Gasification and Syngas R&D:

Transcription

1 Gasification and Syngas R&D: Underpinning clean and efficient energy products from fossil and renewable fuels David Harris CSIRO ENERGY TECHNOLOGY

2 Outline Continuing role of coal in world energy mix Gasification for power, chemicals and fuels Gasification of other hydrocarbon feedstocks R&D Challenges Feedstock properties and performance impacts on gasification technologies Coal & alternative feedstocks wastes, biomass etc Optimising design and operation of gasification and syngas technologies Supporting technology development and deployment appropriate scale and cost

3 Global energy demand continues to increase Coal remains a core power source World energy consumption World electricity generation World energy consumption increases by 56% from Coal-fired electricity decreases from 40 to 35% Fossil fuels currently 82% of world energy Expected to decrease to ~75% by 2040 Source: US Energy Information Administration, International Energy Outlook 2013

4 Gasification: a flexible enabling technology Brown Gasification EOR and CO 2 storage opportunities Source: Shell 2007

5 Coal gasification capacity and planned growth Gasification Capacity Cumulative Syngas Capacity (MWth) World coal gasification capacity projected to grow 120% in Plans for 250% growth by Data source: Gasification Technologies Council (2013)

6 World Gasification Capacity and Planned Growth (2010) Feedstock Product Region 2010 Gasification capacity expected to grow 70% by 2015 Strongest activity: coal gasification Asia & North America Power, chemicals & synfuels products Source: Gasification Technologies Council (2010)

7 Coal Gasification Capacity and Planned Growth (2013) Region Product Syngas (MW th ) Planned Installed Syngas (MW th ) Planned Installed 0 Asia Africa North America Europe 2013 Major expansion of plans in China 140,000MW th syngas planned in China alone Strong emphasis on chemicals and gaseous fuels (SNG, fuel gas) 0 Chemicals Liquid fuels Power Gaseous fuels Source: Gasification Technologies Council (2013)

8 World electricity production Coal remains the core fuel in future scenarios Electricity demand increases by 70% Regional coal-fired power generation projections Total coal fired electricity generation increases by ~35% Share reduces from 41% to 33% by 2035 Strong growth in China and India China to add nearly 500GW new coal capacity exceeds total US and Japan capacity 46% of world coal power generation by 2035 Renewables and gas increase significantly Source: IEA World Energy Outlook, 2012, 2013

9 Technology mix drives global efficiency improvements Average efficiency increases from ~35% to ~40% by percentage point improvement in efficiency for current average plant results in 2-3% reduction in CO 2 emissions CCS remains limited - only 56GW or 3% of total coal power with CCS by (IEA, 2006) Source: IEA World Energy Outlook 2013

10 Industrial energy demands Continuing growth in chemicals & fuels China dominates ongoing growth in chemicals and pulp & paper current per capita consumption in China and SE Asia is ~ 0.25 of OECD level. Growth rates in steel & cement reduces construction boom in China reduces, improved technology efficiency Gasification has strong role in chemicals and plastics industries Coal especially important as gas prices rise Source: IEA World Energy Outlook 2013

11 Coal conversion pathways Syngas platform enables many commercial options

12 Coal to Products in Australia Increasing gas prices driving innovation Some early projects in Australia New Hope Coal (Qld) Two technologies being evaluated - direct & indirect CtL Pyrolysis of New Acland coal for diesel, jet fuel, power 1 tonne/h pilot scale pyrolysers being commissioned Latrobe Fertilisers Ltd (partner with Hubei Yihua, China) Victorian brown coal (low cost $1-2/GJ) (2mtpa -5mtpa) 520,000 tpa urea (stage 1), 1.3mtpa (stage 2) Siemens gasifier(s) (Chinese build) Planned commissioning Dec 2015 Perdaman Chemical Company On hold due to coal contract negotiations KHI Brown coal to Hydrogen (Vic) CCS in association with CarbonNet project Feasibility study in progress * Yoshino et al, Feasibility study of CO 2 free hydrogen chain utilizing Australian brown coal linked with CCS, Energy Procedia 29 (2012) 701-9

13 KHI CO 2 free hydrogen chain Gasification of Australian brown coal with CCS Source: Yoshino et al, Feasibility study of CO 2 free hydrogen chain utilizing Australian brown coal linked with CCS, Energy Procedia 29 (2012) JPY ~ US$0.30

14 Gasification: a flexible enabling technology Brown Gasification EOR and CO 2 storage opportunities Source: Shell 2007

15 Gasification and syngas research

16 Gasification Research Topics Understanding fuel performance in gasification technologies, supporting: Use of Australian coals in new technologies Implementation of advanced gasification technologies in Australia Removal of barriers to industrial scale biomass and waste gasification Development of high efficiency IGCC-CCS and CtX systems High pressure, high temperature coal conversion measurements Effects of reaction conditions and coal type Feedstock - technology matching Fundamental investigations of gasification reactions mechanisms, kinetics, models Slag formation and flow Syngas cleaning & processing Gas separation (H 2 /CO 2 ) Technology performance models

17 Interrogating the Gasification Process Laboratory investigations to understand the important processes that combine to gasify coal under practical conditions. Larger-scale testing to recombine process steps under process conditions Gas Analysis Predictive capability of gasification behaviour Assess coals for specific gasification technologies Develop operating strategies Troubleshooting gasification processes Support technology development & cost reduction O 2 CO/CO 2 CO + H 2 CO 2 and H 2 O Its not all about simulating the industrial process! slag flux

