Development and Modelling of 3 rd Generation Gasification Concepts for Low Grade Coals

Transcription

1 Institute of Energy Process Engineering and Chemical Engineering Development and Modelling of 3 rd Generation Gasification Concepts for Low Grade Coals Martin Gräbner, Alexander Laugwitz, Bernd Meyer International Freiberg Conference on IGCC & XtL Technologies May 3rd May 5th 2010 Dresden, Germany Paper # 06-1 TU Bergakademie Freiberg I Institute of Energy Process Engineering and Chemical Engineering Reiche Zeche I Freiberg I Tel. +49(0)3731/ I Fax +49(0)3731/ evt@iec.tu-freiberg.de I Web

2 Outline 1. The 3 rd generation of gasifiers 2. Low grade coal in the sense of this study 3. Introduction of research approach 4. Development of ternary gasification diagram for standard coal Process conditions Performance parameters 5. Overview of proposed gasifier concepts Introduction of the INCI-concept 6. Application of the ternary diagram for high-ash coal 7. Conclusion & Outlook 2

3 1. The 3 rd generation of gasifiers 1 st generation 2 nd generation 3 rd generation [1] GE HTW INCI [10] [7] KBR Winkler Lurgi dry ash etc. Koppers- Totzek [2] [3] [10] BGL ConocoPhillips SFGT MHI PWR [8] [10] [10] Shell [4] [5] etc. [6] + new concepts for 2 nd generation [9] Since 1920s 1970s ~1990 [1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle Technologien und Projekte in Deutschland, DGMK, Hamburg, 2008 [2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002 [3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993 [4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005 [5] Lynch, T. A.: Conoco Phillips Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005 [6] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology Today s Solutions and Developments, 2nd IFC, Freiberg, 2007 [7] Smith, P. et al.: KBR Transport Gasifier, GTC, San Francisco, 2005 [8] Ota, K.: PRB Coal Gasification Test Results with Air-Blown IGCC, GTC, Washington DC, 2006 [9] Hartung, J.: PWR Compact Gasification System, GTC, Washington DC, 2006 [10] IEC Material 3

4 2. Low grade coal in the sense of this study High-ash coals in gasification processes South Africa USA Coal (typical) Pittsburgh #8 [11] Coal rank (ASTM [11]) HV C Bit. HV A Bit. Moisture wt% Proximate analysis (dry basis) Ash wt% Volatiles wt% Fixed carbon wt% Ultimate analysis (dry & ash free basis) Carbon wt% Hydrogen wt% Oxygen wt% Nitrogen wt% Sulphur wt% Calorific Value (dry basis) Lower Heating Value MJ/kg Technical limitations e.g.: - Carbon conversion (encapsulated C) - Efficiency due to physical heating/cooling and melting of ash - Coal preparation (grinding, de-ashing, drying, slurry energy density) - Vast amounts of fines available Ash property issues: - Flux material addition - Oxygen consumption by mineral matter (e.g. Fe 3 O 4, FeS 2 ) - CO 2 emission by heating of carbonates (e.g. calcination of CaCO 3 ) - Increased fouling in HRSG due to increasing amounts of vaporized ash compounds [11] Miller, B. G.; Tillman, D. A.: Combustion Engineering Issues For Solid Fuel Systems, Academic Press, New York,

5 3. Introduction of research approach Pathway to systematic and unified concept evaluation Basis: Public domain data of 2 nd generation gasifiers Thermodynamic modeling and validation of gasifiers and gas cooling (Aspen Plus) Standardization of boundary conditions Development of ternary diagram for Pittsburgh #8 coal Incorporation and evaluation of proposed concepts Diagram extension to high-ash coals and systematic concept evaluation 5

6 4. Development of ternary gasification diagram 4.1 Process conditions domain of combustion (O 2 excess, oxyfuel) domain of kinetic limitation - Contacting various mass flows of Pittsburgh #8 coal with gasifying agents H 2 O and O 2 - Definition of process temperature by equilibrium calculation - Definition of residual carbon iso-lines, indicating conversion domain of gasifier operation 6

7 4. Development of ternary gasification diagram 4.1 Process conditions SFGT - Incorporation of gasifier operation domains GE - Location of existing gasification systems [4] ConocoPhillips [5] [6] [2] [1] Shell Prenflo HTW Lurgi FB [3] [1] [1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle Technologien und Projekte in Deutschland, DGMK, Hamburg, 2008 [2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002 [3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993 [4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005 [5] Lynch, T. A.: Conoco Phillips Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005 [6] Schingnitz, M et al.: Siemens IGCC and Gasification Technology Today s Solution and Developments, 2nd IFC, Freiberg, Germany, 2007 [12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen

8 4. Development of ternary gasification diagram 4.2 Performance parameters domain of η CGE > 80 % - Calculation of cold gas efficiency on LHV basis - Maximum cold gas efficiency identical to 100 % carbon conversion line - Definition of methane yields in product gas 8

