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FUTURE ENERGY GmbH, Germany CCT 2005

The GSP-PROCESS Entrained-Flow Gasification of different Types of CoalDr. Manfred Schingnitz; Friedemann Mehlhose

History of GSP Gasification TechnologyYear 1956 1977 Fixed-bed gasification 24 gasifiers constructed in the gas combine Schwarze Pumpe Entrained-flow gasification

DBI

Demonstration plants Freiberg1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Lignite Saliferous lignite

Commercial plants

3 MW

DBI

130 MW42 lignite varieties 15 hard coal varieties (international) Pulverized hard coal and lignite Lignite Saliferous lignite

Schwarze Pumpe

Natural gas 15 municipal and industrial sewage sludges, MSW, waste oil, wood, straw Slurry, fly ash Industrial waste and residues Waste oil, tar oil Slurry Tar oil/solid sludges

Noell

5 MW

Chlorinated organics Nitrogen waste organics Black liquor

Nitrogen waste organics 13 t/h Seal Sands

BabcockBioslurry, coal Hard coal Tar oil

Vesov

FUTURE ENERGYFig. 4

Advantages of GSP Entrained-flow Gasifier with Cooling ScreenFuel Burner Pressur. water outlet Oxygen, Steam

- High carbon conversion > 99 %- Raw synthesis gas without hydrocarbons, i.e.

absolutely tarfree - No dioxin/furan formation despite high chlorine content in the gasification feed - No heed to be given to ash content and ash compositionCooling jacket Gas outlet

Cooling screen

Pressur. water inlet Quench water

- High gasifier performance - High availability - Short start-up and shutdown time (about one hour) - Multipurpose feeding - Cooling screen life time >10 years

Water overflow

Granulated slag

Fuel Preparation Reference ValueFuels Petcoke Anthracite Hard coal(low reactivity, Vdaf > > > > > 99 % < 250 m 100 % < 500 m 94 % < 250 m 100 % < 500 m 94 % < 250 m 100 % < 500 m 55 % < 100 m 99 % < 500 m 94 % < 250 m 100 % < 500 m

Moisture Content

< 2 wt.-%

Pyrolysis coke Hard coal(high reactivity, Vdaf> 28 %)

< 2 wt.-% < 2 wt.-% < 8 wt.-% < 12 wt.-% < 10 wt.-%

Hard brown coal Soft brown coal Sewage sludge

Particle Size Distribution of Pulverized Coal at a Carbon Conversion Rate of >99 % Hard coal0.1 1 Sieve 2 oversize in % 5 10 15 20 30 40 50 60 70

Lo

w -re ac

ti v e

Petcoke

Pyrolysis char

80 85 90

Lignite, sewage sludge Wood flour

95 0.01

Hi gh

-re

ac

tiv e

0.02 0.03

0.1 0.05 0.2 Particle diameter in mm

0.3

0.5

1Fig. 12

Pneumatic Conveying and Feeding System for Pulverized Solid MaterialsMaterialLIA PI

Waste air

Storage binTI

N2

Depressurization

M

M

Depressurization

P IC

P IC

Lock hopperLIC

H LIC L

H L

Lock hopperM

N2

M

N2

FIC

UC LIC

Q

S

Material to gasifier

Feeding vesselPI

N2

M

Fig. 10

Burner for Coal GasificationIgnition voltage

Flame signal Fuel gas to pilot Cooling water Cooling water Oxygen/steam Cooling water Cooling water Pulverized coal

Cooling water Cooling water

Pulverized Coal Burner

Cooling water

Oxygen/ HP steam

Cooling water Cooling water

Pilot burner gas

2x

3x

Oxygen Pulverized Cooling coal water Cooling water

Cooling Screen of the Gasification ReactorLiquid slag

Membran wall Solid slag Pressurized water

Ramming mass

Pipe coil with studsFig. 6

GSP Entrained-flow GasifierFuel Oxygen, SteamBurner Pressur. water outlet Fuel Oxygen, Steam

