Prof. Fuchen Wang Ph.D. Xiaolei Guo. Page 1

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1 Opposed Multi-Burner (OMB) Gasification Technology New Developments and Update of Applications Prof. Fuchen Wang Ph.D. Xiaolei Guo Key Laboratory of Coal Gasification of Ministry of Education Institute of Clean Coal Technology (ICCT) East China University of Science and Technology (ECUST) Page 1

2 Outline 1. Applications of coal gasification technology in China 2. OMB coal gasification update & outlook Page 2

3 Applications of coal gasification technology in China Page 3

4 Coal gasification is the key and core technology Page 4

5 2007 Output of coal in China: 2.52 billion tons Page 5

6 Ammonia Industry Ammonia industry is the biggest consumer of gasification technology in China. Coal-based synthetic ammonia accounts for about 75% of total output. Consume 50 Mt coal per year. Most of them use anthracite lump coal and fixed bed gasifier with high energy consumption, and lead to high pollution. Page 6

7 Methanol industry and downstream products The methanol output in 2007 was Mt, which consumed about 12 Mt coal since coal-based methanol accounted for about 80% of total output. Most gasifiers are fixed bed. It is estimated most gasifiers will be the entrained bed in 3 years. DME, MTO, MTP. Fuel gas Fuel gas consumes 45 Mt coal/a. Most gasifiers are fixed bed. Coal liquefaction, IGCC power generation Page 7

8 Prediction of increased coal in 2020: 220~360 Million tons coal Production value of related industry: ~300 Billion RMB/a Coal gasification technology is regarded as the key research field in National plan in Sci. & Tech. development for medium and long term Page 8

9 Coal Gasification R&D History in China Investigation g on coal gasification technology in China started in the end of 1950s all study works were interrupted. Early 1980s pilot gasifier was built up in Lintong Fertilizer Research Institute. Pilot fluidized bed gasifier in1990s; 2001 commercial fluidized bed gasifier started t up, capacity 200t coal/d. The entrained-flow gasification technology has been researched and developed by ECUST for more than 20 years, and OMB CWS gasification technology was demonstrated in Yankuang group in Page 9

10 OMB coal gasification update & outlook Page 10

11 OMB CWS Gasification Process A V III II I IV A III VI Commercial OMB Gasifier Flame tests from small OMB gasifier hot model A A Flow fields of OMB gasifier from large cold model Page 11

12 Features High carbon conversion and low oxygen/coal consumptions: opposed dburner and dbetter mixing i process. Easy to scale up ( tons coal/day): multi-burner. High efficiency of syngas primary purification section: low process pressure drop and low fly-ash content in syngas (1mg/Nm 3 syngas) using Step-by-Step method. High heat recover efficiency and stability in slag water treatment section: direct heat exchange between grey water and vapor from flash of slag water. Page 12

13 OMB Gasifier R&D History Innovation & Pilot Plant 22TPD Industrial Demo. 1150TPD Scale up 2200TPD. Integrated in Poly-gen., IGCC 1996~ ~ ~ Page 13

14 Industrial Applications Hualu Hengshen Chemical Co.Ltd. 1 gasifier 750 TPD 6.5 MPa Startup on Dec Final Product: MeOH, NH3 6 5 MP 4.0 MPa Yankuang Cathay Coal Chemicals Co. Ltd. 3 gasifiers (2+1) 1150 TPD Startup on Oct Final Product: MeOH, Power, HAc Yankuang Lunan Fertilizer Plant 1 gasifiers 1150 TPD 4.0 MPa Startup on July 2008 Final Product: MeOH, NH3 Page 14

15 13 Projects, 33 Gasifiers Applications update in China: The most large single capacity: 2200TPD HuaLu HengSheng 1 6.5MPa-750TPD Ammonia Tengzhou Fenghuang 3 6.5MPa-1500TPD Methanol YankuangLunan 1 4.0MPa-1150TPD Methanol ShenhuaNingmei 3 4.0MPa-2000TPD Methonal YankuangCathy 3 4.0MPa-1150TPD Methanol,Power ShengdaNingdong 2 6.5MPa-2000TPD Methanol JiangsuSopo 3 6.5MPa-1500TPD Methanol ShandongJiutai 6 6.5MPa-2000TPD Methanol JiangsuLinggu 2 4.0MPa-1800TPD Ammonia AnhuiHuayi 3 6.5MPa-1500TPD Methanol GuizhouKaiyang 2 4.0MPa-1200TPD Ammonia Huadian Banshan 1 3.5MPa-2200TPD Power NingboWanhua 3 6.5MPa-1200TPD Methanol,Ammonia, CO,H 2 Page 15

