gasification technology development under changing...
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Gasification Technology Development under Changing ConstraintsProf. Dr.-Ing. Bernd Meyer
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Fuel Research at Institute IEC in Freiberg, Germany
DBI-GTI
Institute of Energy Process Engineering and Chemical Engineering IEC
Appointment Erich Rammler BHT Coke
Saxony State Lignite Research Foundation
Institute of Fuel Utilisation
1918
2013
SIEMENS FGT
Deutsches Brennstoffinstitut DBIGerman Fuel Institute
HP POX- Plant
STF Pilot Plant
1990
19491956
1947
1921
2008
2009
2011
2010
Lignite ResearchInstitute
2003
Fixed-Bed Slagging Gasifier2014
2016
DBI-Virtuhcon GmbH
1965 10 bar Oil Gasification
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CTO Plant in Baotou, Inner Mongolia; Xia, 2011
Impacts on Gasification Technology Development
1990th 2005 2010
Political support forclean coal to power
IGCC power plants Maximize ηel R&D on HRSG Optimize ASU integration and
O2 purity (or air gasific.) …
Strong increase inoil and gas prices
Coal to Chemicals Demands on syngas-
quality Pressures up to 60 bar …
Shale gas boomGas to Power and Heat
Gas to power and heat Excess coal pushes into
chemicals market Fluctuating coal qualities …
Annual Energy Outlook, US EIA, 2013IGCC Bugegnum; Kanaar, 20023
Impacts on Gasification Technology Development
2013 2015 ???
Fluctuating power production from renewables (esp. in EU)
Flexibility Energy storage (Power to
SNG or MeOH) Polygeneration Partial load operation …
Environmental concerns eps. in China
Improve ecological footprint Water consumption Higher standards on
emissions and waste water disposal
…
- Optimize value added chain- Renewables to Chemicals
Horizontally integrated production routes From mining to refining (ibi) With staged conversionRenewables to H2 to Chemicals Annex concepts (Add CtL to PCC)
Fast changing constraintsCost reduction is a key issueUtilization of low-quality and high-ash coals 4
Cost Reduction
Efficiency
• Reduced O2 consumption(e.g. mild gasification)
• Reduced steam consumption
Availability
• Robustness• Design simplification • Gravimetric feeding
Space-Time-Yield
• Higher pressure (up to 100 bar)• Plug flow instead of STR
• Quench conversion (partial quench)• HRSG• Feed pumps
• Compact gasifiers• Increase thermal input per unit
• Lower degree of integration (e.g. ASU)• Knowledge about coal and ash
properties
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Gasifier Development Timeline
Theory Bench-Scale Pilot Demo Commercial
Reduce development periods for evolution/adaption of existing technology and new approaches
Past:25 yearse.g. BGL, HTW, AFB, E-Gas, Shell
Today:15 yearse.g. OMB
Still too long
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Demands on R&D towards reduced development periodsGoal: 1) Less scale-up steps
2) Direct application of new components in existing large-scale unitsMethod: Process VirtualizationNeeds: New insights in underlying physical and chemical processes
at HP/HT and reducing atmosphere
Advanced ModelingCFD
Optimization
Process Chain Modeling
1D Tools
Thermo-dynamics
Predictive SimulationFrom empirically driven process
adaptation towards thermo-dynamically and fluid-dynamically optimized solutions
Advanced Experimental Procedures
Fuel properties and kinetics Material and corrosion testing Property database and interpolation In situ measurements
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Demands on R&D towards reduced development periodsAdvanced Experimental
Procedures Fuel properties and kinetics Material and corrosion testing Property database and interpolation In situ measurements
Determination of chemical & physical material properties
Reflect conditions of large-scale gasifiers
Scope: particle level High resolution
Comprehensive property databases
and models
Measurement of selected supporting points only
Interpolation
CFD assisted Experiments & In-situ
measurements
Flow conditions inside experimental equipment
Measurements in large units
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Advanced Experiments – Material Properties
Chemical and physical property data at condition valid for real processes Fuel characterization (standard, no R&D needs)
Pyrolysis and gasification kinetics valid for HP/HT and high heating rates by drop tube reactors in
lab/pilot-plant scale PEFR (CSIRO), PITER (TU Munich), KIVAN and PYMEQ (TU-Freiberg)
Measurement of ash/slag properties at gasification atmosphere, HT (surface tension, viscosity,
heat conductivity, density)
Lab scale investigation of refractory corrosion at gasification atmosphere, HP and HT and
application of advanced analytical methods (HP/HT-XRD, SEM-EDX/WDX-EBSD)
