IEA BIOENERGY Task 36. Waste challenges and Ecoloop technology. KIT ITC, 05. December page 1

Transcription

1 IEA BIOENERGY Task 36 Waste challenges and Ecoloop technology KIT ITC, 05. December page 1

2 Agenda 1. Technology key messages and highlights 2. Technology discription 3. Unique selling propositions 4. R&D activities 5. Outlook page 2

3 We have a technology to make syngas from high calorific waste Our process is simple, emission free and economic Our process is particularly advantageous for critical waste Ecoloop s technology could be an efficient supplement to waste incineration page 3

4 Opportunity to make waste utilization chains more valuable High calorific waste Incineration Steam Turbine Heat Power Making waste utilization more valuable by syngas as product from waste page 4

5 Key ecoloop highlights Awarded breakthrough process technology Very simple and high economic process by using a circulated lime moving bed for turning even difficult waste streams into clean syngas Plastics 5 ton/h Lime 0,8 ton/h Fine fraction 1,3 ton/h Lime loop 15 ton/h Syngas Nm3/h Standard and proven equipment for full scale realisiation Long term success by meeting mega trends Time Waste Volume Waste vol. growth due to: growing Population reduction of land fill Time Availability Expiering fossil valuables limited valuable ressources worse ecological balances Strong USP s as basis for huge market potential Gas quality - allows valuable output applications Efficiency more than 80% of feedstock is converted into gas Lime moving bed: Multifunctional key Input flexibility - no heat value limit; high chlorine and sulphur contents Emissions - no air emissions and no formation of dioxins or furans Syngas production in addition to incineration power + heat from steam Incineration Product:Syngas Time Public Acceptance Droping of public acceptance for incineration due to discussion about: emissions + toxic residues page 5

6 Key corporate accomplishments First basis patents applied Start of erection alpha plant Commissioning alpha plant Take over 100% ecoloop shares by Conera Process Solutions GmbH Start company capital founding process Ecoloop GmbH founded German innovation award Hot startup alpha plant Re start alpha plant Start feasability study for beta plant project Start of joint venture with Xella group Hugo Junkers award Start of plastic waste gasification Stop of cooperation with Xella group / stop of alpha plant operation Patent apply for modified technology Decision for subsidies from german government for alpha plant Start of re engineering phase alpha plant Basis engineering for beta plant concept Foundational IP and technology established page 6

7 Agenda 1. Technology key messages and highlights 2. Technology discription 3. Unique selling propositions 4. R&D activities 5. Outlook page 7

8 First industrial 32 MW plant Power Grit Alpha-Version was built on a lime production site in order tu use syngas as natural gas substitute. Die Gesprächsstrategie mit PS wird aufgrund der Zäsur grundlegend geändert page 8

9 Lime loop concept Fine Fraction 1,3 t/h page 9

10 Lime loop concept Fine Fraction 1,3 t/h page 10

11 The ecoloop process That s how it works. 1 Input material is mixed with lime before entering the hot reactor zones 2 Input material colume forms atmospheric seal 3 Material is driven by own gravity and controlled by a rotating table 4 After gasification in the upper pyrolysis and reduction zone the coke residue is burned in the oxidation zone while providing energy for the process. In the cooling zone water is added 5 Syngas is removed at the reactor top while pollutants are bound on the fine lime surface 6 Pollutants are sieved out together with fine lime and ash 7 Lump lime is used for the next loop again The technological key is a moving lime bed as a reaction surface page 11

12 Lime loop concept Fine Fraction 1,3 t/h page 12

13 Input What can be used? Carbon containing materials in 2d and 3d particle forms Municipal solid waste fractions (MSW) Critical Carbons (f.e. salty coal) Ecoloop can gasify Particle sizes between 5 to 300 mm Unlimited chlorine and sulfur content Examples Plastic waste (f.e. car shredder) Segregation residues (f.e. yellow sack) Critical biomass (f.e. contam. Wood) Sulfur containing oil sands and oil shells Bituminous materials (f.e. tar lakes) Contaminated soil and oil residiues Heating value above 10 Mj/kg (unlimited) Sewage Sludge from waste water treatm. Contaminated hydro carbons In case of municipal solid waste (MSW), Ecoloop ecoloop is a part of an integrated concept together with a mechanical biological separation (MBS) Houses Glas Waste Separation Paper Plastics Mechanical/biological Separation (MBS) Metals Recycling High calorific residues Fines Ecoloop Electr.Power page 13