16 Client Gasifier Specification Pressure MPa Throughput t/d Product Remarks Hualu Hengsheng 1*Φ2.8m Ammonia Starting up in 2005 Yankuang Cathy 2*Φ3.4m Methanol, Starting up in 2005 Power Yankuang Cathy 1*Φ3.4m Methanol Starting up in 2007 Yankuang Luhua 1*Φ3.4m Methanol Starting up in 2008 Tengzhou Fenghuang 3* Φ3.4m Ammonia Methanol Starting up in 2009 Jiangsu Linggu 2*Φ3.8m Ammonia Starting ti up in 2009 Jiangsu SOPO 3*Φ3.4m Methanol Acetic acid Starting up in 2009 Shenhua Ningmei 3*Φ3 Φ3.8m Dimethyl Starting up in 2009 Ningbo Wanhua 3*Φ3.2m Methanol Starting up in 2009 Ammonia Shengda Ningdong 2*Φ3.8m Methanol Starting up in 2010 Hangzhou Banshan 1*Φ3.8m IGCC Starting up in 2010, radiant boiler process Shandong Jiutai 6*Φ3.6m Methanol Starting up in 2010 Anhui Huayi 3*Φ3.4m Methanol Starting up in 2010 Guizhou Kaiyang 2*Φ3.8m Ammonia Starting up in 2010, dry feed, membrane Page wall 16

17 Performance update of fthe OMB gasification technology Page 17

18 Demonstration project updates Company: Yankuang Cathy Coal Chemical Co., Ltd. Single Capacity: 1150 TPD, 4.0MPa 2 Gasifiers+1 Spare(A#, B# and C#); Burner tip lifespan: more than 90 days C# is improved gasifier : Optimization for burner position Lifespan comparison of refractory brick (h) Gasifier Start up Dome Cylinder Bottom A# or B# Oct.2005 ~5000 ~20000 ~24000 C# (optimized) Sep.2007 ~8000 ~20000 ~24000 Page 18

19 A New Starting up of OMB CWS Gasifier Company: Yankuang Lunan Fertilizer Plant Location: Tengzhou city, Shandong province Gasification capacity: 1 gasifier, 1150 TPD First Start t up: 6:00AM, July 1, 2008 Consecutive running 78 days at its first startup, indicating excellent reliability. Slurry Syngas composition V% concentration Wt% CO H2 CO2 CO+H2 CH4,PPM ~ ~ Page 19

20 Development of dry-fed membrane wall OMB gasification technology Page 20

21 R&D History Pilot trial of dry-fed OMB refractory gasifier with 30TPD (2001~2004) 2004) National key technology R&D program Pilot trial with CO 2 gas as carrier (2005) 2 Demonstration of OMB gasification technology fed with high ash fusion point coal (2007~2010) HI-TECH R&D program of China (863 Program) Pilot trial of membrane wall gasifier with 30TPD (2007) Pilot trial of membrane wall gasifier fed with high ash fusion point coal (2008) Page 21

22 Pilot trial of dry-fed OMB gasifier in 2004 Page 22

23 Pilot trial of membrane wall gasifier in 2007 Page 23

24 Pilot Performance of membrane wall gasifier Beisu Coal analysis (Dry basis, wt%) Syngas composition(vol%) Feed rate H 2 N 2 CO CO 2 CO+H 2 (kg/h) ~ ~1000 Page 24

25 Pilot Performance of membrane wall gasifier Baodian coal analysis (Dry basis, wt%) Feed rate Syngas composition,v% kg/h CH4,PPM H2 N2 CO CO2 CO+H Page 25

26 Demonstration of OMB gasification technology of pulverized coal (National HI-TECH R&D program) Company: Guizhou Kaiyang Chem. Co., Ltd. Location: Guizhou Province Number of membrane wall OMB Gasifiers: 2 Final product: Ammonia Single capacity: 1,100 TPD Operation pressure: 4.0MPa Design Coal: FT >1400,ash:~27%(wt,dry basis) Planned startup date: Dec Page 26

27 OMB gasification technology Process of pulverized coal Clean High efficiency Large scale Low cost Membrane wall Multi-burner Mature Process Dry feed Water quenching Page 27

28 A new membrane wall gasifier with one burner Process of commercial demonstration plant Demonstration company: China BlueChemical Ltd. Location: Inner mongolia; 2 gasifiers; single capacity 1000 TPD; Operation pressure: 4.0MPa Final product: Methanol; Planned startup: t 2010 Page 28

29 Sum up Gasifier Lining style Feed style OMB gasifier Refractory One burner gasifier Membrane wall Coal-water slurry Pulverized coal Pulverized coal Quench style Water quench Radiant boiler Water quench Water quench Capacity State 1100~2200 TPD Commercialization widely from TPD Commercial demostration in ~45 TPD Pilot tests accomplished in TPD Commercial demostration in 2010 Membrane Pulverized Water Commercial wall Pulverized coal Water quench 1000 TPD Commercial demostration in 2010 Different applications, different gasification process! Page 29

30 National Hi-tech R&D Program (863 Program): Coal-based Poly-generation 2000 TPD CWS gasification technology: Huadian Group (Hangzhou city) 200MW IGCC plant 2000 TPD Pulverized coal gasification technology: Huaneng Group (Tianjin city) 250MW IGCC plant Yankuang Group 1Mt/year F-T plant with 200MW IGCC. Lu an Group 1Mt/year F-T plant with 200MW IGCC. Page 30

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