the bgl-commercial plants and pilot testing status and ... · the bgl-commercial plants and pilot...

6th International Freiberg Conference 2014

ENVIROTHERM

The BGL-Commercial Plants and Pilot Testing

Status and Perspectives on

Envirotherm BGL-technology

Hansjobst Hirschfelder

6th International Freiberg Conference on IGCC &XEL Technology

May 19 – 22, 2014 Dresden/Radebeul, Germany

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ENVIROTHERM

CLEAN ENERGY CLEAN AIR

(Air pollution control)

Bamag International

Water Purification and

Waste Water Treatment

Technologies

CLEAN WATER

Bamag MENA

Waste Water

Treatment Technologies

Envirotherm

Modern

Gasification Technologies

Envirotherm

Multi-Purpose

Combustion Technologies

Envirotherm

Sewage Sludge Incineration

Envirotherm

Highly Efficient

Flue Gas Cleaning Technologies

Envirotherm

Production and Distribution of

Honeycomb SCR Catalysts

Envirotherm Group

Environmental technologies company offering engineering services to customers in the

energy, air pollution control and water sector

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ENVIROTHERM

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• BGL advanced pressurized, slagging fixed bed gasification

(former British Gas/Lurgi, today co-ownership of Envirotherm and

ZEMAG)

• CFB atmospheric gasification in the circulating fluid bed

• involvement in design build, test and further develop of the

demonstration plant at the IEC in Freiberg

Envirotherm’s Involvement in Gasification


ENVIROTHERM

CFB Gasification

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ENVIROTHERM The CFB Gasification Process:

Development and References

• Fluid bed technology was developed in the early 1920s (original Winkler fluid process)

• Lurgi developed the circulating fluid bed (CFB) applying high “slip velocity”, introduced CFB to

power plants and applied the process to gasification of various feedstock

• Fluid beds are operated at temperatures below ash softening point (i.e. 800-950 °C) with an

even temperature profile in the reactor and excellent heat and mass transport

• Proven technology with numberless references

• Envirotherm acquired the CFB gasification process from Lurgi/Lentjes in 2003

• Envirotherm’s commercial reference plants include

- first CFB gasification in the cement industry – Ruedersdorf, Germany

- CFB gasification of demolition wood – Geertruidenberg, The Netherlands

- CFB gasification of high ash Indian coal – Barbil, India

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ENVIROTHERM The CFB Gasification Process:

Key Benefits

Crude Gas

to Consumer

Recycling

Cyclone

Fuel

Nozzle Grate

Ash

Seal Pot

CFB

Gasifier

• fuel flexibility: nearly all types of (high ash) coal and

other carbonaceous fuels, e.g. waste

• gasifier vessel is made from mild steel

• modular design (spare/reliability)

• atmospheric circulating fluidized bed gasifier, well

suited for fuel gas production

• air blown gasifier, no ASU required

• low calorific syngas

• excellent heat and mass transfer due to high

turbulence of inert bed inventory

• high thermal stability

• high carbon conversion

• HP steam production

• bottom ash can be reutilized

• low requirement for fuel preparation

Gasification Agent

(Air + Steam)

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ENVIROTHERM CFB – Selected References:

Jindal Steel & Power, India

Barbil / Orissa, India:

• two CFB gasifiers in parallel

• fuel: domestic Indian coal up to 40% ash, 8% moisture

• per gasifier: 23t/h coal, 50,000 m³n/h syngas

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ENVIROTHERM

Solid

Fuel

Bed

Material

Bed Ash

Air

Air

Air

Air C.W.

C.W.

Cyclone CFB

Gasifier

Radiation

Pass

Turbine / Generator

Steam Drum

Deaerator

Su

pe

rhe

ate

r

Eva

po

rato

r Quench

Wet ESP

Clean Fuel Gas

Recirculation Pump

Ash Tar

Dust

Water

Prim. Air

Sec. Air

C.W.

Seal Pot

Water

CFB – Selected References:

Jindal Steel & Power, India

Barbil / Orissa, India: Process Flow Diagram

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ENVIROTHERM

BGL Gasification

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ENVIROTHERM

• The improved “slagging” version of the existing Lurgi Gasifier was jointly developed

with British Gas from 1974 onwards in Westfield/Scotland to:

- have a reactor to produce non-leachable vitreous slag rather than dry ash

- improve specific reactor throughput

- increase fines content acceptable in feed

- reduce steam consumption and consequently gas condensate production

- recycle tars/oils to extinction

- increase CO/H2-yields

• Technology successfully tested with a wide range of coals and proven on

commercial size gasifier units until 1991

• First commercial plant at Schwarze Pumpe, Germany, from 2000 until 2007, using

a broad range of feedstock including waste

• Technology jointly owned by Envirotherm GmbH and ZEMAG Clean Energy

Technology GmbH

Introduction to BGL

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ENVIROTHERM

Operational

• Extensive development history

• High cold gas efficiency between 82% and 93% /

high specific throughput

• Low oxygen consumption (ca. 0.5-0.6 kg / kg Coal)

• Low steam consumption (ca. 0.3-0.4 kg / kg Coal)

• Lower aqueous liquor production

• Fuel flexibility (nearly all coal types and other types of

fuels (e.g. waste) can be processed)

