KIT – Universität des Landes Baden-Württemberg und
nationales Forschungszentrum in der Helmholtz-Gemeinschaft www.kit.edu
Engler-Bunte-Institut, Chemische Energieträger – Brennstofftechnologie, EBI ceb
Institut für Technische Chemie, Vergasungstechnologie, ITC vgt
The Entrained Flow Gasifier in the KIT bioliq® process
Thomas Kolb, Bernd Zimmerlin
2SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
De-centralized / central concept
Energy density: 2 GJ/m3 25 GJ/m3 36 GJ/m3
Energy densification of biomass in regional
distributed plants by bioliqSyncrude production
Economic conversion in large scale to syngas
and further refining into fuels & chemicals
3SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Process chart
bioSyncrude
bioSyncrude
Synfuel
Bio
ma
ss
Syngas
De-central Centralized
Fuel
synthesis
DME
synthesis
Filter Sorption CO2 and water
separationCatalyst
O2 (Steam)
Gas cleaning and conditioning
High pressure
entrained flow
gasification
Slag
Fast pyrolysis
Pre-treatment
4SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Status of the bioliq project
Stage I Stage II Stage III Stage IV
Process Fast pyrolysis High pressure
entrained flow
gasification
Gas cIeaning
and Synthesis I Synthesis II
Product BioSyncrude Synthesis gas Dimethyl ether Gasoline
Capacity 2 MW (500 kg/h) 5 MW (1 t/h) 150 kg/h < 100 l/h
Realization 2005 - 2008 2008 - 2013 2009 - 2011
State In operation In operation In operation
Partners: TCI: 64 Mio.EUR
5SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Fast pyrolysis
(2 MW, 500 kg/h)
EFG
(5 MW, 1 t/h)
Synthesis
(2 MW, 50 kg/h)
Gas Cleaning
(2 MW, 700 Nm3/h)
Tankfarm
Feed
Preparation
Slurry
Preparation
bioliq® Pilot Plant
6SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Pyrolysis flow chart
In cooperation with:
7SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
0% 20% 40% 60% 80% 100%
Rape straw
Empty Fruit Bunches
Corn straw
Miscanthus
Bagasse
Corn Cobs
Eucalyptus
char and condensate fraction of different biomasses (ar) after fast pyrolysis
char incl. ash condensate incl. moisture of biomass
Liquid/solid-ratio
5:1
4:1
2:1
1,5:1
Pyrolysis char/liquid yields
Wheat straw
8SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
R&D
• Storage stability of fuel
• Sedimentation
• Instrumentation
• Corrosion, abrasion
• Plugging, fouling
Rheological investigation of suspension fuel for gasification
Suspension Experimental Plant - SEP
9SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Pressurized Atomization Test Rig - PAT
Technical data:
• L = 3 m
• D = 0.3 m
• Optical access
• 3-D traverse
Operating conditions:
•pReactor = 1 – 20 bar (ü)
•TLiq = 10 – 50 °C
• MLiq = 10 – 200 kg/h
• ηLiq.max = 1000 mPa.s
Pressurized Atomization Test Rig - PAT
10SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Pressurized Atomization Test Rig – PAT
Influence of reactor pressure on SMD
• 𝑴𝑳𝒊𝒒 = 20 kg/h (water)
• z = 200 mm nozzle dist.𝑾𝒆 =𝝆𝒈𝒂𝒔 𝒖
𝟐 𝑳
𝝈= const.
