CUSTOM-MADE COMPONENTS FOR GASIFICATION PLANTS

Transcription

1 CUSTOM-MADE COMPONENTS FOR GASIFICATION PLANTS Bruno Bülow 9th Gasification Conferece India 2018 on November, Dwarka, New Delhi

2 AGENDA General & Organization - History Profile MSW / Biomass Black Liquor Coal and Petcoke POx page 2

3 FROM KASSEL WORLDWIDE SUCCESSFUL ARVOS GMBH SCHMIDTSCHE SCHACK 350 employees, order intake more than 150 Mio. /a Kassel Headquarter & Workshop SCHMIDTSCHE SCHACK Düsseldorf SCHMIDTSCHE SCHACK Kobe, Japan SCHMIDTSCHE SCHACK Wexford, PA SCHMIDTSCHE SCHACK Own fabrication in Kassel, Germany India Kapil Girotra C/o Oranje Kracht Engg. Pvt. Ltd. A- 161, Main Road, Opp. Honda Hallmark Showroom Wagle Indu. Estate (west), Thane , India page 3

4 REPRESENTATIVES IN ALL MAJOR MARKETS Slovak Republic Russia & CIS Mexico United States & Canada Chile Argentina Brazil Czech Republic Spain Uruguay Egypt Turkey Saudi Arabia & GCC Iran China India Korea Japan Taiwan Thailand Singapore Support to the sales team: 21 Representatives working for SCHMIDTSCHE SCHACK page 4

5 SCHMIDTSCHE SCHACK ARVOS GMBH COMPANY HISTORY 2014 Triton acquires Alstom's Auxiliary Components business 2001 ALSTOM Power Air Preheater GmbH merges into ALSTOM Power Energy Recovery GmbH 2000 merger of the power sectors of Alstom and ABB 1998 GEC ALSTHOM listed at the stock exchange in London, Paris and New York 1995 merger of SHG with SCHACK into SHG-SCHACK GmbH REKUPERATOR SCHACK GmbH 1989 acquisition of the EVT-Gruppe by GEC ALSTHOM 1979 acquisition by EVT Stuttgart 1956 acquisition by DIDIER AG 1910 Founding of Schmidt sche Heissdampf -Gesellschaft mbh page 5

6 ARVOS GMBH MAIN OFFICE KASSEL SCHMIDTSCHE SCHACK ENGINEERING & FABRICATION 250 EMPLOYEES, ENGINEERING HOURS WORKSHOP HOURS page 6

7 SCHMIDTSCHE SCHACK PROCESS HEAT TRANSFER INDUSTRIAL HIGH-PRESSURE/HIGH-TEMPERATURE PROCESSES PROCESSES HEAT TRANSFER SOLUTIONS Ethylene Gasification SNG Methanation Ammonia, Methanol, Hydrogen Carbon Black DRI Metallurgy Nitric Acid Various Municipal Sludge Incineration Collaboration with process developers in R&D and engineering for new processes Transfer Line Exchangers Syngas Coolers (Radiant + Convective) Waste Heat Recovery Systems including Steam Superheaters Process Gas Coolers, Convection Banks, Fired Heaters, HP Superheaters CB Air Preheaters, Quench Boilers, Tailgas Boilers, Rotary Dryers Convection Banks Waste Heat Recovery Systems Fired Heaters, Waste Heat Boilers for FCC Units Waste Heat Recovery Systems Solutions, Sophisticated Process Components page 7

8 CLASSIFICATION OF SYNGAS COOLING TECHNOLOGIES Entrained Flow Fluidized Bed Moving Bed ~1500 C Sticky Ash Zone ~1000 C ~500 C Cold Gas Quech Chemical Quech Water Quech Connective Syngas Cooling Radiant Cooling Radiant Cooling Water Quech Full Water Quech page 8

9 SYNGAS COOLER FOR ABENGOAS FULCRUM MSW GASIFICATION SCHMISCHE SCHACK Scope of Supply: Burner POX Refractory RSC with Sump, CSC Steam Drums Separate Superheater with internal bypass Ash Handling System Services Delivery: Jan 19/ Mai 19 page 9

10 SYNGAS COOLER FOR COAL AND BIOMASS GASIFICATION The Radiant Syngas Cooler (RSC) design principle put into service in 3 coal gasification. We delivered new additional heating surface for the TAMPA RSC in year 2006 and recently new tubes for the CSC s The design concept has been developed further and today offered for several biomass and municipal waste gasification projects. Radiant Cooler for a Coal Gasification Plant Convective Cooler for a Biomass Gasification Plant page 10

