Coupling gasification and metallurgical applications · Coupling gasification and metallurgical...

Coupling gasification and metallurgical applications

Robert Pardemann, Tanja Schaaf, Jochen Grünig, Katharina Förster, Andreas Orth

International Freiberg Conference on IGCC & XtL Technologies12–16 June 2016 – Cologne/Germany

© Outotec – All rights reserved

Outline

Working for resource efficiency

About Outotec

Gasification and metallurgical applications

Outotec’s development activities andofferings

2 June 13, 2016 R. Pardemann | Coupling gasification and metallurgical applications | 8th International Freiberg Conference on IGCC & XtL Technologies


3

A century of accumulated expertize

June 13, 2016 R. Pardemann | Coupling gasification and metallurgical applications | 8th International Freiberg Conference on IGCC & XtL Technologies


4

Sustainable use, recovery and recycling of resources

RESOURCE EXTRACTION PRIMARY PRODUCTION RECYCLING

Green color shows Outotec`s impact

MANUFACTURING USERS

FERTILIZERPRODUCTION

AGRICULTURE ENERGYPRODUCTION

PHOSPHORUS

SULFURIC ACIDPHOSPHORUSLandfill

BackfillEnergyrecovery

INDUSTRIALMINERALS

METALSSALTS

CHEMICALSSLAG

RECYCLE REMANUFACTURE

EffluentTreatment

AirboneemissionWater

management

Airboneemission

CO2CO2 CO2 CO2

MINING

Equipmentreuse

Reuse

Urbanmine

POWER PRODUCTION

NATURALRESOURCES

ORESMINERALS

WATER

BIOMASS

SERVICES ANDSOLUTIONS

COMBUSTIBLEWASTE

MUNICIPAL SLUDGE

MINERALPROCESSING

METALPROCESSING

Constructionmaterials

CONCENTRATES



Local operations, global presence

Wide supplier network with established long-term relationships

5

R&D, salesand servicecenters in

32countries

Deliveries tomore than

80countries

Experts ofover

60nationalities

Sales

1.2bnEUR in 2015Over

4,800employees

Listed on Nasdaq Helsinki since 2006

Services

43 %of sales

Environmentalgoods andservices

90%of orders

In 2016

3rdmost

sustainablecompany



Outline


About Outotec





Outotec‘s technology background

Fluidized bed as core technology for Outotec‘s Metalls and Energy business (reference listof more than 500 fluidized bed plants)

Bubbling fluidized bed, Circulating fluidized bed, Annular fluidized bed, Flash reactors

Strong background in pyro-processes for minerals beneficiation and metallurgy (calcination,reduction, smelting, roasting*)

Need for supply of heat to the process (today mainly through internal combustion of NG or fuel oil,*exception: roasting)

Gasification (at Outotec relying on fluidized bed):Stand-alone process for small/medium-scale energy production (biomass, sewage sludge, residues)Option for fuel gas provision to pyro-metallurgical process but requires:

Careful consideration of impact of fuel gas obtained from gasification on downstream processTailored solutions for each plant



Objective: Substituting NG or fuel oil as fuel by locally abundant (often low-grade) solidfuels (e. g. coal, biomass, residues) for the pyro-metallurgical processes

Typical thermal output requirement for gasification: 40–130 MW(th)

Requirements / challenges:

Fuel gas provision at small to medium scaleNeed for low-cost technology solutionMinimization/limitation of gas cleaning effort dependent on application

Impurities and parameters to be considered for coupling of gasification and metallurgical processFuel gas heating valueTarsDust (fly ash)Acidic gases

Gasification coupled to Pyro-metallurgical Processes



Example processes with potential for fuel substitution

Effort for gas cleaning:Lower gas cleaning effort for higher fuel qualities (limited contaminant concentration)Adjustment of gas cleaning to meet maximum allowable impurity limits no “over-designing”General premise: avoidance of tar handling problems

Gasification coupled to Pyro-metallurgical Processes

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Sensitivity towards impurities Adaptation of gas purification system

Dust Tars Acid gases

Cement calcination(preheating)

Alumina calcination

Pelletizing

Clay calcination(clinker substitute)

June 13, 2016

(-)

(-)(-)

(-)

x (dep. on application) x xKaolin calcination

R. Pardemann | Coupling gasification and metallurgical applications | 8th International Freiberg Conference on IGCC & XtL Technologies


Possible gas purification schemes

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Gasifier Waste HeatBoiler Multiclone

ScrubberGasCompressing

Coal

Air / Oxygen

ash ash ashwater

steam

water waterbleed

To Calcination Tar Removal

tar stripperair

Gasifier Waste HeatBoiler Candle Filter

Coal

Air / Oxygen

ash ash ashwater

steam

To Calcination

Direct utilization of raw gas(stay as hot as possible)

Comprehensive gas cleaning

June 13, 2016

High-temp.filter

(e.g. ESP,candle filter)



Outline


About Outotec





Outotec‘s activities in the field of gasification

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Wide range of test facilities and know-how, applied in the context of gasification for:Gasification tests to obtain comprehensive process understandingDevelopment and optimization of new concepts, processes, components and technologiesTesting and development of metallurgical processes under realistic conditions

Technology and service offerings


I. Test services and case studies on customer demand

IV. Performance services

II. Engineering services: Technology evaluation / Feasibility assessment /Engineering and design of entire process chains

III. Construction of new and retrofitting of existent plants


Outotec‘s CFB-based gasification concept

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700 mm FB plant

Outotec‘s pilot-scalefacilities applied forgasification tests

June 13, 2016

200 mm CFB plant 250 mm FB plantAlternative: use of oxygen as gasification agent



Extended test facility base

Gas cleaning test facilities available at Outotec’s Frankfurt Research Centre:Filters installed at each fluidized-bed facilityDry ESP and Wet ESPVenturi scrubberRadial scrubberCO2 scrubbingGas scrubbing for removal of SO2 and other components

