training courses - gasification- · pdf filetraining courses gasification/syngas production...

TRAINING COURSES Gasification/Syngas Production n Syngas Treatment n Syngas Utilisation

organised by

Chair of Energy Process Engineering and Thermal Waste Treatment

Institute of Energy Process Engineering and Chemical Engineering

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Topic Overview 4 Internal Technical Tours 6 Laboratory equipment 6 Bench-scale test facilities 7 Pilot-scale gasification and synthesis plants 8External Technical Tours 11 Test facility at Siemens Fuel Gasification Technology GmbH & Co. KG 11 Sokolevská uhelná IGCC plant (CZ) 12 Romonta Montan Wax Production Factory 13 Schwarze Pumpe Power Plant 13Course Overview 14 Compact Course Fundamentals of gasification processes 14 Short Course Gasification processes 16 Short Course Flow sheet simulation and economic evaluation 18 Short Course Upgrading and conversion of fossil and renewable fuels 20 Customised Course 21General Information 22 Registration Details 22 Cancellation Policy 22 Social Programme 22 Audience 23 Accommodation 23Lecturers 24 Internal Lecturers 22 External Invited Lecturers 22Impressions 27Directions to IEC 28Contact 29

Content

Topic Overview

The courses are designed to provi-de deeper knowledge about scientific fundamentals, processes and techno-logies linked to gasification/syngas generation, gas purification and treat-ment and syngas utilisation. The follo-wing topics are currently addressed by the courses:

FUELSn Primary energy sourcesn Fuel characterisation,

classification and analysis

GASIFICATION BASICSn Chemical and fluid dynamic

fundamentalsn Overview of industrial gasification

technologies (classification, opera-tional parameters, applications, market trends, technology trends)

GASIFICATION TECHNOLOGIESExperienced experts are invited to pre-sent on the following topics:n Slagging fixed-bed gasificationn Entrained-flow gasification for solid,

liquid and gaseous feedstock (Shell, Siemens, GE, Prenflo, Air Liquide, Chinese technologies, etc.)

n Fluidised-bed gasification (e.g. HTW)

n Underground coal gasification

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SYNGAS TREATMENT AND UTILISATIONn Processes for gas purification and

CCSn IGCC concepts and economics

BIOMASS GASIFICATIONn Industrial gasification technologies (overview, characteristics, feed-

stock, related problems)n BtL routes (concepts, balances,

costs, environmental impacts)

SIMULATIONn Flow sheet modelling of

gasification processesn CFD modelling of gasificationn Modelling of trace elements and

ash/slag behaviour

ANALYTICS FOR FUEL AND PROCESS CHARACTERISATIONn Standard analyses: fuel analy-

sis (proximate, ultimate, heating value, ash composition and mel-ting point, porosimetry, BET surface area, grain size), water analysis, gas analysis

n Mineral matter analyses under realistic process conditions (e.g. XRF, XRD, FT-ICR mass spectrome-try, SEM, FIB-SEM, viscometry)

n Characterisation of pyrolysis and gasification through applying fur-naces reflecting realistic process conditions, e.g. drop tube furna-ces (e.g. KIVAN*, PYMEQ*, LPA*, DPA*, ALPA*), quench chambers, high-pressure high-temperature thermo-balances

n Process analyses using bench-scale reactors, e.g. COORVED gasifica-tion reactor* or pilot-scale plants, e.g. HP-POX*, STF* and SBV* plant

*More details can be found on the next pages.

Equipment, Test Facilities and Pilot

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Topic Overview

Plants at IECThe Chair of Energy Process Enginee-ring and Thermal Waste Treatment (EVT) at the Institute of Energy Process Engineering and Chemical Enginee-ring (IEC) is leading research in the field of industrial gasification pro-cesses in Germany. EVT focuses on efficient and sustainable use of fossil and renewable energy raw materials by thermo-chemical conversion pro-cesses (gasification, pyrolysis, coking, etc.) by carrying out theoretical and experimental investigations of single processes and comprehensive process chains.

To comprehensively perform fuel and gasification research, a wide range of laboratory and pilot-scale equip-ment is operated by EVT. These inclu-de a fuel technological laboratory, a variety of customised high-pressure and high-temperature facilities for ga-sification, pyrolysis and mineral matter investigations, pilot-scale gasifiers and a synthesis plant.

Three tours around the institute are offered focussing on different equip-ment: (I) laboratory equipment for mi-neral matter characterisation, gasifica-tion and pyrolysis tests, (II) bench-scale test facilities for pyrolysis and gasifica-tion investigations and (III) pilot-scale gasification and synthesis plants.

