the bgl-commercial plants and pilot testing status and ... · the bgl-commercial plants and pilot...
Post on 10-Mar-2021
11 Views
Preview:
TRANSCRIPT
6th International Freiberg Conference 2014
ENVIROTHERM
The BGL-Commercial Plants and Pilot Testing
Status and Perspectives on
Envirotherm BGL-technology
Hansjobst Hirschfelder
6th International Freiberg Conference on IGCC &XEL Technology
May 19 – 22, 2014 Dresden/Radebeul, Germany
1
6th International Freiberg Conference 2014
ENVIROTHERM
CLEAN ENERGY CLEAN AIR
(Air pollution control)
Bamag International
Water Purification and
Waste Water Treatment
Technologies
CLEAN WATER
Bamag MENA
Waste Water
Treatment Technologies
Envirotherm
Modern
Gasification Technologies
Envirotherm
Multi-Purpose
Combustion Technologies
Envirotherm
Sewage Sludge Incineration
Envirotherm
Highly Efficient
Flue Gas Cleaning Technologies
Envirotherm
Production and Distribution of
Honeycomb SCR Catalysts
Envirotherm Group
Environmental technologies company offering engineering services to customers in the
energy, air pollution control and water sector
2
6th International Freiberg Conference 2014
ENVIROTHERM
3
• BGL advanced pressurized, slagging fixed bed gasification
(former British Gas/Lurgi, today co-ownership of Envirotherm and
ZEMAG)
• CFB atmospheric gasification in the circulating fluid bed
• involvement in design build, test and further develop of the
demonstration plant at the IEC in Freiberg
Envirotherm’s Involvement in Gasification
6th International Freiberg Conference 2014
ENVIROTHERM
CFB Gasification
4
6th International Freiberg Conference 2014
ENVIROTHERM The CFB Gasification Process:
Development and References
• Fluid bed technology was developed in the early 1920s (original Winkler fluid process)
• Lurgi developed the circulating fluid bed (CFB) applying high “slip velocity”, introduced CFB to
power plants and applied the process to gasification of various feedstock
• Fluid beds are operated at temperatures below ash softening point (i.e. 800-950 °C) with an
even temperature profile in the reactor and excellent heat and mass transport
• Proven technology with numberless references
• Envirotherm acquired the CFB gasification process from Lurgi/Lentjes in 2003
• Envirotherm’s commercial reference plants include
- first CFB gasification in the cement industry – Ruedersdorf, Germany
- CFB gasification of demolition wood – Geertruidenberg, The Netherlands
- CFB gasification of high ash Indian coal – Barbil, India
5
6th International Freiberg Conference 2014
ENVIROTHERM The CFB Gasification Process:
Key Benefits
Crude Gas
to Consumer
Recycling
Cyclone
Fuel
Nozzle Grate
Ash
Seal Pot
CFB
Gasifier
• fuel flexibility: nearly all types of (high ash) coal and
other carbonaceous fuels, e.g. waste
• gasifier vessel is made from mild steel
• modular design (spare/reliability)
• atmospheric circulating fluidized bed gasifier, well
suited for fuel gas production
• air blown gasifier, no ASU required
• low calorific syngas
• excellent heat and mass transfer due to high
turbulence of inert bed inventory
• high thermal stability
• high carbon conversion
• HP steam production
• bottom ash can be reutilized
• low requirement for fuel preparation
Gasification Agent
(Air + Steam)
6
6th International Freiberg Conference 2014
ENVIROTHERM CFB – Selected References:
Jindal Steel & Power, India
Barbil / Orissa, India:
• two CFB gasifiers in parallel
• fuel: domestic Indian coal up to 40% ash, 8% moisture
• per gasifier: 23t/h coal, 50,000 m³n/h syngas
7
6th International Freiberg Conference 2014
ENVIROTHERM
Solid
Fuel
Bed
Material
Bed Ash
Air
Air
Air
Air C.W.
C.W.