9 4. Development of ternary gasification diagram 4.2 Performance parameters GE SFGT - Incorporation of gasifier operation domains and location of existing gasification systems ConocoPhillips [5] [2] [6] [4] [1] Shell Prenflo Lurgi FB HTW [1] [3] [1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle Technologien und Projekte in Deutschland, DGMK, Hamburg, 2008 [2] Ratafia-Brown, J. et al.; Major Environmental Aspects of Gasification-Based Power Generation Technologies - Final Report; DOE/NETL; December 2002 [3] KoBra 300 MW IGCC Power Plant Goldenberg, Supplement of Modern Power Systems, February 1993 [4] Radtke, K et al.: Renaissance of Gasification based on Cutting Edge Technologies, VGB PowerTech 9/2005 [5] Lynch, T. A.: Conoco Phillips Operational Experience at the Wabash River Project, IGCC Project Development and Finance Seminar, St. Louis, USA, 2005 [6] Schingnitz, M et al.: Siemens IGCC and Gasification Technology Today s Solution and Developments, 2nd IFC, Freiberg, Germany, 2007 [12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen

10 5. Overview of proposed gasifier concepts Selction: Siemens partial water quench Shell partial water quench Prenflo full water quench [15] [13] [14] [12] GE posimetric feeding system ConocoPhillips Entrained slagging transport reactor INCI Internal Circulation gasifier concept [18] [16] [17] [12] PRENFLO Broshure 2nd Edition, Uhde GmbH, Gelsenkirchen [13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology Today s Solutions and Developments, 2 nd International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007 [14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, [15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, May 2009 [16] Zuiker, J.R.: Building on History the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4-7 October 2009 [17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October 2004 [18] Gräbner, M.; Messig, D.; Uebel, K.; Meyer, B.: Development and Modelling of 3 rd generation gasifiers for low-rank and high-ash coals, ICCST, Cape Town, South Africa

11 5.1 Introduction of Internal Circulation Gasifier - INCI Δp Agglomerates IEC coal cooling water cooling water gasification agent tuyres primary gasification agent Lessons learnt from analysis of established systems [1] : - Water jacket, no brick lining + fluidised bed gasifiers features - Slag-free tuyere nozzles [19] - Ash particle agglomeration - Outlet temperature of ~ C - Internal circulation (transport-principle, CFB) + entrained flow gasifiers features - High central flame temperatures > 2,000 C - Dust feeding + new principle of post-gasification (similar to fixed bed) - Enhanced carbon conversion by O 2 /H 2 O- or O 2 /CO 2 -mixtures (5..13 %vol O 2 ) - Sensible and fusion heat recovery into gasification process (H 2 O/O 2 ) [1] Schmalfeld, J., Editor: Die Veredlung und Umwandlung von Kohle Technologien und Projekte in Deutschland, DGMK, Hamburg, [19] Lambertz, J.: Process for gasifying carbonaceous solids, and fluidized bed reactor for carrying out the procss, German Patent DE ,

12 6. Application of the ternary diagram for high-ash coal Ash properties under reducing atmosphere: - Softening temperature: 1290 C - Flow temperature: 1430 C Sticking zone (w/o flux): C General comments to high-ash coal: - Shifting towards lower temperature (generally favorable for η CGE ) - No moderator necessary - Smaller domain of carbon presence 12

13 6. Application of the ternary diagram for high-ash coal [14] [15] 2 3 Mixing lines [13] 1 [17] T>1600 C More moderator 1 3 [16] 2 Slurry 66/34 [13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology Today s Solutions and Developments, 2 nd International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007 [14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, [15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, May 2009 [16] Zuiker, J.R.: Building on History the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4-7 October 2009 [17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October

14 6. Application of the ternary diagram for high-ash coal [14] [15] [17] 900 C < T < 1100 C [13] %vol O [16] [18] [13] Hannemann, F.; Schingnitz, M.; Zimmermann, G.: Siemens IGCC and Gasification Technology Today s Solutions and Developments, 2 nd International Freiberg Conference on IGCC & XtL Technologies, Freiberg, 2007 [14] de Graf, J. D.: Shell Coal Gasification Technology, Eindhoven University of Technology, NL, [15] Radtke, K.; Heinritz-Adrian, M.: PRENFLO PSG and PDQ, 4th International Conference on Clean Coal Technologies, Dresden, Germany, May 2009 [16] Zuiker, J.R.: Building on History the Next Generation of Technology, GTC Annual Conference, Colorado Springs, CO 4-7 October 2009 [17] Amick, P: ConocoPhillips Technology Solutions: Gasification Update, GTC Annual Conference, Washington, DC, 3-6 October [18] Gräbner, M.; Messig, D.; Uebel, K.; Meyer, B.: Development and Modelling of 3 rd generation gasifiers for low-rank and high-ash coals, ICCST, Cape Town, South Africa 2009

15 7. Conclusion & Outlook Conclusion: -Development of an unified ternary diagram for gasification processes -No focus of 3 rd generation concepts on high-ash coals (fines) -INCI gasification concept & ConocoPhillips ESTR concept show high potential for high ash coals -Most of the technology providers favor - Dry feeding systems (even look hopper-free) - Flexible gas cooling concepts -Development of INCI gasifier concept for low grade coals Outlook: [20] -Construction 10 kg/h INCI lab scale plant (COORVED-project ID# ) -Finishing numerical modeling of the INCI process with FLUENT -Extension of the diagram to low-rank coals (lignite) and other gasification agents [20] Gräbner, M.; Uebel, K.; Messig, D.; Meyer, B.: Development and Numerical Simulation of 3rd Generation Gasifiers for High-ash Coals, ICCES Paper # ICCES , Las Vegas, USA,

16 End of Presentation Freiberg, Germany Thank you for your attention Questions? 16