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Validation, optimization and application of empirical/physical models for property data Pyrolysis models CPD, FG-DVC Models for heterogeneous gasification reactions CBK Property databases that allow for interpolation between measured supporting points Improved property data models/correlations for reduced analytical/experimental effort
CFD-based evaluation of experimental data Analysis of nonhomogeneous temperature and velocity distribution in
drop tube reactors (residence time, recirculation) Detailed heat and mass transfer in TGA CFD-based improved analysis of HT/HP experiments estimation of data that cannot be measured directly
Particle tracks in KIVAN reactor, IEC
Advanced Experiments – Databases and Models
CFD Assisted Experimentation
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In-situ measurement of process data at HP/HT High quality process data for validation Improved process understanding
Single particle reactionsOPTISOS, HP-POX® Slag flow
Advanced Experiments – In-Situ Measurement
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Demands on R&D towards reduced development periods
Advanced ModelingCFD
Optimization
Process Chain Modeling
1D Tools
Thermo-dynamics
Coupling CFD with e.g. Flow-Sheet
CFD results used as supporting point for faster 0D and 1D Tools
AdvancedCFD & Validation
Accurate reflection of physics and chemistry
More aspects of importance included Improved sub-models
Validation against large units Prove of Process Virtualization
ComputationalReactiveFlowOptimization
Significant speed-up in computation time
Automated case studies Grid generation Defining numerical set-up Result evaluation
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Advanced CFD Modeling & Validation
Integration of sophisticated sub-models for pyrolysis, char gasification, slag film
Physic-based sub models instead of empirical correlations
Implementation of material properties based on advanced experiments
Validation against large-scale experiments
Requirement forvirtual up and down-scaling without pilot-scale experiments
Successful Process Virtualization
2 mm anthracite; 1500K
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Process levelTypical tasks: Determination of material and heat
balance Kinetic and thermodynamic modelling Optimization of operating conditions Stationary and dynamic process modeling Estimation and scaling of equipment size Cost estimation
Identification of bottlenecks CFD investigation
Process chain levelTypical tasks: Determination of overall material and heat
balance (at different levels of detail) Overall process integration and optimization Stationary and dynamic process modeling Evaluation of overall efficiency, economics
and environmental performance
Investigation and optimization of overall process economics or efficiency
Fuel Raw Gas Syngas ProductGasification Gas Treatment Synthesis or Power Generation
Advanced Flow-Sheet Simulation
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Coupling CFD and e.g. Flow-Sheet
reaction rate H2 [kg/m2 s]
CFD simulation of WGS in quench chamber
Correlate dimensionless numbers, that are applicable to both simulations
CFD results
Correlation
Improved Flow-sheet model for quench conversion
Improved Flow-sheet for total plant
scrubber
mill and feeding system
gasifier
quenchroom
make upwater
CO-shiftstage 1
CO-shift stage 2
coolingwater
acid gasremoval
clean gassaturator
clean dry gas
saturated clean gas to CC
H2S to Claus-plant
HP-steam to CCB
P-471
Air Separation Unit
N2 to CC
A
ambient air to MAC
O2 to CC(preheating)
I
condensate
feedstock
coal
raw gas
slag waterdischarge
water discharge
CO2
excess N2 to environment
IP-steamfrom CC
waterdischarge
O2
make upwater
condensate
make up water
pureGAN
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1000 CFD sim. in 7 daysOptimum
Computational Reactive Flow Optimization
Optimization for single componentse.g. reaction chambers, burners, experimental equipment,…
Sensitivity analyses of numerical or physical parameters
New Design
H2/CO ratioH2/CO ratio
Original Design(Quench Conversion)
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Summary
What we need:
Market compliant gasification technologies (new technologies, components and systems) at faster time to market by
- Recently obtained broad operating experiences- New fundamental process and feedstock understanding- Process Virtualization
• CFD assisted experiments
• Combining simulation tools
• Large-scale validation
• …
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Thank You
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Nuon Power Buggenum; Kanaar; GTC, 2002
China gasification market outlook; Xia; ASIACHEM 2011
Annual Energy Outlook 2013; US Energy Information Administration
Biomass fluidized bed gasification for fuel gas; Yongqi Zhang; ICC-CAS; 2014
E-Gas Technology Gasification for the Refining and Coal Chemical Industries; P. Amick; CoalGas 2014
Presentation Material, ECUST, 2015
Sources
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