Customised Gasifier Feed Pumps. Daniel M. Nägel FELUWA Pumpen GmbH

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1 Customised Gasifier Feed Pumps Daniel M. Nägel FELUWA Pumpen GmbH

2 Hydrostatic displacement Pumps Oscillating Pumping Characteristic Piston Pump The conveyed fluid is in contact with sliding seals Diaphragm Piston Pump Hermetically sealed! The conveyed fluid is not in contact with sliding seals V L = Leckagevolumen Pressure air vessel 2. Safety valve 3. Discharge valve 4. Suction valve 5. Suction air vessel 6. Conveyed fluid 7. Piston seal 8. Piston 9. Crank shaft 10. Diaphragm 11. Hydraulik oil 12. Plunger 13. Plunger seal 14. Crosshead

3 Traditional hydraulically actuated Process Pumps Hydraulically actuated diaphragm pump Typical diaphragm clamping (risk of sedimentation and damaging in the clamping area) Disadvantage: The utilisation of traditional diaphragm pumps is limited when it comes to the handling of solids-carrying i fluids. In the event of a diaphragm failure the conveyed fluid will penetrate t into the hydraulic drive end and come in contact with sliding seals and the cylinder face, which in turn results in considerable damaging (cost!).

4 Traditional Double Diaphragm Piston Pump In order to get rid of the hidden danger in the first generation diaphragm pumps, FELUWA tried to developed a kind of double-diaphragm diaphragm pumps, as shown above. This design concept ist good, but it can not solve the problem fundamentally. The two diaphragms have the same shape and are installed in the same way. When one of them is broken, the other one will be worn out soon.

5 Stresses of Double Flat Diaphragms 1,00 0,83 0, ,50 0,33 0,17 0,00

6 Evolution of Pumps MULTISAFE Hose-Diaphragm Pump Outlet Outlet Piston in rear position = End of suction stroke Piston in front position = End of discharge stroke Piston Piston Inlet Inlet

7 MULTISAFE Double Hose Diaphragm Pump Bionics in the construction of pumps Inner hose diaphragm Outer hose diaphragm Hydraulic load onto hose-diaphragms Hydrostatic pressure by means of surrouding hydraulic fluid Identical pressure inside and outside ofthe hose diaphragm dap ag The hose diaphragm is not subject to physical load, but to static load only The conveyed fluid is in contact with the hose diaphragm only Hydraulic fluid Incompressible coupling fluid between both hosediaphragms (compatible to the conveyed fluid)

8 Stresses of Double Hose-Diaphragms 000 0, , , , , , ,00

9 Customised Gasifier Feed Pumps Other significant features of FELUWA double hose-diaphragm pumps Check valve Pressure switch Vent valve Hose failure monitoring As shown in the photo on the left side, the gap between the inner and the outer hoses is connected to a pressure switch. Before the pump is put into operation, the gap is to be filled with liquid to get rid of air. When the pump is started up, air and liquid are vented and drained from the air venting valve with the pressure increase in the pump head. At this time, there is no pressure in the gap between the two hoses. When any of them is broken, the pressure inside the gap will go up, then the pressure switch will give out an alarm. Such a hose failure alarming system is very sensitive, instant and reliable.

10 Customised Gasifier Feed Pumps Valves Necessity of Double Valves

11 Ball Valve vs. Cone Valve Valve ball Ball guide Ball Valve Guide bush Cone top guide Compression spring Rubber ring Cone Valve Valve seat (reversible) Cone valve disc Valve seat Cone guide

12 Unexpected Particles and Foreign Matters Found in Regular Coal Slurry

13 Special Configurations - Double Valves - Double valves are used for critical processes which do not allow interrupted flow. Double valves provide double safety against smallest leakages. Double valves reduce valve wear and increase maintenance intervals.

14 Customised Gasifier Feed Pumps Pump Speed

15 Wear Related to Speed

16 Characteristics of displacement Pumps Single-acting one-cylinder pump Double-acting one-cylinder pump Three-cylinder pump

17 Unique pulsation dampener - Kinematic Irregularity - FELUWA PULSORBER + (PULSORBER with integrated air vessel and automatic filling device) Provides optimum protection against water hammer. Solenoid valve (v1) Solenoid valve (v2) Air outlet Hose-diaphragm condition monitoring Gas cushion Level indicator FELUWA hose-diaphragm pulsation dampener Double hose-diaphragm Actuation fluid Discharge pipe Compressed air Client s compressed air network Bladder-type accumulator Fluctuating hydraulic fluid Medium

18 Permanent monitoring of all Permanent monitoring of all components and operating parameters that are relevant to functioning

19 Quintuplex MULTISAFE Process Pumps Permanent Operation Monitoring Operation Monitoring: The detection of inadmissible Option: Automatic behaviour operating conditions safe guards against sudden under alarm condition failure. Pre Compression Hydraulic Temperature Suction Pressure! Monitoring System Local Temerature of Flow of Gearbox Oil DCS Motor Temperature Temerature and Flow of Intermediate Gearbox Oil Frequencyenc Converter SIEMATIC S7 300 Remote Service

20 Quintuplex MULTISAFE Process Pumps Permanent Operation and Condition Monitoring of all Components that are relevant to Fuctioning Condition Monitoring: The detection of incipient wear of typical wearing parts reduces maintenance cost and increase life span. Valve Wear Option: Automatic behaviour under alarm condition. Monitoring System Local DCS Hose Diaphragm Frequencyenc Converter SIEMATIC S7 300 Remote Service

21 Customised Gasifier Feed Pumps COAL GASIFICATION High Pressure Gasifier Feeding Configuration Options

22 COAL GASIFICATION - Configuration Options 2 Gasifiers - 4 Burner System 1 2 Pump Q p P Units m³/h MPa kw FELUWA Quadruplex HDP ZGL 300/250 2 K SM 460 HD

23 FELUWA HDP Hose-Diaphragm and MULTISAFE Pumps with FHDP Pulsation Dampener for Coal Gasification Front: FELUWA Hose Diaphragm Pump ZGL 300/250-2K 180-4SM 460 HD Rear: FELUWA MULTISAFE Process Pump TGK 400/400 K 150 DS 100 HD-U

24 COAL GASIFICATION - Configuration Options 2 Gasifiers - 1 Burner System 2 1 B A P0201 B P0201 A Pump Q p P Units m³/h MPa kw Triplex FELUWA MULTISAFE TG 180/200 K 180 DS 100 HD

25 FELUWA MULTISAFE Hose-Diaphragm Pumps with PULSORBER Pulsation Dampener for Coal Gasification Ti Triplex FELUWA Hose Diaphragm Pump ZGL 300/250-2K 2K 180-4SM 460 HD

26 FELUWA Pumps in Coal Gasification Industry In China, a high number of coal gasification plants are used to produce syngas. Nowadays, FELUWA s share of reactor feeding pumps is about 90%. The coal gasification plants are operated with a total of 361 FELUWA pumps With an overall driving power of 70,135 kw, they are pumping a total volume of 14,491 m³ coal slurry per hour at pressures up to 100 bar By means of the FELUWA pumps, 575 million cubic meters of syngas (in terms of CO2 and H) are produced per day The pumps are regarded as the most important item within the plant and none of them has ever caused an emergency shutdown of the facility.

27 Thank you for your attention - Questions? Dipl -Ing Daniel M Naegel Dipl. Ing. Daniel M. Naegel nageld@feluwa.de