• Excellent load following capabilities

• Modularity (spare/reliability)

• Slag as by-product is non-leachable (vitrified) and can

be utilized (road work)

Capital/Investment

• Simple gasifier design (no exotic materials, no

sophisticated heat exchangers)

• Smaller air separation unit (ASU) due to low oxygen

requirements

/ WASTE

Gasification

700 – 1,100ºC

Combustion

2,000 – 2,100ºC

Drying and Pyrolysis

< 700ºC

Raw Gas

600 - 800ºC

The BGL Gasification Process:

Key Benefits

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ENVIROTHERM BGL Gasifier

Process Applications (overview)

BGL

Gasifier

Air Separation

Unit

Alternative

Feedstock

Input Gasification

Shift Reactor Gas Clean-Up

Methanol

Synthesis

Methanation

Fischer Tropsch Synthesis

Chemicals/ Gasoline

Synthetic natural gas

Fuels

Oxygen

Coal

Power

Products Additional Processing Conversion

CO2 IGCC

Ammonia Synthesis

Fertilizers

Typical BGL Gas Composition

for bituminous coal

H2 33 %

CO 56 %

CO2 4 %

CH4 7 %

• BGL Process has clear investment and operational

advantages in a wide range of application.

• According to gas composition BGL is well suited to

SNG production because of its high efficiency and the

presence of CH4 in product gas

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ENVIROTHERM

China

Commercial BGL

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ENVIROTHERM

Client Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC

Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier, Inner Mongolia, PRC

Location of facility Hulunbeier, Inner Mongolia, PRC

Application Syngas for the production of 500,000 t/year Ammonia,

800,000 t/year Urea

Feedstock Domestic dried and briquetted lignite

Features Two (2) + one (1) BGL gasifiers (40 barg operating pressure)

Synthesis gas production 119,000 Nm³/h

Status - Installation of entire plant completed in 2011

- Gasifiers have been operated for limited time (limited feedstock)

- Technical issues with plant units (briquetting unit and ASU)

BGL in China - Hulunbeier

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ENVIROTHERM BGL in China - Hulunbeier

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ENVIROTHERM BGL in China - Hulunbeier

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ENVIROTHERM

Client China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC

Location of Facility Luoyang, Henan Province, PRC

Application Fuel gas for industrial complex –

Substitution of 18 existing

fixed bed low pressure gasifiers

Feedstock Local hard coal

Features One (1) + one (1) BGL gasifiers

Gas production 43,000 Nm³/h

Start-up 2014

Status Detailed Design finished in 2011

Work in progress

BGL in China - Yituo

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ENVIROTHERM

Client China National Coal Development Co. Ltd, Beijing, PRC

China National Coal Corp, Beijing, PRC

Location of facility Ordos Tuke, Inner Mongolia, PRC

Application Syngas for the production of 1,000,000 t/year Ammonia,

1,750,000 t/year Urea

Feedstock bituminous coal

Features Five (5) + two (2) BGL gasifiers (40 barg operating pressure) with stirrers

Synthesis gas production 295,000 Nm³/h

Start-up 2013 / 2014

BGL in China – China National Coal

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ENVIROTHERM

India

Commercial BGL

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ENVIROTHERM

Client Shriram EPC Ltd., Chennai, India

Location of Facility Dharma, Orissa, India

Application Syngas for the production of synthetic ammonia

Features Two (2) BGL gasifiers, one relocated from Germany, second gasifier

built identically to relocated one, using high ash domestic hard coal

Raw gas production 150,000 Nm³/h

Feedstock Indian high ash coal

Start-up 2016

Status on hold

BGL in India

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ENVIROTHERM

Demonstration Plant Freiberg

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Pilot Scale Slagging Gasifier in Freiberg, Germany

• Pilot scale gasifier installed at the IEC, TU

Bergakademie Freiberg, next to HP-POX and

STF unit

• Scale down design of pilot plant was

challenging as certain process equipment had

to be newly designed and adapted to make it

fit for purpose

• Commissioning Q2 2014

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• Pilot plant comprises of coal intermediate storage, feeding

system, reactor, gas cooling and gas water system

• Gasifier features:

- 0.6 m inner diameter

- three tuyères (inlet nozzles for gasification agents)

- reactor and quench in one vessel

• Characteristics / Consumption figures:

- Operating pressure 40 bar

- 1.38 t/hr bituminous coal (Polish coal, bench mark)

- 430 Nm³/hr O2 consumption

- 450 kg/hr steam consumption

- Reactor capacity approx. 8.5 MW (LHV gas)

- Approx. 2,300 Nm³/hr product gas

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ENVIROTHERM

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• Principal R&D goal:

• investigation of liquid slag behaviour under high pressure

• characterisation of slag for a variety of fuels with different ash compositions

• Further, the facility allows for testing of coals to demonstrate the applicability of “unknown”

feedstock without interrupting the operation of a commercial plant. Thus the risk for an

operating company to loose valuable production capacity while testing components or process

adaptions is significantly lowered.

• The plant allows for a full HMB, to allow a for a lower safety margin in designing commercial

facilities.

• Minimize tar/oil in gas → target: increase usable gas output for IGCC application

• Maximize tar/oil in gas → target: recovery and sale

Research and Development


ENVIROTHERM

Thank you for your attention!

Questions?

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