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MEGAMEGA--GSP PROCESSGSP PROCESSEntrainedEntrained--FlowFlow GasificationGasification of of CoalCoal,, Biomass Biomass and and WasteWaste
FUTURE ENERGY GmbH, GermanyFUTURE ENERGY GmbH, Germany
International FreibergInternational Freiberg ConferenceConference on on IGCC & IGCC & XtL TechnologiesXtL Technologies
JuneJune 16 16 -- 18, 200518, 2005
Dr. Manfred Dr. Manfred SchingnitzSchingnitz, Friedemann Mehlhose, Friedemann Mehlhose
FUTURE ENERGY GmbH in Freiberg
3MW
5MWOffice
DBI
Freiberg city center
Advantages of GSP Entrained-Flow Gasifier with Cooling Screen
• high carbon conversion > 99 %
• raw synthesis gas without hydrocarbons, i.e. absolutely tarfree
• no dioxin/furan formation despite high chlorine content in the gasification feed
• no heed to be given to ash content and ash composition
• high gasifier performance
• high availability
• short startup and shutdown time (about one hour)
• multiple-fuel feeding
• cooling screen life time >10 years Granulated slag
Cooling screen
Pressur. water
Quenchwater
inlet
overflowWater
Gas outlet
Cooling jacket
Oxygen, SteamFuel
Pressur. wateroutlet
Burner
Particle Size Distribution of Pulverized Coalat a Carbon Conversion Rate of >99 %
in %
Sieve
Hard coal
High-re
active
Low-re
active
21
0.1
5
10
20
30
15
60
50
70
40
oversize
Pyrolysis char
Petcoke
10.50.30.2
Wood flour
0.10.05Particle diameter in mm
85
90
0.0295
0.01 0.03
Lignite,sewage sludge
80
Pneumatic Conveying and Feeding System for Pulverized Solid Materials
Material
N2
Depressu-rization
Storage bin
Waste air
Depressu-rization
Lock hopperLock hopper
Feeding vessel
Material togasifier
LIA PI
TI
LIC
PIC
H
L LLIC
H
PIC
M
M M
M
UC Q S
FIC
LIC
PI
M
2N
N2
N2
Burner for Coal Gasification
Cooling water
Oxygen/steam
Cooling water
Cooling water
Flame signal
Cooling water
Cooling water
Ignition voltage
Fuel gas to pilot
Cooling water
Pulverized coal
Pulverized Coal Burner
Oxygen
watercoalPulverized Cooling
3x
HP steamOxygen/
waterCooling
waterCooling
2x
Pilot burner gas
Cooling
Coolingwater
water
GSP Entrained-Flow Gasifier
Granulated slag
Cooling screen
Pressur. water
Quenchwater
inlet
overflowWater
Gas outlet
Cooling jacket
Oxygen, SteamFuel
Pressur. wateroutlet
Burner
Oxygen, SteamFuel
Raw gasSlag
Slag discharge unit
Views of the Cooling Screen after 10 Years in Service
Cooling Screen of the Gasification Reactor
Liquid slag
Solid slag
Membran wall
Pressurized water
Ramming mass
Pipe coil with studs
Anthracite
PetcokeLean coal
Forge coal
Fat coal
Medium-volatile coal
High-volatile coal
Hardbrown coal
Softbrown coal
95
90
85
80
75
70
65
60
55
Carbon content Cdaf
[wt.-%]
0 10 20 30 40 50 60 70
Volatile matter content Vdaf [wt.-%]
52
51 41
272621
28
232422
25
29
1401
02
15
13
12
04
11
03
Coals Gasified in theTest Facilities ofFUTURE ENERGY GmbH
SOFT BROWN COALS01 GERMANY Schwarze Pumpe02 GERMANY Braunsbedra03 BULGARIA Elhovo04 AUSTRALIA Mine Bowmans
HARD BROWN COALS11 SPAIN Teruel12 RUSSIA Kansk-Atschinsk13 CHINA Harbin14 CZECH REPUBLIC Most15 CZECH REPUBLIC Sokolov
HARD COALS21 GERMANY Ruhrgebiet22 POLAND Sosnica 2/123 POLAND Sosnica24 SPAIN Puertollano A (washed coal)25 SPAIN Puertollano (unwashed coal)26 AUSTRALIA Drayton27 AUSTRALIA Newlands28 SOUTH AFRICA Koornfontein29 COLOMBIA Cerrajon
41 Petcoke
ANTHRACITES51 GERMANY Doberlug52 GERMANY Ruhrgebiet
Ø2000
3500
5250
Ø2900
Ø3650
6700
Size Relation of Different Scale GSP Entrained-flow Gasifiers (2.5 MPa)
200 MW
500 MW
1000 MW
Adverse Characteristics of Biomass
l low density, i.e. large volumes to be handled