Cyclone CFB
Gasifier
Radiation
Pass
Turbine / Generator
Steam Drum
Deaerator
Su
pe
rhe
ate
r
Eva
po
rato
r Quench
Wet ESP
Clean Fuel Gas
Recirculation Pump
Ash Tar
Dust
Water
Prim. Air
Sec. Air
C.W.
Seal Pot
Water
CFB – Selected References:
Jindal Steel & Power, India
Barbil / Orissa, India: Process Flow Diagram
8
6th International Freiberg Conference 2014
ENVIROTHERM
BGL Gasification
9
6th International Freiberg Conference 2014
ENVIROTHERM
• The improved “slagging” version of the existing Lurgi Gasifier was jointly developed
with British Gas from 1974 onwards in Westfield/Scotland to:
- have a reactor to produce non-leachable vitreous slag rather than dry ash
- improve specific reactor throughput
- increase fines content acceptable in feed
- reduce steam consumption and consequently gas condensate production
- recycle tars/oils to extinction
- increase CO/H2-yields
• Technology successfully tested with a wide range of coals and proven on
commercial size gasifier units until 1991
• First commercial plant at Schwarze Pumpe, Germany, from 2000 until 2007, using
a broad range of feedstock including waste
• Technology jointly owned by Envirotherm GmbH and ZEMAG Clean Energy
Technology GmbH
Introduction to BGL
10
6th International Freiberg Conference 2014
ENVIROTHERM
Operational
• Extensive development history
• High cold gas efficiency between 82% and 93% /
high specific throughput
• Low oxygen consumption (ca. 0.5-0.6 kg / kg Coal)
• Low steam consumption (ca. 0.3-0.4 kg / kg Coal)
• Lower aqueous liquor production
• Fuel flexibility (nearly all coal types and other types of
fuels (e.g. waste) can be processed)
• Excellent load following capabilities
• Modularity (spare/reliability)
• Slag as by-product is non-leachable (vitrified) and can
be utilized (road work)
Capital/Investment
• Simple gasifier design (no exotic materials, no
sophisticated heat exchangers)
• Smaller air separation unit (ASU) due to low oxygen
requirements
/ WASTE
Gasification
700 – 1,100ºC
Combustion
2,000 – 2,100ºC
Drying and Pyrolysis
< 700ºC
Raw Gas
600 - 800ºC
The BGL Gasification Process:
Key Benefits
11
6th International Freiberg Conference 2014
ENVIROTHERM BGL Gasifier
Process Applications (overview)
BGL
Gasifier
Air Separation
Unit
Alternative
Feedstock
Input Gasification
Shift Reactor Gas Clean-Up
Methanol
Synthesis
Methanation
Fischer Tropsch Synthesis
Chemicals/ Gasoline
Synthetic natural gas
Fuels
Oxygen
Coal
Power
Products Additional Processing Conversion
CO2 IGCC
Ammonia Synthesis
Fertilizers
Typical BGL Gas Composition
for bituminous coal
H2 33 %
CO 56 %
CO2 4 %
CH4 7 %
• BGL Process has clear investment and operational
advantages in a wide range of application.
