The BGL-Commercial Plants and Pilot Testing. Status and Perspectives on Envirotherm BGL-technology. Hansjobst Hirschfelder

Transcription

1 The BGL-Commercial Plants and Pilot Testing Status and Perspectives on Envirotherm BGL-technology Hansjobst Hirschfelder 6 th International Freiberg Conference on IGCC &XEL Technology May 19 22, 2014 Dresden/Radebeul, Germany 1

2 Envirotherm Group Environmental technologies company offering engineering services to customers in the energy, air pollution control and water sector CLEAN ENERGY CLEAN AIR (Air pollution control) CLEAN WATER Envirotherm Modern Gasification Technologies Envirotherm Highly Efficient Flue Gas Cleaning Technologies Bamag International Water Purification and Waste Water Treatment Technologies Envirotherm Multi-Purpose Combustion Technologies Envirotherm Production and Distribution of Honeycomb SCR Catalysts Bamag MENA Waste Water Treatment Technologies Envirotherm Sewage Sludge Incineration 2

3 Envirotherm s Involvement in Gasification BGL advanced pressurized, slagging fixed bed gasification (former British Gas/Lurgi, today co-ownership of Envirotherm and ZEMAG) CFB atmospheric gasification in the circulating fluid bed involvement in design build, test and further develop of the demonstration plant at the IEC in Freiberg 3

4 CFB Gasification 4

5 The CFB Gasification Process: Development and References Fluid bed technology was developed in the early 1920s (original Winkler fluid process) Lurgi developed the circulating fluid bed (CFB) applying high slip velocity, introduced CFB to power plants and applied the process to gasification of various feedstock Fluid beds are operated at temperatures below ash softening point (i.e C) with an even temperature profile in the reactor and excellent heat and mass transport Proven technology with numberless references Envirotherm acquired the CFB gasification process from Lurgi/Lentjes in 2003 Envirotherm s commercial reference plants include - first CFB gasification in the cement industry Ruedersdorf, Germany - CFB gasification of demolition wood Geertruidenberg, The Netherlands 5 - CFB gasification of high ash Indian coal Barbil, India

6 The CFB Gasification Process: Key Benefits fuel flexibility: nearly all types of (high ash) coal and other carbonaceous fuels, e.g. waste gasifier vessel is made from mild steel modular design (spare/reliability) atmospheric circulating fluidized bed gasifier, well suited for fuel gas production air blown gasifier, no ASU required low calorific syngas excellent heat and mass transfer due to high turbulence of inert bed inventory high thermal stability high carbon conversion HP steam production bottom ash can be reutilized low requirement for fuel preparation Fuel CFB Gasifier Nozzle Grate Ash Crude Gas to Consumer Recycling Cyclone Seal Pot Gasification Agent (Air + Steam) 6

7 CFB Selected References: Jindal Steel & Power, India Barbil / Orissa, India: two CFB gasifiers in parallel fuel: domestic Indian coal up to 40% ash, 8% moisture per gasifier: 23t/h coal, 50,000 m³ n /h syngas 7

8 Superheater Evaporator CFB Selected References: Jindal Steel & Power, India Barbil / Orissa, India: Process Flow Diagram Turbine / Generator C.W. Steam Drum Solid Fuel Bed Material Deaerator CFB Gasifier Cyclone Quench Clean Fuel Gas Air Air Air Sec. Air Prim. Air C.W. Seal Pot Radiation Pass Wet ESP Recirculation Pump Air C.W. Bed Ash Ash Water Tar Dust Water 8

9 BGL Gasification 9

10 Introduction to BGL The improved slagging version of the existing Lurgi Gasifier was jointly developed with British Gas from 1974 onwards in Westfield/Scotland to: - have a reactor to produce non-leachable vitreous slag rather than dry ash - improve specific reactor throughput - increase fines content acceptable in feed - reduce steam consumption and consequently gas condensate production - recycle tars/oils to extinction - increase CO/H 2 -yields Technology successfully tested with a wide range of coals and proven on commercial size gasifier units until 1991 First commercial plant at Schwarze Pumpe, Germany, from 2000 until 2007, using a broad range of feedstock including waste Technology jointly owned by Envirotherm GmbH and ZEMAG Clean Energy Technology GmbH 10

11 The BGL Gasification Process: Key Benefits Operational Extensive development history High cold gas efficiency between 82% and 93% / high specific throughput Low oxygen consumption (ca kg / kg Coal) Low steam consumption (ca kg / kg Coal) Lower aqueous liquor production Fuel flexibility (nearly all coal types and other types of fuels (e.g. waste) can be processed) Excellent load following capabilities Modularity (spare/reliability) Slag as by-product is non-leachable (vitrified) and can be utilized (road work) Capital/Investment Simple gasifier design (no exotic materials, no sophisticated heat exchangers) Smaller air separation unit (ASU) due to low oxygen requirements Raw Gas ºC Drying and Pyrolysis < 700ºC Gasification 700 1,100ºC Combustion 2,000 2,100ºC / WASTE 11