Cooling screen

Pressur. water inlet Quench water Cooling jacket Gas outlet

Slag discharge unit

Water overflow

Raw gas Slag

Granulated slagFig. 5

Views of the Cooling Screen after 10 Years in Service

Fig. 7

GSP Gasification Test Facilities of FUTURE ENERGY GmbH in Freiberg

5 MW 3 MW Office

Gasifier VV100 Reactor with cooling wall 2-3 MW max. 30 bar Gasifier Reactor with cooling screen 3-5 MW max. 30 bar

Pulverized fuel dosing and feeding system up to 10 t/h

Inert gas plant 1000 m3i.N./h 80 bar

Oxygen plant max. 300 m3i.N./h 80 bar

Slurry feeding 300 kg/h

Sewage sludge drier 500 kg/h Pyrolysis unit 500 kg/h

SulFerox desulfurization unit Waste water treatment COS hydrolysis HCN hydrolysisFig. 3

Schematic Flow Diagram of the Test Facility (NKV)Pulverized fuel feedingPulverized fuel Vent gas

GasificationOxygen/Steam

Quenching/ Scrubbing

SulFerox Raw gas COS cooling Hydrolysis Unit

Inert gas

el

Syngas

Inert gas Slurry

Granulate discharge system Slurry feedingWaste water treatment Feed water Air

Sulfur

Feed water

SlagS3

Anthracite

Forge coal Fat coal

Mediumvolatile coal Highvolatile coal

Hard brown coal Soft brown coal

Petcoke Lean coal 95 52 51 90 Carbon content Cdaf [wt.-%] 85 41

Coals Gasified in the Test Facilities of FUTURE ENERGY GmbH

27 21 28 24 23 22 25 13 12 15 02 29 26

SOFT BROWN COALS 01 GERMANY Schwarze Pumpe 02 GERMANY Braunsbedra 03 BULGARIA Elhovo 04 AUSTRALIA Mine Bowmans HARD BROWN COALS 11 SPAIN Teruel 12 RUSSIA Kansk-Atschinsk 13 CHINA Harbin 14 CZECH REPUBLIC Most 15 CZECH REPUBLIC Sokolov HARD COALS 21 GERMANY Ruhrgebiet 22 POLAND Sosnica 2/1 23 POLAND Sosnica 24 SPAIN Puertollano A (washed coal) 25 SPAIN Puertollano (unwashed coal) 26 AUSTRALIA Drayton 27 AUSTRALIA Newlands 28 SOUTH AFRICA Koornfontein 29 COLOMBIA Cerrajon 41 Petcoke ANTHRACITES 51 GERMANY Doberlug 52 GERMANY Ruhrgebiet 70

80

75

70 14 04 65 11 60 01

03 55 0 10 20 30 40 [wt.-%] 50 60

Volatile matter content Vdaf

Fig. 13

Fuel Burner

Gas to pilot burner Oxygen

Advantages for our customers : optimize feedstock preparation

Pressur. water outlet

Cooling screen

determine optimum gasification processPressur. water inlet Quench water Cooling jacket

conditions allow optimization of reactor or burner design allow reliable scale-up test materials of construction and components gain information about products and wastes

Gas outlet

Water overflow

Granulated slag

Gasification Project in the Czech RepublicAutothermal Oil Conversion PlantClient Location, country Commissioning Technical data

Sokolovsk uheln, a.s. Vesov, Czech Republic planned 2005 entrained-flow, cooling wall 140 MWth 28 bar 1400 C 15 m3 full quench liquid feeding spray scrubber lock hopper depressurization and vapor condensation, sedimentation, chamber filter press Generator tar and other liquid by-products of 26 fixed bed gasifiers for 440 MW IGCC3D computer simulation

Type of reactor Capacity thermal Pressure Temperature Reactor volume Type of quench system Equipment / subsystemes Feeding system Gas cleaning Slag discharge Soot water treatmentFeedstock

Products / by-products / effluent Raw gas to IGCC / slag, soot cake / waste waterFig. 20

Size Relation of Different Scale GSP Entrained-flow Gasifiers (2.5 MPa)1000 MW

500 MW 150 MW

5250

3500

3650 2900

2000

6700

Thank you very much!

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