Internal Technical Tours

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LABORATORY EQUIPMENT

Liquids and gas analysis: n Pyrolysis facility coupled with gas

chromatograph and mass spectro-meter (Pyrolysis-GC-MS)

Ash/slag analysis: n Plasma ashing devicen X-ray analysis (X-ray fluorescence

analysis: XRF, X-ray diffractome-trical analysis (also under high temperature and pressure): XRD)

n Electron microscopy (SEM, FIB-SEM)

n Thermo-optical measurement systems for surface tension and characteristic ash melting tempe-ratures (with atmosphere control: TOM-AC, without atmosphere control: TOMMI)

n High-temperature viscometers n Two-chamber double thermo-

balance

BENCH-SCALE TEST FACILITIES

List of bench-scale and larger test facilities:n COORVED gasification reactor for

low-rank high-ash coalsn High-temperature drop tube

reactor: HTRn Pressurised gasification measu-

rement equipment (drop tube): GMEQ

n Kinetic test reactor (high-pressure high-temperature drop tube reac-tor): KIVAN reactor

n Laboratory pyrolysis facility: LPAn Advanced laboratory pyrolysis

facility: ALPAn Pressurised pyrolysis reactor

(fixed-bed and drop tube mode): DPA

n High-pressure pyrolysis measu-rement equipment (drop tube reactor): PYMEQ

Furnaces: n Quenching test facility: QTF

(in-house development)

Solid fuels characterisation facili-ties: n Ruhr dilatometers n Gieseler plastometer n Facility to determine the coke reac-

tivity index (CRI) and coke strength after reaction (CSR)

n Facility to determine reactivity in fixed bed: RiFix

n Quartz glass reactors to determine reactivity with CO2

n Camsizers (Determination of par-ticle size distribution)

n Simple particle disintegrator: SPaltor

n Thermo-analyses: TG, DTA, DSC (under pressure, gas athmosphere, gas analysis)

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PILOT-SCALE GASIFICATION AND SYNTHESIS PLANTS

Pilot plant for the gasification of liquid and gaseous hydrocarbons by high-pressure partial oxidation – HP-POX (operated for research since summer 2004)

Process applications: n Autothermic catalytic reforming

(ATR) of gaseous feedstock at pressures up to 70 bar(g)

n Autothermic non-catalytic partial oxidation of gaseous feedstock (Gas POX) at pressures up to 100 bar(g)

n Autothermic non-catalytic gasification of liquid hydrocarbons (Oil POX) at pressures up to 100 bar(g)

Feedstock:n Natural gasn Light and heavy oilsn Heavy residues from crude oil

processing

Operating parameters:n Temperature: up to 1450 °Cn Pressure: up to 100 bar(g)n Input: up to 500 m³(STP)/h natural

gas or 500 kg/h liquid feedsn Syngas output:

up to 1500 m³(STP)/h

Objectives:n Variation of steam-to-feed ration Investigation of influence of

pressure and temperaturen Analysis of product streams

including trace componentsn Energy, exergy and material

balancing

Scientific topics:n Gasification process design and

modelling (auto-thermic non- catalytic partial oxidation at up to 100 bar, auto-thermic catalytic partial reforming of natural gas at up to 70 bar)

n Reactor and burner design and modelling (gasification of liquid hydrocarbons)

n Modelling and understanding of trace component behaviour (mechanisms of formation and distribution of technologically relevant trace components)

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Pilot plant for the synthesis of high-octane gasoline from syngas – Syngas-to-Fuel: STF (start-up in 2010)

STF plant characteristics:n Pilot-scale synthesis plant for

demonstration of the production of high-octane gasoline from synthesis gas

n Input: 700 m3(STP)/h of syngas (provided by the HP-POX)

n Two-stage reactor concept: 1st stage: methanol synthesis at 50 bar, 2nd stage: gasoline synthesis

n Output: 120 l/h of stabilised gasoline

STF process innovations:n New heat exchanger concept

and reactor design allowing for isothermic operation of the gasoline synthesis reactor

n Application of a newly developed catalyst for the selective yield of isomeric hydrocarbons instead of aromats during gasoline synthesis

n New catalytic waste water treatment for minimisation of process waste water production

STF gasoline quality:n Gasoline quality meeting DIN

standard and achieving an octane number higher than 93

n Substitution of aromats by isomers (Aromatic content <35 %)

STF project partners during the first funding period (May 2008 till June 2013):n Chemieanlagenbau Chemnitz

GmbH jointly with – SAPR Neftechim – Techno Trading Ltd

n TU Bergakademie Freiberg with – Institute of Energy Process

Engineering and Chemical Engineering (IEC) – Institute of Technical Chemistry

(ITC)

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Pilot-scale fixed-bed slagging gasifier for difficult solid feedstock – SBV (commissioned in 2013)

Characteristics of the slagging gasifier:n Pilot-scale gasifier for solid

feedstockn Operating pressure: 40 bar(g)n Input: – 1.38 t/h hard coal (equivalent

to 10 MW(th)) – Up to 430 m³(STP)/h of oxygen

and up to 450 kg/h of steamn Output: ca. 2300 m³(STP)/h

raw gas

Plant infrastructure: n Coal hoppern Lock hopper system for coal

feeding and slag extractionn Gasification reactor with slag tap

and quenchn Gas cooling and gas water

storage n Gasifier steel structure

(12 x 12 x 22 m)

Research topics:n Investigation of fuel influence

and fluxing agents on ash/slag behaviour

n Generation of material property data for application oriented modelling

n Characterisation of ash/slag systems under real process conditions

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TEST FACILITY AT SIEMENS FUEL GASIFICATION TECHNOLOGY GMBH & CO. KG

Headquartered in Freiberg, Germany, SIEMENS Fuel Gasification Technology GmbH & Co. KG is a wholly owned subsidiary of SIEMENS AG, Munich. It was acquired by Future Energy/Sustec in 2007. Its core business segment is the marketing of the SFG (formerly GSP) gasification process. The compa-ny is part of the energy sector within the SIEMENS Group.

