Research and Development of Gasification and CO2 Capture

Copyright 2009 ITRI 1

Research and Development of Gasification and CO2 Capture

Technologies of ITRI

Heng-Wen Hsu

Industrial Technology Research InstituteEnergy and Environment Research Laboratories

July 27, 2009


Development and Application of CCT (1/2)Since 1988, MOEABOE has aided in research of combustion pollution control

Flue Gas Desulfurization（SO2 removal reaches 95%）

Low NOx burner, and De-NOx technologies(SNCR, Combustion Modification)

1998～2001, MOEABOE has supported to study, introduce, and promote the highly efficient clean coal technology

Planning of introducing and promotion strategies for Integrated Gasification Combined Cycle (IGCC) technologyTo plan the strategy for the use of CCT in power generation and energy-intensive industries

2002～2005, ITRI is commissioned execute “Application Study of Fossil-fuels Gasification Technology” four-year project

To establish an experimental system of pressurized gasification with a capacity of two metric tons of coal per dayTo carry on further coal and petroleum coke research to verify their gasification characteristics


Development and Application of CCT (2/2)2006～2009, ITRI is commissioned to execute the second four-year project, called “Development of gasification and clean coal technologies”

To establish gasification and syngas conversion technologies:Development for feedstock of dry and liquid burners Establishment of gasification characteristic databases for coal, petroleum coke and heavy oil…etc.Establishment of the technology ability of planning, design and operation for gasification system

To establish CO2 capture/separation technologies:Establishment of the bench-scale system technology with CaCO3/CaO looping to capture CO2, and carry out modification study of CaO Development an mesoporous silica-based particles (MSP) adsorbent

To demonstrate and promote applications of syngas:Promotion for installation of gasification plant in industrial park and establishment of ability for feasibility studyDemonstrations of combustion and power generation for syngas, and enhancing the cooperation with industries on application technologies


ITRI’s Experience in Coal GasificationSet up the first pressured gasification experimental system in Taiwan

2 ton coal/day entrained-flow gasifier (located at Kaohsiung)Oxygen blown, dry feedstock, operating pressure below 10bar

Establish the gasification characteristics for coal and petroleum coke

Testing of gasification characteristics for six types of coals and CPC’s petroleum cokeCarbon conversion rate and cold gasification efficiency are 95% and 75%, respectivelyDevelop the application of syngas for power generator and combustion system

Demonstration of the power generator (47kW Gas Engine, 30kW Micro-Turbine)Demonstration of the combustion application (500kg/hr Boiler and 30,000 kcal/hr industrial furnace)

Establish ability of evaluation for gasification and IGCC with Thermoflow and Aspen Plus

2Ton Coal/Day Pressurized Gasification Testing Facility

Control Room ofGasification Testing Facility

Presenter

Presentation Notes


ITRI’s Gasification Plant

Gasifier

Control Room

N2, O2 Liquefy Tanks

Raymond Coal Mill

Wet Scrubber

500T/Hr Boiler47kW Gas Engine

Industrial Furnace

Conversion MeOH Experimental facilityPulverized

Coal or Slurry

N2

O2, Steam

Syngas

Syngas

GranularMoving Bed

Filter

Coal Water Slurry Prepare Equipment


Application Potential of Coal Gasification in Taiwan

Application for power generationBase on the MOEABOE plan, the new installed capacities with coal-fired will need for 7,098MW from 2008 to 2017, the IGCC with CCS will be more potential for application in the future

Application for industriesCeramic, Steel and iron

Syngas for heating furnaces and boilersCO act as a reduction agent for steel refinery furnacesReduce a reliance on NG, COG, heavy oil usage, and other fuels

Petrochemical, paper and man-made fiber industriesCogeneration plants with gasification technology can produce electricity and steamThe CO and H2 from the superfluous syngas of gasification can be used to produce chemicals or fuels Pet cokes, V.R. - as feed stocks for gasification to increase their economic effectiveness

Energy integration of gasification plant in industrial park


Energy Integration of Gasification Plantin Industrial Park

The price of electric power is relatively cheap and the fuel price is expensive in Taiwan. Therefore, the syngas is preferable to be a fuel for heating process instead of power generationThe coal gasification plant can provide the cheap syngas and process steam centrally

The Syngas replaces the LNG and fuel oil as fuels for boilers, heating furnaces, and co-generationTo produce hydrogen by water shift reaction, H2 can act as raw material and CO2could be sequestered or reused

Generator

Conversion

O 2 ,S te a m

S la g g in g

C le a n S y n G a s

C o a l

S y n G a s

S te a m

C o o le rC le a n u pS y s te m

Syngas (CO, H2)

GasificationSystem

Steam

gas grid Fuel

SeparationCO2

Storageor

ReuseH2

CO2Capture

Syngas(CO, H2, CO2)

FuelCell

Electricity

Coal

Biomass

Boiler

HeatingFurnace

CO2Storage

orReuse

Electricity

Cogen


ITRI’s Current research of Coal GasificationSet up the coal slurry as feedstock of gasifierDevelop the wet feedstock of burner

adopt impinging atomization technology

Establish gasification characteristics data of coal and heavy oil Found the wet feedstock of gasification technology with 2 tons coal per day of pressure entrained bedSimulate the gasification reaction of coal slurry, fluid field and temperature field of gasifier with Aspen Plus software

FeedingArea

GasificationSection

Syngascooling

Slagtank

R - 300

TE 300 - 6300 -7

TE 300 -4 / 5

TE 300 -9300 -8

TE TE

TE TE

B 2B 1

B 4B 3


CO2 Capture Technology Approach - ITRI

PBI: polybenzimidazoleITM: ion transport membraneMOF: metal organic framework

CAR: Ceramic Autothermal RecoveryOTM: oxygen transport membrane

Ref.：Advances in CO2 capture technology – The U.S. Department of Energy’s Carbon Sequestration Program,” International Journal of Greenhouse Gas Control 2, (2008) 9 ~ 20.

