process control:n LabView (c)

Slag analysis:n Slag Simulator (ih): prediction of slag layer thickness in

entrained flow gasifiers

Thermodynamics: n FactSage (c), SimuSage (c)

Visualization:n e!Sankey (c), MathType (c), MS Visio (c), Paraview (os),

Tecplot (c)Aspen

Reactor simulation

SEM Micrograph of crystalline slag

The IEC offers intensive courses in English language in the field of gasification technologies. The main aim of the cour-ses is a detailed introduction to the scientific fundamentals and technologies of:n Gasificationn Synthesis gas productionn Synthesis gas purificationn IGCC power plants

Leading large-scale gasification technologies, such as those of Shell, GE, Siemens etc. are presented in detail. Furthermore, the course program covers introductions to various simulation software tools and visits to lab facilities and pilot plants.

Training Courses

The courses cater to:n Process and development engineersn Plant engineersn Executives of companies in the fields of plant construc-

tion and energy supplyn Development companies in the fields of thermal fuel

technology, power plant technology, waste manage-ment etc. who would like to update and expand their knowledge on gasification processes and technologies

The limited number of course participants allows for an intensive and comprehensive presentation of this scientific field tailored to individual participants. By request, speci-al courses for different audiences or participants can be arranged to meet specific needs. To ensure a high level of quality, experienced specialists from different companies are invited to present special topics in the courses.

Since 2006, the IEC has offered two to three courses per year. Representatives from nationally and internationally leading companies have participated in the courses, for ex-ample Shell, Linde, Alstom, RWE, Haldor Topsoe, Siemens, BASF, E.ON, Total, Hydro Oil and Energy, GSP China Tech-nology, MAN and Lurgi.

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Dr.-Ing. Sindy Bauersfeld

Phone: +49 (0) 3731 39-4536Email: [email protected]: http://tu-freiberg.de/en/iec/evt/events/ compact-courses

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Networking – International Freiberg Conference

Since 2005, the IEC has organized the “International Freiberg Conference on IGCC & XtL Technologies“. This event addresses a wide range of topics relating to the thermo-chemical conversion of carbonaceous feedstock and related process chains. It provides a high-level discus-sion forum to facilitate the exchange of information and expertise. Studies, new developments, current projects and operational experiences in the fields of IGCC and XtL tech-nologies are presented, focusing on:n Fundamentals of coal conversion

(e.g. characterization, reaction kinetics)n Mineral matter characterization and behaviorn Fuel preparation and upgrading

(e.g. drying, feeding and deashing)n Low-temperature conversion processes

(e.g. extraction torrefaction and pyrolysis)n Upgrading of low-temperature conversion products

(e.g. tar reforming)n Gasification technology: status/development/co-

gasification (for solid, liquid and gaseous feedstock)n Synthesis gas treatment: status/developmentn Carbon dioxide capture, storage and utilizationn Synthesis technologies and synthesis gas applications:

status/developmentn Combined-cycle and gas turbine developments for

IGCC and polygeneration

n Entire concept evaluationsn Integration of coal and renewables for chemical

storage n Numerical modeling of high-temperature conversion

processesn Coke productionn Direct liquefaction of coaln Underground coal gasificationn Public acceptance, trends and global boundary con-

ditions (economic, regulatory and political) for fuel conversion to chemicals, transportation fuels and electricity

The 7th International Freiberg Conference, taking place from 7–11 June 2015, will be the first to take place outside Germany – directly in the world’s center of CtL activities: Inner Mongolia, China. This event is jointly organized by the Institute of Energy Process Engineering and Chemical Engineering, Synfuels China Technology Co., Ltd. and our international partners.


Phone: +49 (0) 3731 39-4536Email: [email protected]: http://www.gasification-freiberg.com

Partners are:

Networking – Energy Raw Materials Network (ERN)

The Energy Raw Materials Network (ERN) continues the activities of the former information platform “German Centre for Gasification Technologies” (DeZeV). Currently, eleven partners from science and industry in the fields of energy and resource conversion are active in the ERN.

The network provides a platform for collaboration, knowledge transfer and exchange through regular meetings, courses, workshops and conferences.