14 Lime loop concept Fine Fraction 1,3 t/h page 14

15 Output and Application Potentials Ecoloop Output: Syngas Raw gas flare Plant kaltes Tal Syngas Quality Syngas composition (Vol %) CO 24,5 bis to 16,3 H 2 19,9 bis to 13,3 CH 4 9,8 bis to 6,6 C 2 H 6 1,1 bis to 0,7 N 2 43,0 bis to 62,0 CO 2 1,7 bis to 1,1 Summe 100 bis to 100 Heating value: 2-2,4 kwh/nm³ Free from chlorine and sulfur Dust: < 1 mg/nm 3 Examples for Output Applications Power production via efficient gas engines Phosphor Recycling from mun. sludge Chemical Recycling f.e. alcohols Thermal use as substitute for fossil fuels page 15

16 Lime loop concept Fine Fraction 1,3 t/h page 16

17 Fine Fraction Utilisation Potentials Ecoloop Output: Fine Fraction Fine Fraction is milled to a particle size < 12 mm and transported by standard silo trucks. Main components: CaO and Ca(OH) 2 heavy metals Chlorine as CaCl 2 Fine Fraction Quality Typical composition Component. Value CaO M% 22,8 Ca(OH)2 M% 14,9 EBS-Asche M% 41,9 CaSO4 M% 5,7 CaCl2 M% 12,1 CaF2 M% 0,1 Cadmium M% 0,0013 Thalium M% 0,0004 Quecksilber M% 0,0002 Arsen M% 0,0006 Kobalt M% 0,0014 Chrom M% 0,0322 Kupfer M% 1,7576 Mangan M% 0,0255 Nickel M% 0,0120 Blei M% 0,0787 Antimon M% 0,0347 Zinn M% 0,0284 Vanadium M% 0,0163 Zink M% 0,4511 Selen M% 0,0006 Tellur M% 0,0006 Beryllium M% 0,0003 Titan M% 0,0003 Total HM M% 2,4422 Examples for Fine Fractions Applications Cement Industry as raw material after Cl-eluation Soda Industry as chemical agent Chemical Industry as neutralising agent for cont. waste water Disposal Mountain Filling (f.e. in salt mines) page 17

18 Agenda 1. Technology key messages and highlights 2. Technology discription 3. Unique selling propositions 4. R&D activities 5. Outlook page 18

19 Breakthrough by using lime as reaction bed Chemistry Carbon rich materials are gasified - not burnt Pollutants are neutralised in lime e.g.: Clorine and other halogens are bound as Ca-salts Sulfur is bounded as Ca-salt Heavy metals are bounded on huge specific surface of fine lime Lime is a catalyst for gasification Process Costly off gas treatment fully avoided, off-gas cleaning is not necessary. Halogen corrosion at high temperature can be avoided, due to the bounding of halogens. Formation of dioxins and furans is fully avoided. Innovative engineering concept with lowest complexity Ecoloop provides a gasification process with simple but effective system efficency page 19

20 Ecological and efficient solution for problematic waste streams Critical high calorific waste Incineration Upper limit due to technical issues and capacity reduction High maintenance efforts reduce availability and increase OPEX Toxic dioxins and furans are formed High temperature corosion reduces efficiency and increases specific CO 2 -emissions Toxic ash and solids disposal Hydrogen formation from ash in case of alu input Low power generation efficiency and high effort for flue gas cleaning increase OPEX and reduces profits Calorific value Chlorine Environmental impact Economics unlimited Clorine is captured on lime as uncritical Casalt. Forming of dioxins and furanes is system immanent impossible No emission Ash free from high toxic dioxins and furanes and without hydrogen forming potential CO 2 reduction due to high efficiency in case of thermal use of syngas Very economic due to attractive profit from high gate fee rates and valuable syngas as product. Ecoloop a stainable and profitable solution for critical high calorific waste page 20