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External Technical Tours

SIEMENS FGT disposes of one of the world‘s most comprehensive testing facilities for gasification technology. The heart of the facility is a gasificati-on reactor with an output of 5 MW(th), complemented by various conveying and feeding systems and the appur-tenant synthesis gas and wastewater treatment installations.

In summary, SUAS has been able to transform its Vresová gas works into an important centre for clean coal techno-logy, while simultaneously adapting to deteriorating feedstock quality.

Key milestones have been the tripling of electric power output with two syngas-fired combined cycle plants including their integration into the combined heat and power system, the installation of the wet sulphuric acid plant and the addition of the selective catalytic reduction unit (SCR) to the thermal incinerator using internally generated ammonia.

SOKOLEVSKÁ UHELNÁ IGCC PLANT (CZ)

Although not originally designed as such, the 400 MW(el) power plant operated by Sokolovská uhelná, právní nástupce, a.s. (Sokolov Coal Corporation or SUAS) at its Vresová gas works in the Czech Republic has for the last 16 years been one of the world’s largest coal-fired IGCC. Twenty-six Lurgi-type fixed-bed gasi-fiers processing brown coal from the company’s own local open cast mines form the basis of the plant. The raw gas from the gasifiers is treated by a Rectisol process and fed into two GE licensed 9E gas turbines.

The Vresová gasworks began operation in 1969, supplying town gas to a large area of the western part of the Czech Republic. It was at the time the largest gas producer in the country. Located on the same site, there are a conventional 220 MW(el) boiler plant and a 300,000 t/a briquetting plant, both using the company’s brown coal as feedstock. The plant supplies dis-trict heating to Karlovy Vary and other neighbouring towns.


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© ROMONTA

ROMONTA MONTAN WAX PRO-DUCTION FACTORY

ROMONTA is the world’s largest pro-ducer of crude montan wax, with a nearly 100-year-old tradition of lignite upgrading. The fossil wax is extracted from bitumen-rich lignite mined from the company‘s own open-cast mine in Amsdorf. Crude montan wax was first extracted using a method patented by the Hamburg chemist Edgar von Boyen. The modern high-tech process applied today is the culmination of years of steady improvement in Romonta‘s production technology.

Its special characteristics make mon-tan wax an important raw material for many industry branches. This has enabled montan wax products from Amsdorf to maintain their competitive position in the world market despi-te the development of countless new types of synthetic waxes.

SCHWARZE PUMPE POWER PLANT

The Schwarze Pumpe lignite power plant is a double-unit plant with two 800 MW(el) units. It is the first of a new generation of lignite-fired power plants ensuring reliable, economical, and environmentally acceptable elec-tricity generation in Germany.

The plant, which went into operation in 1998, operates predominantly at base load and thus guarantees the stability of the high-voltage grid. At the same time, each of the two 800 MW power plant units is able to operate flexibly and rapidly down to a theoreti-cal load minimum of 400 MW(el) per block, to balance grid fluctuations re-sulting from electricity generated from renewable sources.

Course Overview

COMPACT COURSE Fundamentals of gasification pro-cesses

The compact course “Fundamentals of gasification processes“ provides a general overview of gasification technologies and related issues. The three days course gives a broad overview of the fundamentals of gasi-fication along the entire process chain. The first day focuses on theoretical fundamentals of gasification and rele-vant feedstock and provides a general overview of gasification processes. The second day is dedicated to biomass gasification technologies, flow sheet simulation and CFD modelling aspects. This day is completed by an evening lecture on underground coal gasifica-tion. The last day focuses on gas puri-fication and ash/slag behaviour.

Several technical tours round off the course programme. An example cour-se schedule is provided below.

Duration 3 days (Lectures) + 1 day (Technical tour optional)

Level Beginners, refresher course

Fee/person 2.250 € (Registration fee) + 100 € (Technical tour optional)

DAY 1

08:00 – 08:15 Welcome

08:15 – 10:00 Dr. S. Krzack

Introduction to gasif ication processes - Terms and definitions of thermo-chemical conversion

- Mechanism and reactions of gasification

- Thermodynamic and kinetic aspects of gasification

- Conversion criteria - Process classification

10:30 – 12:00 D. Reichel

Fuels for gasif ication processes - Fuel classification and characterisation

- Fuel analyses - Sample preparation - Characterisation and chemical analyses of solid, liquid and gas samples from technical plants