SM
D [
µm
]
uG
as
[m/s
]
11SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
We = 500 at 1 und 21 bar
12SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
High pressure entrained flow gasification
Technical Data
• 5 MW (Mfuel = 1000 kg/h)
• 40 bar (research), 80 bar (production)
• Gasification agents: O2, steam
• Feed: bioSyncrude® (slurry)
13SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
bioliq® Gasifier- Prozess Optimization
14SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Mass, Species and Energy balances
15SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
V1 (40bar) V14 (80bar)
Balances Raw dataAlteration
waste water streamRaw data
Alteration
waste water stream
M balance Input ṁ [kg/h] 3942 3942 3748 3748
Output ṁ [kg/h] 4543 3942 7022 3748
Difference ṁ [kg/h] 601 115,25% 0 100,00% 3274 187,37% 0 100,00%
C balance Input ṁ [kg/h] 386 386 405 405
Output ṁ [kg/h] 369 369 402 402
Difference ṁ [kg/h] -17 95,58% -17 95,58% -3 99,28% -3 99,28%
H balance Input ṁ [kg/h] 290 290 292 292
Output ṁ [kg/h] 385 319 655 291
Difference ṁ [kg/h] 95 132,84% 29 109,84% 363 224,29% -1 99,74%
O balance Input ṁ [kg/h] 2854 2854 2749 2749
Output ṁ [kg/h] 3362 2828 5601 2691
Difference ṁ [kg/h] 508 117,79% -26 99,09% 2852 203,76% -58 97,89%
N balance Input ṁ [kg/h] 388 388 329 329
Output ṁ [kg/h] 386 386 364 364
Difference ṁ [kg/h] -1 99,66% -1 99,66% 35 110,73% 35 110,73%
Q balance Input kW 17674 17674
Output kW 18359 17561
Difference kW 685 103,88% -113 99,36%
Mass and species balance
16SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT
Helmholtz Virtual Institute
for Gasification Technology
High Pressure Atomization
Fuel Conversion
Entrained Flow Gasification
Numerical Simulation
Measuring Techniques
Process Control
Slag Control
bioliq® EFG5MW
80 barSlag
O2 / Steam
fuel
Process Efficiency
Raw Syngas
Materials
Integrated Research on Gasification
PAT
REGA
Helmholtz Virtual Institute for Gasification Technology – HVIGasTech
Research Field Energy
Thomas Kolb │ KIT
18
WP1 Data Evaluation
• Particle kinetics
• Slag
• Heat transfer
WP3 Validation
• Gasification, atmo.
• Gasification, pressure
• Diagnostics
WP2 Simulation
• LES / RANS
• EF-Gasifier
Model of reacting
multi-phase flow
at high pressure
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0.10.20.30.40.50.60.70.80.9
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
ternary lines
Na6Si
8O
19
Na2SiO
3
Na2Si
2O
5
Na6Si
2O
7
Na4SiO
4
Al6Si
3O
13
NaAlO2
NaAl9O
14
Na2Al
12O
19
NaAlSiO4
NaAlSi3O
8
ternary points
W(A) W(B) W(C) o
C0.40792 0.21201 0.38007 1519.420.42251 0.19540 0.38209 1505.510.88518 0.01816 0.09666 1470.060.54021 0.16640 0.29338 1275.750.44654 0.39125 0.16221 1254.260.44174 0.43333 0.12493 1177.650.67037 0.12095 0.20868 1112.210.61689 0.14329 0.23982 1066.450.77440 0.08320 0.14240 1048.170.35263 0.62645 0.02092 991.550.41326 0.54413 0.04261 982.160.17265 0.81468 0.01267 970.050.42828 0.51801 0.05371 962.790.42218 0.53200 0.04583 952.360.20999 0.77849 0.01153 933.580.73407 0.18613 0.07980 869.850.71991 0.24417 0.03593 736.290.70900 0.24848 0.04252 736.290.62044 0.23136 0.14821 706.870.59874 0.24282 0.15844 706.860.60031 0.23540 0.16429 677.830.60155 0.23193 0.16653 659.73
1:2:3:4:5:6:7:8:9:
10:11:12:13:14:15:16:17:18:19:20:21:22:
12
3
4
56
7
8
9
10
11
12
1314
15
161718
19
202122
NaAlO2_HT
Na 2
SiO3
NaA
lSi3O8
SMIM
Al2O
3 (s)
NaA
l9O14 (s)
neph
Na6Si
2O
7
Na4SiO
4
Na2Si
2O
5
Na6Si
8O
19
Na2O Al2O3mass fraction
carn
A = SiO2, B = Na2O, C = Al2O3
SiO2
Na2O
SiO2
Engineering tool for design and scale-up of
technical entrained flow gasifiers
Scientific Approach and Work Packages
Thomas Kolb │ KIT
19
Objectives
Data for particle conversion process at high
heat-up rates, T and p
Analysis of feed and intermediates (WP 3.1)
Development of advanced methods
Effective Reactivity as function of Particle
History (WP 2.1, 2.2)Results
Unique data for various fuels from
comparison of different exp. methods
Intrinsic reaction kinetics at p = atmo. as
function of heating rate
Generation of secondary chars at relevant
process conditions
Temperature dependent release of K from
