R.P. Lee, A. Laugwitz, F. Mehlhose, B. Meyer Institute of Energy Process Engineering and Chemical Engineering (IEC)TU Bergakademie Freiberg

Berlin, Germany3-8 June 2018

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Waste gasification: Key technology for closing the carbon cycle

- Coupling the Energy, Chemical and Recycling Sectors-

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Content

Closing the Carbon Cycle

Key Global Challenges, Motivation

Gasification as Key Technology

Technological Needs for Closed Carbon Cycle

Key Global Challenges

Economic & population growth and

natural resource depletion

Reduce primary resource consumption;

Increase utilization of secondary resources

Growing waste problem; impacts for humans &

environment

Transform linear to circular economy

Key Factors: Sustainability, Competitiveness, Supply Security,

Societal Acceptance

Global warming &2°C Goal (Paris-Agreement)

Increase utilization of renewable energy;

GHG Neutrality

Emissions Reduction Goals for Diverse Sectors

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ActivitySector

1990 (in Mio.t CO2-Equi.)

2014(in Mio.t CO2-Equi.)

2030(in Mio.t CO2-Equi.)

2030(Reduction in % against 1990)

Energy 466 358 175 – 183 62 – 61%

Building 209 119 70 – 72 67 – 66%

Transport 163 160 95 – 98 42 – 40%

Industry 283 181 140 – 143 51 – 49%

Agriculture 88 72 58 – 61 34 – 31%

Subtotal 1209 890 538 – 557 56 – 54%Others 39 12 5 87%

Total 1248 902 543 – 562 56 – 55%Klim aschutzplan 2050, pp. 26-27

• Net zero emissions à not only for GHG emissions but also for rest

emissions (e.g. heavy metals, organic & inorganic traces, fine particles)

• Resource efficiency• Resource conservation• Minimize carbon leakage

LONG-TERM OBJECTIVES

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Motivation Closing the Carbon Cycle forDomestic Carbon Resources

ReduceGHG Emissions

Address Global Waste Problem

ConserveNatural Resources

Achieve a Circular Economy

Support Structural Change

Reduce Import Dependency

Reduce“Carbon Leakage”

Technology Leadership

Closing the

Carbon Cycle

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Content

Closing the Carbon Cycle

Key Global Challenges, Motivation

Gasification as Key Technology

Technological Needs for Closed Carbon Cycle

Waste Hierarchy:(Reduce, reuse,

recycle, incinerate,

landfill)

Sustainable utilization of primary & secondary

carbon resources

Stepwise release of coal from

power generation

Political Framework in Germany

Circular Carbon Economy=

Global undertakingfor the 21st Century

Energy Transition„Energiewende“

Circular Economy Law„Kreislaufwirtschaftgesetz“

Circular Carbon Economy„Kohlenstoffkreislaufwirtschaft“

From Linear to Circular Carbon Economy

Dom

estic

Car

bon

Res

ourc

esG arzw eiler M ine Pow erP lant N iederaußem

Spitte lau Incineration P lant, V ienna

Combustion to CO2

Pri

mar

yS

econ

dary

Combustion to CO2

C + O2 à CO2 Combustion

From Linear to Circular Carbon Economy

Dom

estic

Car

bon

Res

ourc

esN C PP 1 in N ingxia, C hina (S IEM EN S G asification, 5 x 500 M W )G arzw eiler M ine Pow erP lant N iederaußem

Spitte lau Incineration P lant, V ienna

Verbrennungzu CO2

Pri

mar

yS

econ

dary

Verbrennungzu CO2

Synthesis to Chemical Products

Synthesis to Chemical Products

(1) 2C+ 0,5 O2 + 2H2O à CO2 + CO + 2H2(Syngas)

(2) CO + 2H2 à -CH2- + H2O(Syngas) (Olefins)

Gasification

Synthesis

Show a D enko, Japan

Show a D enko, Japan

Proposed Concept: Closing the Carbon Cycle with Sector Coupling via Interface Technology Gasification

Minimum CO2 emissions & minimal demand on renewable energy to achieve net zero emissions

Lee, R .P ., W olfersdorf, C ., K eller, F ., M eyer, B . 2017. Tow ards a closed carbon cycle and achieving a circu lar econom y for carbonaceous resources. Erdöl, Erdgas, K ohle, H eft 6, 2017, S . 77 – 80

Sectors

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CO2-Reduction Potential by new Sector Coupling (in mill. t/a)

CO2

CO2

CO2CO2

Lignite

Carbon Waste 100 C

100 C

Electricity & Heat

Electricity & Heat

100 C100 C

Coal Power Plant

Sector coupling withreduced CO2

emissions

Carbon Waste 100 C

Lignite 100 C

96 C*

104 C*

Sector couplingWITHOUT CO2

emissions

0 C*

200 C*

“green” H2

Today: Combustion, w/o sector coupling, linear approach

Chemical products w/ 100%recycled carboncontent (Methanol to Olefin)