12 BGL Gasifier Process Applications (overview) Input Gasification Additional Processing Conversion Products Air Separation Unit CO2 IGCC Power Oxygen Methanol Synthesis Chemicals/ Gasoline Coal BGL Gasifier Shift Reactor Gas Clean-Up Methanation Synthetic natural gas Alternative Feedstock Fischer Tropsch Synthesis Fuels Ammonia Synthesis Fertilizers Typical BGL Gas Composition for bituminous coal H 2 33 % CO 56 % CO 2 4 % CH 4 7 % BGL Process has clear investment and operational advantages in a wide range of application. According to gas composition BGL is well suited to SNG production because of its high efficiency and the presence of CH 4 in product gas 12

13 Commercial BGL China 13

14 BGL in China - Hulunbeier Client Location of facility Application Feedstock Features Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier, Inner Mongolia, PRC Hulunbeier, Inner Mongolia, PRC Syngas for the production of 500,000 t/year Ammonia, 800,000 t/year Urea Domestic dried and briquetted lignite Two (2) + one (1) BGL gasifiers (40 barg operating pressure) Synthesis gas production 119,000 Nm³/h Status - Installation of entire plant completed in Gasifiers have been operated for limited time (limited feedstock) - Technical issues with plant units (briquetting unit and ASU) 14

15 BGL in China - Hulunbeier 15

16 BGL in China - Hulunbeier 16

17 BGL in China - Yituo Client China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC Location of Facility Luoyang, Henan Province, PRC Application Fuel gas for industrial complex Substitution of 18 existing fixed bed low pressure gasifiers Feedstock Local hard coal Features One (1) + one (1) BGL gasifiers Gas production 43,000 Nm³/h Start-up 2014 Status Detailed Design finished in 2011 Work in progress 17

18 BGL in China China National Coal Client Location of facility Application Feedstock Features China National Coal Development Co. Ltd, Beijing, PRC China National Coal Corp, Beijing, PRC Ordos Tuke, Inner Mongolia, PRC Syngas for the production of 1,000,000 t/year Ammonia, 1,750,000 t/year Urea bituminous coal Five (5) + two (2) BGL gasifiers (40 barg operating pressure) with stirrers Synthesis gas production 295,000 Nm³/h Start-up 2013 /

19 Commercial BGL India 19

20 BGL in India Client Shriram EPC Ltd., Chennai, India Location of Facility Dharma, Orissa, India Application Features Syngas for the production of synthetic ammonia Two (2) BGL gasifiers, one relocated from Germany, second gasifier built identically to relocated one, using high ash domestic hard coal Raw gas production 150,000 Nm³/h Feedstock Indian high ash coal Start-up 2016 Status on hold 20

21 Demonstration Plant Freiberg 21

22 BGL Gasifier Pilot Scale Slagging Gasifier in Freiberg, Germany Pilot scale gasifier installed at the IEC, TU Bergakademie Freiberg, next to HP-POX and STF unit Scale down design of pilot plant was challenging as certain process equipment had to be newly designed and adapted to make it fit for purpose Commissioning Q

23 BGL Gasifier Pilot Scale Slagging Gasifier in Freiberg, Germany Pilot plant comprises of coal intermediate storage, feeding system, reactor, gas cooling and gas water system Gasifier features: m inner diameter - three tuyères (inlet nozzles for gasification agents) - reactor and quench in one vessel Characteristics / Consumption figures: - Operating pressure 40 bar t/hr bituminous coal (Polish coal, bench mark) Nm³/hr O 2 consumption kg/hr steam consumption - Reactor capacity approx. 8.5 MW (LHV gas) - Approx. 2,300 Nm³/hr product gas 23

24 BGL Gasifier Pilot Scale Slagging Gasifier in Freiberg, Germany 24

25 Research and Development Principal R&D goal: investigation of liquid slag behaviour under high pressure characterisation of slag for a variety of fuels with different ash compositions Further, the facility allows for testing of coals to demonstrate the applicability of unknown feedstock without interrupting the operation of a commercial plant. Thus the risk for an operating company to loose valuable production capacity while testing components or process adaptions is significantly lowered. The plant allows for a full HMB, to allow a for a lower safety margin in designing commercial facilities. Minimize tar/oil in gas target: increase usable gas output for IGCC application Maximize tar/oil in gas target: recovery and sale 25

26 Thank you for your attention! Questions? 26