Techno-economic Optimization Potential of High Temperature Syngas Treatment in Gasification Processes

Transcription

1 Techno-economic Optimization Potential of High Temperature Syngas Treatment in Gasification Processes Robert Mai, Manuel Meßmer, Hans Leibold, Dieter Stapf, Prof. Dr.-Ing. Dieter Stapf Pyrolysis Storage of biosyncrude Gasifier Synthesis Stage KIT The Research University within the Helmholtz Association

2 Outline bioliq process HTHP syngas cleaning Proof of concept Scale-up from 1 to 25 t/h (i.e. 5 to 125 MW th ) Flow sheet simulation for a realistic quantification of the potential for power and steam generation Comparison of efficiency and costs for HTHP and standard gas treatment Conclusions / Outlook 2

3 The bioliq process biosyncrude O 2 (steam) Gas cleaning and conditioning Biomass Pre-treatment High pressure entrained flow gasification Filter Sorption Catalyst CO 2 and water Syngas separation Slag Synfuel Fast pyrolysis biosyncrude Fuel synthesis DME synthesis Decentralized Centralized 3

4 Motivation for dry HTHP syngas cleaning Gasification C Filtration Sour gas sorption Organics, NH 3, HCN removal CO 2 removal Utilization 800 C HTHP C SOFC / MCFC 500 C 350 C RTI warm gas cleanup < 500 C IGCC C SNG C Shift C MeOH, DME, FT 50 C SELEXOL amine scrubbing (MEA, DEA, mdea) C RECTISOL 4

5 HTHP syngas cleaning design 5

6 bioliq HTHP syngas cleaning to synthesis filter with CPP tank fixed bed reactors 2 nd heat exchanger pressure buffer flow control valve to flare 6

7 Filter design and grade efficiency Proof of particle 25 C, atm. pressure overall efficiency E > 99,9 % N 2 Tank Recleaning Valves Dust Dosage Raw Gas Clean Gas Particulate Filter Grade efficiency Total efficiency 99,92 % 100,0% 99,5% 99,0% 98,5% 98,0% 97,5% 0, Particle size in µm Filter structure Filter specification 4 sections à 5 filter elements Type DIA-SCHUMALITH N Material SiC grain ceramic / mullite Dimensions 60/40 x 250 mm 7

8 H 2 S, COS Nov, 2014 fixed bed #1 Na 2 CO 3 / ZnO (G-92C / G-72D) fixed bed #2 ZnO / ZnO (G-72D / G-72D) H 2 S separation efficiency c raw gas 150 ppm EE > = % 240 kg/h 240 m³/h STP 40 bar C HCl < 100 ppb HCN < 100 ppb (NH 3 < 50 ppm) 8

9 Proof of Concept Successful commissioning of HTHP syngas cleaning in 2014 Successful commissioning of on-line syngas analysis of the relevant trace species H 2 S, COS, HCl, HCN and NH 3 November 2014 the very first time, that the HTHP syngas cleaning stage fulfilled the stringent requirements of the following synthesis stage and biofuel could be produced in a BTL process To do Long term operation by additional entrained flow sorption High temperature CO 2 -separation by a solution-diffusion-membrane process (results presented at IFC 6, Radebeul) 9

10 Outline bioliq process HTHP syngas cleaning Proof of concept Scale-up from 1 to 25 t/h (i.e. 5 to 125 MW th ) Flow sheet simulation for a realistic quantification of the potential for power and steam generation Comparison of efficiency and costs for HTHP and standard gas treatment Conclusions / Outlook 10

11 Scale-Up Basis / Assumptions Scale-Up of the bioliq process chain bioliq 1 t/h biosyncrude medium size plant 25 t/h biosyncrude Entrained flow gasifier H 2 :CO = 1:1 (needed for 1-step DME synthesis) based on experimentally validated data No WGS reactor needed Partly water quench to hot gas cleaning temperature 800 C Optimum energy system integration Heat and power generation Syngas temperature of 280 C (ident. to DME reactor conditions) Dry hot gas treatment versus standard methanol scrubbing (Rectisol process) 11

12 HTHP Gas Treatment biosyncrude O 2 (Steam) Entrained Flow Sorption Syngas to Synthesis Entrained Flow Gasifier Water Separation Slag Particle Filter Fixed Bed Reactor Catalytic Stage CO 2 Separation 800 C C 280 C 12

13 Standard Gas Treatment (Rectisol ) Absorption Desorption H 2 S, COS biosyncrude O 2 (Steam) MeOH Deep Cooling Cooling Water Entrained Flow Gasifier Steam CO 2 Water Quench Water Treatment Syngas to Synthesis Slag 300 to 200 C ( C ) 280 C 13

14 HTHP Gas Treatment + Back Pressure Turbine Flow Sheet Simulation 14

15 Standard Gas Treatment (Rectisol ) + Back Pressure Turbine Flow Sheet Simulation 15

16 Standard Gas Treatment (Rectisol ) + Condensing Operation Flow Sheet Simulation 16

17 Total Process Efficiency [%] 90 Total Process Efficiency HTHP Gas Treatment + Back Pressure Turbine Rectisol + Back Pressure Turbine HTHP Gas Treatment + Condensing Turbine Rectisol + Condensing Turbine HTHP Gas Treatment process efficiency exceeds Standard Heißgasreinigung Gas Treatment hat höheren Rectisol Wirkungsgrad process efficiency als Rectisol-Wäsche Nutzung der im Synthesegas enthaltenen Wärme Generation Gegendruckbetrieb of power hat + steam höheren offers Wirkungsgrad higher potential als Vollverstromung Nutzung der Kondensationswärme 17

18 Cost Structure Theoretical Syngas Cost [Mio /year] Byproducts [Mio /year] ,5 4 3, HTHP Gas Treatment + Condensing Turbine HTHP Gas Treatment + Back Pressure Turbine Rectisol + Condensing Turbine Rectisol + Back Pressure Turbine Variable Operation Costs Fixed Operation Costs Annuity 3 2,5 2 1,5 1 0,5 0 HTHP Gas Treatment + Condensing Turbine HTHP Gas Treatment + Back Pressure Turbine Rectisol + Condensing Turbine Rectisol + Back Pressure Turbine Steam Electric Power Product costs are dominated by capital investment and feedstock material

19 Conclusions / Outlook Proof of Concept of HTHP syngas cleaning Scale-up Use of latent heat needs complex heat recovery Compared to standard Rectisol process total process efficiency is 10 % higher (abs.) overall costs are 10 % lower benefit of 5 % for power / steam generation no waste water problem To be solved: regeneration / deposition of spent sorbents scale-up of CO 2 membrane process (alternatively HT PSA can be used) 19

20 Acknowledgement Work has been funded by Industry partners BMELV FNR - Fachagentur nachwachsende Rohstoffe Förderkennzeichen: Synthesekraftstofferzeugung aus Biomasse Bauabschnitt III und IV - Gasreinigung und Kraftstoffsynthese Wirtschaftsministerium Baden-Württemberg EFRE - Europäischer Fonds für regionale Entwicklung 20