HydroMax: Breakthrough Molten-Metal Coal Gasification Technology

Transcription

1 HydroMax: Breakthrough Molten-Metal Coal Gasification Technology Steven Schenk Vice President, Special Programs October

2 Who is Diversified Energy? Alternative and renewable energy technology, project development, and services company Working in two alt-energy areas - Gasification (HydroMax, OMR) - Biofuels (Centia TM, Simgae TM ) Focus on commercialization of technology Headquartered in Gilbert, Arizona Core team in place and key partnerships established to support development Strong State and Federal Gov t relationships Develop and mature alternative energy technologies, systems, and projects to economically address United States and World energy demand Core Strengths: Systems Engineering, Project Management, Project Development, and Finance GTC 2007 HydroMax Presentation 2

3 Overview of Gasification Areas of Expertise GTC 2007 HydroMax Presentation 3

4 HydroMax Technology Patented breakthrough gasification technology developed by Alchemix Corp. 5 years of private investment & development work 4 patents with 240 claims of inventions Innovative chemical pathway to produce syngas (CO+H 2 & hydrogen (H 2 )) Laboratory & bench-scale demonstrations have proven basic science Technology and capital cost estimates validated by independent, reputable third party evaluators (Aker Kvaerner) Diversified Energy has invested in, and holds a license to the HydroMax technology Major risk management program is currently underway Pursuing Government funding & support to accelerate technology development 3 Government projects awarded to date Technically Sound, Economically Feasible, and Environmentally Friendly GTC 2007 HydroMax Presentation 4

5 HydroMax Technical Overview Oxidation Cycle Cooled Lining Steam Injection H Slag (FeO 2 O + Fe H 2 + FeO Increasing) Refractory Lined Hearth Fe/Sn Melt (Fe Decreasing) % Feed Rate (k-mol/sec) Syngas (H 2 Rich) Steam Coal/Air Injection Injection Slag (FeO Decreasing) Fe/Sn Melt (Fe Increasing) Reduction Cycle Syngas (CO Rich) Coal/Air Injection Coal + FeO CO + Fe Coal + O 2 CO 2 + heat Carbon Monoxide Steam Time (minutes) 2.5 Hydrogen 2.50 Coal Hydrogen Carbon Monoxide %Fe in Melt % Fe in Melt % FeO in Slag %FeO in Slag Time (minutes) Oxidation Reduction Syngas Rate (k-mol/sec) HydroMax uses a Two-Step Process for Creating H 2 & Syngas that can be cyclic (separate cycles) or continuous: Step 1: Oxidation. Steam reacts with molten iron to form iron-oxide & release H 2 Chemistry: H 2 0+Fe Fe0+H 2 Step 2: Reduction: Carbon fuel reacts with iron-oxide to produce Syngas Chemistry: FeO+C Fe+CO(endo) C+1/2O 2 CO (exothermic) Cyclic Operation Separates Syngas Streams The Fundamental HydroMax Chemistry is Identical to Conventional Gasification, However, the Pathways are very Different GTC 2007 HydroMax Presentation 5

6 HydroMax Features and Benefits CO and H2 Produced in Separate and Distinct Streams Reduced gas handling/cleaning equipment needed Output flexibility hydrogen, F-T, Electricity, process heat Lower capital costs Basis: A-K Report 10/02 Maximizes hydrogen production from coal Feedstock Flexibility High thermal inertia enables use of everything from coal to biomass and high moisture content MSW Sulfur Removal via Tin Sulfide Ability to utilize high sulfur coals More hydrogen available to be used Simple and Proven Reactor Design Improved reliability Lower capital costs Robust economics Easily Scalable Industrial Applications HydroMax Design Offers Output Flexibility, Robust Feedstock Accommodation and Attractive Economics in a Simple, Compact Design GTC 2007 HydroMax Presentation 6 DEC00352

7 Current HydroMax Funded Programs DEC has been awarded 3 separate Government funded programs in the last several months Hardware Programs 1). U.S. Department of Energy Industrial Gasification Phase I SBIR Objective: Reduce natural gas consumption through coal gasification Project partner: CertainTeed Scope: Bench-scale tests at PMET (~6 Diameter Reactor) using PRB and Ill#6 coals System design for CertainTeed industrial application 2). State of California Public Interest Energy Research (PIER) Objective: Reduce CA natural gas consumption through biomass gasification Project partners: Evergreen Pulp Inc., EERC Scope: Design, build, and install a small HydroMax reactor at Evergreen Pulp to offset the plant natural gas usage Design/Analysis Programs 3). U.S. Department of Defense Alternative Fuels Phase I SBIR Objective: Design a transportable gasification to liquid fuels system to support forward deployed military operations Project partner: Velocys Scope: Feasibility and system design study for portable liquid fuel production using HydroMax (gasification) and Velocys (FT) technologies GTC 2007 HydroMax Presentation 7