• According to gas composition BGL is well suited to
SNG production because of its high efficiency and the
presence of CH4 in product gas
12
6th International Freiberg Conference 2014
ENVIROTHERM
China
Commercial BGL
13
6th International Freiberg Conference 2014
ENVIROTHERM
Client Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC
Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier, Inner Mongolia, PRC
Location of facility Hulunbeier, Inner Mongolia, PRC
Application Syngas for the production of 500,000 t/year Ammonia,
800,000 t/year Urea
Feedstock Domestic dried and briquetted lignite
Features Two (2) + one (1) BGL gasifiers (40 barg operating pressure)
Synthesis gas production 119,000 Nm³/h
Status - Installation of entire plant completed in 2011
- Gasifiers have been operated for limited time (limited feedstock)
- Technical issues with plant units (briquetting unit and ASU)
BGL in China - Hulunbeier
14
6th International Freiberg Conference 2014
ENVIROTHERM BGL in China - Hulunbeier
15
6th International Freiberg Conference 2014
ENVIROTHERM BGL in China - Hulunbeier
16
6th International Freiberg Conference 2014
ENVIROTHERM
Client China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC
Location of Facility Luoyang, Henan Province, PRC
Application Fuel gas for industrial complex –
Substitution of 18 existing
fixed bed low pressure gasifiers
Feedstock Local hard coal
Features One (1) + one (1) BGL gasifiers
Gas production 43,000 Nm³/h
Start-up 2014
Status Detailed Design finished in 2011
Work in progress
BGL in China - Yituo
17
6th International Freiberg Conference 2014
ENVIROTHERM
Client China National Coal Development Co. Ltd, Beijing, PRC
China National Coal Corp, Beijing, PRC
Location of facility Ordos Tuke, Inner Mongolia, PRC
Application Syngas for the production of 1,000,000 t/year Ammonia,
1,750,000 t/year Urea
Feedstock bituminous coal
Features Five (5) + two (2) BGL gasifiers (40 barg operating pressure) with stirrers
Synthesis gas production 295,000 Nm³/h
Start-up 2013 / 2014
BGL in China – China National Coal
18
6th International Freiberg Conference 2014
ENVIROTHERM
India
Commercial BGL
19
6th International Freiberg Conference 2014
ENVIROTHERM
Client Shriram EPC Ltd., Chennai, India
Location of Facility Dharma, Orissa, India
Application Syngas for the production of synthetic ammonia
Features Two (2) BGL gasifiers, one relocated from Germany, second gasifier
built identically to relocated one, using high ash domestic hard coal
Raw gas production 150,000 Nm³/h
Feedstock Indian high ash coal
Start-up 2016
Status on hold
BGL in India
20
6th International Freiberg Conference 2014
ENVIROTHERM
Demonstration Plant Freiberg
21
6th International Freiberg Conference 2014
ENVIROTHERM BGL Gasifier
Pilot Scale Slagging Gasifier in Freiberg, Germany
• Pilot scale gasifier installed at the IEC, TU
Bergakademie Freiberg, next to HP-POX and
STF unit
• Scale down design of pilot plant was
challenging as certain process equipment had
to be newly designed and adapted to make it
fit for purpose
• Commissioning Q2 2014
22
6th International Freiberg Conference 2014
ENVIROTHERM BGL Gasifier
Pilot Scale Slagging Gasifier in Freiberg, Germany
• Pilot plant comprises of coal intermediate storage, feeding
system, reactor, gas cooling and gas water system
• Gasifier features:
- 0.6 m inner diameter
- three tuyères (inlet nozzles for gasification agents)
- reactor and quench in one vessel
• Characteristics / Consumption figures:
- Operating pressure 40 bar
- 1.38 t/hr bituminous coal (Polish coal, bench mark)
- 430 Nm³/hr O2 consumption
- 450 kg/hr steam consumption
- Reactor capacity approx. 8.5 MW (LHV gas)
- Approx. 2,300 Nm³/hr product gas
23
6th International Freiberg Conference 2014
ENVIROTHERM BGL Gasifier
Pilot Scale Slagging Gasifier in Freiberg, Germany
24
6th International Freiberg Conference 2014
ENVIROTHERM
25
• Principal R&D goal:
• investigation of liquid slag behaviour under high pressure
• characterisation of slag for a variety of fuels with different ash compositions
• Further, the facility allows for testing of coals to demonstrate the applicability of “unknown”
feedstock without interrupting the operation of a commercial plant. Thus the risk for an
operating company to loose valuable production capacity while testing components or process
adaptions is significantly lowered.
• The plant allows for a full HMB, to allow a for a lower safety margin in designing commercial
facilities.
• Minimize tar/oil in gas → target: increase usable gas output for IGCC application
• Maximize tar/oil in gas → target: recovery and sale
Research and Development
6th International Freiberg Conference 2014
ENVIROTHERM
Thank you for your attention!
Questions?
26
top related