First Ever Meeting of IEA International Energy Agency Thermal Gasification of Biomass Task in Germany

Transcription

1 First Ever Meeting of IEA International Energy Agency Thermal Gasification of Biomass Task in Germany November 21 to 23, 2001 Innovations How to transform tar residues into a product? Author: Dipl.-Ing. N. Topf, Dr. G. Liebisch, Dipl.-Ing. D. Hahn VER GmbH, Kesselsdorfer Str. 216, D Dresden Foil 1

2 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 2

3 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 3

4 Business objects VER develops processes and plant concepts for thermal drying of industrial and municipal sludges of any kind with the patented steam-fluid drying process (DFT ) and the thermalmechanical treatment process (TMA ) VER engineers, constructs and operates material and thermal recycling plants VER supplies gasification plants for residue-free, decentralised thermal recycling of dried products based on the proprietary and patented air crossflow process (LQV ) Foil 4

5 Corporate Development DFT : LQV: Formation of VER Steam-fluid drying Air-cross flow gasification Constru c- tion of LQV pilot plant Freital for R&D Becker AG Strategicalliace DFT and LQV patent application Constructionbegin VZR Construction Pilot Drying plant Research & development DFT und LQV with different input materials, engineering DFT Start of operations VZR, 1st Development stage Market opening Mulityear contracts VW, Daimler Developme nt TMA Start of overseas activities China Brazil Canada Japan Indonesia Major order SVZ to deliver DFT Delivery pilot gasifier to TU Dresden Foil 5

6 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 6

7 Generation of tar, Strategy of utilization and avoidance steps of material and energy transformation: drying pyrolysis gasification energy utilization basic material: 1 kg wood 150 g H 2 O 850 g solid 150 g smoulderwater 100 g tar 750 g charcoal 3 m³ Fuel gas 5 g tar + 5 g dust 50 g charcoal+ash possibility for use: electricity, warmth, methanolproduction production of industrial fuel final product Foil 7

8 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 8

9 LQV Air Crossflow Gasification < 150-h duration test > Wood 20 kg/h Additive dosing Gasifier ca. 600 C 57 m³/h 171 g/h Tar Fuel gas ca. 300 C Cooling water Washer Fan Cooling water ca. 60 C M Dust separator Purification liquid Cooling water Filter BHKW Electricity 25 kw Energy transformation Gasification air Residue 350 g/h Tar sludge Heat Ash 0,8 kg/h Temperatures of gasifier and raw gas at one day of 150-h duration test Temperature [ C] :00 2:00 4:00 6:00 8:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 0:00 Time Max. Gasifier Temperature Producer Gas Temperature Aver. Max. Gasifier Temperature Foil 9

10 LQV Air Crossflow Gasification < 150-h duration test > Temperatures of gasifier and raw gas at one day of 150-h duration test Temperature [ C] :00 2:00 4:00 6:00 8:00 10:00 12:00 14:00 16:00 18:00 20:00 22:00 0:00 Time Max. Gasifier Temperature Producer Gas Temperature Aver. Max. Gasifier Temperature Foil 10

11 Gas calorific value vs. gasification air flow < 150-h duration test > Lower calorific value[kj/m 3] Overall gasification air [m³/h] Air + flue gas Air + water Air Foil 11

12 Gas calorific value vs. gasification air flow < 150-h duration test > Gas composition (SGF-gasification) (O 2 -content < 0.1 Vol-%) CO [Vol-%] CO 2 [Vol-%] H 2 [Vol-%] CH 4 [Vol-%] N 2 [Vol-%] Calorific value [kj/m³ i.s. ] 18,9 10,5 12,7 0,9 57, Particulates and tar concentration in LCV-gas from SGF-gasification [mg/m³ i.s. ] Particulates Haevy oils Phenols Naphthalene P A H 150-h duration test Foil 12

13 LQV Air Crossflow Gasification Wood 20 kg/h Additive dosing Gasifier ca. 600 C 57 m³/h 171 g/h Tar Fuel gas ca. 300 C Cooling water Washer Fan Cooling water ca. 60 C M Dust separator Purification liquid Cooling water Filter BHKW Electricity 25 kw Energy transformation Gasification air Residue 350 g/h Tar sludge Heat Ash 0,8 kg/h Foil 13

