update on stf technology – freiberg test plant for the ......m. kuschel at international freiberg...

M. Kuschel at International Freiberg Conference, Leipzig 2012

Update on STF technology –Freiberg test plant for the production of high octane gasoline from synthesis gas

Dr. Mario Kuschel, May 2012


2 First Results

3 Outlook

1 Review STF technology


Natural gasNatural gas

Crude oil associated gas

Crude oil associated gas

CoalCoal

BiomassBiomass

……

Gasoline

Gasoline

Raw MaterialSynthesis gasgeneration

Production ofgasoline

Syngas to Methanol

Syngas to Methanol

Methanol to Fuel

Methanol to Fuel

Partial non catalytic oxidation

Partial non catalytic oxidation

Catalytic auto thermal reforming

Catalytic auto thermal reforming


Fresh synthesis

gas

Methanol synthesis reactor

Fuel synthesis reactor

Cooling and separation

Circulation compressor

Fuel

stabilization column

Flare

Overhead product

Stable fuel

Produkt -

Lager

Instable fuel

Recycle gas

Process waste water

Steam condensate system

Boiler feed water

Steam

Steam

Absorption refri-gerating machine

Recooling plant

Nitrogen supply

Feed water buffer vessel

Control room

Power supply

Analytics

Instrument and compressed air

supply

Electric energy

Instrument & compressed

air

Feed water Catalytic waste water purification

CO + H2 gas

Purifed water

Cooling and separation

Circulation compressor

Heavy fuel

Recycle gas

Methanol separation column

Methanol


STF plantSTF plant

Technical University Bergakademie Freiberg,

Department of Energy Process Engineering and Chemical Engineering,

“Reiche Zeche“

Synthesis gas plant

Synthesis gas plant


Novelties of Technology:

� Employment of new isothermal reactorsAdvantage: more stabile and better product quality

� Employment of new developed catalysts in section of gasoline production and treatment of process water (formed in process)Advantage: higher product yields and better product quality

� Lower rate of circulation gases in combination with isothermal plant operation

Advantage: Lower rates of circulation gases are necessary in comparison toadiabatic operation mode.


1 Die Chemieanlagenbau Chemnitz GmbH stellt sich vor

2 First results


2.2 Results of full load mode

2.3 Results of partial load mode

3 Outlook

2.1 Test campaigns


Test campaigns:

1. June 2010 2 weeks2.1 December 2010 2 weeks2.2 Feb./March 2011 4 weeks3. Aug./Sept. 2011 4 weeks

total 12 weeks

forecast:5. May/June 2012 6 weeks


1st campaign:15.06.2010Feed of synthesis gas and Start-up of main process units in test mode17.06.2010Sampling of first STF fuel produced in test facility

2nd campaign:(Febr./March 2011)Supply Syngas 95 hMethanol, pure 9,170 kgGasoline, instable 4,000 kg

3rd campaign:(Aug./Sept. 2011)Supply Syngas 240 hMethanol, pure 12,850 kgGasoline, instable 8,800 kg


°C-40 – 186Boiling range

kPa

% vol.

% vol.

wt%

wt%

wt%

wt%

kg/kmol

kg/m³

max. 10066,7Steam pressure

min. 82,584 – 85Motor octane number

min. 9193 – 95Research octane number

max. 3Durene

max. 10,2 – 0,4Benzene

max. 3534 – 36Aromatic compounds

7 – 9Naphthenes

max. 184 – 6Olefins

30 – 40Paraffins

95 – 96Molecular mass

720 – 775750 – 760Density (15°C)

DIN EN 228:2004-03

gasoline, regular

STF fuel

Properties of STF fuel

��

��

��

��

��

��

��

��


Drehzahl [1/min]

1000 2000 3000 4000 5000 6000

Be

ff [

g/k

Wh

]250

275

300

325

350

375

400

pm

e [

ba

r]

12

14

16

18

20

22

24

26 STF Benzin Charge 2 Basis Benzin ROZ95

Zü

nd

win

ke

l [-

]

-12

-8

-4

0

4

8

12

16

in cooperation with:

First results of „full load“ mode:

• tests with a modern fuel injection motor (Downsizing Concept)

• Comparative fuel: Gasoline RON 95 („Super E10“with 5.1% Ethanol)

Valuation of Results:

• With STF gasoline nearly same results under full load at constant charging pressure

• Ignition angle with STF gasoline minimal later (ca. 1°KW), this means knocking behavior slightly higher

• Specific fuel demand Beff until 4000 1/min for both fuels identical, at higher speed (number of revolutions) slightly higher

Speed [1/min]

Ign

itio

n A

ng

le [

-]


in cooperation with:

First results of „partial load“ mode:

• fuel consumption for STF similar to commercial gasoline, with ethanol addition increasing value due to decreasing cross value

• with STF increased HC emissions at higher loads, slight decrease through E10

• NOx with STF at level of commercial gasoline, STF E20 as expected at lowest level

HC

[p

pm

]

0

250

500

750

1000

1250

1500

NO

x [

pp

m]

050010001500200025003000350040004500

pme [bar]

0 2 4 6 8 10 12 14 16

Be

ff [

g/k

Wh

]

200

280

360

440

520

600

ROZ 95

ROZ98

STF1

STF3

STF3 E10

STF3 E20


2 First Results

3 Outlook



Open points:

• Constant operation with all units• Optimization of process parameters of gasoline synthesis

• especially heat transfer• Development of improved reactor for gasoline synthesis• Variation in methanol quality and investigation of impurities due to different sources of methanol• Improvement of sampling

• e.g. Sampling under high pressure

Target:• First commercial plant in Engineering Phase

latest end of 2013


The project is supported with public funding by the Saxon State Ministry for Economic Affairs and Labour (SMWA) represented by the Sächsische AufbauBank (SAB) financed by the European Regional Development Fund (ERDF)

as well as by private investors.

European Union – European Regional Development Fund

Acknowledgement


Chemieanlagenbau Chemnitz GmbHAugustusburger Str. 34

09111 ChemnitzGermany

Phone: +49 371 68 99 0Fax: +49 371 6899 342

Internet: www.cac-chem.deEmail: [email protected]

update on stf technology – freiberg test plant for the ......m. kuschel at international freiberg...

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