8 U.S. Department of Energy Industrial Gasification SBIR Project DEC00352 Two Small-Scale Bench HydroMax Tests at PMET using Ill#6 and PRB coals in the early 2008 timeframe Preliminary System level plant design for CertainTeed Application Coal Gas Quench Heat Exchanger 0.1m Diameter HydroMax Reactor Steam/Pet Coke Inlet Lances Syngas Outlet Reactor #1 SnS Furnace Coal Prep Tin Roast Sulfur Heat Exchanger Filter Gas Cleanup Air Gas Quench Valves Compressor Steam Generator Reactor #2 Tin Roast SnS Gas Quench Sulfur Heat Exchanger Ash Particulate Air Stream Syngas to Dryer Combustors Existing test set-up at PMET Reactor #3 SnS /Steam Stream Syngas Stream Tin Roast Sulfur Coal/Ash/Sulfur Stream Notional System Plant Layout GTC 2007 HydroMax Presentation 8

9 HydroMax State of California Development Project GTC 2007 HydroMax Presentation 9

10 HydroMax State of California Development Project (Cont) DEC00352 HydroMax Demonstration Reactor size: ~ ø0.5m HydroMax Reactor Process: Continuous due to high moisture content feedstock HydroMax system on-site at EPI for a 12 month demonstration period starting ~November 2009 Wood Fines (50% Moisture Content) Steam Conveyor Warm Moist Air Wood Hopper Air Syngas Air Wood Natural Gas Steam Throttle Valve Quench Heat Exchanger Air Compressor HydroMax Reactor Slag Air Compressor Dry Syngas Storage Tank Throttle Valve Thermal Oxidizer Heat exchanger provides hot air for drying of wood prior to injection into reactor Syngas is input to Thermal Oxidizer to offset Natural Gas Consumption GTC 2007 HydroMax Presentation 10

11 U.S. Department of Defense Portable FT-Fuels SBIR Program DEC m Reactors Provide split syngas stream of H 2 and H 2 /CO mix Reactors sized to meet all system power and heating needs in addition to providing syngas for FT backend HYDROMAX PLANT Steam Feedstock/ O2 or Air SnO 2 Pump HydroMax Reactor 1 HydroMax Reactor 2 HydroMax Reactor 1 VELOCYS F-T PLANT Sn Roaster SO 2 CO + 2H 2 Gasoline/Naptha JP-8 Power Generation For Compressor/Pumps/Other SnS Removal Filter Heat Pump Distillation Syngas Cooler Gas Cleanup -AGR -Scrub -Misc CO2 Other ZnO Guard Bed H 2 (Ox. Cycle) H 2 (Ox.) H 2 (Ox.) Syngas Stream Combiner (2:1 H 2 /CO ratio) Syngas Compressor FT Synthesis Reaction Pump Partial Boiling H 2 Hydrocracker CO + 2H 2 Re-Feed C 1 C 5 C 5 + H 2 Heat CO/H 2 Steam Generator CO/H 2 (Red. Cycle) Heat Ex Sat. Steam Distillation OUTPUT: -(CH2)n- + H2O Control valves blend stream to desired 2/1 H 2 :CO ratio Waste heat from FT backend preheats water to reactor for better system performance HydroMax Feedstock & Output Flexibility due to High Thermal Inertia of the Molten Metal Bath Ideal for Portable F-T Plant GTC 2007 HydroMax Presentation 11

12 HydroMax Development/Testing History Steam/Pet Coke Inlet Lances 0.1m Diameter HydroMax Reactor Syngas Outlet PMET 0.1m Reactor Test Steam Injection Rate Demonstration Ideal Flow Rate ~Mach 0.49 Furnace PMET 0.1m Reactor Test Hydrogen Stream Production Demonstration Blew Steam in FeSn Bath CSIRO 0.3m Reactor Test Proof-of-Concept Test Cyclic Process Demonstrated PMET 0.1m Reactor Test Lock Cycle Test Carbon & Steam Injection Future HydroMax Testing Systematic Approach to Engineering Bench Testing Results in a Well Understood Process Backed by Analysis Correlation PMET 0.1m Reactor Test Continuous Cycle Test Demonstration Carbon & Steam Injection DOE SBIR (Early 2008) CA PIER ( ) GTC 2007 HydroMax Presentation 12

13 HydroMax AspenPlus Analysis Model Set ALLOY OXYGEN2 REDUCTN B3 B1 OXIDTN CFEED RYIELD SYNGAS FLUX MIX MOLTEN GAS CHNS MELT REDALLOY B4 OUT STEAM Oxidation OXYGEN MELT Reduction RETURN ALLOY Lock Cycle OXYGEN2 OXIDTN REDUCTN B3 B1 FLUX MIX MOLTEN GAS SYNGAS WATER STEAM OXYGEN MELT PETCOKE REDALLOY B4 OUT Lock-cycle defined as repeatable cycle where slag and alloy conditions are the same for the end of oxidation as the beginning of reduction. Lock-cycle RETURN model inputs water in fuel as separate stream A HydroMax AspenPlus Model Exists for Accurate Prediction of HydroMax Operations, Test Correlation and Optimization GTC 2007 HydroMax Presentation 13