11 SYNGAS COOLER FOR 6 MW BIOMASS GASIFICATION Convective Type Heat Exchanger 1100 C Inlet temperature 25 g/nm³ ash from Charcoal Main Advantage Incorporates the lessons learned from various syngas cooler arrangements in many gasification plants Avoids cost driving arrangements like complex heating surface arrangements, high alloy materials, or pure forced circulation systems page 11

12 ONE TRAIN BLG Black Liquor GASIFIER GAS COOLER STEAM GENERATOR Cooling water ABSORBER LIME KILN Synthesis of product Oxygen BFW Fuel gas REACTOR Raw syngas LP Steam Oxygen (optional QUENCH LIME KILN Green Liquor CO 2 + H 2 S Weak Wash Condensate Amine solution LP Steam CHP (Gasturbine/Gas engine w. HRSG) page 12

13 SCHMIDTSCHE SCHACK SCOPE OF SUPPLY FOR BLG BLG island and installation Deep expertise in technology and equipment Equipment quality assurance Long established reputation as a top-quality supplier to the syngas industry Support and Services during and after construction and startup page 13

14 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN Top Oval Header Inner Tube Outer Tube Bottom Oval Header Design Principle Double Tube Advantages in fire- and water tube boiler designs due to well-defined flow paths on both sides Intensive cooling of each tube Straight tubes for easy gas side cleaning Downflow minimizes creation of fouling Low water volume for faster response to load variations page 14

15 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN Riser Header Refractory Water/ Steam Outlet Downcomer Distributor Special features Gas inlet temperature up to C Applicable for high gas and dust load Resistant against erosion on tube inlet Ferrules are not needed Water Inlet page 15

16 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN Gas Flow Pattern Funnel-tube inlets guarantee an equal gas distribution into each individual tube Low turbulence No gas recirculation Limited erosion rate No temperature peaks page 16

17 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN Steam / Water side circulation Lower density of the water steam mixture compared to the density of the water in the downcomer pipes drives the circulation The overall mass flow through the system is limited by the pressure drop in the system page 17

18 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN Design Principles Oval Header: Flexible Member The oval header acts as a flexible member that compensates for the difference in thermal expansion between the inner and outer tube, reducing the mechanical stresses on the system, especially at the inlet to the transfer line exchanger. (exaggerated elongation displayed Mechanical and thermal stresses are reduced by using thin-walled oval header, pipes and tubes. thin-walled system is more flexible and temperature gradients across the wall thickness are lower. protecting the magnetite layer by mitigating and / or eliminating high thermal and mechanical stress page 18

19 SCHMIDT SCHE SYNGAS COOLERS BIGGEST GASIFICATION PLANT WORLDWIDE Reference: Jamnagar 10 Schmidt sche Syngas Coolers ordered for the world's biggest gasification plant under construction in India Biggest and heaviest Syngas Coolers ever built Feedstock: Petcoke/Coal Gasification process: CB&I (E-Gas) Each syngas cooler has a transportation weight of 700 t and a length of 45 m page 19

20 SCHMIDT SCHE SYNGAS COOLERS FOR INDIA 700 t Schmidt sche syngas cooler transport to Jamnagar site. Designed and manufactured in Kassel, Germany. page 20

21 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN FOR THE ETHYLENE PRODUCTION Ethylene Feedstock 60 % of the globally produced plastics is generated with the help of Schmidt sche Transfer Line Exchangers TLEs delivered page 21

22 SCHMIDT SCHE OVAL HEADER/ DOUBLE TUBE DESIGN Based on SCS s success with Schmidtsche Oval Header Double Tube heat exchangers for ethylene plants, SCS applied this design in syngas coolers for gasification processes. page 22

23 SYNGAS COOLER FOR PARTIAL OXIDATION page 23

24 SYNGAS COOLER FOR PARTIAL OXIDATION page 24

25 RETROFIT AND DESIGN STUDIES IMPROVEMENTS IN EXISTING GASIFICATION PLANT Retrofit and Design Studies Analyze bottlenecks via recalculation Improve efficiency and reliability Give reliable information for financial planning Ensure the overall success of a project SCS experts are pleased to share their experience with plant owners and operators to identify ways of optimizing the operation of their process heat recovery systems. page 25

26 SUMMARY SCHMIDTSCHE SCHACK has more than 50 years experience in design and fabrication of Syngas Cooling Systems for gasification processes Well-proven, best fitting and continuously optimized heat transfer solution are available and offered for various gasification process types Design studies support the project from the very first beginning in order to find the optimal solution Design, engineering, manufacturing and project management is in one hand and thus guarantees the overall success page 26

27 THANK YOU FOR YOUR ATTENTION!