- Relevance of feed properties for gasification processes

12:00 – 13:00 Lunch

13:00 – 17:00 C. Higman (15 min coffee break included)

Overview on industr ial gasif ication technologies - Description of principal characteristics of different gasification reactors (e.g. bed types, feed systems, syngas cooling systems, etc.) with advantages and disadvantages of each

- Review of major commercialised and near commercialised systems

- Process selection: criteria, process and summary

18:00 – 22:00 Evening event

DAY 2

08:00 – 10:00 L. Waldheim

Industr ial gasif ication technologies for biomass -‐ Worldwide overview about gasification technologies for biomass

-‐ Characteristics/technical data (e. g. fuel input, kind of fuel, application, reactor principle etc.) for the different technologies

-‐ Feedstock related problems during biomass gasification

10:30 – 11:30 A. Laugwitz

Introduction into f low sheet s imulation of gasif ication processes - General basics on flow sheet modelling

- Common software packages

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Course Overview

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DAY 1

08:00 – 08:15 Welcome

08:15 – 10:00 Dr. S. Krzack

Introduction to gasif ication processes - Terms and definitions of thermo-chemical conversion

- Mechanism and reactions of gasification

- Thermodynamic and kinetic aspects of gasification

- Conversion criteria - Process classification

10:30 – 12:00 D. Reichel

Fuels for gasif ication processes - Fuel classification and characterisation

- Fuel analyses - Sample preparation - Characterisation and chemical analyses of solid, liquid and gas samples from technical plants

- Relevance of feed properties for gasification processes

12:00 – 13:00 Lunch

13:00 – 17:00 C. Higman (15 min coffee break included)

Overview on industr ial gasif ication technologies - Description of principal characteristics of different gasification reactors (e.g. bed types, feed systems, syngas cooling systems, etc.) with advantages and disadvantages of each

- Review of major commercialised and near commercialised systems

- Process selection: criteria, process and summary


DAY 2

08:00 – 10:00 L. Waldheim

Industr ial gasif ication technologies for biomass -‐ Worldwide overview about gasification technologies for biomass

-‐ Characteristics/technical data (e. g. fuel input, kind of fuel, application, reactor principle etc.) for the different technologies

-‐ Feedstock related problems during biomass gasification

10:30 – 11:30 A. Laugwitz

Introduction into f low sheet s imulation of gasif ication processes - General basics on flow sheet modelling

- Common software packages

- Detailed view on a standard software (e.g. ASPEN Plus®)

- GUI and process units of the software

- General modelling approach - Examination of general dependencies between input variations and gasifier performance (e.g. sensitivity analysis)

11:30 – 12:30 Lunch

12:30 – 14:30 Dr. A. Richter

CFD modell ing of gasif ication - Fundamentals - Physical sub processes: particle modelling; heterogeneous/ homogeneous reactions; turbulent flows

- Software overview

15:00 – 17:00 F. Mehlhose

Technical tour to Siemens FGT GmbH & Co. KG

18:30 – 20:30 Evening Presentation

18:30 – 20:30 Dr. J. van Dyk (combined with dinner)

Underground coal gasif ication (UCG) - What is UCG? - Comparison of UCG with other gasification technologies

- History of UCG and current global activities

- Environmental and UCG (emissions, groundwater, etc.)

- Viability of UCG projects - Coal characterisation for UCG - UCG towards products - Future R&D needs

DAY 3

08:00 – 10:00 Dr. R. Pardemann

Processes for gas purif ication and carbon capture - Short overview about typical gas impurities (pollutants impurities/ inerts)

- Gas quality requirements (typical syntheses and IGCC)

- General layout of gas purification chains

- Fundamental separation mechanisms for gas purification

- Scrubbing processes for the removal of acid gases (H2S, CO2) and trace components

- Overview gas conditioning - Criteria for choosing appropriate purification processes and design of gas purification process chains

10:30 – 12:00 Dr. S. Guhl

Ash/slag behaviour in gasif ication processes - Chemical and physical properties

- Detailed view on a standard software (e.g. ASPEN Plus®)

- GUI and process units of the software

- General modelling approach - Examination of general dependencies between input variations and gasifier performance (e.g. sensitivity analysis)

11:30 – 12:30 Lunch

12:30 – 14:30 Dr. A. Richter

CFD modell ing of gasif ication - Fundamentals - Physical sub processes: particle modelling; heterogeneous/ homogeneous reactions; turbulent flows

- Software overview

15:00 – 17:00 F. Mehlhose

Technical tour to Siemens FGT GmbH & Co. KG

18:30 – 20:30 Evening Presentation

18:30 – 20:30 Dr. J. van Dyk (combined with dinner)

Underground coal gasif ication (UCG) - What is UCG? - Comparison of UCG with other gasification technologies

- History of UCG and current global activities

- Environmental and UCG (emissions, groundwater, etc.)

