die ressourcenuniversität. seit 1765. - fapesp schwarze pumpe (4 m fbdb) envirotherm (4 m sbg)...
TRANSCRIPT
TU Bergakademie Freiberg I Institut für Energieverfahrenstechnik und Chemieingenieurwesen
Reiche Zeche I 09596 Freiberg I Tel. +49(0)3731/39 4511 I Fax +49(0)3731/39 4555
E-Mail [email protected] I Web www.iec.tu-freiberg.de
Institut für
Energieverfahrenstechnik und
Chemieingenieurwesen
Die Ressourcenuniversität. Seit 1765.
Gasification Process Research at the IEC – Lab investigations and large-scale research facilities
Prof. Dr.-Ing. Bernd Meyer
I General introduction to the IEC
II Lab-scale experimental research
III Large-scale experimental research and operating experiences
2
Outline
3
Fuel Research in Freiberg
3
GTI
1990
1949
1956
Institut für
Energieverfahrenstechnik und
Chemieingenieurwesen IEC
Department of Energy Process
Engineering and Chemical Engineering
Berufung Erich Rammler
Appointment Erich Rammler
BHT Coke Institut für technische
Brennstoffverwertung
Institute of Fuel Utilisation Braunkohlenforschungsinstitut
Lignite Research Institute
1947
1921 Sächsische Braunkohlenstiftung
Saxony State Lignite Research
Foundation 1918 L
iqu
id F
ue
ls
Co
ke
/To
wn
Ga
s
Syn
ga
s,
Fu
els
,
Ele
ctr
icit
y
1991
SIEMENS FGT
(CHOREN)
Deutsches
Brennstoffinstitut DBI
German Fuel Institute
Start-up
HP POX plant 2003
2008
2009
2011
Start-up
STF plant 2010
4
Organizational Chart of the IEC
4
Department of Energy Process Engineering and Chemical Engineering
Chair of Energy Process Engineering and Thermal Waste Treatment
Prof. Dr.-Ing. Bernd Meyer
Chair of Reaction Engineering Prof. Dr. rer. nat. Sven Kureti
Thermochemical Conversion/ Biomass
HP Gasification / POX
Gasifier Development
Flowsheet Simulation
Reaction Engineering
Refining/Hydrogenation
Esterification/Oxidation
Chair of Numerical Fluid Dynamics
Prof. Dr.-Ing. C. Hasse
Reacting Flow Systems
Interphase Phenomena
Multi Phase Systems
Mineral Matter Reactions
German Energy Raw Materials Centre
POX + ATR of gaseous and liquid fuels Slagging fixed bed + fluidized bed coal gasif.
5
Comprehensive Research on Fuel Utilization
Gasification
Gas Treatment
Synthesis or
Power Generation
Fuel Raw Gas Syngas Product
Macromolecule of hard coal and its decomposition
Distillation of the „mobile“ phase
Rupture of low bonds
Hydro-
genation
Coke
formation Gasification
Bonds between clusters
Aromatic-hydroaromatic complexes
Aliphatic bridges
Ether bridges
Experimental research at IEC:
Lab Scale
Large Scale
Dependent on: Fuel characteristics and conversion behaviour Process conditions Process technology
Low and high-temperature conversion of coal and biomass
Syngas-to-Fuels plant
CFD
Flow Sheet
Gaseous and liquid fuels: POX Coal: Fixed bed, entrained flow and fluidized bed
Modeling-based research at IEC:
Comprehensive stationary and dynamic modelling, concept development and technological, energetic, ecological and economic evaluation
Projects COORAMENT TEIMAB SFGT: dyn. modeling HotVeGas I & II
Industry Coop. Lurgi/Air Liquide Siemens (5 MW(th)) Choren, Phillips66
Test-Facilities HP POX® (5 MW(th) KIVAN
Projects COORIVA (PHTW) CCPP
Industry Coop. RWE (HTW:
150 MW(th), 10 bar 20 MW(th), 25 bar)
GTI (Students Exchange)
Test-Facilities INCI gasifier
Projects SBV
(10 MW(th))
Industry Coop. SVZ Schwarze
Pumpe (4 m FBDB)
Envirotherm (4 m SBG)
Test-Facilities RiFix
Background – Technical Know How in Gasification
6
Moving Bed Gasification
Feed
Raw gas
Gasifying agent (GA)
Ash/Slag
Fluidized Bed Gasification
Raw gas
Ash
GA Feed
6
Entrained Flow Gasification
Feed + GA
Slag
Raw gas
Slag
Raw gas
Feed + GAFeed + GA
Projects COORVED
Industry Coop. EDL Pörner
Test-Facilities COORVED/INCI
gasifier (100 kW, 5 bar)
3rd Generation Gasification
I General introduction to the IEC
II Lab-scale experimental research
III Large-scale experimental research and operating experiences
7
Outline
8
Common fuel characterization (mainly ambient pressure):
