On the Challenges of Coal Gasification Based Syngas Conversion Systems

Transcription

1 On the Challenges of Coal Gasification Based Syngas Conversion Systems Yong-Wang Li Synfuels Americas, Inc (Leesburg, VA ) Synfuels China LTD (Beijing) ywl@sxicc.ac.cn

2 Global Energy Supply System Upstream resources: Coal/Minerals, Oil, Natural gas, Nuclear minerals, Biomass/wastes Geothermal, Winds, Sea wave, Solar Down stream products: Science & technology from resources to products large centered facilities: footprint controls Electricity, Civil fuels, Motor fuels (gasoline/jet fuel/diesel)

3 Status: China Hydro/Nuclear/Wind 9.6% 20% (?) Oil 17.8% (?) Natural gas 5.1% 10% (?) Coal 67.5% 60% (?) Importing oil & gas Security, trade balance Practical: coal conversion New energy technology China has to find solutions to completely replace fossil fuels with new energy resources within about 100 years.

4 Coal to oils:the strategic field Pilot 20b/d Demon 5000b/d Scientifically hard topic: Experiences Germany/South Africa Lessons China and US Synfuels China

5 Synfuels China (founded 2006, Beijing) Synfuels China R&D (Beijing) 150 researchers 50 engineers Lab R&D Pilot testing Synfuels China Engineering Design/EPC/commissioning 500 engineers Synfuels Americas (Leesburg) International project Development 10 members Synfuels China Catalysts (Erdos) 200 staff t/y F-T catalyst ChemEssen (Korea-based, Suoel) Chemical data base development applications

6 Syngas conversion: using hard materials CH 4 (CNG/LNG) Olefin (C 2 /C 3 ) Hydro-Pyrolysis Residue Separation Chemicals Coal H 2 /CO CH 4 CH 3 OH Oil Solvent Gasoline Gasification Purification Conv. SG H 2 /CO Product up-grading Jet fuels Diesel Biomass CH 4 Lubricate Catalytic Gasification Separation & Purification Others Syngas conversion Development: New materials, reaction mechanisms, thermal data, new catalysts, unit technologies, new products and processes, integration of a process Engineering skills: Design and construction Understanding Gasification: Improve gasifiers, integration, water handling

7 Synfuels R&D Efforts MTFT technology formulation ( ) LAB 1.0L PP Φ 0.3m DEMO Φ 5.Xm Industrialization Φ 10.Xm 1000 t syncrude /t Fe catalyst Catalysis and catalyst Reactor and process

8 Synfuels China R & Efforts: Catalysis technologies So far correct structure Research from fundamental (QM,CFD) to application (catalyst, reactors..) Pilot plant testing, engineering design of plants, operation of plants Fundamental research Application development Industrial operation Seamless working environment for whole chain of R&D application?

9 Catalyst related problems work but not the best

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11 Synfuels China - IDL Projects overview Shenhua Ningxia project b/d liquid Dry feed gasifers (24) Linda ASU (10) SFC F-T 2 trains 8 reactors Capital cost 58 billion RMB 85% construction completed FT+ upgrading design/construction services by SFC engineering 2016 commissioning

12 Synfuels China - IDL Projects overview Luan project 25000b/d liquids 4 Shell gasifiers Air products ASU SFC F-T 1 trains 2 reactors Capital cost 18 billion RMB 95% construction completed SFC engineering overall design FT+ upgrading design/construction EPC by SFC engineering 2016 commissioning

13 Synfuels China - IDL Projects overview Yitai HJQ project 25000b/d liquids 6 HTL gasifiers Air products ASU SFC F-T 1 trains 2 reactors Capital cost 15 billion RMB 65% construction completed SFC engineering overall design FT+ upgrading design/construction EPC by SFC engineering 2017 commissioning

14 Synfuels China - IDL Projects overview Yitai Dalu /Guizhou projects 50000b/d liquids NM gasifers 10 SFC F-T 1 trains 4 reactors Capital cost 29.5 billion RMB With new version of design 3 t water /t oil Super-clean gasoline

15 Synfuels China The Stepwise Process Technology improvement Energy efficiency Product quality Stepwise liquefaction 18-20MPa Stepwise liquefaction 3-5MPa Recycling solvent Biomass H 2 Hydro-liquefaction Residues SEP&HYDRO Chemicals Gasoline Kerosene Younger coal O 2 /H 2 O Products up-grading Diesel Solvent Gasification DCL Process + F-T synthesis ICTL Process

16 Synfuels China The Stepwise Process Analysis instrument ESR, GC-MS, FTIR, NMR, XPS,XRD The hydropyrolysis test at capacity of 1t coal /h facility: Several low rank coals tested, ash contents limited to < 10% Two coals are successfully operated to increase the liquefaction efficiency from 44% (IDL) 60% (STWL) Estimated Capital cost 1 million liquids: from 16.0 billion RMB 12.0 billion RMB