- Viability of UCG projects - Coal characterisation for UCG - UCG towards products - Future R&D needs

DAY 3


Processes for gas purif ication and carbon capture - Short overview about typical gas impurities (pollutants impurities/ inerts)

- Gas quality requirements (typical syntheses and IGCC)

- General layout of gas purification chains

- Fundamental separation mechanisms for gas purification

- Scrubbing processes for the removal of acid gases (H2S, CO2) and trace components

- Overview gas conditioning - Criteria for choosing appropriate purification processes and design of gas purification process chains

10:30 – 12:00 Dr. S. Guhl

Ash/slag behaviour in gasif ication processes - Chemical and physical properties

of ash/slag - Description and modelling of ash/slag behaviour

- Problems and solutions regarding ash/slag behaviour in gasification processes

12:00 – 13:00 Lunch

13:00 – 14:00 M. Klinger D. Reichel

Visi t of laboratories and test faci l i t ies - Advanced lab equipment: thermo balances, x-ray analysis tools, thermo-optical measurement

- Test facilities: pyrolysis apparatuses, drop-tube reactor

14:00 – 15:30 Dr. P. Seifert O. Schulze

On-site vis i t of larger-scale test faci l i t ies/pilot plants

15:30 – 15:45 Closing ceremony

Course Overview

SHORT COURSE Gasification processes

The short course “Gasification proces-ses“ provides a general overview of major gasification technologies and related issues. The two days course aims for a broad as well as detailed examination of gasification processes. Starting with some fundamentals on gasification and relevant feedstock, the major section of the course is dedi-cated to introduction and discussion of different gasification technologies with their principal characteristics, advan-tages and disadvantages of different reactor types and process selection criteria regarding e.g. syngas applica-tion, feedstock quality or operational flexibility. An example course schedule is provided below.

Duration 2 days (Lectures)

Level Advanced learners, refresher course

Fee/person 2.000 € (Registration fee)

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Course Overview

DAY 1

08:00 – 08:15 Welcome

08:15 – 10:00 A. Laugwitz

Overview of industr ial gasif ication technologies - Introduction of selected

gasification processes including main operational parameters

- Comments on proposed concepts and technology trends

10:30 – 12:00 Prof. B. Meyer

HTW gasif ication technology - Classification and

characterisation of fluidised bed gasifiers

- Detailed discussion of the HTW gasifier, including technology principles, historical development and performance data; insight in divers plant equipment, e.g. coal feeding system, nozzles, hot gas filter

12:00 – 13:00 Lunch

13:00 – 14:30 W. Vogel

Shell gasif ication technology - Different Shell gasification

processes - Possible lay-outs of the Shell coal

gasification process (SCGP) - Features of the SCGP

15:00 – 16:30 B. van der Drift

Biomass and waste gasif ication - Technology options with pros and

cons - Systems and products - Gas cleaning and upgrading - Status and some examples

17:00 – 18:30 C. Higman

Chinese gasif ication technologies - Main Chinese processes (ECUST OMB, TPRI Two-stage, ICC Fluid- bed, HT-L) - Acid gas removal - Component manufacture

20:00 – 22:00 Evening Event

DAY 2

08:00 – 9:30 C. Higman

GE gasif ication technology - Description and process flowsheet, with discussion of different syngas cooling options

- Advantages and limitations - Typical reference plants and applications

- Current research and development areas

10:00 – 12:00 H. Hirschfelder, O. Schulze

BGL gasif ication technology and i ts application; tour to BGL test plant - Introduction into BGL gasification technology

- Design features of the process and comparison with other

DAY 1

08:00 – 08:15 Welcome

08:15 – 10:00 A. Laugwitz

Overview of industr ial gasif ication technologies - Introduction of selected

gasification processes including main operational parameters

- Comments on proposed concepts and technology trends

10:30 – 12:00 Prof. B. Meyer

HTW gasif ication technology - Classification and

characterisation of fluidised bed gasifiers

- Detailed discussion of the HTW gasifier, including technology principles, historical development and performance data; insight in divers plant equipment, e.g. coal feeding system, nozzles, hot gas filter

12:00 – 13:00 Lunch

13:00 – 14:30 W. Vogel

Shell gasif ication technology - Different Shell gasification

processes - Possible lay-outs of the Shell coal

gasification process (SCGP) - Features of the SCGP

15:00 – 16:30 B. van der Drift

Biomass and waste gasif ication - Technology options with pros and

cons - Systems and products - Gas cleaning and upgrading - Status and some examples

17:00 – 18:30 C. Higman

Chinese gasif ication technologies - Main Chinese processes (ECUST OMB, TPRI Two-stage, ICC Fluid- bed, HT-L) - Acid gas removal - Component manufacture

20:00 – 22:00 Evening Event

DAY 2

08:00 – 9:30 C. Higman

GE gasif ication technology - Description and process flowsheet, with discussion of different syngas cooling options

- Advantages and limitations - Typical reference plants and applications

- Current research and development areas

10:00 – 12:00 H. Hirschfelder, O. Schulze

BGL gasif ication technology and i ts application; tour to BGL test plant - Introduction into BGL gasification technology

- Design features of the process and comparison with other

technologies - Process application for BGL - Historical and future development of the BGL gasifier