High importance of process neutral analysis and characterization of fuels, conversion behaviour and products
Minimum 4 persons (skilled and experienced lab. staff)
Appropriate building infrastructure
Requirement for approx. 2 Mio. EUR initial investment into standard lab equipment
Fuel characterization under realistic conditions :
Need for tailored lab-equipment: - elevated pressures - process specific analysis
Investigation of: - petrography - drying and particle defragmentation - pyrolysis of carbonaceous feedstock - gasification of pyrolysis products - ash/slag behaviour
Specialized and experienced scientists and technicians
1–2 years for design, construction, installation
1–2 years learning curve for each equipment use and optimization
Lab Facilities for Fuel Characterization – Introduction
Experience/ qualification
low inter-
mediate high
Infrastructural requirement
Equipment on offer
Operating costs
Effort for equip. acquisition
Experience/ qualification
low inter-
mediate high
Infrastructural requirement
Equipment on offer
Operating costs
Effort for equip. acquisition
9
Typical Fuel Test Program
Process-neutral lab-scale analysis of fuel properties and conversion
behavior
Proximate, ultimate and sulphur analysis
LHV-determination
Characteristic ash temperatures
Pyrolysis balances
Pyrolysis product characterization
Char gasification reactivity
Petrography
etc.
Gasification process
selection
Specific lab-scale analysis
Dependent on process – analysis of fuel properties and conversion behavior
Ash composition and vaporization
Ash viscosity
Gasification kinetics
Particle defragmentation
etc.
Broad properties and conversion characteristics database for process modeling, design and engineering
Modeling
CFD
Flow sheet simulation
Thermodynamic equilibrium (multiphase systems)
Optional: Large-scale
testing
Fundamental/Common Lab Facilities
Multi Element Analysis with XRF High Pressure Thermo-
gravimetric Analysis High-temperature/high-
pressure XRD chamber
(1.000 °C, 20bar)
10
High-temperature XRD
Fuel analysis
Standard fuel analysis laboratory (e.g. elemental analysis, LHV analysis etc.)
Chromatography (GC, HPLC)
Mass spectrometry (MS, GC-MS-coupling)
Atomic absorption spectrometry (AAS)
X-ray diffractometry (high temperature and high temperature and high pressure)
Multi element analysis with XRF and trace component analysis
Online gas analysis (IR, FTIR, FID)
Thermo-analysis (TG/DTA/DSC)
Rotating viscosimetry
Mercury porosimetry
BET surface area determination
11
Advanced fundamental (process neutral) test facilities
Amb. press. Elev. press.
Analysis of feed and product structure
Pressurized pyrolysis Drop tube/ fixed bed
Closure of elemental and heat balance possible
Atm.: Ar, H2, CO2, H2O, CH4 up to 30 bar/ 800 °C
xpart: 0,04–1 mm
Coal pyrolysis Drop tube
Closure of elemental and heat balance possible
Atm.: Ar, H2, CO2, H2O, CH4 up to 100 bar/ 800 °C
xpart: 0,04–1 mm
Lab-scale pyrolysis Fixed bed
Closure of elemental and heat balance possible
Atm.: Ar up to 1.000 °C
xpart up to 10 mm
Rotating kiln reactor Rotating kiln
Char production and tar production
Atm.: Ar or N2 up to 800 °C (large amounts)
xpart up to 10 mm
Retort oven Fixed bed
Char preparation for gasification Atm.: Ar, N2, H2, CO up to 1.100 °C
Retort: 200x200x400 mm
Pyrolysis GC-MS/FID Micro fixed bed
Analysis of liquid pyrolysis products
Atm.: Ar up to 34 bar/ 1.400 °C
xpart: 0.4–1 mm
Investigation of gasification and pyrolysis kinetics
RIFix Fixed bed
Determination of reactivity of char/coke
Atm.: Ar, CO2, H2O, CO, H2 up to 5 bar/ 1.450 °C
xpart up to 20 mm
HTR Drop tube
Determination of char gasification kinetics
Atm.: Ar, CO2, H2O, CO, H2 up to 1.359 °C
xpart up to 0,5 mm
Magnetic suspension balance TGA-MS
Fixed bed
Determination of pyrolysis and gasification kinetics
Atm.: Ar, N2, CO2, H2O, H2, O2 up to 40 bar/ 1.100 °C
xpart up to 10 mm
KIVAN Drop tube
Determination of hetrogeneous gasification kinetics and particle defragm.
