Development and Modelling of 3 rd Generation Gasification Concepts for Low Grade Coals

(1)

TU Bergakademie Freiberg

I

Institute of Energy Process Engineering and Chemical Engineering

Reiche Zeche

I

09596 Freiberg

I

Tel. +49(0)3731/39 4511

I

Fax +49(0)3731/39 4555

Email [email protected]

I

Web www.iec.tu-freiberg.de

Institute of Energy Process Engineering and

Chemical Engineering

Development and Modelling of

3

rd

Generation Gasification

Concepts for Low Grade Coals

Martin Gräbner, Alexander Laugwitz,

Bernd Meyer

International Freiberg Conference on IGCC & XtL Technologies

May 3rd – May 5th 2010 – Dresden, Germany

(2)

2

Outline

1.

The 3

rd

generation of gasifiers

2.

Low grade coal in the sense of this study

3.

Introduction of research approach

4.

Development of ternary gasification diagram for standard coal

•

Process conditions

•

Performance parameters

5.

Overview of proposed gasifier concepts

•

Introduction of the INCI-concept

6.

Application of the ternary diagram for high-ash coal

(3)

3

1. The 3

rd

generation of gasifiers

1

st

generation

2

nd

generation

3

rd

generation

Since 1920s

1970s

~1990

etc.

GE

ConocoPhillips

BGL

HTW

Shell

SFGT

KBR

MHI

Lurgi dry ash

Winkler

Koppers-

Totzek

etc.

PWR

INCI

[1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle – Technologien und Projekte 1970-2000 in Deutschland, DGMK, Hamburg, 2008 [2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002 [3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993

[4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005

[5] Lynch, T. A.: Conoco Phillips – Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005 [6] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology – Today’s Solutions and Developments, 2nd IFC, Freiberg, 2007 [7] Smith, P. et al.: KBR Transport Gasifier, GTC, San Francisco, 2005

[8] Ota, K.: PRB Coal Gasification Test Results with Air-Blown IGCC, GTC, Washington DC, 2006 [9] Hartung, J.: PWR Compact Gasification System, GTC, Washington DC, 2006

[10] IEC Material

[1]

[2]

[3]

[10]

[4]

[5]

[6]

[8]

[9]

[7]

[10]

+ new

concepts for

2

nd

generation

(4)

4

2. Low grade coal in the sense of this study

South Africa

USA

Coal

(typical) Pittsburgh #8

[11]

Coal rank (ASTM [11])

HV C Bit.

HV A Bit.

Moisture

wt%

6.0

2.4

Proximate analysis (dry basis)

Ash

wt%

25.0

10.2

Volatiles

wt%

23.0

36.1

Fixed carbon

wt%

52.0

53.7

Ultimate analysis (dry & ash free basis)

Carbon

wt%

80.0

83.3

Hydrogen

wt%

4.0

5.7

Oxygen

wt%

13.0

8.3

Nitrogen

wt%

2.0

1.4

Sulphur

wt%

1.0

1.3

Calorific Value (dry basis)

Lower Heating Value

MJ/kg

21.9

31.5

[11] Miller, B. G.; Tillman, D. A.: Combustion Engineering Issues For Solid Fuel Systems, Academic Press, New York, 2008

Technical limitations e.g.:

-

Carbon conversion (encapsulated C)

-

Efficiency due to physical

heating/cooling and melting of ash

-

Coal preparation (grinding, de-ashing,

drying, slurry energy density)

-

Vast amounts of fines available

Ash property issues:

-

Flux material addition

-

Oxygen consumption by mineral matter

(e.g. Fe

3

O

4

, FeS

2

)

-

CO

2

emission by heating of carbonates

(e.g. calcination of CaCO

3

)

-

Increased fouling in HRSG due to

increasing amounts of vaporized ash

compounds

(5)

5

3. Introduction of research approach

Pathway to systematic and unified concept evaluation

Basis: Public domain data

of 2

nd

generation gasifiers

Thermodynamic modeling and validation

of gasifiers and gas cooling

(Aspen Plus)

Standardi-

zation of

boundary

conditions

Development of

ternary diagram for

Pittsburgh #8 coal

Incorporation and evaluation

of proposed concepts

Diagram extension to

high-ash coals and

systematic concept

evaluation

(6)

6

4. Development of ternary gasification diagram

-

Contacting various mass

flows of Pittsburgh #8

coal with gasifying

agents H

2

O and O

2

-

Definition of process

temperature by

equilibrium calculation

-

Definition of residual

carbon iso-lines,

indicating conversion

domain of combustion

(O

2

excess, oxyfuel)

domain of gasifier

operation

domain of

kinetic

limitation

4.1 Process conditions

(7)

7

Lurgi FB

[1]

GE

[2]

ConocoPhillips

[5]

SFGT

[6]

Shell

[4]

Prenflo

[1]

HTW

[3]

-

Incorporation of gasifier

operation domains

-

Location of existing

gasification systems

4.1 Process conditions

[5] Lynch, T. A.: Conoco Phillips – Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005 [6] Schingnitz, M et al.: Siemens IGCC and Gasification Technology – Today’s Solution and Developments, 2nd IFC, Freiberg, Germany, 2007