- Current BGL activities - Field trip to SBV plant at IEC

12:00 – 13:00 Lunch

13:00 – 14:30 F. Mehlhose

Siemens Fuel Gasif ication technology - Description of Siemens Gasification Technology

- Plant design, scope & applications - Information about main equipment

- Test center Freiberg and main R&D activities

- Referent plants and current activities

15:00 – 17:00 Dr. P. Seifert

HP-POX technology; tour to HP-POX test plant and gasoline synthesis plant (STF) - Catalytic and non-catalytic reforming of gaseous and liquid hydrocarbons

- Basic concept parameters - HP POX project and test plant (introduction, modelling, results)

- New technology for production of high-octane gasoline from synthesis gas

- STF project and test plant - Field trip

17:00 – 17:15 Closing Ceremony

Course Overview

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SHORT COURSE Flow sheet simulation and economic evaluation

The objective of this application- oriented course is to provide information on fundamentals and methods of modelling in addition to simulation of single processes and complex process chains for energetic and non-energetic conversion of fuels. Furthermore, specific features of typical software tools are outlined. Theoretical knowledge provided in the lecture blocks is deepened and applied in seminars using typical soft-ware. Moreover, modelling knowled-ge is imparted through using the example of a simple process chain. The course also includes an introduction into static and dynamic methods for cost estimation and economic evaluation using modelling results. By using the example of a commercial project for syngas-based coal utilisa-tion, an invited lecturer from industry will discuss different levels of enginee-ring and stages of project development associated with details of cost estima-tes. An example of the course structure is provided below.




Optional Determination of syngas composition for entrained-flow gasification (Requirement: provision of the coal composition at least 4 weeks before course beginning, must be suitable for modelling purposes)

Extra-costs: 500 €, only bookable for participants of the course

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Course Overview

Lectures on fundamentals of f low sheet simulation, PC seminar

08:00 – 08:15 Welcome


Introduction into stationary f low sheet simulation - Definition of substances and

substance streams - Selection of physical property

methods


Definit ion of the process and modell ing - Unit operations for single processes and flow sheet simulation

- Abstraction of individual processes in models


Model control and process analysis - Calculators and design

specifications - Sensitivity analysis and

optimisation - Convergence difficulties

12:30– 13:30 Lunch


Modell ing of complex process chains - Combination of individual

models in process chains - Reduction of model complexity

using hierarchies - Application of parameters to

complex modelling tasks - Linking of different software tools

using MS Excel

15:00 – 16:00 A. Laugwitz

Seminar 1 - Presentation of typical flow sheet

simulation software - Introduction into modelling of

gasification processes on the basis of two selected models


PC seminars on f low sheet simulation, Lectures on economic project evaluation


Seminar 2 - Short revision of Seminar 1 - Modelling of syngas treatment processes (gas cleaning and conditioning)


Seminar 3 - Modelling of syngas conversion processes on the example of the methanol synthesis

11:30 – 12:30 R. Stahlschmidt

General procedures for est imating investment costs - Introduction of different methods

Lectures on fundamentals of f low sheet simulation, PC seminar

08:00 – 08:15 Welcome


Introduction into stationary f low sheet simulation - Definition of substances and

substance streams - Selection of physical property

methods


Definit ion of the process and modell ing - Unit operations for single processes and flow sheet simulation

- Abstraction of individual processes in models


Model control and process analysis - Calculators and design

specifications - Sensitivity analysis and

optimisation - Convergence difficulties

12:30– 13:30 Lunch


Modell ing of complex process chains - Combination of individual

models in process chains - Reduction of model complexity

using hierarchies - Application of parameters to

complex modelling tasks - Linking of different software tools

using MS Excel

15:00 – 16:00 A. Laugwitz

Seminar 1 - Presentation of typical flow sheet

simulation software - Introduction into modelling of

gasification processes on the basis of two selected models


PC seminars on f low sheet simulation, Lectures on economic project evaluation


Seminar 2 - Short revision of Seminar 1 - Modelling of syngas treatment processes (gas cleaning and conditioning)


Seminar 3 - Modelling of syngas conversion processes on the example of the methanol synthesis


General procedures for est imating investment costs - Introduction of different methods of plant and investment cost estimation

12:30 – 13:30 Lunch


Simplif ied methods to evaluate economics and determine product costs - Annuity method, Net Present Value method (NPV)

15:00 – 16:30 Company presentation


Closing Ceremony

Course Overview

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SHORT COURSE Upgrading and conversion of fossil and renewable fuels

Participants of the course will obtain an introduction into the different routes for energetic or non-energetic utilisation of solid fuels. Lectures cover mechanical and thermal upgrading processes and their innovative combination in process chains. Analytical instruments and test facilities for investigations on such pro-cesses can be visited on site at the IEC. The course is dedicated to industry professionals (e.g. from the energy or chemical sector), authorities or others. An example of topics covered in the course is provided below.