ETS* penaltyETS* allow ance *Em issions Trading System

Incinerator

2025+: Conventional Chemical Utilization with Sector Coupling

2050+: Future Chemical Utilization with Sector Coupling

Chemical products w/ ~ 50% recycled carbon content (Methanol to Olefin)

Carbon Waste 100 C

100 CLignite

* ow n process chain evaluation

* ow n process chain evaluation

Lee et al.. Chemie, Ingenieur, Technik, 6; 2017

Strategy for Sustainable Utilization of Domestic Carbon Resources

Chemical Utilizationof Waste

~13 Mio t/a C combusted

Closing the

Carbon Cycle

High Potential for Closing the Carbon Cycle: Example Plastic Waste in Germany

(Quelle: Consultic, 2015)

Only 1% chemically recycled.

Approx. 11 Mio. t CO2 /year

Material

Recycling

3,14 Mio. t (53%)Combusted

Combusted

Incineration of plastic waste generates approx. 11 Mio. t CO2/year à High potential for chemical utilization & emission reduction(PLUS untapped potential of all other types of waste e.g. industry and biomass waste)

Total EBS (Substitute Fuel)~ 5 Mio t/year

(in 30 coal power plants)

Over 2200 incinerationplants worldwide

Treatment of around 225 Mio t per year

Strategy for Sustainable Utilization of Domestic Carbon Resources

Chemical Utilizationof Coal

Chemical Utilizationof Waste

~46 Mio t/a C combusted

~13 Mio t/a C combusted

Closing the

Carbon Cycle

Domestic Coal as Partner for Waste in Closing the Carbon Cycle

Not all chemical products re-enter

carbon cycle as waste materials

after utilization

“Top up” this gap with domestic

coal to maintain quantity of

chemical production

Carbon Losses

Demand for stable process for

syngas production and reliable

operation

Coal as co-feedstock with waste to

support formation of solid carbon

required for a stable process

Technological Requirement

Strong market competition for waste

as feedstock (e.g. incinerator, as

substitute fuel in power plants, …)

Gap in waste resources to be met

with domestic coal resources

Market Competition

Lee et al., IRRC 2017

Strategy for Sustainable Utilization of Domestic Carbon Resources

Chemical Utilizationof Coal

Chemical Utilizationof Waste

New Technologies especially Gasification

~46 Mio t/a C combusted

~13 Mio t/a C combusted

Closing the

Carbon Cycle

Overview of International Coal Gasification Technologies

Entrained Flow coal gasification technologies increasingly dominating the market, HOWEVER, also not suitable for waste gasification & closing the carbon cycle

R-Gas(GTI)

GE Energy (Texaco)

Prenflo(Thyssen

Krupp)Shell

CB&I(E-Gas)

BGL(Enviro-

therm)

TRIG (KBR)

OMB (ECUST)

Mitsu-bishi(MHI)

U-Gas (GTI)

HTW(Thyssen

Krupp)ash-free

Conventional fuels

Reactor with cooling screen

ash-containing

Industrial andchemical wastes

ash-containing

Reactor with specialcooling screen and quench

Industrial and chemical wastes

Fuel gas

PowerHeat

high-salt ash-free

Reactor with cooling wall

FertilizersOxoalcohols

Recovered resources

Syngas

HydrogenMethanol Raw syngas

Siemens (GSP)

Clean Coal Gasifier

(Choren)

Tsinghua 2-stage-oxygen

HT-L

(CECO)

TPRI2-stage-

coal

MCSG(NRI)

Lurgi FBDB

AirLiquide

2nd generationFluidized BedFixed Bed Entrained Flow

Strategy for Sustainable Utilization of Domestic Carbon Resources

Chemical Utilizationof Coal

Chemical Utilizationof Waste

~46 Mio t/a C combusted

~13 Mio t/a C combusted

Closing the

Carbon Cycle

“Green” H2 from Renewable Electricity

New Technologies esp. Gasification

Chemical Products from Domestic Carbon

Resources

Demand:~20 Mio t/a C

75%

18%5%

2%

Net Zero Emissions Olefins Production with Gasification Technology

Renewable H2 Demand: 0.235 kg/kg C

19(Source: own calculation)

Gasification

Auxiliaries & Electrolysis

Syngas cleaning

Renewable electricity

H2

Waste & Coal

MeOH & MTO-Synthesis Olefins

Diffuse CO2 recovery

Net Zero Emissions

O2

Diffuse CO2

Concentrated CO2

Renewable electricity

Legend

Raw gas/Syngas

11.1

GW

(10 Mio. t/a)

SyngasComposition

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Content

Closing the Carbon Cycle

Key Global Challenges, Motivation

Gasification as Key Technology

Technological Needs for Closed Carbon Cycle

Gasification enhances Recycling Rates

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+ a wide range of plastics cannot be recycled for material utilisation

