FUTURE ENERGY GmbH, Germany International Freiberg Conference on IGCC & XtL Technologies June 16-18, 2005 MEGA-GSP GSP PROCESS Entrained-Flow Gasification of Coal, Biomass and Waste Dr. Manfred Schingnitz,, Friedemann Mehlhose
FUTURE ENERGY GmbH in Freiberg 5MW Office 3MW DBI Freiberg city center
Advantages of GSP Entrained-Flow Gasifier with Cooling Screen Burner Cooling screen Pressur. water inlet Quench water Fuel Pressur. water outlet Oxygen, Steam Granulated slag Cooling jacket Gas outlet Water overflow high carbon conversion > 99 % raw synthesis gas without hydrocarbons, i.e. absolutely tarfree no dioxin/furan formation despite high chlorine content in the gasification feed no heed to be given to ash content and ash composition high gasifier performance high availability short startup and shutdown time (about one hour) multiple-fuel feeding cooling screen life time >10 years
Particle Size Distribution of Pulverized Coal at a Carbon Conversion Rate of >99 % 0.1 Hard coal Sieve oversize in % 1 2 5 10 15 20 30 40 50 Petcoke Pyrolysis char Low-reactive High-reactive 60 70 80 85 Lignite, sewage sludge 90 Wood flour 95 0.01 0.02 0.03 0.05 0.1 0.2 Particle diameter in mm 0.3 0.5 1
Pneumatic Conveying and Feeding System for Pulverized Solid Materials Material Waste air LIA Storage bin PI TI N2 M M Depressurization Depressurization PIC PIC Lock hopper N 2 M H LIC L H LIC L Lock hopper M N 2 FIC LIC UC Q S Material to gasifier Feeding vessel PI N 2 M
Burner for Coal Gasification Ignition voltage Flame signal Fuel gas to pilot Cooling water Cooling water Oxygen/steam Cooling water Cooling water Pulverized coal Cooling water Cooling water
Pulverized Coal Burner Cooling water Oxygen/ HP steam Cooling water Cooling water Pilot burner gas 2x 3x Oxygen Cooling water Pulverized Cooling coal water
GSP Entrained-Flow Gasifier Fuel Oxygen, Steam Fuel Oxygen, Steam Burner Pressur. water outlet Cooling screen Pressur. water inlet Quench water Cooling jacket Gas outlet Slag discharge unit Water overflow Raw gas Slag Granulated slag
Viewsof the Cooling Screen after 10 Years in Service
Cooling Screen of the Gasification Reactor Liquid slag Membran wall Pressurized water Solid slag Ramming mass Pipe coil with studs
95 Anthracite Petcoke Lean coal Forge coal Fat coal Mediumvolatile coal Highvolatile coal Hard brown coal Soft brown coal Coals Gasified in the Test Facilities of FUTURE ENERGY GmbH 90 Carbon content C daf [wt.-%] 85 80 75 70 65 60 55 52 51 41 27 21 26 28 24 23 29 22 25 13 12 15 02 14 01 04 11 03 0 10 20 30 40 50 60 70 Volatile matter content V daf [wt.-%] SOFT BROWN COALS 01 GERMANY Schwarze Pumpe 02 GERMANY Braunsbedra 03 BULGARIA Elhovo 04 AUSTRALIA Mine Bowmans HARD BROWN COALS 11 SPAIN Teruel 12 RUSSIA Kansk-Atschinsk 13 CHINA Harbin 14 CZECH REPUBLIC Most 15 CZECH REPUBLIC Sokolov HARD COALS 21 GERMANY Ruhrgebiet 22 POLAND Sosnica 2/1 23 POLAND Sosnica 24 SPAIN Puertollano A (washed coal) 25 SPAIN Puertollano (unwashed coal) 26 AUSTRALIA Drayton 27 AUSTRALIA Newlands 28 SOUTH AFRICA Koornfontein 29 COLOMBIA Cerrajon 41 Petcoke ANTHRACITES 51 GERMANY Doberlug 52 GERMANY Ruhrgebiet
Size Relation of Different Scale GSP Entrained-flow Gasifiers (2.5 MPa) 1000 MW 500 MW 200 MW 6700 3500 Ø2900 5250 Ø3650 Ø2000
Adverse Characteristics of Biomass low density, i.e. large volumes to be handled heterogeneous structure requiring high chopping expense low heating value compared with conventional fuels high oxygen content in the organic matrix high-alkaline fuel ash bad grindability
