PRENFLO TM for biomass and coal (co-) gasification by Max Heinritz-Adrian

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1 MA-PR Nov Uhde 03/2007 \\kupresentation.kud.krupp.com\kupresentation\englisch\pre sentation ppt Seite 1 PRENFLO TM for biomass and coal (co-) gasification by Max Heinritz-Adrian presented at

2 PRESENTATION OUTLINE Uhde s experience in gasification PRENFLO TM (PSG / PDQ) B-CTL via MTG The BioTfueL project Summary Page 2

3 PRESENTATION OUTLINE Uhde s experience in gasification PRENFLO TM (PSG / PDQ) B-CTL via MTG The BioTfueL project Summary Page 3

4 Uhde s first of s in Coal Gasification: 1909: first Koppers Gas Generators (a total of 536 built) 1941: Invention of first Entrained-Flow Gasification: Koppers-Totzek: dry-fed, membrane wall, multiple burners Development, Design and Construction of first Koppers-Totzek Coal Gasification Plant first Rummel-Otto Slag Bath Coal Gasification Plant first Saarberg-Otto Coal Gasification Plant first Texaco (GE) Coal Gasification Plant first HTW Coal Gasification Plant first Shell-Koppers Coal Gasification Plant first PRENFLO Coal Gasification Plant Page 4

5 Over 100 Gasifiers designed, built and put into successful operation by Uhde Uhde s Gasification History TGP TCGP PRENFLO HTW Koppers- Totzek 1953 TGP-License 1941 Koppers-Totzek 1926 Winkler Process 1959 Las Palmas, Spain 1960 Lisabon, Portugal 1971 Rhodes, Australia 1973 Start Development 1978 Demoplant, Holten 1974 Pressurised Entrained Flow: Start of Development 1980 Demoplant, Hamburg 77 Koppers Totzek Reactors 1973 Development 1978 Frechen 1991 Oberhausen, D 1986 Oberhausen, D 1982 Essen, Germany PSG 1986 Fürstenhausen PDQ 1988 Kafue, Zambia 1985 Berrenrath 1989 Wesseling 1993 KoBra (not real.) 1998 Bharuch, India 2000 Wesseling, D 1997 Puertollano, Spain 2013 BioTfueL, France 2000 SHI, Japan 2002 Vresova, Cz. Page 5

6 PRESENTATION OUTLINE Uhde s experience in gasification PRENFLO TM (PSG / PDQ) B-CTL via MTG The BioTfueL project Summary Page 6

7 Demonstration plants Shell-Koppers plant in Hamburg / Germany 150 t/d coal PRENFLO TM plant in Fürstenhausen / Germany 48 t/d coal Page 7 7

8 : Twelve years PRENFLO TM at Puertollano, Spain, the largest solid-fuel-based IGCC power plant worldwide erection of gasifier internals lifting of gasifier / HP boiler gasifier building Page 8

9 PRENFLO TM with Steam Generation 1200 MWth, 42 bar PSG Features dry coal/petcoke powder feed 4 horizontal co-annular burners membrane wall waste heat boiler (PSG) Page 9

10 PRENFLO TM with Direct Quench 1200 MWth, 42 bar PDQ Features dry coal/petcoke powder feed 4 horizontal co-annular burners membrane wall direct water quench Page 10

11 PRENFLO TM gasifier with steam generation (PSG) direct quench (PDQ) Waste heat boilers Feed, oxygen Feed, oxygen same gasifier design Direct Quench Raw gas Raw gas (incl. fly ash) Slag Slag Raw gas Page 11

12 The PRENFLO TM process with Direct Quench Why direct quench? PDQ Optimize PRENFLO TM technology for chemical and hydrogen applications Identify areas of significant Capital Cost Reduction Water Quench instead of Gas Quench and Waste Heat Boiler Keep commercially proven elements of PRENFLO TM technology Design of a robust system Page 12

13 PRENFLO TM : comparison PSG vs. PDQ Impact on cost typical process configuration for H 2 plant PSG PSG Gasifier Gas Quench Waste H. Boiler FA Filter Scrubber Saturator Raw Gas S/G=1.3 CO- Shift H 2 Gas Steam substituted by Direct Quench PDQ Gasifier Direct Quench Scrubber Raw gas S/G=1.3 CO- Shift H 2 Gas PDQ Steam Page 13