CaCO3/CaO loopingLimestone (CaCO3) is cheap and abundant in TaiwanCaO has high adsorption capacity

Mesoporous silica-based particle(MSP) with spray aerosol process

Low regeneration energy consumption and low degradationEasy to scale up


CaCO3/CaO looping

Solid sorbentmesoporous silica-based particles

Schematics of CO2 Capture Technology Approach

H2O

Carbonation fluidized bed

650℃

calcinationmoving bed 850℃

Flue Gas

Flue Gas CO2, H2O

heating

CaCO3CaO

cyclonecooler

heat

heatcooler

CO2 + CaO → CaCO3 + 178.8 kJ

CaCO3 → CO2 + CaO – 178.8 kJ

carbonation

calcination

Flue Gas

Steam

CO2


The study investigates various process conditionsSteam hydration calcination, sorbent dispersion in a calciner, use of a high thermal conductivity N2 gas.

Conversion rateHigher than 30% after 10 times of calcination/carbonation cycle at CO2= 10% condition

Physical PropertiesSpecific surface area reaches 38.28 m2/g , pore size is around 17～120 nm (30 nm is the major)

Pore Size Distribution

0

0.1

0.2

0.3

0.4

0.5

0.6

0 500 1000 1500

Pore Diameter (nm)

Qua

ntity Adsorbe

d (cm3/

g)

17~120nm佔95.4%

30nm

0

0.1

0.2

0.3

0.4

0.5

0.6

0 16 32 48 64 80 96 112 128 144 160 176 192 208 224

Time (min)

Con

vers

ion

rate

N2

N2+Steam

Studies on CaO Modification


Establish a bench scale SystemSet up the carbonation/calcination loopingCarbonation: fluidized bed to remove CO2Calcination: moving bed, reaction time controlled by adjusting steam and nitrogen flow rates

CO2 capture using the bench-scale equipment90% removal efficiency sustain for 40 and 85 minutes, respectively for 16.1% and 7.5% CO2 concentrations

CaCO3/CaO Looping Bench Scale Studies

Feed cylinder

Carbonator

CalcinerControl Panel0

10

20

30

40

50

60

70

80

90

100

15 24 37 49 61 73 88 101 120 140 172 195 215 235 256 290 330 352 364 376 390 434 471 510 551 591 631

吸附

效率

(%)

Time (min)CO2 16.1% CO2 7.5%

carbonator temperature ≧650°C, retention time 9.3 sec; calciner temperature ≧ 850°C, retention time ≧30 minutes.

0.0

20.0

40.0

60.0

80.0

100.0

Effic

ienc

y (%

)

20 40 60 80 100Bench scale System


Precursor (TEOS)Surfactant (CTAB)Other solvents (HCl)

Nano-porous particles

Chemicalreaction

Spray aerosol process Gas-to-particle

conversion

Energy input

To develop MSP with aerosol processThe MSPs have high specific surface area, high selectivity and adsorption capacity, stable adsorption capacity after repeated cycles.Adsorbent of impregnated/grafted and scale up for MSA preparation by spray drying technology will key items.

Mesoporous silica-based Particle (MSP)

28.742.9

78.9

102

0

20

40

60

80

100

120

Raw EDA modified

qe (m

g/g)

15% CO250% CO2

0

10

20

30

40

50

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

n

qe(m

g/g)

1)Adsorption condition：CO2 =15%, T =60℃, RH=0%2)Desorption condition : T=120℃(Air), RH=0%, Time=20 min/cycle 3)EDA: Ethylenediamine

After 20 times thermal recycles, the CO2 capacity still maintains at 39~42 (mg/g)

The results by lab study

Surface area＞1000 m2/g, Pore size is uniform and around 2.38~2.80 nm


Scale Up for MSP Preparation

MSP preparation capacity increases from 1g/8-hr to 100g/hr

Comparison of the physical properties

Flow Chart of pilot scale of MSPs preparation

Materials SBETa

(m2/g)dBJH

c

(nm)Capacity(mg/g)

MSP(from Lab-scale) 1153 2.4 42.9

MSP(from pilot-scale) 1054 2.4 30.1

Adsorption condition：CO2 =15%, T =60℃, RH=0%, EDA modified


Future Development

GasificationDevelopment of Commercialized Small Scale Gasification Technology

20~100 tons coal/day gasification system design and planningCo-gasification with biomass to reduce CO2 emissionChemical looping gasification of solid fuels

Direct gasification with in-situ CO2 capture and H2 production

CaCO3/CaO LoopingAdvancement to the process technology in pre-combustion captureApplication in post-combustion capture

From bench scale up to 1-3 MW post-combustion CO2 capture pilot plant Industrial application for small to medium scale gasification systems

Capture CO2 in the syngas process without any shiftIntegrated and commercial-ready gasification system

MSPScale up of MSP preparation for adsorbent productionApplication in industrial furnaces and co-gen power plants


Final Remarks

Coal is an excellent resource due to its cheap price and richdeposits. With the help of gasification technology, coal canbe easily converted to clean gas for fuels.

The price of electricity is relatively cheap and the fuel priceis expensive in Taiwan. Therefore, the syngas from coal has amarket and long-term prospect advantages over traditionalpetro-based fuels.

ITRI has been doing the pioneer work in Clean CoalTechnology for industry in Taiwan. The gasification andCO2 capture studying facility are expected to speed uprealization of coal gasification and CCS plant in Taiwan.

Documents

Research and Development of Gasification and CO2 Capture