Coupling gasification and metallurgical applications Robert Pardemann, Tanja Schaaf, Jochen Grünig, Katharina Förster, Andreas Orth International Freiberg Conference on IGCC & XtL Technologies 12 16 June 2016 Cologne/Germany
Outline Working for resource efficiency About Outotec Gasification and metallurgical applications Outotec s development activities and offerings 2 June 13, 2016
A century of accumulated expertize 3 June 13, 2016
Sustainable use, recovery and recycling of resources RESOURCE EXTRACTION PRIMARY PRODUCTION RECYCLING Airbone emission SERVICES AND SOLUTIONS RECYCLE REMANUFACTURE NATURAL RESOURCES ORES MINERALS WATER MINING Backfill MINERAL PROCESSING Water management Equipment reuse CONCENTRATES INDUSTRIAL MINERALS Airbone emission METAL PROCESSING Effluent Treatment METALS SALTS CHEMICALS SLAG Energy recovery MANUFACTURING Reuse Urban mine USERS COMBUSTIBLE WASTE MUNICIPAL SLUDGE Landfill Construction materials PHOSPHORUS SULFURIC ACID BIOMASS FERTILIZER PRODUCTION AGRICULTURE PHOSPHORUS ENERGY PRODUCTION CO 2 CO 2 CO 2 CO 2 POWER PRODUCTION Green color shows Outotec`s impact 4 June 13, 2016
Local operations, global presence Experts of over 60 nationalities Environmental goods and services 90% of orders Over 4,800 employees Deliveries to more than 80 countries Sales 1.2bn EUR in 2015 R&D, sales and service centers in 32 countries Listed on Nasdaq Helsinki since 2006 In 2016 3 rd most sustainable company Services 43 % of sales Wide supplier network with established long-term relationships 5 June 13, 2016
Outline Working for resource efficiency About Outotec Gasification and metallurgical applications Outotec s development activities and offerings 6 June 13, 2016
Outotec s technology background Fluidized bed as core technology for Outotec s Metalls and Energy business (reference list of more than 500 fluidized bed plants) Bubbling fluidized bed, Circulating fluidized bed, Annular fluidized bed, Flash reactors Strong background in pyro-processes for minerals beneficiation and metallurgy (calcination, reduction, smelting, roasting*) Need for supply of heat to the process (today mainly through internal combustion of NG or fuel oil, *exception: roasting) Gasification (at Outotec relying on fluidized bed): Stand-alone process for small/medium-scale energy production (biomass, sewage sludge, residues) Option for fuel gas provision to pyro-metallurgical process but requires: Careful consideration of impact of fuel gas obtained from gasification on downstream process Tailored solutions for each plant 7 June 13, 2016
Gasification coupled to Pyro-metallurgical Processes Objective: Substituting NG or fuel oil as fuel by locally abundant (often low-grade) solid fuels (e. g. coal, biomass, residues) for the pyro-metallurgical processes Typical thermal output requirement for gasification: 40 130 MW(th) Requirements / challenges: Fuel gas provision at small to medium scale Need for low-cost technology solution Minimization/limitation of gas cleaning effort dependent on application Impurities and parameters to be considered for coupling of gasification and metallurgical process Fuel gas heating value Tars Dust (fly ash) Acidic gases 8 June 13, 2016
Gasification coupled to Pyro-metallurgical Processes Example processes with potential for fuel substitution Sensitivity towards impurities Adaptation of gas purification system Dust Tars Acid gases Cement calcination (preheating) Alumina calcination Pelletizing Clay calcination (clinker substitute) (-) (-) (-) (-) Kaolin calcination x (dep. on application) x x Effort for gas cleaning: Lower gas cleaning effort for higher fuel qualities (limited contaminant concentration) Adjustment of gas cleaning to meet maximum allowable impurity limits no over-designing General premise: avoidance of tar handling problems 9 June 13, 2016
Possible gas purification schemes Direct utilization of raw gas (stay as hot as possible) Coal Air / Oxygen Gasifier steam Waste Heat Boiler High-temp. filter Candle Filter (e.g. ESP, candle filter) To Calcination ash ash water ash Comprehensive gas cleaning Coal Air / Oxygen Gasifier steam Waste Heat Boiler Multiclone ash ash water ash To Calcination Gas Compressing Scrubber Tar Removal water water bleed tar stripper air 10 June 13, 2016
Outline Working for resource efficiency About Outotec Gasification and metallurgical applications Outotec s development activities and offerings 11 June 13, 2016
Outotec s activities in the field of gasification Wide range of test facilities and know-how, applied in the context of gasification for: Gasification tests to obtain comprehensive process understanding Development and optimization of new concepts, processes, components and technologies Testing and development of metallurgical processes under realistic conditions Technology and service offerings I. Test services and case studies on customer demand II. Engineering services: Technology evaluation / Feasibility assessment / Engineering and design of entire process chains III. Construction of new and retrofitting of existent plants IV. Performance services 12 June 13, 2016