Atm.: Ar, N2, CO2, H2O, H2, O2, CO up to 100 bar/1.600 °C
xpart up to 0,5 mm
12
Typical Test Program
Amb. press. Elev. press.
Investigation of ash/slag behavior
Furnaces Fixed bed Preparation of ash samples from carbon feedstock
Atm.: Ar, air, H2, CO, CO2, H2O up to 30 bar/ 1.800 °C
Atm.: Ar, N2, CO, H2 up to 1.800 °C
Viscosimeter Atm.: N2, Ar, (H2/CO) up to 1.800 °C
Special furnaces (TOM-AC, TOM-I)
Measurement of dimensional changes (shrinkage, sintering,…), option for in-situ FTIR
Atm.: Ar, N2, Ar/N2 up to 2.100 °C
Double-chamber TGA Determination of devolatilization and condensation of mineral compounds
Atm.: N2/H2 or Ar/H2 possible up to 1.500 °C (ΔTmax = 700 K)
Particle defragmentation
KIVAN Option for laser based measurement
See slide 12
See slide 12 See slide 12
PSD analyzer
DPA: Pressurized pyrolysis reactor Operation as drop tube or fixed bed Tube diameter d = 20 mm
heated length: 1.1 m p ≤ 30 bar T ≤ 800 °C Atmosphere: Ar, H2, H2O, CO2, CH4 (400 l(STP)/h)
PDO: Rotating kiln reactor (continuous mode) ambient pressure T ≤ 800 °C Feed rate: 3 kg/h
PYMEQ – Pressurized drop tube Tube diameter d = 20 mm
heated length: 2,2 m p ≤ 100 bar T ≤ 800 °C Atmosphere: Ar, H2, H2O, CO2, CH4 (400 l(STP)/h) 2 sampling points over heated length (tar, gas) Optical port between feeding system and
heated zone
Lab Facilities – Small-scale Pyrolysis Equipment (selection)
13
14
Feeds
Coal / biomass
Particle size: 40…500 µm
Moisture: < 10 wt.%
Feed rate: up to 10 g/min
Equipment Heated length: 1,100 mm Reactor ID: 20 mm 3-stage condensing system (-20 °C ethylene glycol/H2O) Online micro GC
Process conditions
Temperature: ≤ 800 °C
Pressure: ≤ 30 bar (g)
Gas atmosphere: Argon
Volume flow rate argon:
≤ 130 l/h (STP)
Coal feeding
Coalparticle
Partiallypyrolysedparticle
Coke particle
Electricalfurnace
Argon feeding
Argon feeding
Electric traceheating
Pyrolysis gas + argon
Coke collectorwith electrictrace heating
Reactor tube
Zufluss Argon
Pyrolysegas
+ Argon
Biomasse-
schüttung
Zufluss Argon
Pyrolysegas
+ Argon
Biomasse-
partikel
Biomasse-
zufuhr
Koks-
partikel
Zufluss Argon
Tw. pyro-
lysierte
Partikel
Schüttung aus
Kokspartikeln
Argon
Pyrolysegas
Reaktorbeheizung
Metallisches
Innenrohr
Begleitheizung
Begleitheizung
Koksauffang-
behälter
Begleitheizung
b) Fallrohra) Festbett
Pyrolysis gas
Pressurised drop tube reactor – experimental results
15
0
10
20
30
40
50
60
70
80
0 5 10 15 20 25 30 35
Pro
du
ct y
ield
s in
wt.
