The Entrained Flow Gasifier in the KIT bioliq process

Transcription

1 The Entrained Flow Gasifier in the KIT bioliq process Thomas Kolb, Bernd Zimmerlin Engler-Bunte-Institut, Chemische Energieträger Brennstofftechnologie, EBI ceb Institut für Technische Chemie, Vergasungstechnologie, ITC vgt KIT Universität des Landes Baden-Württemberg und nationales Forschungszentrum in der Helmholtz-Gemeinschaft

2 De-centralized / central concept Energy densification of biomass in regional distributed plants by bioliqsyncrude production Economic conversion in large scale to syngas and further refining into fuels & chemicals Energy density: 2 GJ/m 3 25 GJ/m 3 36 GJ/m 3 2

3 Biomass Process chart biosyncrude O 2 (Steam) Gas cleaning and conditioning Pre-treatment High pressure entrained flow gasification Filter Sorption Catalyst CO 2 and water separation Syngas Slag Synfuel Fast pyrolysis biosyncrude De-central Fuel synthesis Centralized DME synthesis 3

4 Status of the bioliq project Stage I Stage II Stage III Stage IV Process Fast pyrolysis High pressure entrained flow gasification Gas cieaning and Synthesis I Synthesis II Product BioSyncrude Synthesis gas Dimethyl ether Gasoline Capacity 2 MW (500 kg/h) 5 MW (1 t/h) 150 kg/h < 100 l/h Realization State In operation In operation In operation Partners: TCI: 64 Mio.EUR 4

5 bioliq Pilot Plant Fast pyrolysis (2 MW, 500 kg/h) EFG (5 MW, 1 t/h) Synthesis (2 MW, 50 kg/h) Feed Preparation 5 Slurry Preparation Tankfarm Gas Cleaning (2 MW, 700 Nm 3 /h)

6 Pyrolysis flow chart In cooperation with: 6

7 Pyrolysis char/liquid yields Wheat straw Eucalyptus Corn Cobs Bagasse Miscanthus Corn straw Empty Fruit Bunches char and condensate fraction of different biomasses (ar) after fast pyrolysis Rape straw Liquid/solid-ratio 5:1 4:1 2:1 1,5:1 0% 20% 40% 60% 80% 100% char incl. ash condensate incl. moisture of biomass 7

8 Rheological investigation of suspension fuel for gasification Suspension Experimental Plant - SEP R&D Storage stability of fuel Sedimentation Instrumentation Corrosion, abrasion Plugging, fouling 8

9 Pressurized Atomization Test Rig - PAT Technical data: L = 3 m D = 0.3 m Optical access 3-D traverse Operating conditions: p Reactor = 1 20 bar (ü) T Liq = C M Liq = kg/h η Liq.max = 1000 mpa. s Pressurized Atomization Test Rig - PAT 9

10 SMD [µm] u Gas [m/s] Pressurized Atomization Test Rig PAT Influence of reactor pressure on SMD We = ρ gas u 2 L σ = const. M Liq = 20 kg/h (water) z = 200 mm nozzle dist. 10

11 We = 500 at 1 und 21 bar 11

12 High pressure entrained flow gasification Technical Data 5 MW (M fuel = 1000 kg/h) 40 bar (research), 80 bar (production) Gasification agents: O 2, steam Feed: biosyncrude (slurry) 12

13 bioliq Gasifier- Prozess Optimization 13

14 Mass, Species and Energy balances 14

15 Mass and species balance Balances Raw data V1 (40bar) Alteration waste water stream Raw data V14 (80bar) M balance Input ṁ [kg/h] Output ṁ [kg/h] Alteration waste water stream Difference ṁ [kg/h] ,25% 0 100,00% ,37% 0 100,00% C balance Input ṁ [kg/h] Output ṁ [kg/h] Difference ṁ [kg/h] ,58% ,58% -3 99,28% -3 99,28% H balance Input ṁ [kg/h] Output ṁ [kg/h] Difference ṁ [kg/h] ,84% ,84% ,29% -1 99,74% O balance Input ṁ [kg/h] Output ṁ [kg/h] Difference ṁ [kg/h] ,79% ,09% ,76% ,89% N balance Input ṁ [kg/h] Output ṁ [kg/h] Difference ṁ [kg/h] -1 99,66% -1 99,66% ,73% ,73% Q balance Input kw Output kw Difference kw ,88% ,36% 15

16 Integrated Research on Gasification High Pressure Atomization Process Control PAT fuel O 2 / Steam Fuel Conversion Entrained Flow Gasification REGA Raw Syngas Process Efficiency Numerical Simulation Measuring Techniques Slag Materials bioliq EFG 5MW 80 bar Helmholtz Virtual Institute for Gasification Technology Slag Control 16

