commercially proven prenflo and high temperature … · prenflo (pdq) (direct quench) prenflo (psg)...

4th EU-SA Coal and Clean Coal Working

Group Meeting

Commercially proven Prenflo and High

Temperature Winkler Gasification By Bruce Bassett

Johannesburg, 6 th November 2012

6 th November 2012 – Johannesburg –

Copyright TK Uhde 2012

ThyssenKrupp and Uhde

Uhde‘s experience and expertise in gasification

PRENFLO (PSG / PDQ)

High Temperature Winkler (HTW)

Updates on Projects and Alliances

Presentation Outline



ThyssenKrupp Group Business Segments and Business Areas

Materials

Steel

Europe

Steel

Americas

Stainless

Global

Materials

Services

Technologies

Elevator

Technology

Plant

Technology

Components

Technology

Marine

Systems

ThyssenKrupp Uhde

Fiscal Year 2010/2011: Sales € 49.1 billion Employees 180,000



BA PT builds plants – focus on markets- Fiscal Year 2010/2011 A strong segment with 13,500 employees and an annual sales of 4.6 bn €

Ma

rke

ts

Engineering Procurement Construction

A homogeneous business model reflected in 8 market segments

Business Area Plant Technology Order intake: 4.6 bn EUR Employees: ~13.500

Mining

Service

Automotive

Plants Minerals

Service

Cement

Service

Fertilizers

Service

Contracting

Services

Service

Polymers

Service

Base

Chemicals

Service

Companies within the Business Area Plant Technology

o Engineer and build small to large-scale plants

o Use in-house or third-party technology

o Provide single work packages as well as turnkey (EPC) plants

o Deliver worldwide

TK Födertechnik TK Polysius TK Uhde TK System Eng.



ThyssenKrupp Uhde Global Network The global engineering network combines local knowledge with global expertise and provides 7.2 million engineering hours per year

Melbourne Johannesburg Rio de Janeiro

Mexico City Mumbai/ Pune

Cairo

Bangkok

Hanoi

Al Khobar

Dubai

Shanghai

Tokyo

Nizhny Novgorod

Dzerzhinsk

Moscow

Calgary Pittsburgh, PA Cleveland, OH

Germany

Beijing

Americas

Employees: 450

Eng. hours: 560,000

Europe/Africa

Employees: 3.100

Eng. hours: 4,000,000

Asia/Pacific

Employees : 650

Eng. hours : 700,000

India/Middle East

Employees: 1.400

Eng. hours: 1,850,000 Central Engineering

Hub: Uhde Mexico Central Engineering

Hub: Uhde Russia Central Engineering

Hub: Uhde India Central Engineering Hub: Uhde Thailand



Overview of our Product divisions

Electrolysis Ammonia &

Urea Hydrogen &

Nitrates Refining

Technologies

Org. Chemicals/ Polymers

Gas Technologies Polyester

Coke Plant Technologies





PRENFLO (PSG / PDQ)






What is Gasification?

o Combustion is full oxidation:

2 (CH2) + 3 O2 2 CO2 + 2 H2O

o Gasification is partial oxidation:

2 (CH2) + O2 2 CO + 2 H2



Synthesis Gas as a Central Part of Uhde‘s Process Chain Gasification: Feedstock - Process - Product

Gas, Naphtha

Oil/Residues

Steam

Reformer/

ATR

HTW

Gasification

Synthesis

Gas

CO +H2

Methanol

Ammonia

Power Plant (IGCC)

FischerTrops

ch Synthesis

CO-

Conversion

Methanation

Diesel

Petrol +

LPG

Urea

Diesel,

Naphtha

Petroleum

Coke

Hard Coal

Biomass

PRENFLO

Gasification

Biomass

Brown Coal

Waste

Lubricants

MTO

MTG

Feedstock Gasification Syngas Product Further processing

Hydrogen

Synthetic

NaturalGas

Electricity

Fertilizer

Oil

Gasification



PRENFLO PSG, PDQ

entrained-flow gasification

HTW (High Temperature Winkler) fluidized-bed gasification

Various Materials require various Gasification Technologies Uhde‘s Gasification Portfolio

http://de.wrs.yahoo.com/_ylt=A0WTf2kk_DZMGm8AlDg1CQx.;_ylu=X3oDMTBpdnJhMHUzBHBvcwMxBHNlYwNzcgR2dGlkAw--/SIG=1g4842u2h/EXP=1278758308/**http%3a//de.images.search.yahoo.com/images/view%3fback=http%253A%252F%252Fde.images.search.yahoo.com%252Fsearch%252Fimages%253Fp%253D%2525C3%2525B6ltropfen%2526ei%253Dutf-8%2526fr%253Dyfp-t-708%26w=345%26h=477%26imgurl=ms-collection.de%252Fbilder%252F114.jpg%26rurl=http%253A%252F%252Fwww.ms-collection.com%252Fartists%252Flarge%252Fb114.htm%26size=61k%26name=114%2bjpg%26p=%25C3%25B6ltropfen%26oid=0eae4851b51b2a0a%26fr2=%26no=1%26tt=9%26sigr=11j7ac62m%26sigi=10v5ka7t1%26sigb=12m4gcl56%26type=JPG

http://en.wikipedia.org/wiki/File:Oil_well.jpg



Gasification Technologies

550 °C 1350 – 1600 °C 800 – 1100 °C



Uhde‘s Gasifiers

PSG PDQ HTW

Entrained-flow gasification Fluidized bed gasification



Classification of Feedstock

PRENFLO HTW





PRENFLO (PSG / PDQ)