+ Parts of waste are not suitable for combustionè Such waste streams can be a useful, high energy feedstock for gasification after a pre-treatment

(extraction of metals and glass )

Environmental benefits:§ Decreases GHG emissions§ Reduces use of imported fossil fuels§ Reduces use of virgin materials § Enhances recycling rates§ Changes waste to value feedstock§ Reduces waste deposits and problems of ocean wastes

Alternative Forms of Chemical Waste Recycling

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• Produce fuels - BUT: chlorine contamination of products• No technical solutions at present to prevent chlorine contamination

à Pre-selected polyolefin required as feedstock• Example: SYNTROL® facility in Mannheim; further development of

BASF‘s patented process; under construction since 2012 (??)

1) Pyrolysis

Costs & Chlorine

Contamination

• Produce fuels – BUT: chlorine contamination of products (as per pyrolysis)

• No technical solutions at present to prevent chlorine contamination

• Example: Kohleölanlage Bottrop (1990’s – 2000)

2) Direct Liquefaction Costs & Chlorine

Contamination

Overview of Waste Gasification Projects – Germany

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Rheinbraun, Berrenrath

SVZ, Schwarze Pumpe

1985-1997700 tpd coal-waste-mixture à 350 tpd MeOHHTW fluidized-bed gasifier

1991-20071300 tpd coal-waste-mixture à 300 tpd MeOHFBDB® gasifier, BGL gasifier, GSP gasifier

• Extended technological experience in Germany• Various waste mixtures tested• Different waste preparation technologies developed

è BUT not placed on the marked

• SVZ: 1991 – 2007 in East Germany• Processed 3.6 million tons of waste• Co-gasification of up to 75% waste with coal

- Shredder pellets (from cars) - Municipal waste- Dried sewage sludge- Used plastics- Contaminated wood- Tars & other liquid waste

• Uneconomic after changes to the German waste management regulations

• Key operation issues:- Chloride condensation- Low raw gas quality, fluctuating quantity- Extensive tar/oil-extraction and gasification

Experience from Schwarze Pumpe in Germany (SVZ)

Insights from IEC collaboration with SVZ

Source: IEC Internal SVZ Report

Overview of Waste Gasification Projects - International

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Showa Denko, Kawasaki, JPN

Since 2003, expansion in 2015

2 x 195 tpd waste à hydrogen for ammonia synthesis

EBARA PTFIG fluidized-bed gasifier

Enerkem, Edmonton, CAN

Since 2015

300 tpd waste à 80 tpd MeOH or Ethanol

Enerkem fluidized-bed gasifier

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Content

Closing the Carbon Cycle

Key Global Challenges, Motivation

Gasification as Key Technology

Technological Needs for Closed Carbon Cycle

Fixed Bed

FluidizedBed

EntrainedFlow

Net Zero Emissions

Synthesis Gas Quality

Synthesis Gas Yield low (C H 4, tars, o ils) moderate (C H 4) high

Carbon-free Ash yes no yes

Suitability forco-gasificationFeedstock coarse fine to coarse pulverized

Demands on Gasification Technologies for Closing the Carbon Cycle

R&D required to further develop fixed-bed and fluidized bed-technologies for closing the carbon cycle

R&DR&D

The Way Forward for Gasification Technology Development to Close the Carbon Cycle – Carbon Balance (1)

Internal Circulation Gasifier(INCI)

Circulating Fluidized Bed Gasifier(HTW)

Fludized-Bed Technology Further R&D

• High concentration of carbon in ash• No direct ash melting

• Lower concentration of carbon in ash• Improved gas quality• No direct ash melting

Test gasifier at IEC in Freiberg:• Improvement of Design• Testing of waste mixture• Improvement of gas quality

Fixed Bed Slagging Gasifier (BGL Gasifier)

Fixed Bed Dry Bottom Gasifier (FBDB)

The Way Forward for Gasification Technology Development to Close the Carbon Cycle – Carbon Balance (2)

Fixed-Bed Technology

• High concentration of carbon in ash• No direct ash melting• Low Gas Quality & Gas fluctuations

• Vitrified ash – unleachable slag• Low Gas Quality (Tar)• Gas fluctuations

Test gasifier plantat IEC in Freiberg:• for testing of design changes

and application of waste gasification

• Optimisation of gas quality• Test of different waste qualities

and mixtures

Further R&D

Planned Demonstration Project CARBONTRANS

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Start Engineering2021

Start Demonstration2024

Demonstration of closed carbon technology by using secondary sources implemented in a chemical plant site

IEC

Friedemann MehlhoseInstitute for Energy Process Engineeringand Chemical Engineering (IEC)TU Bergakademie Freiberg

Email: Friedemann.Mehlhose@iec.tu-freiberg.deTel: 0049 3731 39 4126

Thank You& Glück Auf!