% (
d)
Pressure in bar
0
10
20
30
40
50
60
70
80
0 5 10 15 20 25 30 35
Pro
du
ct y
ield
s in
wt.
% (
d)
Pressure in bar
Char Liquid product Gas
0
4
8
12
16
20
0 5 10 15 20 25 30 35
Pro
du
ct y
ield
s in
wt.
% (
d)
Pressure in bar
Liquid product Reaction water Tar/oil
0
4
8
12
16
20
0 5 10 15 20 25 30 35
Pro
du
ct y
ield
s in
wt.
% (
d)
Pressure in bar 60
0 °
C
80
0 °
C
Pressure ↑
Main effect on product yields up to about 10 bar
Decrease of char and liquid product yield
Increase of pyrolysis gas yield
Tar yield shows minimum at 5 bar
Temperature ↑
slightly decreasing char and liquid product yield
strong rise in gas yields
Pressurised drop tube reactor - Pressure influence on product yields
Rubotherm – Magnetic Suspension Balance p ≤ 40 bar T ≤ 1.100 °C Pyrolysis: determination of kinetics and pressure
influence Gasification: CO2 and H2Od kinetics Atmosphere: Ar, N2, CO2, O2, H2, CO, H2Od
RIFix – Fixed bed gasification Reaction chamber: d = 20 mm p ≤ 5 bar T ≤ 1.450 °C Sample ≤ 5 g Atmosphere: CO2, H2O, CO, H2, Ar
HTR – Drop tube reactor
Tube diameter: d = 30 mm heated length: 1,75 m
Ambient pressure T ≤ 1300 °C Atmosphere: CO2, H2O, CO, H2, Ar
16
Lab Facilities – Small-scale Pyrolysis and Gasification Equipm.
17
Rubotherm TGA … magnetic suspension balance with various gases
and MS gas analysis
Weight loss of different coals at 10 bar
40
50
60
70
80
90
100
200 400 600 800 1000 1200
m/m
0in
wt.
-% (
d)
Temperature in °C
K3-3
K2-1
K2-2
K2-4
K2-5
K2-3
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
0 200 400 600 800 1000 1200
gas
yiel
d in
(m
l/m
in)/
g co
al
Temperature in °C
Sum PyGas
H2
CO
CO2
N2
CH4
COS
H2S
H2O
Gas release of K2-4 (Colombian hard coal)
Thermo-gravimetric analysis of coal pyrolysis – Rubotherm TGA
Influence of pressure and coal rank on: Decomposition behavior Mass loss curves Char yields Conversion rates Shift of conversion temperatures Gas release Composition of pyrolysis gas Temperatures of gas specie formation Yields of total gas and single species Experimental conditions: up to 1100 °C 5 K/min inert atmosphere (Ar) 1, 5, and 10 bar (40 bar in preparation)
KiVan = Kinetische Versuchsanlage (pressurized drop tube) High pressure heterogeneous
kinetic data Investigation of diffusion controlled
reaction regime Investigation of inhibition effects Feed: Coal and coke dust (≤ 1 mm) < 28 g/min Heated length: 2,8 m (d=70 mm) Atmosphere : O2, H2O, CO2, CH4,
Ar, H2, CO 4 levels of gas sampling points and optical
ports over heated length
18
Lab Facilities – Investigation of Gasification (KIVAN)
Pressurized Furnace p ≤ 30 bar T ≤ 1.800 °C Atmosphere: Ar, H2, Air, CO, CO2, H2O(g)
Large Sample Furnace T ≤ 1800 °C Ar, N2, CO, H2
Sample space: 500 x 600 mm E.g. testing of refractory linings
TOM-AC = Thermooptical measuring device with controlled atmosphere Non-contact measuring of dimensional changes
(shrinkage, sintering, …) Weight measuring device Option for In-situ FT-IR Ambient pressure T ≤ 2.100 °C Atmospheres: Ar, N2, Ar/N2
Lab Facilities – Small-scale Pyrolysis Equipment (selection)
19
20
Investigation of wedding behavior New developed refractories of different
ceramic systems Test with different ashes/slags
(acid, intermediate, basic) Experimental conditions: Up to 1450 °C 10 K/min Reducing atmosphere
(5 vol.-% H2 in Ar) Results: Images of sample at each
temperature Automatic shape detection
(height, width, area, contact angle etc.)