Effective Use of Biomass in cooperation between Karlsruhe research center (FZK) and FUTURE ENERGY input energy plants harvest remains by-products / wastes wood bark / forest residues wood shavings miscanthus straw / hay lignin / bagasse napier grass wood remainders sewage sludge triticale branches liquid manure 1. step 2. step biomass preparation: collecting / pre-drying / chopping / storage local fast pyrolysis to generate bio-oil / bio-char or a slurry from bio-oil & bio-char at 1 bar (15 psi) & ~500 C (900 F) - capacity: ~50 MW each ~ 10 t/h (20,000 lb/hr) local area 3. step liquid fossil fuels rail transport of the products from different local units to a centralized large-scale gasification unit solid fossil fuels 4. step entrained-flow gasification process by FUTURE ENERGY ~1400 C (2500 F); 40-60 bar (550-900 psi) capacity: op to 1000 MWth generation of a tar free raw synthesis gas 5. step gas treatment cleaning / conditioning final use generation of generation of generation of synthetic motor fuels electrical energy fertilizers / chemicals central system / plant
Composition of Raw Gas from Different Feedstocks Component Heating value (dry) Hard Unit Petcoke Lignite Oil Biomass Domestic coal refuse Sewage sludge MJ/kg 25-32 34-36 18-25 39-42 17-19 12-15 10-13 H 2 vol.-% 27 22 31 45 27 29 32 CO vol.-% 64 65 55 48 50 49 49 CO 2 vol.-% 3 5 8 4 14 16 12 CH 4 vol.-% < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 < 0.1 N 2 vol.-% 1.5-5.5 1.0-6.5 3.5 0.5 4.0 4.0 4.5 H 2 S vol.-% 0.46 1.3 0.20 0.1 0.12 0.36 0.28 COS vol.-% 0.04 0.16 0.02 0.01 < 0.1 0.02 0.02 HCN mg/nm 3 1.0 0.8 1.0 0.2 0.3 0.01 2.0 NH 3 mg/nm 3 0.4 0.3 0.24 0.4 0.4 0.25 0.3 Heating value MJ/Nm 3 11.1 10.9 10.3 11.2 9.3 9.4 9.7
GSP Gasification Test Facilities of FUTURE ENERGY GmbH in Freiberg 5 MW 3 MW Office Gasifier VV100 Reactor with cooling wall 2-3 MW max. 30 bar Pulverized fuel dosing and feeding system up to 10 t/h Inert gas plant 1000 m 3 i.n./h 80 bar Oxygen plant max. 300 m 3 i.n./h 80 bar Gasifier Reactor with cooling screen 3-5 MW max. 30 bar Slurry feeding 300 kg/h Sewage sludge drier 500 kg/h Pyrolysis unit 500 kg/h SulFerox desulfurization unit Waste water treatment COS hydrolysis HCN hydrolysis
Advantages for our Costumers Fuel Oxygen, Steam Burner Pressur. water outlet Cooling screen Pressur. water inlet Quench water Cooling jacket Gas outlet Water overflow optimize feedstock preparation determine optimum gasification process conditions allow optimization of reactor or burner design allow reliable scale-up test materials of construction and components gain information about products and wastes Granulated slag
Autothermal Oil Conversion Plant Gasification Project in the Czech Republic Client Sokolovská uhelná, a.s. Location, country Vresová, Czech Republic Commissioning 2005 Technical data Type of reactor Capacity Pressure entrained-flow, cooling wall design 140 MW th 28 bar Temperature 1400 C Reactor volume 15 m 3 Type of quench system Equipment / subsystems Feeding system Gas cleaning Slag discharge Soot water treatment full quench liquid feeding spray scrubber lock hopper depressurization and vapor condensation, sedimentation, chamber filter press 3D computer simulation Feedstock Products / by-products / effluent Generator tar and other liquid by-products of 26 fixed bed gasifiers of a 440 MW IGCC Raw gas to IGCC / slag, soot cake / waste water
Thank you very much!