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On the Challenges of Coal Gasification Based Syngas Conversion Systems
Yong-Wang LiSynfuels Americas, Inc (Leesburg, VA )
Synfuels China LTD (Beijing) [email protected]
Global Energy Supply System
Upstream resources: Coal/Minerals , Oil, Natural gas, Nuclear minerals, Biomass/wastesGeothermal, Winds, Sea wave, Solar
Down stream products:Electricity, Civil fuels, Motor fuels (gasoline/jet fuel/diesel)
Science & technology from resources to products large centered facilities: footprint controls
Status: China
Importing oil & gas Security, trade balance
Practical: coal conversion New energy technology
China has to find solutions to completely replace fossil fuels with new energy
resources within about 100 years.
Hydro/Nuclear/Wind 9.6%20% (?) Oil 17.8% (?) Natural gas 5.1% 10% (?) Coal 67.5% 60% (?)
Coal to oils：the strategic field
1938-1962 1997-2010
Scientifically hard topic: Experiences Germany/South AfricaLessons China and US
1980-1993
• Pilot 20b/d 2000-2008• Demon 5000b/d 2006-2009
Synfuels China
Synfuels China (founded 2006, Beijing)
Synfuels China R&D (Beijing)150 researchers 50 engineersLab R&DPilot testing
Synfuels China Engineering Design/EPC/commissioning500 engineers
Synfuels China Catalysts(Erdos) 200 staff12000 t/y F-T catalyst
Synfuels Americas (Leesburg)International projectDevelopment10 members
ChemEssen (Korea-based, Suoel)Chemical data base development applications
Syngas conversion: using “hard” materials
•Syngas conversion Development: New materials, reaction mechanisms, thermal data, new catalysts, unit technologies, new products and processes, integration of a process
• Engineering skills: Design and construction • Understanding Gasification: Improve gasifiers, integration, water handling……
Olefin (C2/C3)
Solvent
Gasoline
Lubricate
CH4 (CNG/LNG)
Product up-grading
Hydro-Pyrolysis Separation
H2/CO
Biomass
CatalyticGasification
GasificationPurification Conv. SG
Separation & Purification
H2/CO
CH4CH3OHOil
Chemicals
Jet fuels
Diesel
Others
CH4
Coal
Residue
Synfuels R&D EffortsMTFT technology formulation (1997-2015)
LAB1.0L
PPΦ 0.3m
DEMOΦ 5.Xm
IndustrializationΦ 10.Xm
1000 t syncrude /t Fe catalystCatalysis and catalyst Reactor and process
Synfuels China— R & Efforts： Catalysis technologiesSo far correct structure
• Research from fundamental (QM,CFD) to application (catalyst, reactors..)• Pilot plant testing, engineering design of plants, operation of plants
Fundamental research Application development Industrial operation
Seamless working environment for whole chain of R&D application ?
Catalyst related problems work but not the best
Synfuels China- IDL Projects overview
Shenhua Ningxia project• 100000b/d liquid • Dry feed gasifers (24)• Linda ASU (10)• SFC F-T 2 trains 8 reactors • Capital cost 58 billion RMB
• 85% construction completed• FT+ upgrading
design/construction services by SFC engineering
• 2016 commissioning
Synfuels China- IDL Projects overview
Luan project• 25000b/d liquids • 4 Shell gasifiers• Air products ASU• SFC F-T 1 trains 2 reactors • Capital cost 18 billion RMB
• 95% construction completed• SFC engineering overall design• FT+ upgrading
design/construction EPC by SFC engineering
• 2016 commissioning
Synfuels China- IDL Projects overview
Yitai HJQ project• 25000b/d liquids • 6 HTL gasifiers• Air products ASU• SFC F-T 1 trains 2 reactors • Capital cost 15 billion RMB
• 65% construction completed• SFC engineering overall design• FT+ upgrading
design/construction EPC by SFC engineering
• 2017 commissioning
Synfuels China- IDL Projects overview
Yitai Dalu /Guizhou projects• 50000b/d liquids • NM gasifers 10• SFC F-T 1 trains 4 reactors • Capital cost 29.5 billion RMB• With new version of design • 3 t water /t oil • Super-clean gasoline
Synfuels China– The Stepwise Process
Energy efficiencyProduct quality
Stepwise liquefaction
DieselProducts
up-grading
Gasification
O2/H2O
Gasoline
Kerosene
Solvent
…
ChemicalsResidues
DCL Process
Technology improvement
F-T synthesis
18-20MPa 3-5MPaStepwise liquefaction
SEP&HYDRO
Recycling solvent
H2Hydro-liquefaction
ICTL Process＋
Biomass
Younger coal
Synfuels China– The Stepwise Process
The hydropyrolysis test at capacity of 1t coal /h facility: Several low rank coals tested, ash contents limited to < 10% Two coals are successfully operated to increase the liquefaction efficiency from 44% (IDL) 60% (STWL)Estimated Capital cost 1 million liquids: from 16.0 billion RMB 12.0 billion RMB
Analysis instrument ESR, GC-MS, FTIR, NMR, XPS,XRD……
Conversion Processes
Syngas conversion• Fischer-Tropsch fuels straight chain based chemicals• MTO C2-C4 olefines• Lurgi gasifier SNG ( methanation ~ inefficient)
Major issues• Fischer-Tropsch catalysts and integration philosophy
Syncrude processing Fe gasoline and diesel Co diesel
• MTO catalysts • SNG economics & waste water management
Synfuels China/US EffortsSynfuels Americas- Initializing International activities
Atom
ic le
vel r
esea
rch
to u
nit d
evel
opm
ent
Pilo
t sca
le (2
0b/d
) to
com
erci
alsc
ale
(110
000/
d)
50000b/d virtual Plant based on mathematic models
Industrialized Gasifiers in China
GasifiersTerms Moving Bed Shell HTL GSP Choren NM SE Water
slurry ECUST
Feed PelletsDry
powder
Dry
powder
Dry
powder
Dry
powder
Dry
powder
Dry
powderSlurry Slurry
Hydrodyn
-amic
Moving
beds G-up
Entrained
G-up
Entrained
G-down
Entrained
G-down
Entrained
G-down
Entrained
G-down
Entrained
G-up
Entrained
G-down
Entrained
G-down
Major
points
Waste water
Steam comsup.