Calculation of surface tension Microscopic examination of the contact
surface refractory/slag (after experiment)
TOM-AC … Thermo Optical Measuring System with Atmosphere Control
10
15
20
25
30
35
800 900 1000 1100 1200 1300 1400 1500
Wid
th in
mm
Temperature in °C
Slag A
Slag B
start of sintering (shrinking)
different slags on same refractory
1204 °C 1309 °C 1355 °C 1383 °C
Slag A (short melting interval)
Slag-refractory interactions – TOM-AC
I General introduction to the IEC
II Lab-scale experimental research
III Large-scale experimental research and operating experiences
21
Outline
22
Semi-scale and Large Test Facilities – Introduction
Installation and operation of 3 large-scale test plants and 1 semi-scale test plants:
Since 2003: HP POX unit - 5 MW(th) gasifier for gaseous and liquid hydrocarbons
Since 2010/11: Syngas-to-fuels plant – 2 t/d capacity gasoline synthesis
Under construction: Slagging fixed-bed gasifier – 10 MW(th)
Under commissioning: Internal Circulating Mild Transport Gasifier (INCI) – 100 kW (beginning of construction: 2010)
Objectives:
Demonstration and optimization of new process technologies at an up-scalable capacity
Investigation of particular fuel conversion phenomena and processes
Needs:
Highly trained technical and scientific staff for operation and research (sufficient for research campaigns lasting several weeks)
2–3 years for design and construction plus 2 – 3 years for 1st research period
High-level infrastructure (oxygen supply, steam generation, flares etc.)
Experience/ qualification
low inter-
mediate high
Infrastructural requirement
Equipment on offer
Operating costs
Effort for equip. acquisition
23
Semi-scale and Large Test Facilities – Introduction
HP POX© plant
STF plant
Construction site Fixed-bed slagging gasifier
COORVED/INCI gasifier
Demonstration of the INCI Gasifier Concept = Internal Circulating mild transport gasifier Funded by the German Federal Ministry of Economics and Technology (BMWi) Design and demonstration of a 100 kW mild
transport gasifier (standard pressure) Gasification of coals of different grades Prove superior performance for processing
low grade coals Gasifier modeling (flow sheet & CFD) Plant features: Ambient pressure
T ≤ 1.100 °C (resistively heated, flame ≈ 1.800 °C) Atmosphere: H2O, O2, CO2, H2, CO, Ar, N2 Feed: coal and coke dust (≤ 0,5 mm, ≤ 15kg/h) Measurement equipment: - Online-GC
- Online-FTIR - Radiometric densitometry - Particle Image Velocimetry - Thermography (visible light range)
9 levels of gas sampling , 3 levels with optical ports
24
Coal Gasification Projects – COORVED
Under commissioning
Fixed bed slagging (slag bath) gasifier for the utilization of low-grade fuels Funded by the European Development Fund and the Federal State of Saxony (Sächsische Aufbaubank – SAB) Ground breaking: 05/2012 Comissioning planned for 05/2013 IEC activities/project objectives: Operation of a 10 MW(th)
slagging fixed-bed gasifier at 40 bar
Investigating of slag formation and behavior at high pressures: Studies on fuel influence Collecting material property
data Application-oriented slag
modeling
Coal Gasification Projects – SBV
25
Status: 9/5/2012
26
HP POX® test plant
Gasification modes ATR (autothermal catalytic reforming of natural gas) Gas-POX (autothermal non-catalytic reforming of natural gas) MPG (autothermal gasification of liquid feeds)
Feedstock Natural gas Light or heavy fuel oils Residues of oil processing
System specifications Max. pressure: 100 bar Temperature:
1200 – 1500 °C Thermal power: 5 MW
≈ 500 m³(STP)/h NG ≈ 500 l/h liquid fuels
Adjustable reactor volume
technology First test runs: 2004
Partial Oxidation of Gaseous and Liquid Hydrocarbons
27
water treatment
storage
compressor and
heater
pump and
vaporiser
fresh water
liquid feeds
natural gas
liquid O2
high pressure
steam generator
reactor and quench
quench water
cooler soot water
droplet separator
flue gas
flue gas chimney
desulphurisation
reactor
soot water flasher
control roominstrumentation air
supplypower supply measuring stationnitrogen supply
syngas
HP steam: 380 °C, 115 bar
Oxygen: 280 °C, 110 bar
Reactor design: max. 1.500 °C, 100 bar
HP natural gas: 650 °C, 113 bar
Liquid fuels storage, max. 160 °C
HP POX® Plant Layout
28
Head
Free space
Quench
HP POX project
10/01 01/02 04/02 07/02 10/02 01/03 04/03 07/03 10/03 01/04 04/04 07/04 10/04 01/05 04/05 07/05 10/05 01/06
Design Installation Cold tests ATR tests Gas-POX MPG
COORAMENT project
01/06 04/06 07/06 10/06 01/07 04/07 07/07 10/07 01/08 04/08 07/08 10/08 01/09 04/09 07/09 10/09 01/10 04/10 07/10
ATR + Gas-POX MPG (bio-tar and oil) MPG (different heavy feeds)
European Union – European Regional
