Update on Technology and ProjectsPresented by Dirk Volkmann
Gasification Technologies Conference, Washington D.C., Oct. 2004
• Historical background• Feedstocks and
Applications• New Projects• New Development / R&D• New Alliances
outlet
Pressur. water
Quench
inlet
Cooling screen
Burner
Pressur. water
Fuel
Granulated slag
overflowWater
Gas outlet
Cooling jacket
Gas to pilot burnerOxygen
water
Gasification Technology Experience
Dem onstration p lants Com m ercial-scale p lants
Fixed-bed gasification 1956 1977 24 gasifiers constructed in the G as Com bine „Schw arze Pum pe“
Entrained-flow gasification
1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
Lignite
Saliferous lignite
42 lignite varieties 15 hard coal varieties
(international)Pulverized hard coal and lignite
Petro l coke, fly ash
15 m unicipal and industrial sew age sludges, M SW , w aste o il, w ood, straw Slurry, , fly ashInd ustrial w aste and residues
Chlorinated organic feedsNitrogen w aste organicsBlack liquor
Lignite
Saliferous lignite
Natural gasW aste o il, tar o il
S lurry Tar o il / so lids sludges
Nitrogen w aste organics13 t/h
Year DBI
DBI
Noell
Babcock
FU TURE ENER G Y
2000 2001 2002
2003 2004
Tar o il
Gasification Facilities of FUTURE ENERGY GmbH in Freiberg
Sewage sludge drier500 kg/h
Pyrolysis unit500 kg/h
Inert gas plant1000 Nm³/h
80 bar
Oxygen plantmax. 300 Nm³/h
80 bar
Pulverized fueldosing and feeding system
up to 10 t/h
Gasifier VV100Reactor with cooling wall
2-3 MWmax. 30 bar
GasifierReactor with cooling screen
3-5 MW, max. 30 barCOS hydrolysisHCN hydrolysis
SulFerox desulfurization unitWaste water treatment
Slurry feeding300 kg/h
Proprietary Gasification Technologies
R3
Cooling screen
Raw syngas
Pyrolysis gasification
Clean gas
Iron and non-ironmetals to utilization
Mill
OxygenPyrolysis gasSlurryPyrolysis coke
MSW
high-salt low-ash ash-free ash-containing
Reactor with cooling screen and quench
OxygenFuelOxygenBlack Liquor
Burner flange
Cooling screen
Smelt outlet
Quench system
Gas outlet
Green liquor
ash-containing ash-containing
Reactor with cooling screen
Entrained-flow
Recoverable fuel
Chemical wastes Conventional fuels Residual and waste materials
FE Entrained-Flow Gasification
FE Entrained-Flow Gasification
FE Entrained-Flow Gasification
Noell Conversion Process
SyngasMethanolHydrogenFertilizers
Oxoalcohols
Gas to energetic use
Power Heat
Fuel gas
Recovered resources Hydrochlorid acid
Clean salts Granulated slag
Green liquor
Black LiquorResidual oils + tail gasesSynthesis residues Chlor. org. materials Nitrogen organic waste
OilNatural gasBiogas
TarHeavy oilOil sludgeSewage sludge
Hard coalBrown coalPetroleumcoke
MSWHazardous wasteBio-mech. treat- ment fractionsWaste classif. res.
Pyrolysis plus gasificationReactor with cooling wall
Gas outlet
Cooled wall
Refractoryliner
Coat
Partial quench system
Cooling water
Gas outlet
Granulated slag
Wateroverflow
Pressur. waterinlet
Pressur. wateroutlet
Quench-water
OxygenFuel
Coolingjacket
• Historical background• Feedstocks and
Applications• New Projects• New Development / R&D• New Alliances
outlet
Pressur. water
Quench
inlet
Cooling screen
Burner
Pressur. water
Fuel
Granulated slag
overflowWater
Gas outlet
Cooling jacket
Gas to pilot burnerOxygen
water
Potential productsReduction gas(iron ore, steel)Potential feeds
Gasifier islandwith ASU andgas cleaning
(Natural gas)
Refinery gas
Residual oil
Petroleum coke
Sewage sludge
Waste oil
Biomass (wood)
Black liquor
Municipal waste
Chemical residues
Coal
Combinedcycle
Oxygen
Nitrogen
Argon
Carbon dioxide
Sulfur/sulfuric acid
Steam
Electrical energy
Chemicalproduction
Hydrogen
Carbon monoxide
Fertilizers
Chemicals
Methanol
Fischer-Tropschsynthesis
Slag tobuilding industriesor metals recovery Acetic acid
Motor fuels
Chemicals
Market Strategy
• Europe– Gasification of chemical residues– Biomass to Liquids (BTL)
• The Americas– Coal to power and chemicals– Gasification of chemical residues and waste
• Asia– Coal to power and chemicals– Biomass to Liquids (BTL)
• Australia / NZ– Coal to power and chemicals
• Historical background• Feedstocks and
Applications• New Projects• New Development / R&D• New Alliances
outlet
Pressur. water
Quench
inlet
Cooling screen
Burner
Pressur. water
Fuel
Granulated slag
overflowWater
Gas outlet
Cooling jacket
Gas to pilot burnerOxygen
water
Autothermal Oil Conversion PlantSokolovská Uhelná, a.s., Vřesová (1)
