RecoPhos Bench Scale Reactor Design and Modelling Andreas Schönberg, Daniel Hariri RecoPhos Demonstration Event February 24th 2015
Content Basic of Development Setup and Design Modelling and Simulation Bench Scale Plant 2
Basic of Development Idea of Process Setup and Design Modelling and Simulation Experimental Work Bench/Pilot Scale Plant 3 Scale Experiments
Setup and Design required Reactor Atmosphere required Reactor and Packed Bed Dimensions required Power Distribution Design and construction of Induction Heating Systems required Power Supply required Periphery Design Process hand in hand with Modelling & Simulation and experimental work. 4
Lab Scale Induction Heating Measuring Equipment Power Supply 5 Resonance Circuit Switching Circuit
Modelling Slag Flow 6 Volume fraction slag
Modelling Slag Flow 7 Simplification of the computational mesh from 3D to 2D axsymmetric
Modelling Slag Flow Mass fraction of tracer at same time after pulse injection Viscosity low Viscosity high 8 µ 20 times higher
Modelling Slag Flow Effect of the dynamic viscosity of the molten ash on the RTD function during steady state variable 9
InduCarb Reactor Melting zone Ash feed P 2, CO Reaction zone Output area 10
InduCarb Reactor Unit 1 Unit 2 Unit 3 11
InduCarb Reactor Temperature 7 kg/h Ash -3,5 kw (melting) Heating power 70 % -1,75 kw (reactions) 40 % -1,75 kw (reactions) 40 % 12
Heating Test 13
Experimental Run 14
Process Flow Diagram (PFD) Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 15
Bench Scale Plant Combustion chamber Dosing system Scrubber IC- Reactor Heat exchanger Vessel 16
Bench Scale Plant Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 17
Construction & Commissioning of the Bench scale Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 18
Piping and Instrumentation Diagram (PID) & Process Automation Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 19
Bench Scale Plant 20
Bench Scale Plant Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 21
Gas supply Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 22
Process Automation, HMI Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 23
Process Automation, Control cabinet Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 24
Process Automation, HMI FRIP Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 25
Modelling of essential parts Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com Surface Temperature profile ensuring Temperature protection 26
Operation Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 27
Trend reporting Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 28
Data reporting Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 29
www.recophos.org Project RecoPhos H-CPE Hariri Chemical Process Engineering Hauptstrasse 16 4132 Muttenz, Switzerland Tel.: +41 (0)61 461 8075 daniel.hariri@h-cpe.com www.h-cpe.com 30