21 Mitigating technical risk by using proven standard equipment Reactor (proven lime kiln technology) Solid handling (proven technology) Breakthrough gasification technology Syngas filtration (proven carbide technology) Control system + Safety (world class standard) Syngas cooling (proven carbide technology) Breakthrough gasification + standard equipment page 21

22 Agenda 1. Technology key messages and highlights 2. Technology discription 3. Unique selling propositions 4. R&D activities 5. Outlook page 22

23 Ecoloop research at the university of Clausthal Technical University of Clausthal Institute for energy process engeneering Prof. Dr. Roman Weber German ministry of economics promoted research with 0,8 Mio Runtime end doctoral thesis 4 5 diploma thesis Gasification in a lime moving bed offers new research potentials page 23

24 Ecoloop research at the university of Clausthal Test and pilot lab Practical orientated research Research equipment had to be developed and constructed Gasification kinetic research including lime influence Pressure loss tests Reaction front research Simulation of whole process The Ecoloop process will be completely simulatable page 24

25 Ecoloop research at KIT KIT Institute for Technical Chemistry Institute for technical chemistry Prof. Dr. Dieter Stapf First experimental studies of sewage sludge gasification in presents of CaO. Gasification tests of new pellet generation from high calorific waste fractions Long term R&D cooperation within new government aid project Results showing the real technology potential, experimental conditions to be optimised! page 25

26 Beta reactor: Higher specific performance and lower investment Syngas Crute CaO + Waste Syngas Reactor head Reduction of rector height Simplyfied charging concept Changed gas flow direction makes former dust sedimentation impossible Air NG Charging Zone Chargier- Chargier- Zone Pre Heating Zone Air NG Pyrolysis zone Pyrolyse- Zone 450 Pyrolysis Zone 450 Pyrolysis Zone Counterflow changed to parallel flow concept. Therefore pressure drop reduction and capacity increase Pyrolysis Zone Pyrolyse- Zone Neben- Schacht Heavy Light Oil Oil Reduction Zone Oxidation Zone Light Heavy Oil Oil Shaft design Changed from zylinder to negative cone construction Therefore optimized solid bed flow and linear gas flow rate Pyrolysis Gas Reduktions- Reduction Gas Reduktions- Zone Reduction Zone Zone Oxidations- Zone Kühl-Zone NG Air Steam Cooling Zone 150 Air NG Steam Cooling zone Optimized gas distribution increases effciency Symplified discharging system reduces particle abrasion 150 Kühl-Zone Zone 150 Air M CaO + Ash Air Air Alpha reactor Re Engineering by joint expert team provides further process potential CaO + Ash Beta reactor page 26

27 Agenda 1. Technology key messages and highlights 2. Technology discription 3. Unique selling propositions 4. R&D activities 5. Outlook page 27

28 German Beta Plant Project Current Situation 2017 Steel production site Shredder plant Car recycling Steel Plastic fraction Metal fraction Steel converter Raw iron Blast furnace Building fraction Waste Incineration Furnace gas Power Steel production Site Steel company activities Natural Gas Demand Power plant New project activities page 28

29 German Beta Plant Project Target Situation 2021 Steel production site Shredder plant Car recycling Steel Plastic fraction Beta Plant Project Metal fraction Steel converter Raw iron Pre Conditioning Blast furnace Building fraction Production of specified pellets with defined heating value Furnace gas Power Steel production Site Steel company activities Power plant New project activities Fine fraction with impurities page 29

30 Closed recycling loop out of two key areas of living Special instant pellets Urban mining EBS / PU waste fractions Steel production Energy efficent living Shredder fractions Consciously construction Heatinsulation production Car recycling Car life time Car production page 30

31 Power Grit Thanks very much for your attention! Die Gesprächsstrategie mit PS wird aufgrund der Zäsur grundlegend geändert page 31