• Feed stock: 15 to/h generator tars and3 to/h secondary fuel
• Reactor conditions: 28 bar at 1.400 °C
• Reaction-Volume: 15 m3
• Gas utilization: 440 MW Combined Cycle Power Plant
• Syngas production: 50.000 Nm3/hdry = 140 MWth
• Reactor: Ø 3.4 m, h with quench 11.8 m, refractory lined
• Effluents: waste water 4-8 m3, soot 100 – 240 kg/h, vents ~ 500 Nm3 /h
Autothermal Oil Conversion PlantSokolovská Uhelná, a.s., Vřesová (2)
• Input: O2 17,500 Nm3/hdry, steam 7.2 t/h, N2 400 Nm3/hdry
• FE BE scope: product feeding / media supply systems / gas cleaning / gasifier system incl. cooling, monitoring purging / special burner design / soot water treatment plant / slag discharge
• Supplies: Gasifier/Quench, refractories, burners
• Project status: under construction(start-up 2005)
Vresóva Plant
24 fixed-bedgasifiers28 bar
24 fixed-bedgasifiers28 bar
CondensationCondensation Rectisolplant
Rectisolplant
GuDcombined-cycle
plant
GuDcombined-cycle
plant
Hard brown coal
Oxygen
Entrained-flowgasification
28 bar
Entrained-flowgasification
28 bar
TarSteam
Oxygen
Steam
Waste water
Electricity
440 MW
Raw gas
Fischer-Tropsch Demonstration PlantFUTURE ENERGY site Freiberg, Germany (1)
• Location: FE test facility in Freiberg
• Input: Tar/coke slurry 500 kg/hOxygen 450 Nm3/h
• Output: Synthesis gas (H2/CO = 2:1) 1010 Nm3/hDiesel 125 kg/h
• Reaction conditions: pressure 25 bar
temperature 1,400 °Cvolume 276 l
Fischer-Tropsch Demonstration PlantFUTURE ENERGY site Freiberg, Germany (2)
• Equipment addedto existing plant: slurry feeding & preparation, CO-shift-
conversion, WWT, gas synthesis (F-T) product upgrading, hydro-cracking, fractioning
• Project Status: selection of F-T technologystart of BE in 2004(start-up 2006)
• Historical background• Feedstocks and
Applications• New Projects• New Development / R&D• New Alliances
outlet
Pressur. water
Quench
inlet
Cooling screen
Burner
Pressur. water
Fuel
Granulated slag
overflowWater
Gas outlet
Cooling jacket
Gas to pilot burnerOxygen
water
Generation of Hydrogen from Biomass(Straw*, hay*, wood, paper/cardboard, waste plastics)
delivery, storage
Educt preparationchopping, pre-drying
Fast pyrolysis1 bar, ~500 °C, t few s
Chaff
Heat transfermedium loop
Oil/char slurry
Rail transport of slurryfrom 20 to 40 pyrolysis plants
to a large-size centralizedsyngas generation + utilization plant
Tarfree raw syngas
Gas cleaningGas conditioning
Residual gas Technical hydrogen
Electrical energy
Reg
iona
l 50
MW
(th)
fast
pyr
olys
is p
lant
s
Entrained-flow gasification~1300 °C, >60 bar, t 2-3 s-
* critical biofuels having high ash, K and Cl contents
PROPERTIES OF SLURRIESFROM BIOMASS PYROLYSIS OIL AND CHAR
porosityε 0.5 - 0.8
charparticle
• critical particle volume fraction φcritdepends on shape (aspect ratio) and size spectrum:~ 0.6 spherical, ~ 0.45 regular crystals
• viscosity η (slurry) = η (liquid) (1+ 5/2φ + 6.2 φ2);/ one order reduction from 20 to 80 °C
• density: oil ~ 1200 kg/m3, char (true) ~ 1500 kg/m3
slurry ~ 1300 kg/m3, char (bulk) ~ 200 - 400 kg/m3
30 % char/raw tar slurry
spec
. CO
2-em
issi
ons
[g C
O2/k
m]
year2000 2010 2020 2030
NG bio-mass Solar-H2
gasoline,diesel SynFuelDieselgasolinespecial CCSfueltransition toSun Fuel hydrogenfuel
Synthesis gas (H2, CO, CO2)
crude
motor withCCS-process
Mild HybridFSI,TDI
FSI,TDIopt. Otto& Diesel
H2-Fuel cell
Source: Volkswagen
New Development / R&D
• New reactor size (upscaling)• New reactor design at 85 bar (dry and slurry
feed)• New recovery boiler development• New concepts for the gasification of
MSW/RDF• New approach for black liquor gasification
Comparison of size of FE-Entrained Flow Gasifiers (25 bara)
130 MW 400 MW 800 MW50.000 m /h3
N 160.000 m /h 320.000 m /h
Ø2000
3500
525 0
Ø2900
Ø3650
6700
N3
N3
• Historical background• Feedstocks and
Applications• New Projects• New Development / R&D• New Alliances
outlet
Pressur. water
Quench
inlet
Cooling screen
Burner
Pressur. water
Fuel
Granulated slag
overflowWater
Gas outlet
Cooling jacket
Gas to pilot burnerOxygen
water
New Alliances
• Forschungszentrum Karlsruhe– Development of a reliable, large scale process chain for the
production of BTL(flash pyrolysis, gasification, F-T)
• Close cooperation (exclusively ?) with a technology based Engineering Company
Get in touch with us !
FUTURE ENERGY GmbHHalsbruecker Strasse 3409599 Freiberg – GermanyT +49-3731-785-300 [email protected] +49-3731-785-352 www.future-energy.de