Optional Analysis of a solid fuel sample (Requirement: provision of the sample at least two months before course be-ginning)

Extra-cost: 500 €, only bookable for participants of the course

Characterisation of solid fuels; Drying and agglomeration processes

08:00 – 08:15 Welcome

08:15 – 09:00 Dr. S. Krzack

Introduction - Refinement routes, raw

materials and products

09:00 – 10:30 D. Reichel

Fuel analysis -‐ Introduction, methods and properties

11:00 – 12:30 Dr. R. Seyfarth

Drying - Introduction and processes

12:30– 13:30 Lunch

13:30 – 15:00 Dr. R. Wollenberg

Agglomeration - Introduction and processes

15:30 – 17:30 F. Fehse

Technical tour: laboratories and test faci l i t ies ( ITUN) - Technical laboratories for drying

and agglomeration


Extraction, pyrolysis/coking and hydrogenation

08:00 – 09:30 Prof. J.-U. Repke

Extraction - Introduction and technology of montan wax production

10:00 – 11:00 D. Reichel

Fundamentals of pyrolysis - Mechanisms and pyrolysis

balances

11:30 – 12:30 TBD

Biomass pyrolysis - Technologies of charcoal

production, flash pyrolysis and fuel treatment

12:30 – 13:30 Lunch

13:30 – 14:30 Dr. S. Krzack

Coal pyrolysis - Technologies of carbonisation

and coking of brown and hard coal

15:00 – 16:00 Dr. Kuchling

Hydrogenation of coal - Direct hydrogenation of coal

16:30 – 17:30 Dr. S. Krzack, D. Reichel

Technical tour: laboratories and test faci l i t ies - Fuel-technological laboratory,

thermo-analytical instruments, pyrolysis plants


Gasif ication and process chains

08:30 – 09:30 Dr. S. Krzack

Fundamentals of gasif ication - Mechanism, reactions and characteristic parameters

10:00 – 11:30 Dr. S. Krzack

Gasif ication technologies - Coal and biomass gasification

11:30 – 12:30 Lunch


Process chains - Concepts for refinement routes based on a non-


08:00 – 08:15 Welcome

08:15 – 09:00 Dr. S. Krzack



09:00 – 10:30 D. Reichel


11:00 – 12:30 Dr. R. Seyfarth


12:30– 13:30 Lunch



15:30 – 17:30 F. Fehse


and agglomeration



08:00 – 09:30 Prof. J.-U. Repke


10:00 – 11:00 D. Reichel


balances

11:30 – 12:30 TBD



12:30 – 13:30 Lunch

13:30 – 14:30 Dr. S. Krzack



15:00 – 16:00 Dr. Kuchling







08:30 – 09:30 Dr. S. Krzack


10:00 – 11:30 Dr. S. Krzack


11:30 – 12:30 Lunch


Process chains - Concepts for refinement routes based on a non-


08:00 – 08:15 Welcome

08:15 – 09:00 Dr. S. Krzack



09:00 – 10:30 D. Reichel


11:00 – 12:30 Dr. R. Seyfarth


12:30– 13:30 Lunch



15:30 – 17:30 F. Fehse


and agglomeration



08:00 – 09:30 Prof. J.-U. Repke


10:00 – 11:00 D. Reichel


balances

11:30 – 12:30 TBD



12:30 – 13:30 Lunch

13:30 – 14:30 Dr. S. Krzack



15:00 – 16:00 Dr. Kuchling







08:30 – 09:30 Dr. S. Krzack


10:00 – 11:30 Dr. S. Krzack


11:30 – 12:30 Lunch


Process chains - Concepts for refinement routes based on a non- energetic utilisation of fuels

14:00 – 14:30 Closing Ceremony

15:00 – 16:00 Dr. P. Seifert, O. Schulze, M. Schurz

On-site vis i t to larger-scale test faci l i t ies - Gasification test facilities and pilot plants

CUSTOMISED COURSE

If you are interested to organise a course customised to the needs of your company or organisation, please use the information provided in this bro-chure as a reference for potential to-pics which could be included in such a course. We invite you to approach us to discuss about customising a course to suit your specific needs.

Duration 1–5 days

Level In compliance with your request

Fee/person In compliance with your request

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Course Overview

General Information

REGISTRATION DETAILSThe registration fee includes:n Printed course documents/teaching

materialsn Beverages in training rooms n Catering during breaksn Lunchn Evening eventsn Shuttle service between accommo-

dation and course locationn Networking opportunities with

other participants and speakers

The registration fee is excluding VAT on catering and the social program fee. Registration can be made by mail, fax or email to the IEC.

Payment must be made in Euro upon receipt of the invoice before the start of the course.

CANCELLATION POLICYCancellations have to be submitted to the IEC in written form. If you can-cel your registration 15 days prior to the course date, the course fee will be reimbursed less a handling charge of 100 €. After this deadline, no refunds will be possible.

If needed, the personal registrations can be changed to a substitute at-tendee. In this case, no cancellation fees or extra costs will be incurred.

