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