pilot plant gasification – fixed bed and entrained flow

Pilot Plant Gasification – Fixed Bed and Entrained Flowas final step in RD&D activities

A. Laugwitz, O. Schulze, F. Mehlhose

Origin

2DBI-Virtuhcon GmbH www.dbi-virtuhcon.de [email protected] +49 (0)3731 39 4558

Excellence inRessources and Education

since 250 Years

Institute of Energy ProcessEngineering & Chemical Engineering

Chair EVT

Excellence inThermo-Chemical Conversion

since 100 Years

Excellence inHigh Temperature Processes

since 2014

Source: TU Freiberg

Overview of technical and laboratory equipment


Pilot plants (5-10 MWth)• GSP gasifier• Fixed-bed slagging gasifier• HP-POX• STF – Syngas-to-fuel

Larger test facilities• COORVED gasifier• Reaction kinetics

pressurized drop tube reactorspressurized TGA

• Pyrolysis:pressurized drop tubespressurized fixed beds

• Large sample furnace

High perfomance laboratory equipment• (T)-XRF• XRD• SEM and FIB-SEM• ICP OES / MS for fluids• Laser- or ETV-ICP OES / MS for solids• Thermo-optical measurement

TOMAC/TOMMI • Thermal analysis

TG, DSC, DTA, EGA• Py-GC-MS/FID• GC*GC TOF MS• FT ICR MS• NMR• IR

Routine analysis systems

Fixed-bed slagging gasifier


Scope:• Feedstock testing

• Fluxing agents screening/ slag discharge

• Crude gas yield

• Measuring and controlling yield of tars and oils

Operated by since 2014

Projects on gasification of:

Petcoke, lignite, RDF, biomass

40 bar

10 MWth

12x12 m

22 m heigh

Fixed bed with liquid slag discharge and slag quench

GSP entrained-flow gasifier


Scope:• Feedstock testing• Fluxing agents screening/ slag discharge• Crude gas yield• Burner design• Dense flow feeding properties

Operated by since 2018

Equipment:

• Gasifier with cooling screen and spray quench• Pulverized fuel dosing & feeding system (or Slurry feeding) • Gas treatment

• Desulphurization unit (Sulferox)• COS/HCN hydrolysis

• Waste water treatment• Gas and water sampling system

25 bar

5 MWth

Gasifier with cooling screen and spray quench

Permission for waste gasification

Feasibility Study

Pre-Basic Design

Experimental Substantiation

Detail Engin. Manufactur.

Process Optimization

Stages of RD&D Activities


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

Diluent N2 from ASU

G

G

ambient air to MAC

O2 to CC(preheating)

A

B

I

I

condensate

feedstock

coal

raw gas

slag waterdischarge

saturated, diluted, preheated fuel gas

water discharge

CO2

excess N2 to environment

IP-steamfrom CC

waterdischarge

O2

make upwater

condensate

make up water

pureGAN

Project Examples – 1st Stage: Feasibility StudiesCoal-to-X for 2 Russian coals


Scope:• Feasibility of CtX routes in Russia

• Coal ash/slag properties

• Comparison of different gasification & synthesis technologies

• Thermodynamic and economic evaluationscrubber

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

Diluent N2 from ASU

G

G

ambient air to MAC

O2 to CC(preheating)

A

B

I

I

condensate

feedstock

coal

raw gas

slag waterdischarge

saturated, diluted, preheated fuel gas

water discharge

CO2

excess N2 to environment

IP-steamfrom CC

waterdischarge

O2

make upwater

condensate

make up water

pureGAN

Calculation case 1 2 3 4

CAPEX 40.31 31.73 44.84 34.17

Fuel costs 8.47 7.46 8.38 7.22OPEX including service 22.66 17.71 25.01 17.79

Annual costs 71.44 56.90 78.23 59.18Revenue for the by-products -13.15 -10.91 -13.38 -10.86

Product costs- in €/MWh product- in €/t product- in €/litre product

58.29697.17

0.54

45.99550.01

0.43

64.85775.63

0.60

48.32577.93

0.45

Data and graphics from Springer

Gasifier 1 Gasifier 1Gasifier 2 Gasifier 2

Gasifier 2 Gasifier 2Gasifier 1Gasifier 1

Project Examples – 2nd Stage: Pre-Basic EngineeringBGL gasifier in Allam Cycle IGCC


K. Uebel, 2015

Scope:• Gasification island

• PFD/Main equip. list

• General arrangement drawings

• Consumers and consumption

• Thermodynamic calculations (key performance indicators)

• Operational experiences from pilot

Project Examples – 3rd stage: Experimental SubstantiationPhosphor recovery from sewage sludge


Scope:• Feed characterization

• Ultimate, proximate, ash composition, fusibility, release of elements at different temperatures

• TGA gasification

Wan an wf an wf an wf an wf an wf an wf an wf an wf an wf

KS-01 (4065) 1.28 35.1 35.5 33.5 33.9 4.76 4.82 4.86 4.92 1.29 1.31 0.15 0.15 1.15 1.16 19.4 19.7 100 100KS-03 (4067) 0.91 39.4 39.8 30.6 30.9 4.37 4.41 4.34 4.38 1.23 1.24 0.34 0.35 0.89 0.9 19.5 19.7 100 100KS-06 (4070) 0.86 37.3 37.6 32 32.3 4.44 4.48 4.71 4.75 1.34 1.35 0.09 0.09 1.25 1.26 19.5 19.6 100 100KS-08 (4072) 0.93 36.8 37.2 32.6 32.9 4.57 4.61 4.66 4.7 1.75 1.77 0.39 0.39 1.36 1.37 19 19.2 100 100KS-10 (4074) 0.55 39.9 40.2 30.4 30.5 4.38 4.4 4.73 4.76 1.1 1.1 0.4 0.4 0.7 0.7 19.4 19.5 100 100KS-11 (4075) 0.76 39.3 39.6 30.7 30.9 4.5 4.54 4.56 4.6 0.99 1 0.27 0.28 0.72 0.72 19.4 19.6 100 100

ProbeN St SA SC O SummeA 815°C C H

Elementaranalyse - Klärschlamm [Ma-%]

0102030405060708090

100

0 100 200 300 400 500 600 700 800 900 1000

m/m

0 in

Ma.

-%

Temperatur in °C

TGA CO2

4065 4067 4070 4072 4074 4075


Scope:• Feed characterization

• Ultimate, proximate, ash composition, fusibility, release of elements at different temperatures

• TGA gasification

• Bench scale gasification trials

Project Examples – 3rd stage: Experimental SubstantiationPhosphor recovery from sewage sludge

Project Examples – 4th stage: Process DesignBiomass gasification


Scope:• Experimental investigation of pyrolyses of torrefied biomass

• Identifying optimal process conditions in a rotary kiln pyrolyzer


Scope:• Experimental investigation of pyrolyses of torrefied biomass

• Identifying optimal process conditions in a rotary kiln pyrolyzer

• Basic Design for a pilot

• Manufacturing and Delivery of rotary pyrolyzer (100 kg/h)

Project Examples – 4th stage: Process DesignBiomass gasification


Scope:• Testing feedstock and fluxing agents• Optimal process temperature

• PCI burners• Testing different burner configurations

Project Examples – 5th stage: Process OptimizationGSP gasifier operation

Thank you for your attention


From bench scale … From flowsheet …

… to pilot scale

Excellence in High Temperature Processes

RD&D Services

… to CFD

pilot plant gasification – fixed bed and entrained flow

Documents