Topics addressed by the ERN include new developments, current projects and operational experiences linked to:n The efficient, sustainable and economical utilization of

fossil fuels, biomass and waste, in particular for the provision of base chemicals, fuels, coke, other carbo-naceous products and hydrogen,

n Strategies, approaches and technologies for reduction of carbon dioxide emissions, e.g. carbon dioxide capture and utilization.

The network activities strive for the promotion of scienti-fic exchange along the whole innovation and value chain from fundamental research to commercial applications. The ERN is based in Freiberg at the Institute of Energy Process Engineering and Chemical Engineering at the TU Bergakademie Freiberg.


Phone: +49 (0) 3731 39-4536Email: [email protected]: http://tu-freiberg.de/en/projekt/ern

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BASF SE

CERA SYSTEMS VS GmbH

EDL Anlagenbau GmbH

Envirotherm GmbH

Linde Engineering Dresden GmbH

German Biomass Research Center

Mibrag mbH

Romonta GmbH

RWE Power AG

Siemens Fuel Gasification Technology GmbH & Co. KG

TU Bergakademie Freiberg - Institute of Energy Process Engineering and Chemical Engineering

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Service Offers

The Chair of Energy Process Engineering and Ther-mal Waste Treatment offers a full spectrum of ser-vices to companies, organizations and individuals (tailored to your business) in the following areas:

1. Scientific consulting:n Identification and evaluation of advantageous conver-

sion routes for carbonaceous fuels, especially solids (biomass and coal),

n Technological evaluation (for example gas to syngas processes, pyrolysis etc.).

2. Lab services and interpretation of analy-sis data:

n Fuel analyses: lower heating value (LHV) or higher he-ating value (HHV), proximate analysis, ultimate analy-sis, trace elements, BET surface etc.,

n Mineral matter analyses and characterization,n Pyrolysis and gasification behavior (kinetics), charac-

terization of feedstock and products.

3. Process routes evaluation:n Development and modeling-based energy and materi-

al balancing of process chains for syngas-based utiliz-ation of carbonaceous fuels (XtY),

n Energetic, environmental and technology evaluation,n Estimation of CAPEX and OPEX (pre-feasibility study

level of accuracy),n Support of feasibility studies, technology selection and

economical evaluation,n Independent technology consulting and attending of

companies being active in the field of XtY technologies,n Supporting different phases of project development

and realization.

4. Performance of pilot-scale testing:n Using existing plant equipment for specific fuels or

research topics,n Determination of fuel suitability or process applicability.

5. Joint process development in the frame of research projects.

6. Offer of patents owned by TU Bergaka-demie Freiberg for commercialization by interested companies. Prof. Dr.-Ing. Bernd Meyer

Phone: +49 (0) 3731 39-4511Email: [email protected]: evt.tu-freiberg.de

Directions to IEC: n Leave A4 at the “Siebenlehn“ exit and travel along the B101 towards Freibergn In Freiberg, turn left at the second set of traffic lights towards Dresdenn After the next traffic lights, go straight aheadn Turn left towards “Silberbergwerke“ in front of the churchn Follow the road until you reach “Reiche Zeche“, “IEC/Energiepark“

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How to contact and find us

GPS: Latitude: 50.92918, Longitude: 13.35831

Postal address and contact data:

TU Bergakademie FreibergInstitute of Energy Process Engineering and Chemical Engineering – EVTFuchsmuehlenweg 9, 09596 Freiberg, Germany

Phone: +49 (0) 3731 39-4511 Fax: +49 (0) 3731 39-4555Email: [email protected]: www.iec.tu-freiberg.de

Imprint

Editor:Prof. Dr.-Ing. Bernd Meyer

TU Bergakademie FreibergInstitute of Energy Process Engineering and Chemical Engineering

Fuchsmuehlenweg 9, 09596 Freiberg/Germany

Phone: +49 (0) 3731 39-4511Fax: +49 (0) 3731 39-4555

Email: [email protected]

Design and Photos: IEC

Status:04/2015

Institute of Energy Process Engineering and Chemical EngineeringChair of Energy Process Engineering and Thermal Waste Treatment

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