Outotec s CFB-based gasification concept Outotec s pilot-scale facilities applied for gasification tests 700 mm FB plant Alternative: use of oxygen as gasification agent 200 mm CFB plant 250 mm FB plant 13 June 13, 2016
Extended test facility base Gas cleaning test facilities available at Outotec s Frankfurt Research Centre: Filters installed at each fluidized-bed facility Dry ESP and Wet ESP Venturi scrubber Radial scrubber CO 2 scrubbing Gas scrubbing for removal of SO 2 and other components Comprehensive process and component testing for validation of models and providing design basis Basis for scale-up and process guarantees CO 2 scrubbing test facility 14 June 13, 2016
Example 1: Case study to evaluate options for fuel substitution Task: Performance of gasification test and feasibility assessment for fuel gas provision from coal Challenge: Blending of coals of different reactivity and baking/swelling behavior Identification of maximum allowable mixing ratio (LHV, gas quality, operability) CoalA CoalB Ash (wf) wt.% 7.8 35.0 Moisture (ar) wt.% 11.1 2.2 Fixed carbon (wf) wt.% 56.9 49.7 Volatile matter (wf) wt.% 35.3 15.3 C (wf) wt.% 74.3 54.8 S (wf) wt.% 0.4 3.2 H (wf) wt.% 4.7 3.1 N (wf) wt.% 0.9 0.8 O (wf) wt.% 11.9 3.1 LHV(wf) kj/kg 29179 21147 Free swelling index 0.5 3.0 CoalA CoalB AFT C 1200 1600 SiO 2 wt.% 37.7 45.5 Al 2 O 3 wt.% 14.6 34.3 Fe 2 O 3 wt.% 12.5 10.2 TiO 2 wt.% 0.6 1.6 CaO wt.% 23.8 4.1 MgO wt.% 1.3 0.7 Na 2 O wt.% 0.9 0.01 K 2 O wt.% 0.9 0.9 SO 3 wt.% 7.0 2.6 P 2 O 5 wt.% 0.04 0.1 15 June 13, 2016
Example 1: Case study to evaluate options for fuel substitution Gasification test results Test conditions: 950 C; 200 mm CFB, p = 1 bar; air/steam ( = 0.35 0.42) Mixing ratio Coal A: Coal B 90:10 80:20 70:30 50:50 CO vol.% 12,3 10,2 11,8 8,1 CO 2 vol.% 8,3 9,1 8,4 8,6 CH 4 vol.% 0,7 0,5 0,6 0,7 H 2 vol.% 8,7 7,3 8,1 6,8 O 2 (false air) vol.% 0,3 0,3 0,3 0,3 Rest (mainly N 2 ) vol.% 69,7 72,6 70,8 75,5 LHV kj/m³(stp) 3141 2588 2863 2556 C-yield (gas) % 76,6 73,6 79,0 59,2 C-conv. % 88.8 91.6 % * average values, dry gas composition, N 2 corrected, constant bed pressure loss at 25 mbar Difference in reactivity for both coals Impact on gas quality Only mixtures with up to 30 % of coal B allow for stable operability Rather high gasification temperature required for high C-conversion Challenge regarding swelling Rather high heat loss of small pilotscale facility Basis for simulation and balancing as part of design work 16 June 13, 2016
Example 1: Case study to evaluate options for fuel substitution Modeling results Modeling-based mass and energy balancing of a 230 MW(th) throughput air-blown coal gasification CFB plant (1 bar / 970 C) (validated on gasification test results) *Gasification at 1 bar/ 970 C Feed Coal (70/30 mix) 20 C kg/h MW 25.207 231 Air Fluidization 77 C / 1,56 bar m³(stp)/h 32.962 Gasification 20 C / 10 bar m³(stp)/h 24.842 Utilities BFW 16 bar / 105 C kg/h 32.770 Steam Gasification 152 C / 5 bar kg/h 1.281 Fluidization 152 C / 5 bar kg/h 1.621 Excess 152 C / 5 bar kg/h 29.868 Cooling Water 20/30 C / 1 bar kg/h 523.841 Solid by-products Fly ash 100 C kg/h 936 Bottom ash 90 C kg/h 3.761 Product gas Temperature/Pressure C/bar 400 / 1,35 Volume flow m³(stp)/h 84.854 CO vol.% 21,5 CO 2 vol.% 7,4 H 2 vol.% 11,7 H 2 O vol.% 3,8 CH 4 vol.% 1,9 N 2 vol.% 53,6 H 2 S vol.% 2,0 NH 3 ppm 6 COS ppm 114 LHV kj/m³(stp) 3.616 17 June 13, 2016
Example 2: Plant reference Cement plant Rüdersdorf Design data: Thermal capacity: 100 MW Fuels: Carbonic ashes, RDF, sludge Product gas: 60 000 m³/h, 3 5.3MJ/m³, 860 920 C Ash: <1 % carbon Advantages: Independent of fuel ash composition and no need of raw material feed adjustment to meet product quality Wide fuel range (coal, biomass, RDF, sewage sludge, carbonic ashes,...) Sewage sludge Phosphor-recovery from gasification ash possible CFB Gasifier 18 June 13, 2016
Conclusions Process approach perspective: Attachment of gasification to metallurgical or mineral applications requires tailored solutions Need for careful evaluation of impact of fuel change on downstream application Additional considerations: - CAPEX of gasification island vs. downstream process - Impact of gasification on plant availability Selection of lowest CAPEX process concept meeting downstream process requirements Economic viability strongly dependent on local conditions (only limited potential of coal gasification for fuel substitution) Outotec s technology perspective: Comprehensive testing as basis for process development, engineering and design and scale-up Broad experience with a wide range of fuels (coals, pet coke, biomass and residues) Focus on concept and equipment development for gasification of alternative fuels (e.g. closedloop steam dryer, ash treatment) Competitive and sustainable technology solutions meeting upcoming legal framework 19 June 13, 2016
Thank you for your attention! robert.pardemann@outotec.com