14 HydroMax Model Correlation to Test Data Predicted Performance vs Test Data Volume % H2 -Ox. H2O - Ox. H2 - Red. H2O - Red. CO - Red. CO2 - Red. Test Analysis Initial Comparison of AspenPlus/FactSage Model with Test Data Shows Good Correlation During Oxidation, and Fair Correlation During Reduction GTC 2007 HydroMax Presentation 14

15 HydroMax Analysis Results - Wood Feedstock Output Versus Reactor Diameter - DEC00352 Optimum slag/melt depth is a function of reactor diameter based on lessonslearned from the smelting industry H2 and CO output doubles ( kmols/hr) while reactor diameter only increases 43% (from ø3.0m to ø4.3m) H 2 + CO Output (kmols/hrs) Wood Feedstock Dry Wood Feed Rate (mt/hr) Reactor Diameter (m) 0 GTC 2007 HydroMax Presentation 15

16 HydroMax Analysis - Various Feedstock - DEC00352 Input (kmols/cycle) Oxidation Cycle Performance Petcoke Dry Wood 25% mc Wood H 2 H 2 O O 2 Steam PRB Coal (High MC) Illinois Coal (High Sulfur) Shows decreasing utility for standalone oxidation cycle for Feedstock with moisture contents (mc) greater than ~25% (reduction cycle cannot convert FeO back to Fe to balance lock-cycle) Analysis for a ø1.0 meter Reactor Reduction Cycle Performance 60 Model predicts very high H 2 /H 2 0 and CO/CO 2 ratios during reduction 2.3 to 2.9 for H 2 /H 2 O 6.9 to 8.6 for CO/CO 2 ) Output (kmols/cycle) Petcoke Dry Wood 25% mc Wood PRB Coal Illinois Coal H 2 H 2 O O 2 CO CO 2 GTC 2007 HydroMax Presentation 16

17 HydroMax as a Hydrogen Producer - Advantages - DEC00352 Input (metric tonnes) HydroMax HydroMax vs Commercial vs. Comm. E-Gas Gasifier (PRB Coal) Predicted HydroMax Performance versus commercial gasifier performance with PRB coal 0 Inlet Feedstock Inlet Inlet Oxygen HydroMax HydroMax kw (theoretical) (theoretical) Comm. E-Gas Comm. Comm. Gas Gasifier Gas (proven) (proven) HydroMax vs Commercial Gasifier (PRB Coal) Used 1.0 mt/hr of PRB coal as basis for comparison. Output (kmols/cycle) Output H 2 Output CO Output H 2 O Output CO 2 HydroMax (theoretical) Comm. Gasifier Comm. Gas (proven) HydroMax Requires Less Input Products ( Consumables ) while Producing Output Products Comparable to Existing and Proven Gasifiers GTC 2007 HydroMax Presentation 17

18 HydroMax Analysis Results - Wood Feedstock Performance - HydroMax Performance Using Wood Feedstock Performance Ratio (kmols/kmols wood) Produced 0.91 Produced 0.33 Consumed H 2 /wood CO/wood O 2 /wood GTC 2007 HydroMax Presentation 18

19 HydroMax Analysis Results - Output Sensitivity to Slag Concentration - SiO 2 Precipitation Region Output (kmols/hr) Output Variation with Slag Concentration Continuous Mode Operating Sweet Spot SiO 2 Precipitation Region Air Consumption (kmols/hr) % 35.00% 40.00% 45.00% 50.00% 55.00% 60.00% 65.00% 70.00% FeO Concentration in Slag (%) H 2 CO Air Syngas Output (H 2 and CO) and Consumption (Air) for Continuous Mode is Constant When HydroMax Operated Within Sweet Spot (40% - 60% FeO Concentration) 300 GTC 2007 HydroMax Presentation 19

20 HydroMax Summary HydroMax is a breakthrough technology that offers an efficient, less costly, feedstock flexible carbon gasification process Previous HydroMax tests have successfully demonstrated the fundamental science and molten-metal (FeSn) process Three funded contracts being executed by Diversified Energy U.S. Department of Energy U.S. Department of Defense State of California HydroMax interest spans multiple applications Industrial scale natural gas replacement Distributed liquid fuels production Modeling and analyses indicate key technology discriminators (water consumption, CO 2 emissions, etc.) HydroMax appears to be ideally suited for industrial scale applications Low-cost at small scales High temperature (1300C) operations results in very clean syngas output Next steps include contract execution of currently funded programs, system scale-up, system integration, and commercialization GTC 2007 HydroMax Presentation 20