(8)

8

4. Development of ternary gasification diagram

domain of

η

CGE

> 80 %

-

Calculation of cold gas

efficiency on LHV basis

-

Maximum cold gas

efficiency identical to

100 % carbon

conversion line

-

Definition of methane

yields in product gas

4.2 Performance parameters

(9)

9

4.2 Performance parameters

-

Incorporation of gasifier

operation domains and

location of existing

gasification systems

Lurgi FB

[1]

GE

[2]

ConocoPhillips

[5]

SFGT

[6]

Shell

[4]

Prenflo

[1]

HTW

[3]

[5] Lynch, T. A.: Conoco Phillips – Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005 [6] Schingnitz, M et al.: Siemens IGCC and Gasification Technology – Today’s Solution and Developments, 2nd IFC, Freiberg, Germany, 2007

(10)

10

5. Overview of proposed gasifier concepts

Selction:

Siemens

– partial water

quench

Shell

– partial water quench

[12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen 27.8.2009

[13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology – Today’s Solutions and Developments, 2nd _{International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007}

[14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, 23.9.2008

[15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, 18-21 May 2009 [16] Zuiker, J.R.: Building on History…the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4 - 7 October 2009

[17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October 2004

[18] Gräbner, M.; Messig, D.; Uebel, K.; Meyer, B.: Development and Modelling of 3rd _{generation gasifiers for low-rank and high-ash coals, ICCST, Cape Town, South Africa 2009}

Prenflo

– full water quench

GE

– posimetric feeding

system

ConocoPhillips

– Entrained

slagging transport reactor

INCI

– Internal Circulation

gasifier concept

[13]

[14]

[15]

[16]

[17]

[18]

[12]

(11)

11

Lessons learnt from analysis of established

systems

[1]

:

-

Water jacket, no brick lining

+ fluidised bed gasifiers features

-

Slag-free tuyere nozzles

[19]

- Ash particle agglomeration

-

Outlet temperature of ~1000 -1100 °C

-

Internal circulation (transport-principle, CFB)

+ entrained flow gasifiers features

-

High central flame temperatures > 2,000 °C

-

Dust feeding

+ new principle of post-gasification

(similar to fixed bed)

-

Enhanced carbon conversion by O

2

/H

2

O- or

O

2

/CO

2

-mixtures (5..13 %vol O

2

)

-

Sensible and fusion heat recovery into

gasification process

cooling

water

cooling

water

primary

gasification

agent

coal

gasification

agent tuyres

Δ

p

Agglomerates

© IEC

5.1 Introduction of Internal Circulation Gasifier - INCI

(H

2

O/O

2

)

[1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle – Technologien und Projekte 1970-2000 in Deutschland, DGMK, Hamburg, 2008.

[19] Lambertz, J.: Process for gasifying carbonaceous solids, and fluidized –bed reactor for carrying out the procss, German Patent DE 3439404, 1985

(12)

12

6. Application of the ternary diagram for high-ash coal

General comments to

high-ash coal:

-

Shifting towards lower

temperature (generally

favorable for

η

CGE

)

-

No moderator

necessary

-

Smaller domain of

carbon presence

Ash properties under

reducing

atmosphere:

-

Softening

temperature:

1290 °C

-

Flow temperature:

1430 °C

Æ

Sticking zone

(w/o flux):

1140-1580 °C

(13)

13

6. Application of the ternary diagram for high-ash coal

[17]

T>1600 °C

More

moderator

1

2

Slurry 66/34

2

3

Mixing lines

[16]

[13]

[14]

[15]

(14)

14

6. Application of the ternary diagram for high-ash coal

[17]

[16]

[13]

[14]

[15]

[18]

1

2

[17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October 2004

[18] Gräbner, M.; Messig, D.; Uebel, K.; Meyer, B.: Development and Modelling of 3rd _{generation gasifiers for low-rank and high-ash coals, ICCST, Cape Town, South Africa 2009}

900°C

< T <

1100°C

2

5-13 %vol O

2

1

(15)

15

7. Conclusion & Outlook

Conclusion:

-

Development of an unified ternary diagram for gasification

processes

-

No focus of 3

rd

generation concepts on high-ash coals (fines)

-

INCI gasification concept & ConocoPhillips ESTR concept

show high potential for high ash coals

-

Most of the technology providers favor

-

Dry feeding systems (even look hopper-free)

-

Flexible gas cooling concepts

-

Development of INCI gasifier concept for low grade coals

Outlook:

-

Construction 10 kg/h INCI lab scale plant (COORVED-project

ID# 0327865)

-

Finishing numerical modeling of the INCI process with FLUENT

-

Extension of the diagram to low-rank coals (lignite)

and other gasification agents

[20] Gräbner, M.; Uebel, K.; Messig, D.; Meyer, B.: Development and Numerical Simulation of 3rd Generation Gasifiers for High-ash Coals, ICCES Paper # ICCES1020091117059, Las Vegas, USA, 2010

(16)

16

End of Presentation

Thank you for your attention – Questions?

[email protected]