Modeling and experimental results of heavy oil injection into a high pressure entrained flow gasifier

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1 Modeling and experimental results of heavy oil injection into a high pressure entrained flow gasifier André Bader 1, Paul Tischer 1, Peter Seifert 1, Andreas Richter 2, Bernd Meyer 1 Institute of Energy Process Engineering and Chemical Engineering 14th June 2016, Cologne, Germany

2 Content 1. Experiments: Setup and Results 2. Simulation of non-reacting oil-injection 3. Impact of the particle size on the gasifier simulation 4. Summary 2

3 Experiments are conducted at IEC s 5 MW th HP POX test plant Process application: Entrained flow gasifier Autothermal non-catalytic partial oxidation (one of three operation modes) Feedstock: (Natural gas) Light and heavy oils Heavy residues from crude oil processing Operating parameters: Temperature: up to 1450 C Pressure: up to 100 bar (g) Input: up to 500 kg/h liquid feeds Syngas output: up to 1500 m³(stp)/h Not drawn to scale 3

4 Experiments: Setup und Results Optical access Camera Rotating device Hydraulic unit Flange connection Reactor top Optical eye 4

5 Experiments: Setup und Results Observation of oil injection at reactor top / nozzle tip Visual window Small spray angle Experimental setup: Reactor volume: 460 liter Pressure: 55 bar Steam inlet: 161 kg/h total Oil inlet: 330 kg/h 5

6 Experiments: Setup und Results Experimental results injection Recirculation detected after 2 s 6

7 Simulation of non-reacting oil-injection Model setup General setup: ANSYS Fluent D geometry Euler-Lagrange approach DPM Model two-way coupling k-ω-sst turbulence model P-1 radiation model Incompressible ideal gas Injection modeling: Wave model (suitable for high Weber numbers whereby Kelvin-Helmholz instabilities dominate droplet breakup) Use model settings from validated case for oil injection from Vuokila et al 1 Initial droplet diameter is set to the inner nozzle diameter 1 A. Vuokila et al, CFD-Modeling of Heavy Oil injection into Blast Furnace, Steel Research Int., No. 11,

8 Simulation of non-reacting oil-injection Model validation with particle recirculation time 8

9 probability density function, %/µm Simulation of non-reacting oil-injection Result comparison After secondary breakup: Diameter Range: µm Median ~ 15 µm Direct after injection Diameter Range: µm Median ~ 100 µm Typical applied Rosin-Rammler-Sperling-Bennett distribution for initial droplet size, determined at small scale experiments and applied in gasifier simulations 1 0,50% Set 1 0,45% Set 2 0,40% Set 3 0,35% d, µm 1 D. Ulber, PhD-Thesis, ,30% 0,25% 0,20% 0,15% 0,10% 0,05% 0,00% 9

10 Simulation of non-reacting oil-injection Non-reactive oil-injection without breakup Previous detailed model considers multiple effects: secondary droplet breakup transient droplet heating temperature dependent fuel viscosity liquid surface tension in the surrounding gasification gas atmosphere fuel conversion into solid coke particles (pyrolysis kinetics) Now the application of simplified model: mono-dispers, inert particles without breakup focus on particle size impact Evaluation of characteristic particle size using recirculation time validation Measured and extrapolated temperature dependent viscosity of applied fuel 10

11 Mass in visual window / injected mass Mass in visual window / injected mass Simulation of non-reacting oil-injection Simulation results injection Recirculation detected after 2 s after 1.5 s after 2.5 s 1,700 1,700 1,600 1,500 1,400 1,300 1,200 1,600 1,500 1,400 1,300 1,200 1,100 1,100 1,000 1,000 0,900 0, d,µm 0,900 0, d, mµ 11

12 Impact of the particle size on the gasifier simulation Reactive simulation: Model setup Pyrolysis Mass Yield ANSYS Fluent 15.0 EDC using DRM-22 Mechanism Euler-Lagrange approach DPM Model two-way coupling k-ω-sst turbulence model P-1 radiation model Incompressible ideal gas Initial droplet model comparison: RRSB distribution Breakup model 10 µm mono-dispers particles 12

13 Reactive simulation Reactor zones Reactive model with initial RRSB distribution Comparison with non-reactive breakup model flame zone recirculation zone plug-flow zone recirculation zone plug-flow zone Breakup zone 13

14 Impact of the particle size on the gasifier simulation Comparison of the temperature contour for different fuel injections Temperature, K RRSB Breakup Flame 10 µm Flame

15 Outlook Temperature, K Goal is a clear observation of the oil gasification flame in future experiments to enable validation of modeling results (limited flame visibility in former experiments due to soot deposits at the optical eye) Classical RRSB Breakup Flame 10 µm Flame

16 Summary 1. The evaluation of the validated CFD model for the large scale experiment indicates a characteristic particle size distribution >1 µm and <75 µm. 2. Reactive entrained flow gasifier models show a high sensitivity concerning the particle in the flame region The large scale experiment helps to understand the process by delivering validation data.

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