biochars (coop. WP 1.2)Fluidized bed reactor
Pressurized TGA
Herman Andreas Philipp
WP 1.1 Particle Kinetics
Thomas Kolb │ KIT
20
Objectives
Extension of thermo-chemical and thermo-
physical databases
Modelling rheological properties in
dependence of slag / gas composition, T, p
Validation with bioliq® slags (WP 3.2)
Results
Inclusion of P2O5, FeO/Fe2O3 in the
database
Slag viscosity model including charge
compensation and the lubricant effect
Kerstin Andre Guixuan Sören
Molecular Beam Mass Spectrometer
Viscosity surface: SiO2-Al2O3-CaO at 1600 °C
WP 1.2 Slag Properties
Thomas Kolb │ KIT
21
Objectives
Models for absorption coefficient / emissivity
of CO2/H2O/CO/H2 mixtures at high p
Scattering coefficient for droplets and
particles
Implementation of models in CFD-Model
(WP 2.2)
Results
Measurements for H2O / CO2 mixtures
up to 1770K at ambient pressure (DTU)
New correlations for emissivity of CO2 at
pressures up to 40 bar
Extension of Hottel’s-graphs to high p
Michael
Gas emission spectrum at 40 bar and 1700 K
Emissivity of CO2 at 40 bar
WP 1.3 Radiation Modeling
Thomas Kolb │ KIT
22
Objectives
LES methods for the simulation of sub-
domains and isolated phenomena of the
gasification process
Interpretation / complementation of
experimental data by num. simulations
Comparison of RANS and LES results
Results
LES coupled with Lagrangian Particle
Tracking for EFG
Sub-model for vaporization of complex
fuels (multiple components, emulsions)
developed and integrated
LES Simulation of REGA burner near-field
(WP 3.1)
Georg
LES of turbulent particle dispersion (testcase)
LES study of burner near field in REGA
WP 2.1 LES/RANS Calculations
Thomas Kolb │ KIT
23
Objectives
CFD based model of multiphase
reacting system at high pressure
Engineering tool for design and scale-up of
technical entrained flow gasifiers
Validated by lab-scale and pilot-scale
experiments
Results
Assessment of sub-models (turbulence,
turbulence-chemistry interaction)
Sensitivity study for simulation sub-models
REGA simulation and validation (WP 3.1)
Literature-based simulation of bioliq®
gasifier (WP 3.2) Kinetics 1 Kinetics 2
Marco
Slurry trajectories in bioliq® gasifier
Validation of REGA numerical simulation
WP 2.1 Numerical Simulation of EFG
Thomas Kolb │ KIT
24
Objectives
Provide detailed EFG data (REGA) for
model development and validation
Local profiles of T, u, c and particles
Mathematical description of single
process steps
Christian
Bench-scale atmospheric EFG REGA
Results
Nozzle design and spray characterization
for WP 2.1, 2.2
Parameter study on fuel specification,
atomization, stoichiometry for WP 2.2
Particle sampling at different conversion
levels for WP 1.1
Application of diagnostics by WP 3.3
WP 3.1 Experimental Validation, atm.
Thomas Kolb │ KIT
25
Objectives
Generation of unique data sets for
model validation at high pressure
species, temperature, slag, balance
Application of advanced diagnostic
tools for process data / monitoring /
control
Results
First test runs at 40 / 80 bar with model
slurry (straw char / wood char in glycol)
Data for mass, species and energy
balance for WP 2.1, 2.2
Slag samples for WP 1.2
Mark
Pilot-scale High Pressure EFG bioliq®
WP 3.2 Experimental Validation, pressure
Process Data EFG bioliq®
Thomas Kolb │ KIT
26
Objectives
Diagnostic tools for high pressure EFG
Laser based systems
Advanced gas / liquid analytics
Generation of validation data
Online process monitoring
Results
Successful application of Laser-induced
incandescence (WP 3.1) soot / REGA
Laser induced breakdown spectroscopy
developed/adopted (WP 3.1) alcaline /REGA
Absorption spectroscopy developed and tested
on lab-facility CO
PSI diagnostic toolbox at REGA / bioliq®
Patrick
Philip
REGA Campaign 2012Optical probe
LII signal
Luminosity of
char clouds
WP 3.3 Diagnostics
Thomas Kolb │ KIT
27
Leading Scientists
Michael Müller
FZJ
Thomas Kolb
KITManfred Aigner
DLR
Reinhold Kneer
RWTHNeda Djordjevic
KITRoman Weber
TUC
Peter Jansohn
PSI
Bram van der Drift
ECNWeihong Yang
KTH
28SGC Gasification Seminar, Malmö, Sweden, October 15-16, 2014 Thomas Kolb KIT