l heterogeneous structure requiring high chopping expense
l low heating value compared with conventional fuels
l high oxygen content in the organic matrix
l high-alkaline fuel ash
l bad grindability
Effective Use of Biomassin cooperation between Karlsruhe research center (FZK) and FUTURE ENERGY
input energy plants harvest remains by-products / wastes
wood bark / forest residues wood shavingsmiscanthus straw / hay lignin / bagasse
napier grass wood remainders sewage sludgetriticale branches liquid manure
1. step
2. stepor a slurry from bio-oil & bio-char
at 1 bar (15 psi) & ~500°C (900 F) - capacity: ~50 MW each ~ 10 t/h (20,000 lb/hr)
3. step
gasification unit
4. step entrained-flow gasification process by FUTURE ENERGY~1400°C (2500 F); 40 - 60 bar (550 - 900 psi) capacity: op to 1000 MWth
generation of a tar free raw synthesis gas
5. step gas treatmentcleaning / conditioning
final use generation of generation of generation ofsynthetic motor fuels electrical energy fertilizers / chemicals
cent
ral s
yste
m /
plan
t
to a centralized large-scale
loca
l are
a
local fast pyrolysis to generate bio-oil / bio-char
rail transport of the products from different local units
biomass preparation: collecting / pre-drying / chopping / storage
solid fossil fuels
liquid fossil fuels
27
64
3
< 0.1
1.5 - 5.5
0.46
0.04
1.0
0.4
11.1
Composition of Raw Gas from Different Feedstocks
ComponentHardcoal
Unit Petcoke Domesticrefuse
Lignite Oil Biomass Sewagesludge
Heating value MJ/Nm3
Heatingvalue (dry) MJ/kg 25 - 32 34 - 36 18 - 25 39 - 42 17 - 19 12 - 15 10 - 13
H2
CO
CO2
CH4
N2
H2S
COS
HCN
NH3
vol.-%
vol.-%
vol.-%
vol.-%
vol.-%
vol.-%
vol.-%
mg/Nm3
mg/Nm3
22
65
5
< 0.1
1.0 - 6.5
1.3
0.16
0.8
0.3
10.9
31
55
8
< 0.1
3.5
0.20
0.02
1.0
0.24
10.3
45
48
4
< 0.1
0.5
0.1
0.01
0.2
0.4
11.2
27
50
14
< 0.1
4.0
0.12
< 0.1
0.3
0.4
9.3
29
49
16
< 0.1
4.0
0.36
0.02
0.01
0.25
9.4
32
49
12
< 0.1
4.5
0.28
0.02
2.0
0.3
9.7
GSP Gasification Test Facilities of FUTURE ENERGY GmbH in Freiberg
Sewage sludge drier500 kg/h
Pyrolysis unit500 kg/h
Inert gas plant1000 m3
i.N./h80 bar
Oxygen plantmax. 300 m3
i.N./h80 bar
Pulverized fueldosing and feeding system
up to 10 t/h
Gasifier VV100Reactor with cooling wall
2-3 MWmax. 30 bar
GasifierReactor with cooling screen
3-5 MWmax. 30 bar
Slurry feeding300 kg/h
5 MW
3 MW
Office
SulFerox desulfurization unitWaste water treatment
COS hydrolysisHCN hydrolysis
• optimize feedstock preparation• determine optimum gasification process
conditions
• allow optimization of reactor or burner design
• allow reliable scale-up
• test materials of construction and components
• gain information about products and wastes
Advantages for our Costumers
Granulated slag
Cooling screen
Pressur. water
Quenchwater
inlet
overflowWater
Gas outlet
Cooling jacket
Oxygen, SteamFuel
Pressur. wateroutlet
Burner
Autothermal Oil Conversion PlantClient Sokolovská uhelná, a.s.Location, country Vresová, Czech Republic
Commissioning 2005
Technical data
Type of reactor entrained-flow, cooling wall design
Capacity 140 MWth
Pressure 28 bar
Temperature 1400 °C
Reactor volume 15 m3
Type of quench system full quench
Equipment / subsystems
Feeding system liquid feeding
Gas cleaning spray scrubber
Slag discharge lock hopper
Soot water treatment depressurization and vapor condensation,sedimentation, chamber filter press
Feedstock Generator tar and other liquid by-products of 26 fixed bed gasifiers of a 440 MW IGCC
Products / by-products / effluent Raw gas to IGCC / slag, soot cake / waste water
Gasification Project in the Czech Republic
3D computer simulation
Thank you very muchThank you very much!!