Summary



PRENFLO burner test rig

6 t/d (450 m³n/h syngas)

PRENFLO Fürstenhausen

48 t/d (3,500 m³n/h syngas)

PRENFLO Puertollano

2,400 t/d (180,000 m³n/h syngas)

Start Up: 1984

Start Up: 1985

Start Up: 1998

Scale Up Factor:

8

Scale Up Factor:

50

Koppers-Totzek Start of development 1941

Shell-Koppers pilot plant Hamburg 150 t/d coal

Start Up: 1978

Developments From Koppers-Totzek to PRENFLO



Features

• dry coal/petcoke powder feed

• 4 horizontal co-annular burners

• membrane wall

• waste heat boiler (PSG)

PRENFLO with Steam Generation (PSG) 1000 MWth, 40 bar



PRENFLO Membrane Wall protected by the slag layer

molten slag

solidified slag

> 1500 °C

Gasification

Reactor Water Tube

(membrane wall)

molten slag flows downwards

BFW, 40-70 bar



ELCOGAS IGCC plant: Gasification Island, Spain



Gasifier - Erection of Internals, Elcogas IGCC, Puertollano / E



Dry-fed, single train IGCC with CCS Pilot Plant at Elcogas, Spain 300 MW net based on petcoke / coal feedstock

PRENFLO Gasification

Gas Treatment

Coal Preparation ASU

Combined

Cycle New CO2 capture

Pilot Plant

implemented



PRENFLO (PDQ)

(Direct Quench)

PRENFLO (PSG)

(Waste Heat Boiler)

PRENFLO Layout Comparison PSG vs. PDQ





PRENFLO (PSG / PDQ)






Start Up: 1988

HTW-Peat Gasification, Kemira

HTW- Pilot Plant

Rheinbraun Wachtberg 40 t/d Lignite, 10 bar

HTW- Demonstration Plant

Rheinbraun Berrenrath 720 t/d Lignite, 10 bar

KoBra IGCC

RWE, Hürth 3700 t/d Lignite 27 bar

Start Up: 1978

Start Up: 1986

Engineering: 1994

Scale Up Factor:

18

Scale Up Factor:

5

Atmospheric Winkler generators 1956 – 1964 260 t/d Lignite

HTW Laboratory Plant RWTH-Aachen 12 t/d Coal, Atm.

Start Up: 1974

HTW-Pilot Plant (WVW)

Rheinbraun Wesseling 185 t/d Lignite, 25 bar

Start Up: 1989

Developments The HTW Process



HTW High Temperature Winkler - Gasifier



25 t/h dried lignite – 140 MWth 34,000 m³/h of syngas ≈ 300 t/d Methanol 67,000 total operating hours 84 % availability (last 10 years) 1986 - 1997

HTW Commercial Scale Demo Plant Berrenrath/Germany



HTW-Precon-Gasification Niihama / Japan 48 t/d Municipal Waste 1999 - 2002

Sumitomo Heavy Industries Ltd.





PRENFLO (PSG / PDQ)






Uhde/EMRE provide full range service for synfuel projects



ICM‘s 18,000 bbl/d CTL Plant in Mongolia Coal-to-Gasoline (CTG) plant *

*) Photo Courtesy TransgasDevelopment

#1 coal preparation

#2 coal gasification

#3 CO-shift reactor

#4 acid gas removal

#5 methanol synthesis #6 methanol-to-gasoline #7 gasoline storage

PRENFLO PDQ

gasifiers

Applying TK Uhde‘s PRENFLO Gasification Technology



Life-cycle analysis for optimum equilibrium between technical-economical

performance and environmental demands

Coal

Petcoke

Wood

Straw etc.

Feedstock Pretreatment Gasification Gas Treatment

Milling

Torrefaction CO-Shift

Synthesis

GaselTM

Fischer-

Tropsch

Synthesis and

Product

Upgrading

Biodiesel;

Biokerosene AGR

Liquid

Residues

BioTfueL – integrated process chain PRENFLO with FT based on solid and liquid feedstock



SGCE – 9,500 bpd CTL, Mozambique PRENFLO PDQ for high-ash coal




C.GEN – 450 MWe IGCC with CCS, Killingholme, UK PRENFLO PDQ selected

Optional hydrogen production

Carbon capture & storage

Synergies due to maximum integration into existing industrial network

High level of standardization – beneficial for future plants

Feedstock: hard coal, petcoke and biomass




Gasification is a proven technology, a vast number of gasifiers are operating since decades successfully on commercial basis

Gasification allows flexibility in feedstock and polygeneration of products

Gasification is environmental friendly

Uhde has more than 70 years of experience in gasification

based on 8 different gasification technologies

… received more than 100 contract awards for gasifiers

… has proven single sourcing capability

… has built the world‘s largest solid fuel based, single train IGCC

… is a process oriented EPC contractor and not only licensor

… has built more than 2,000 plants worldwide

Gasification Summary



PRENFLO IGCC, Puertollano, Spain

Thank you for your attention

www.prenflo.com

[email protected]

www.tkpdna.co.za

mailto:[email protected]

commercially proven prenflo and high temperature … · prenflo (pdq) (direct quench) prenflo (psg)...

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