18 CO 2 -char reaction rate at high temperature 20 bar total pressure, 5 bar CO 2 partial pressure CRC252 Sub bit, high vol CRC272 Bituminous 1673 K 1573 K 1473 K 1373 K 1273 K CRC281 Semi anthracite Char conversion (%) Residence time (s) Residence time (s) Residence time (s) ln(specific rate (g g -1 s -1 )) wall thickness particle size PEFR data FBR data /Temperature (1/K) Thiele modulus and effectiveness factor based on observed particle morphology effective diffusion length Low T intrinsic and high T practical rate data can be reconciled when a detailed understanding of char structure is available

19 Small and Wide Angle X-Ray Scattering (SAXS/WAXS) Investigation of microporosity in chars Exploring technique to try and overcome well known limitation of gas adsorption and other techniques SAXS can probe relevant range of pore size (~0.5µm 3Å) Method development Particle size & sample density important Representative nature of the measurement given size of x-ray spot (~240x120µm) validity of the analytical methods Preliminary results indicate measurable changes in pore size during conversion Opportunities for in-situ measurement during reaction

20 Slag formation and flow Coal mineral matter Condensed phases Volatile species Liquid slag Solid ash Wall slag Coarse slag Fine slag Fly ash Volatile species (in syngas): requirements for syngas cleaning Condensed phases (slag, fly ash): Operational: slag viscosity Utilisation/handling of slag byproducts Physical & chemical properties: trace elements, leaching Tapped slag Quench water and/ or gas cleaning

21 Coal gasification models (D_burner) WSR1 (L_WSR) Gas T Particle flow Carbon conversion (%) CRC-358 (Expt) CRC-274 (Expt) CRC-252 (Expt) 20 CRC-358 (Model) CRC-274 (Model) CRC-252 (Model) 6 (a) Distance from reactor top (m) WSR 2 Conical PFR 1 θ PFR_width PFR_length (i) Entrained-flow reactor Application of transportable fundamental kinetics and structure data Pilot and full scale modelling Integration of coal performance data into process flow sheets Conical PFR 2

22 Gas separation membranes Catalytic membrane reactor concept demonstrated High performance alloys have been developed: These meet DoE performance and cost targets Catalytic Membrane reactor Durability testing and performance with real syngas ongoing commercial WGS catalyst syngas inlet temperature 350 C > 99% CO conversion > 85% H 2 yield H 2

23 Energy from Waste Enabling a waste to energy industry in Australia

24 Increasing renewables penetration Leveraging scale and efficiency of coal R&D Fuel flexibility of gasification systems Biomass, Wastes Co-firing options Reduce seasonal and scale inefficiencies Thermochemical technology integration Solar thermal/fossil fuel hybrid technologies Transforming energy efficiency of biomass systems Double the energy yield from sugarcane biomass Support commercial demo plant (eg Brazil: 800,000 tpa bagasse) Research Waste conversion technologies; matching technologies to waste types Fuel preparation and handling Demonstration of waste to syngas processes integration with power, SNG and FT systems etc

25 Priority waste streams Agricultural Waste Bagasse Cotton gin trash Timber and forestry waste Sawdust, woodchips etc Urban Waste Municipal solid waste Green (garden) waste Biosolids Commercial and Industrial waste Treated construction timber Food and garden Paper Plastics Glass Metals Concrete Timber Other

26 International best practice Landfill is unsustainable Functional Elements of MSW (%) Japan Tiawan Singapore Korea China Current global MSW generation levels are approximately 1.3 billion tonnes per year The rate of production of MSW in Australia has doubled over the last decade 2 million tonnes of MSW are sent to landfill in Queensland alone each year Energy content of MSW 6MJ/kg (LHV w ) US Australia Victoria New South Wales Queensland Lanfilled Composting Recycling WTE Source: Hla et al 2014

27 Nippon Steel The Largest supplier of gasification based WTE plants in Japan 33 in Japan, 2 in South Korea. Fixed bed, updraft gasifier, Co gasification. 23% overall efficiency Oxygen enriched air Reference: Nippon Steel & Sumikin Engineering Co., Ltd, 2013

28 CSIRO s Research Biomass Gasifier Down draft fixed bed New facility for studying gasification behaviour of wood-based material Designed for forestry & green waste integrated with gas-to-liquid test facilities Can be integrated with a 25kW microturbine

29 Summary High efficiency coal technologies will play a key role in achieving long term greenhouse abatement targets Increasing efficiency is a prerequisite for effective CO 2 capture and storage Strong economic drivers for increased gasification for chemicals and fuels Increasing domestic gas prices as export facilities come on line Waste to energy becoming more important Coal properties and performance issues affect many aspects of gasification technology development, deployment and optimisation Advanced coal science capabilities needed to support improved coal characterisation, preparation and utilisation R&D challenges to increase efficiency, improve reliability, reduce costs Gasification provides a high efficiency technology platform for low emissions energy systems Development pathway for power, hydrogen & polygeneration systems New research in key areas where breakthroughs will improve cost and reliability National and international partnerships are needed to facilitate research, development, demonstration and deployment Coordination and critical mass are essential r2.gif

30 Thank you CSIRO Energy Technology David Harris Deputy Chief t e david.harris@csiro.au w ENERGY TECHNOLOGY