14 PRENFLO TM : layout comparison PSG vs. PDQ PRENFLO (PSG) (Waste Heat Boiler) PRENFLO (PDQ) (Direct Quench) Capital Cost Reduction: ~30 % Page 14

15 PRESENTATION OUTLINE Uhde s experience in gasification PRENFLO TM (PSG / PDQ) B-CTL via MTG The BioTfueL project Summary Page 15

16 Uhde/EMRE provide full range service for synfuel projects Page 16

17 Coal / Biomass Methanol to Gasoline Coal to Liquids via MTG Coal Preparation MTG Unit O 2 Products HC Yields PRENFLO TM Gasification Gasoline ~89% Fuel Gas ~1% LPG ~10% CO-Shift Gas Treatment Methanol Synthesis MTG Reactors Fractionation LPG Heavy Gasoline Main Advantage: MTG is uncoupled from gas generation (methanol storage tank) Hydrogen Hvy. Gasoline Treating Gasoline Blending Gasoline Page 17

18 Coal / Biomass Methanol to Gasoline Coal to Liquids via MTG O 2 Coal Preparation PRENFLO TM Gasification Maximisation of Liquid Yield Maximum carbon mitigation efficiency possible Minimisation of other emissions MTG Unit CO-Shift Gas Treatment Methanol Synthesis MTG Reactors Fractionation LPG Heavy Gasoline Hydrogen Hvy. Gasoline Treating Gasoline Blending Gasoline Page 18

19 MTG JAM project in China, started-up June 2009 Picture courtesy of Shanxi Jincheng Anthracite Coal Mining Group Page 19

20 TransGas Coal-to-Liquids complex (18,000 bbl/d) 2 x PRENFLO TM with MTG based on coal; start-up in 2013 Mingo County, West Virginia The images contained herein are the property of "TransGas" Development Systems, LLC" and are protected by intellectual property laws of the United States and other countries Page 20

21 PRESENTATION OUTLINE Uhde s experience in gasification PRENFLO TM (PSG / PDQ) B-CTL via MTG The BioTfueL project Summary Page 21

22 Market Background for the BioTfueL project Biofuels Second Generation Global growth in Energy consumption with limited fossil resources EU-Target for 2020: 10% renewable energy in transportation sector Change in primary energy demand Biofuel Demand Growth (BLUE Map scenario) Source: IEA World Energy Outlook 2009 Source: IEA Energy Technology Perspective 2008 Development of process for production of 2 nd generation biofuels Widening of application of Uhde s PRENFLO TM gasification Page 22

23 Overview BioTfueL (B-XTL process chain) Target: Development and commercialisation of integrated process chain for production of 2 nd generation biofues via thermochemical conversion Uhde Total Sofiproteol Projectbudget and timeline: Mio over 7 years Uhde contribution Gasification partner bringing in its PRENFLO TM PDQ gasification process as well as general know-how on CTL and engineering capabilities Axens IFP CEA Page 23

24 BioTfueL integrated process chain Feedstock Pretreatment Gasification Gas Treatment Synthesis Wood Straw etc. Torrefaction CO-Shift Gasel TM Fischer- Tropsch Synthesis and Product Upgrading Coal Milling AGR Biodiesel; Biokerosene Petcoke Residues Two pilot plants being built in France; start-up targeted for 2012 Life-cycle analysis for optimum equilibrium between technicaleconomical performance and environmental demands Page 24

25 PRESENTATION OUTLINE Uhde s experience in gasification PRENFLO TM (PSG / PDQ) B-CTL via MTG The BioTfueL project Summary Page 25

26 Uhde is the inventor of entrained-flow coal gasification, going back to Koppers-Totzek gasification in 1941 Over 100 gasifiers designed, built and put into successful operation by Uhde, which include: Feeding principles: Dry powder feeding Water-slurry feeding Screw conveyor and gravity pipe (fluidised-bed applications) Syngas Cooling with Gas Quench Water Quench Waste Heat Boiler Radiant Cooler Gasifier Insulation with Refractory lining Membrane Wall Uhde is an integrated licensor and EPC contractor from a single source A number of projects have selected PDQ worldwide, among them: TransGas, CTL / MTG Complex, USA BioTfueL, B-XTL, France Summary All these gasifiers went into successful operation and are fully proven in commercial scale by Uhde! Page 26

27 Thank you for your attention PRENFLO IGCC, Puertollano, Spain September Page 27