14 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 14

15 DFT Plant VZR Foil 15

16 DFT Process Foil 16

17 Tar sludge Vapours Feedstock Filter unit Steam jacket Dry product Foil 17

18 Preparation of industrial sludge Foil 18

19 DFT Plant VZR Foil 19

20 Fuel pellets from industrial waste sludge Moisture content 1,4 % Ash content (815 C) 25,1 % Basic elements (dry basis) Carbon 51,0 % Hydrogen 6,44 % Nitrogen 4,20 % Sulphur, verbr. 0,3 % Chlorine 0,24 % Calorific value kj/kg Fuel pellets - 15 mm Heavy metals (dry basis) As < 0,05 mg/kg Cd < 0,5 mg/kg Cr 268 mg/kg Pb 152 mg/kg Cu 610 mg/kg Ni 30 mg/kg Hg 0,7 mg/kg Zn 249 mg/kg PCB < 0,001 mg/kg Foil 20

21 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 21

22 DFT Plant SVZ Vapours Fe e dstock Filte r unit Steam jacket Dry product Foil 22

23 DFT Plant SVZ Vapours Fe e dstock Filter unit Steam jacket Dry product Plant characteristics Sludge capacity: 20 tons/h Evaporation capacity: kg/h (water) and kg/h (hydrocarbons) Steam pressure: 20 to 35 bar) Dryer length (total) 10 m Weight (one dryer): 75 tons Foil 23

24 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 24

25 Calculation Pos. delivery areafor gasification plant with 1500 kw th and 500 kwel - power two stage plant fixed bed/ fluidised bed asking price [TDM] LQV fixed bed gasifier asking price [TDM] 1.1 fixed gasifier fluid bed reactor gas cleaning auxiliaries devices control system block power heating station gas analytic steel structure A design B planning C installation D commissioning trial operation E auxiliaries sum total sum analytic, special measurement Foil 25

26 Contents 1. VER business fields 2. Generation of tar, Strategy of utilization and avoidance 3. Air Cross Flow gasification (LQV ) results from 150 h duration test 4. DFT Drying of industrial waste sludge 5. Treatment of tar sludge at SVZ as example of usage of DFT 6. Costs for tar treatment 7. Next steps for development at VZR Reichstaedt Foil 26

27 Mechanical Sludge Preparation Paint and lacquer sludge (dry matter > 40 wt.%) Delivery bunker Screw conveyor Paint and lacquer sludge (dry matter < 40 wt.%) Crushing Admixtures Coagulation/ anti-stick treatment Remnants Intermediate product sent to DFT Steam-Fluid Drying Waste water Decanting Foil 27

28 DFT Steam Fluid Drying Exhaust steam Condenser Cooling water Lacquer sludge Solvent Dryer Effluent Fuel pellets Solids cooler Pelletizer Solid cooler Silo Heating steam Cooling water Steam generator Flue gas Cooling water Natural gas Heating steam condensate Foil 28

29 DFT Products: Secondary raw materials, Solvents, Water 100 % paint and lacquer sludge result in: 50 % Secondary raw materials comparable with hard coal 10 % Solvents purity 99 % Fuel pellets Granular material 40 % Water after the cleaning tracing back in the cycle. Foil 29

30 LQV Air Crossflow Gasification Sekundärrohstoffe (LS-Pellets) 1 Technikanlage Q = 100 kw Freital Pilotanlage Q = kw Reichstädt (VZR) Technische Anlagen Q = kw; kw; kw Waschmittelzugabe Wäscher Verdichter Vergaser Kat. CH OH 3 O 2 LQV Rost CO H2 CO 2 Filter Waschmittel Aktivkohlefilter M Restgas (CO; CO ) 2 BHKW Strom Reststoff (Asche) 1 Wärme Foil 30

31 VER GmbH «Verfahren entwickeln Ressourcen schonen» V E R erwertung und ntsorgung von eststoffen GmbH DFT Die Tonne Lackschlamm im Verwertungszentrum Reichstädt Die Tonne Lacks chlamm im Verwertungszentrum Reichstädt Auftrag 2000 Methanol aus CARBOFUEL Foil 31 LQV Pilotanlage V E R DFT VZR Verwertungszentrum Reichstädt erfahren für die nergie- und ohstoffwirtschaft

32 Foil 32 Contact: Mr Norbert Topf (Managing Director) Phone: / ; Mobile: / Ms Antje Gnädig (Director Sales and Marketing) Phone: / ; Mobile: /