17 Conversion Processes Syngas conversion Fischer-Tropsch fuels straight chain based chemicals MTO C 2 -C 4 olefines Lurgi gasifier SNG ( methanation ~ inefficient) Major issues Fischer-Tropsch catalysts and integration philosophy Syncrude processing Fe gasoline and diesel Co diesel MTO catalysts SNG economics & waste water management

18 Synfuels China/US Efforts Synfuels Americas - Initializing International activities Atomic level research to unit development 50000b/d virtual Plant based on mathematic models Pilot scale (20b/d) to comercial scale (110000/d)

19 Industrialized Gasifiers in China Gasifiers Terms Moving Bed Shell HTL GSP Choren NM SE Water slurry ECUST Feed Pellets Dry powder Dry powder Dry powder Dry powder Dry powder Dry powder Slurry Slurry Hydrodyn Moving Entrained Entrained Entrained Entrained Entrained Entrained Entrained Entrained -amic beds G-up G-up G-down G-down G-down G-down G-up G-down G-down Major points Waste water Steam comsup. Capacity Cost Complex H 2 /CO low Black water Carbon eff. Flowing ash H 2 /CO low Black water Carbon eff. Flowing ash H 2 /CO low Black water Carbon eff. Flowing ash H 2 /CO low Black water Carbon eff. Flowing ash H 2 /CO low Black water H 2 /CO low Black water Efficiency Flowing ash Black water Efficiency Flowing ash Existing gasification technologies have not optimized for a whole syngas production processes. It works, and it can be much better

20 Moving bed: Success and Failure Coal LP steam BFW Coal lock Lock gas Raw gas o C BFW BFW BFW Dewater gas Rich in CH 4 Only reason for CNG Gasifer Steam Oxygen Steam Recycling water Ash Ash lock Water jacket Gas water Gas water Gas water CH % in cleaned gas, some tar recovered SNG H 2 /CO= , avoiding WGS in most cases Coal balances coal powder usage Steam consumption is large water saving challenges Waste water with complicated organic contaminates Capacity low

21 Dry Feed Quenching gas recycle ~ 250 o C Shell Clean water Flue gas Steam Pulverized Coal stack Boiler Dusty gas stream ~ 300 o C Dust free raw gas Coal Mill Hot flue gas Coal powder Feeding tank Carrying gas CO2 Coal powder lock Coal + CO 2 Oxygen Black water Oxygen Slag quench Slag lock BFW Slag Dusty gas stream ~ 300 o C Flying ash filters Flying ash Wet ash Wet washing tower Wet ash Black water Dry feed with higher efficiency, less oxygen consumption, steam recovery Much less black water treatment Cost is high, low H 2 /CO = 0.3, water system optimization, Steam for WGS section

22 Syngas conditioning (CO+H 2 ) Basis : Nm 3 /h Shell SCGP Siemens/GSP HTL ECUST GE-Energy Lurgi (Mark IV) CH 4 : Nm 3 /h Coal tar H 2 : CO: CO 2 : 6000 N 2 +H 2 S: <1000 H 2 O: ~3000 H 2 : CO: CO 2 : 6000 N 2 +H 2 S: <1000 H 2 O: > H 2 : CO: CO 2 : 6000 N 2 +H 2 S: <1000 H 2 O: > H 2 : CO: CO 2 : N 2 +H 2 S: <1000 H 2 O: > H 2 : CO: CO 2 : N 2 +H 2 S: <1000 H 2 O: > WGS: CO Adding steam: > Complicated scheme WGS: CO Complicated scheme WGS: CO Simple scheme Waste water : 5 Very difficult water Black water: 1 Black water: 3 Black water : 3 Purification H 2 : CO: 35000

23 Gasification: some points to think High efficiency: Slurry dry feed, ash dust remove, new structure, coal powder delivery Water handling: Desalting and recycling (2000t/d: black water t/h 2-5t/h) Syngas quality: Increase H 2 /CO from 0.3 to , partial water quenching system Safety and availability: Hydrodynamic understanding, more clever design

24 The Funny Cycle 650k years ago Electricity Clean fuels Chemicals How long we need for the complete sustainable system formulation? Technical barriers Ancient Now Future Our destination is where we started, with much harder sustainability

25 Future for Energy Science

26 Research: Fischer-Tropsch

27 Future for Energy Science

28 Would it work at the large capacity?

29 Remarks 1.Syngas conversion: better catalysts smart reactor and process technologies 2.Effort here in China a unique platform advanced clean coal technologies contribution to the world 3.Advanced gasification technologies coal to clean fuels CTL/SNG projects; gasification technologies have to be upgraded with consideration of not only gasifier itself, but also the whole integrated system covering coal delivery to syngas cleaning units 4.Next step very clean and efficient use of coal 5.Long term thinking: bridging what being done today and what to be done tomorrow essential development in SCIENCE highly demanded