Development Fund – ‘Investing in your future‘
(Air Liquide Group)
Project funding since 2001 by:
Industry research
HP POX® Project Schedule
29
Research scopes: Reactor and process modelling : - autothermal non-catalytic reforming of NG up to 100 bar
- autothermal catalytic reforming of NG of up to 70 bar Reduction of reaction mechanisms – „simplification“ of models for implementation into fluid
dynamic simulations Trace elements – mechanisms of formation and distribution of trace components at highest
pressures Atomisation behaviour of liquid feeds
Test runs since 2004 (including gas supply for STF plant since 2010): ATR mode: 19 runs MPG mode: 33 runs
Gas POX mode: 11 runs
Typical test run schedule (24/7 operation):
Staff requirement per shift (2 working shifts): - 2 laboratory workers - 2 operators in the control room - 1 plant operator on the site - 1 technician for process measuring and control devices - 1 operator for sample taking
In total approx. 25 permanent employees
1,5 days for start-up
6–7 days for steady state test runs
1,5 days for shut-down
2–3weeks of maintenance and plant preparation
HP POX® Operating Experiences
30
time
tem
pera
ture
[°C
]
1) free space 2) catalyst bed
1)
2)
end of
pre-heating
nitrogen flushing
start of steam
and natural gas feed
oxygen feed,
ignition: start of ATR
HP POX® Operating Experiences – Typical Start-up Curve
31
CFD model validation by: - Process data - Residence time measurements (tracer tests) - Optical observation of flame size, structure and temperature
Steady state CFD simulations including elementary kinetics are performed to study: - Flame structure - Recirculation behaviour - Temperature and species distribution inside the reactor
Example – CFD modelling of oil gasification (MPG): Simulation of 3D-model of the nozzle and comparison with 2D
Extension of model nozzle to MPG nozzle Simulation in OpenFOAM using lesInterFoam (large eddy simulations) Characterization of quality and propriety of results; search for adequate parameters
to compare results with experimental data
HP POX® – Selected Research Results
32
0,00
0,02
0,04
0,06
0,08
0,10
0,12
0,14
0,16
0,18
0,20
0,22
0,24
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0
relative Verweilzeit t/tm0
Wa
hrs
ch
ein
lic
hk
eit
sd
ich
te E
(t) Signal: OGasR (2)
Signal: Austritt (6)
Anpassung durch Faltung
1
4
5
6
2
3
Example 2: Investigation of the residence to validate assumptions for CFD modelling and to derive a model formed by standard/ideal reactor types for complex CFD modelling
Method: detection of radio-activated argon at multiple levels along the reactor height
Introduction of the tracer material at the top measuring
Derivation of a reactor model based on ideal models (Plug Flow, CSR, DCSR)
HP POX® – Selected Research Results
33
Temperature distribution as modelled in K
Reactions: 113
Species : 28
Example 3: Optical observation of the flame under process conditions to validate CFD simulation results for the different gasifcation modes
Introduction of OPTISOS probe (camera device) into the reactor through the start-up-burner hole
Option for measurement of the whole flame length and
Still need for improved measurement techniques to gain data about concentration and velocity distribution in reducing flames (Problem: limited optical accessibility to high pressure, high temperature gasification reactors for common laser techniques)
HP POX® - Selected Research Results
Feed and products: Feed: 700 m³/h (STP)
syngas from HP POX plant
Main product: Gasoline: 90 kg/h (approx. 120 l/h) meeting the Euro IV standard
By-products – Fuel gas – Feed water
New STF technology – process characteristics:
Funded by CAC Chemitz GmbH, the European Development Fund and the Federal State of Saxony (Sächsische Aufbaubank – SAB)
Conversion in two steps: 1. Syngas Methanol 2. Methanol Gasoline
Novel reactors for isothermal operation
European Union – European Regional Development Fund – ‘Investing in your future‘
STF (Syngas-to-Fuel) Gasoline Synthesis
35
Test campaigns: June 2010 2 weeks December 2010 4 weeks Feb./March 2011 4 weeks Aug./Sept. 2011 4 weeks May/June 2012 6 weeks All runs with HP POX operation too! Results: 15 June 2012 first run on syngas
17 June 2010 first STF gasoline produced Feb./March 2011: - 95 h of operation
- 9.170 kg of produced methanol - 4.000 kg of non-stabilized gasoline
Aug./Sept. 2011: - 240 h of operation - 12.850 kg of produced methanol - 8.800 kg of non-stabilized gasoline
Current activity: Replacement of the gasoline reactor to test another cooling concept
STF (Syngas-to-Fuel) Gasoline Synthesis – Project experiences
36
Thank you for your attention!