17 Helmholtz Virtual Institute for Gasification Technology HVIGasTech Research Field Energy

18 Scientific Approach and Work Packages 1: 2: 3: 4: 5: 6: 7: 8: 9: 10: 11: 12: 13: 14: 15: 16: 17: 18: 19: 20: 21: 22: A = SiO2, B = Na2O, C = Al2O3 o W(A) W(B) W(C) C SiO 2 WP1 Data Evaluation Particle kinetics Slag Heat transfer Na 2 O Na 4 SiO 4 Na 2 SiO 3 Na 6 Si 2 O 7 Na 6 Si 2 O 7 Na 4 SiO 4 Na 6 Si 8 O 19 Na 6 Si 8 O 19 Na 2 Si 2 O 5 Na2SiO3 Na 2 Si 2 O SiO NaAlO2_HT NaAlSi3O8 neph ternary lines ternary points NaAlSi 3 O 8 NaAlSiO 4 Al 6 Si 3 O 13 NaAl 9 O Na 2 O NaAlO 2 Na 2 Al 12 O mass fraction 19 Al 2 O 3 carn SMIM Al2O3(s) NaAl9O14(s) WP2 Simulation LES / RANS EF-Gasifier Engineering tool for Model of reacting design and scale-up of technical multi-phase entrained flow flow gasifiers at high pressure WP3 Validation Gasification, atmo. Gasification, pressure Diagnostics 18 Thomas Kolb KIT

19 WP 1.1 Particle Kinetics Objectives Herman Andreas Philipp Data for particle conversion process at high heat-up rates, T and p Analysis of feed and intermediates (WP 3.1) Development of advanced methods Effective Reactivity as function of Particle History (WP 2.1, 2.2) Pressurized TGA Fluidized bed reactor Results Unique data for various fuels from comparison of different exp. methods Intrinsic reaction kinetics at p = atmo. as function of heating rate Generation of secondary chars at relevant process conditions Temperature dependent release of K from biochars (coop. WP 1.2) 19 Thomas Kolb KIT

20 WP 1.2 Slag Properties Objectives Kerstin Andre Guixuan Sören Extension of thermo-chemical and thermophysical databases Modelling rheological properties in dependence of slag / gas composition, T, p Validation with bioliq slags (WP 3.2) Molecular Beam Mass Spectrometer Results Inclusion of P 2 O 5, FeO/Fe 2 O 3 in the database Slag viscosity model including charge compensation and the lubricant effect Viscosity surface: SiO 2 -Al 2 O 3 -CaO at 1600 C 20 Thomas Kolb KIT

21 WP 1.3 Radiation Modeling Objectives Models for absorption coefficient / emissivity of CO 2 /H 2 O/CO/H 2 mixtures at high p Scattering coefficient for droplets and particles Implementation of models in CFD-Model (WP 2.2) Michael 21 Emissivity of CO 2 at 40 bar Gas emission spectrum at 40 bar and 1700 K Results Measurements for H 2 O / CO 2 mixtures up to 1770K at ambient pressure (DTU) New correlations for emissivity of CO 2 at pressures up to 40 bar Extension of Hottel s-graphs to high p Thomas Kolb KIT

22 WP 2.1 LES/RANS Calculations Objectives Georg LES methods for the simulation of subdomains and isolated phenomena of the gasification process Interpretation / complementation of experimental data by num. simulations Comparison of RANS and LES results Results LES study of burner near field in REGA LES of turbulent particle dispersion (testcase) 22 LES coupled with Lagrangian Particle Tracking for EFG Sub-model for vaporization of complex fuels (multiple components, emulsions) developed and integrated LES Simulation of REGA burner near-field (WP 3.1) Thomas Kolb KIT

23 WP 2.1 Numerical Simulation of EFG Objectives CFD based model of multiphase reacting system at high pressure Engineering tool for design and scale-up of technical entrained flow gasifiers Validated by lab-scale and pilot-scale experiments Marco Results Validation of REGA numerical simulation 23 Kinetics 1 Kinetics 2 Slurry trajectories in bioliq gasifier Assessment of sub-models (turbulence, turbulence-chemistry interaction) Sensitivity study for simulation sub-models REGA simulation and validation (WP 3.1) Literature-based simulation of bioliq gasifier (WP 3.2) Thomas Kolb KIT

24 WP 3.1 Experimental Validation, atm. Objectives Provide detailed EFG data (REGA) for model development and validation Local profiles of T, u, c and particles Mathematical description of single process steps Christian Results 24 Bench-scale atmospheric EFG REGA Nozzle design and spray characterization for WP 2.1, 2.2 Parameter study on fuel specification, atomization, stoichiometry for WP 2.2 Particle sampling at different conversion levels for WP 1.1 Application of diagnostics by WP 3.3 Thomas Kolb KIT

25 WP 3.2 Experimental Validation, pressure Objectives Generation of unique data sets for model validation at high pressure species, temperature, slag, balance Application of advanced diagnostic tools for process data / monitoring / control Mark Results Pilot-scale High Pressure EFG bioliq Process Data EFG bioliq First test runs at 40 / 80 bar with model slurry (straw char / wood char in glycol) Data for mass, species and energy balance for WP 2.1, 2.2 Slag samples for WP Thomas Kolb KIT

26 WP 3.3 Diagnostics Objectives Patrick Diagnostic tools for high pressure EFG Laser based systems Advanced gas / liquid analytics Generation of validation data Online process monitoring Philip Luminosity of char clouds LII signal 26 Results Optical probe REGA Campaign 2012 Successful application of Laser-induced incandescence (WP 3.1) soot / REGA Laser induced breakdown spectroscopy developed/adopted (WP 3.1) alcaline /REGA Absorption spectroscopy developed and tested on lab-facility CO PSI diagnostic toolbox at REGA / bioliq Thomas Kolb KIT

27 Leading Scientists Manfred Aigner DLR Thomas Kolb KIT Michael Müller FZJ Roman Weber TUC Neda Djordjevic KIT Reinhold Kneer RWTH Peter Jansohn PSI Weihong Yang KTH Bram van der Drift ECN 27 Thomas Kolb KIT

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