SOCIAL PROGRAMMEThe lectures will be complemented by social events in the evening, e.g.n Visit to “terra mineralia“,

a collection of the most beautiful minerals in the world

n Evening dinnern Guided city tour through Freibergn Organ concert at the Freiberg

Cathedral

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AUDIENCEThe courses are targeted at persons involved in power generation, refining, plant engineering, chemical proces-sing, thermal biomass utilisation waste treatment etc.

Language Courses will be hold in German or English language (depending on the participants).

The printed course material is provided in English.

Participants Attendance is limited to 20 partici-pants per course.

General Information

ACCOMMODATIONA contingent of rooms will be reser-ved at the local hotel “Alekto“ for course participants at a special room rate. Participants are responsible for making their own hotel bookings. Please use the key word „Gasification Course“.

Contact: Hotel AlektoAm Bahnhof 3 09599 Freiberg Germany

Phone: +49 (0) 3731 7940Email: [email protected]

23

Prof. Bernd Meyer

n Course supervisionn HTW gasification technology

Dr. Stefan Guhl

n Ash/slag behaviour in gasification processes

Lecturers

Dr. Robert Pardemann

n Overview of industrial gasification technologies

n Processes for gas purification and carbon capture

n Flow sheet simulation and economic evaluation

Dr. Steffen Krzack

n Introduction to gasification processes

n BtL-routes – Concepts, mass and energy balances, costs and environmental impacts

INTERNAL LECTURERSThe following experts based at the Chair of Energy Process Engineering and Thermal Waste Treatment are involved in lectures and tours during the courses:

24

Alexander Laugwitz

n Introduction into flow sheet simulation of gasification processes

n Overview of industrial gasification technologies

Dr. Andreas Richter

n CFD modelling of gasification

Dr. Peter Seifert

n HP-POX technology

Lecturers

Denise Reichel

n Fuels for gasification processes

Dr. Marcus Schreiner

n Visit to laboratories and test facilities

25

n Tour to HP-POX test plant and gasoline synthesis test plant (STF)

Shell (Wim Vogel)n Shell gasification technology

Energy research Centre of the Netherlands (Bram van der Drift)n Biomass and waste gasification

Waldheim Consulting (Lars Waldheim)n Industrial gasification

technologies for biomass

Higman Consulting GmbH (Chris Higman)n Chinese gasification technologiesn GE gasification technologyn Overview of industrial

gasification technologies

Envirotherm GmbH (Hansjobst Hirschfelder)n BGL gasification technology and its

application

Siemens FGT Gmbh & Co. KG (Friedemann Mehlhose)n Siemens fuel gasification

technology

Lecturers

EXTERNAL INVITED LECTURERS External lecturers from renowned companies or institutions are invited to present specific topics so as to share their knowledge and experience. Experts involved into earlier courses include:

Energy & Environmental Research Center (EERC), University of North Dakota, USA (Dr. Joshua J. Stanislowski, Dr. Jason D. Laumb)n Experimental design of

gasification experimentsn Economics of IGCCn Ash behaviour in reducing

conditionsn Warm gas cleaning

Tampa Electric Co. (John Mc. Daniel)n GE coal gasification technology

Lurgi (Dr. Mathias Müller-Hagedorn)n MPG gasification

GTI (Bruce Bryan)n U-Gas technology

Babcock & Wilcox Volund (Robert Heeb)n Updraft gasification

African Carbon Energy (Dr. Johan van Dyk)n Underground coal gasification

26

Impressions

Since 2006, the IEC has been offering two to three courses per year with national and international participants from: Shell, Total, Linde, Alstrom, RWE, Haldor Topsoe, Siemens, BASF, E.ON, Air Liquide, Hydro Oil and Energy, GSP China Technology, MAN Lurgi etc.

27

Directions to IEC

28

GPS: Latitude: 50.92918, Longitude: 13.35831

n Leave A4 at the “Siebenlehn“ exit and travel along the B101 towards Freibergn In Freiberg, turn left at the second set of traffic lights towards Dresdenn After the next traffic lights, go straight aheadn Turn left towards “Silberbergwerke“ in front of the churchn Follow the road until you reach “Reiche Zeche“, “IEC/Energiepark“

Dr.-Ing. Sindy Bauersfeld

TU Bergakademie FreibergInstitute of Energy Process Engineering and Chemical Engineering – EVTFuchsmuehlenweg 9, 09596 Freiberg, Germany

Phone: +49 (0) 3731 39-4536 Fax: +49 (0) 3731 39-4555Email: [email protected]: http://tu-freiberg.de/en/iec/evt/events/compact-courses

Contact

29

Notes

30

Imprint

Editor:Prof. Dr.-Ing. Bernd Meyer

TU Bergakademie FreibergInstitute of Energy Process Engineering and Chemical Engineering

Fuchsmuehlenweg 9, 09596 Freiberg/Germany

Phone: +49 (0) 3731 39-4511Fax: +49 (0) 3731 39-4555

[email protected]

Design and Photos: IEC

Status:04/2015

Institute of Energy Process Engineering and Chemical EngineeringChair of Energy Process Engineering and Thermal Waste Treatment

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