Prof. Dr.-Ing. C. Hasse
Chair of Numerical Fluid Dynamics
3D CFD Modelling of chemically reacting flows
Multi-Scale Modelling of turbulence-chemistry interaction
Chemistry modelling for combustion and partial oxidation conditions
Modeling and simulation of turbulence
Multi-phase systems
Professorships at IEC
37
Prof. Dr.-Ing. B. Meyer
Chair of Energy Process Engineering and Thermal Waste Treatment
Prof. Dr. rer nat. S. Kureti
Chair of Reaction Engineering
Solid fuels (coal, biomass, waste), gaseous fuels (natural gas, fuel gas)
Technologies of pyrolysis, gasification, combustion
IGCC and XtL technologies
Fuel gas cleaning and gas treatment
Thermal waste treatment
Development of carbonaceous adsorbents
Liquid fuels (oil, biofuels), chemicals
Kinetics and modelling of processes and reactors
Technologies of industrial organic chemistry
Technologies of biofuels
Technologies of oil processing
Co-processing/hydrogenation of crude oil residues and synthetic materials
38
Research Focus & Partners
Coal
Stranded Gas
Biomass
Waste
Electricity/Heat
Gasoline/Diesel
Basic Chemicals
(Synthetics,
Plastics)
Fertilizers
Hydrogen
SNG CO2-capture
Research on sustainable conversion routes including the key processes…
jointly with our partners (selection):
Gasification Synthesis Refinery
Residuals
Background – Technical Know How – Power/Chemical Plants
39
Stationary modeling of IGCC, chemical & polygeneration plants Dynamic modeling of gasifiers and IGCC plants Projects
55+ IGCC COORIVA Polygeneration ibi Studies for industry
Industry Cooperation RWE, Vattenfall, E.ON, Alstom, Sharyngol, …
Software Know How – Flow Sheet Simulation
40
Validated flow sheet models are available for:
Gasification Processes:
Entrained flow: Shell/Prenflo, Siemens, GE, CoP, Carbo-V, MHI
Fluidized Bed: HTW, Güssing, KBR, U-Gas, KRW
Air Separation Unit:
LP-ASU
HP-ASU
Gas Processing:
Gas cleaning: Water wash, Rectisol, Genosorb/Selexol*, MEA
Gas conversion: sweet/sour CO-Shift, HCN/COS-Hydrolysis
Sulfur recovery: Claus + Tail gas treatment
Pressure swing adsorption
Synthesis Processes:
Methanol
MtG MtO* DME (indirect)
Fischer-Tropsch
DME (direct)
Methanation (SNG)
Ammonia*
Power Block:
Gas turbine (E-class, also part load)
Bottoming cycle
Large tool box of models available:
Complex heat integration and integrated concept development possible (CCS-IGCC, IGCC, Polygeneration, BtL, CtL)
Coupling of all models from several environments possible (Aspen Plus, EBSILON, EES, ChemCAD)
* currently under development, dynamic modelling in Dymola/Modelica
Software Know How – CFD Simulation
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