Capacity
Cost
Complex
H2/CO low
Black water
Carbon eff.
Flowing ash
H2/CO low
Black water
Carbon eff.
Flowing ash
H2/CO low
Black water
Carbon eff.
Flowing ash
H2/CO low
Black water
Carbon eff.
Flowing ash
H2/CO low
Black water
H2/CO low
Black water
Efficiency
Flowing ash
Black water
Efficiency
Flowing ash
Existing gasification technologies have not optimized for a whole syngas production processes. It works, and it can be much better……
Moving bed: Success and Failure
Coal
OxygenSteam
LP steam
Ash
Recyclingwater
Raw gas300-520oC
Gas water Gas water
BFW
Gas water
BFW
BFW
Dewater gas
BFWBFW
Coal lock
Gasifer
Ash lock
Lock gas
SteamWater jacket
Rich in CH4Only reasonfor CNG
• CH4 12-14% in cleaned gas, some tar recovered SNG• H2/CO=1.8-2.5, avoiding WGS in most cases
• Coal balances coal powder usage• Steam consumption is large water saving challenges• Waste water with complicated organic contaminates • Capacity low
Pulverized Coal stack
Mill
Hot flue gas
Coal
Coal powder lock
Coal powderFeeding tank
Carrying gasCO2
Flue gas
Slag quench
Slag lock
Oxy
gen
Oxy
gen
Coal + CO2
BoilerBl
ack
wat
er
Slag
Flying ash
Wet ashBFW
Steam
Flying ash filters
Quenching gas recycle ~ 250oC
Dust
y ga
s str
eam
~ 3
00o C
Dust
y ga
s str
eam
~ 3
00o C
Wet
was
hing
tow
er
Clean water
Black water
Wet ash
Dust free raw gas
Dry Feed Shell
• Dry feed with higher efficiency, less oxygen consumption, steam recovery• Much less black water treatment
• Cost is high, low H2/CO = 0.3, water system optimization, Steam for WGS section
Syngas conditioning
Shell SCGP Siemens/GSP HTL ECUST GE-Energy Lurgi (Mark IV)
(CO+H2) Basis : 100000 Nm3/h
CH4: 15000 Nm3/h
H2: 23500CO: 76500CO2 : 6000N2 +H2S: <1000H2O: ~3000
H2: 23500CO: 76500CO2 : 6000N2 +H2S: <1000H2O: > 100000
H2: 23500CO: 76500CO2 : 6000N2 +H2S: <1000H2O: > 100000
H2: 43000CO: 57000CO2 : 28000N2 +H2S: <1000H2O: > 100000
H2: 65000CO: 35000CO2 : 28000N2 +H2S: <1000H2O: > 30000
Coal tar
Purification
H2: 65000CO: 35000
WGS: 22000 COSimple scheme
WGS: 41500 COComplicated scheme
WGS: 41500 COAdding steam: > 60000Complicated scheme
Black water: 1Black water: 3 Black water : 3
Waste water : 5Very difficult water
• High efficiency: Slurry dry feed, ash dust remove, new structure, coal powder delivery
• Water handling: Desalting and recycling (2000t/d: black water 30-100t/h2-5t/h)
• Syngas quality: Increase H2/CO from 0.3 to 0.7-1.0, partial water quenching system
• Safety and availability: Hydrodynamic understanding, more clever design
Gasification: some points to think
The Funny Cycle
650k years ago
How long we need for the complete sustainable system formulation?
Our destination is where we started, with much harder sustainability
Tech
nica
l bar
riers
Electricity Clean fuelsChemicals
Ancient FutureNow
Future for Energy Science
Research: Fischer-Tropsch
Future for Energy Science
Would it work at the large capacity?
Remarks
1.Syngas conversion: better catalysts smart reactor and process technologies
2.Effort here in China a unique platform advanced clean coal technologies
contribution to the world
3.Advanced gasification technologies coal to clean fuels CTL/SNG projects;
gasification technologies have to be upgraded with consideration of not only gasifier
itself, but also the whole integrated system covering coal delivery to syngas cleaning
units
4.Next step very clean and efficient use of coal
5.Long term thinking: bridging what being done today and what to be done tomorrow
essential development in SCIENCE highly demanded