Comprehensive process and component testingfor validation of models and providing design basisBasis for scale-up and process guarantees

June 13, 201614

CO2 scrubbing test facility



Example 1: Case study to evaluate options for fuelsubstitution

Task: Performance of gasification test and feasibility assessment for fuel gas provision from coalChallenge: Blending of coals of different reactivity and baking/swelling behavior

Identification of maximum allowable mixing ratio (LHV, gas quality, operability)

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Coal A Coal BAsh (wf) wt.% 7.8 35.0Moisture (ar) wt.% 11.1 2.2Fixed carbon (wf) wt.% 56.9 49.7Volatile matter (wf) wt.% 35.3 15.3C (wf) wt.% 74.3 54.8S (wf) wt.% 0.4 3.2H (wf) wt.% 4.7 3.1N (wf) wt.% 0.9 0.8O (wf) wt.% 11.9 3.1LHV(wf) kJ/kg 29179 21147Free swelling index 0.5 3.0

Coal A Coal BAFT °C 1200 1600SiO2 wt.% 37.7 45.5Al2O3 wt.% 14.6 34.3Fe2O3 wt.% 12.5 10.2TiO2 wt.% 0.6 1.6CaO wt.% 23.8 4.1MgO wt.% 1.3 0.7Na2O wt.% 0.9 0.01K2O wt.% 0.9 0.9SO3 wt.% 7.0 2.6P2O5 wt.% 0.04 0.1



Test conditions: 950 °C; 200 mm CFB, p = 1 bar; air/steam ( = 0.35–0.42)

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Mixing ratioCoal A: Coal B

90:10 80:20 70:30 50:50

CO vol.% 12,3 10,2 11,8 8,1CO2 vol.% 8,3 9,1 8,4 8,6CH4 vol.% 0,7 0,5 0,6 0,7H2 vol.% 8,7 7,3 8,1 6,8O2 (false air) vol.% 0,3 0,3 0,3 0,3Rest (mainly N2) vol.% 69,7 72,6 70,8 75,5LHV kJ/m³(STP) 3141 2588 2863 2556C-yield (gas) % 76,6 73,6 79,0 59,2C-conv. % 88.8–91.6 %

* average values, dry gas composition, N2 corrected, constant bed pressure loss at 25 mbar

Difference in reactivity for both coalsImpact on gas quality

Only mixtures with up to 30 % ofcoal B allow for stable operability

Rather high gasification temperaturerequired for high C-conversion

Challenge regarding swelling

Rather high heat loss of small pilot-scale facility

Basis for simulation and balancing as part of design workJune 13, 2016

Example 1: Case study to evaluate options for fuelsubstitution – Gasification test results



Modeling-based mass and energy balancing of a 230 MW(th) throughput air-blown coalgasification CFB plant (1 bar / 970 °C) (validated on gasification test results)

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FeedCoal (70/30 mix) 20 °C kg/h

MW25.207

231Air Fluidization 77 °C / 1,56 bar m³(STP)/h 32.962

Gasification 20 °C / 10 bar m³(STP)/h 24.842UtilitiesBFW 16 bar / 105 °C kg/h 32.770Steam Gasification 152 °C / 5 bar kg/h 1.281

Fluidization 152 °C / 5 bar kg/h 1.621Excess 152 °C / 5 bar kg/h 29.868

Cooling Water 20/30 °C / 1 bar kg/h 523.841Solid by-productsFly ash 100 °C kg/h 936Bottom ash 90 °C kg/h 3.761

Product gasTemperature/Pressure °C/bar 400 / 1,35Volume flow m³(STP)/h 84.854CO vol.% 21,5CO2 vol.% 7,4H2 vol.% 11,7H2O vol.% 3,8CH4 vol.% 1,9N2 vol.% 53,6H2S vol.% 2,0NH3 ppm 6COS ppm 114LHV kJ/m³(STP) 3.616

*Gasification at 1 bar/ 970 °C

June 13, 2016

Example 1: Case study to evaluate options for fuelsubstitution – Modeling results



Example 2: Plant reference – Cement plant RüdersdorfDesign data:

Thermal capacity: 100 MWFuels: Carbonic ashes, RDF, sludgeProduct gas: 60 000 m³/h, 3–5.3MJ/m³,

860–920°CAsh: <1 % carbon

Advantages:Independent of fuel ash composition andno need of raw material feed adjustmentto meet product qualityWide fuel range (coal, biomass, RDF,sewage sludge, carbonic ashes,....)Sewage sludge – Phosphor-recovery fromgasification ash possible

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CFB Gasifier



Conclusions

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Process approach perspective:Attachment of gasification to metallurgical or mineral applications requires tailored solutions

Need for careful evaluation of impact of fuel change on downstream applicationAdditional considerations: - CAPEX of gasification island vs. downstream process

- Impact of gasification on plant availabilitySelection of lowest CAPEX process concept meeting downstream process requirements

Economic viability strongly dependent on local conditions (only limited potential of coalgasification for fuel substitution)

Outotec’s technology perspective:Comprehensive testing as basis for process development, engineering and design and scale-up

Broad experience with a wide range of fuels (coals, pet coke, biomass and residues)Focus on concept and equipment development for gasification of alternative fuels (e.g. closed-loop steam dryer, ash treatment)

Competitive and sustainable technology solutions meeting upcoming legal frameworkR. Pardemann | Coupling gasification and metallurgical applications | 8th International Freiberg Conference on IGCC & XtL Technologies

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Coupling gasification and metallurgical applications · Coupling gasification and metallurgical...

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