Envirotherm GmbH - ООО Инвайро / Enviro Co....

Envirotherm GmbH

- P r o f e s s i o n a l C o m p e t e n c e -

20130514

P r o f e s s i o n a l C o m p e t e n c e 2

Allied Group Structure

Aloe Environment Fund

Paris, France

Dongfang Boiler Group Co. Ltd.

Zigong, Sichuan, China

Allied Resource Corp.

Wayne, PA, USA

Allied Technologies GmbH

Frankfurt a. M.

G. Daradimos (Chairman) J. Kremer

BAMAG Environment GmbH

Butzbach / Germany

W.-Fr. Staab

Envirotherm GmbH

Essen / Germany

G. Daradimos (Chairman)

J. Ladenthin H. Hirschfelder

Allied Syngas (ASC)

Wayne, PA, USA

Puralube Inc.

Wayne, PA, USA

DKC

SCR Catalyst Production

Chengdu, Sichuan, China

70 %

30 %

BAMAG Mena LLC

Cairo, Egypt

Th. Winckler (Chairman)

I. Schmittmann H. A. Ghaffar

Chengdu Huilian Property

Management Stock Co. Ltd.

BAMAG International GmbH

Essen / Germany

G. Daradimos J. Ladenthin

ATG Group


Allied Technologies

• is a member of the Allied Group (www.alliedresourcecorp.com)

• is a strategic holding company with offices in Frankfurt/Main, Germany,

and controls Allied’s engineering entities

o BAMAG Environment GmbH

o Envirotherm GmbH

o BAMAG International GmbH and

o BAMAG Mena LLC

• Allied Technologies Group employs in Germany and in Egypt over 170 total staff,

including about 150 skilled professionals (primarily engineers)

• is able to perform 150,000 (plus) engineering hours annually

Allied Technologies Group (ATG) ATG Group


Technologies within the ATG Group:

• Combustion of fossil fuels, biomass and residues in the Circulating Fluidized Bed

(CFB)

• Gasification of fossil fuels, biomass and residues in the Circulating Fluidized Bed

(CFB) and in the Fixed Bed Gasifier (BGL)

• Incineration of hazardous waste in the rotary kiln

• Destruction of chemical weapons in the bogie hearth furnace (highly toxic waste)

• Flue gas dedusting (dry and wet ESPs, bag houses)

• Flue gas denitrification (SNCR und SCR)

• Wet and dry flue gas scrubbing

• Water purification / waste water treatment

• Thermal treatment of sludges in the bubbling fluidized bed

ATG: Technologies ATG Group


ENVIROTHERM

your experienced and qualified engineering partner with an extensive list of references and strong growth based on a portfolio of

proprietary technologies acquired from Lurgi

Business Segments

CLEAN ENERGY CLEAN AIR

(Air Pollution Control - APC)

Modern

Gasification Technologies

Highly Efficient

Flue Gas Cleaning

Technologies

Multi-Purpose

Combustion Technologies

Production and Distribution of

Honeycomb SCR Catalysts

ENVIROTHERM


Cooperation and License Agreements

SCR Catalysts Production

SCR-Process

• Joint Venture with Dongfang Boiler Group,

Chengdu, Sichuan, China

• Dongfang, SSEP for SCR process in China

• Cooperation with ERC GmbH, Germany

FB/CFB – Power Plants • Cooperation with the Slovak Boiler Manufacturer SES, Tlmače

• DEDINI, Brazil, for fluid bed technologies

Clean Air Activities

• Jeongwoo, for ESP in Korea

• Longking, TFEN, DATANG Group, Londian Hongtai

for fabric filter in China

• VT Corp, ISGEC for ESP in India

Gasification

• Shriram epc, India, fluid bed (CFB) and

fixed bed (BGL) gasification

• Collaboration with CEMEX on CFB gasification in the Cement

Industry (industrial know-how from Ruedersdorf facility)

• University of Clausthal-Zellerfeld, Germany, CUTEC Institute –

R&D in CFB gasification

• TU Bergakademie Freiberg – BGL Pilot Plant and BGL modelling

Cle

an

En

erg

y

Cle

an

Air

ENVIROTHERM


Clean Energy

- Combustion Technologies -

ENVIROTHERM


• Stationary and Circulating Fluid Bed Technologies have a high acceptance and are a base

technology in the utility and other industries for combustion of coal, (high/low rank), biomass

and various residual materials (sludges, RDF).

• Envirotherm’s portfolio includes the stationary (FB) as well as the circulating (CFB) fluid bed

technologies

• Fluid Beds offer a proven and reliable technology with numerous reference plants and excellent

emission values

• Downstream flue gas treatment technologies are available and designed in accordance with the

latest environmental laws/directives


Fluid Bed ENVIROTHERM

P r o f e s s i o n a l C o m p e t e n c e

• Existing 3 trains of CFB steam generators

(150t steam/h, 535°C, 90 bar)

• Original design for subbituminous hard coal (15t/h)

• Engineering for a re-fuelling project to co-fire up to

25% (energy) of biomass and RdF (high CV and

high Cl content)

9

Stadtwerke Flensburg, Germany (combined heat and power plant)


Fluid Bed – Selected References ENVIROTHERM


• Pressurized lignite fired fluidized bed combustor

(82 MWel, live steam 200 t/h, 540 °C,

160 bar and reheat 540 °C, 44 bar)

• Heavy fouling in cyclones, in-bed bundles and

gas turbine inlet vanes – limiting substantially

running time and full load capability

• Envirotherm redesigned and refurbished

cyclones, and reengineered in-bed bundles to

minimize fouling and increase availability – after

modifications full load and longer runs were

achieved

10

Illustration of CHP plant – Cottbus (Germany)

Cottbus, Germany (combined heat and power plant)


Fluid Bed – Selected References ENVIROTHERM



Fluid Bed – Selected References

• Largest FB-combustor built by Lurgi

(nozzle grate area 32 m²)

• Feedstock 16.6 t/h deinking sludge,

6.2 t/h rejects from paper industry,

two feeding points

• Heat Recovery Section to produce

31.3 t/h of 30 bar, 345°C steam

• Gas cleaning with bag filter and SNCR,

addition of Zeolite to remove dioxins and

furanes.

• High content of calcium components in

paper sludge helps to remove acidic

pollutants from flue gas and are removed

in bag filter

11

Grovehurst, England

ENVIROTHERM



Fluid Bed – Selected References

12

ENVIROTHERM


• Base technology for incineration of toxic and hazardous waste

• Feedstock includes but is not limited to toxic activated carbon, contaminated waste,

hazardous process waste, wood

• High temperature post incineration and extensive flue gas cleaning

• Process applied to thermally destroy residual materials from chemical weapons destruction

Contaminated

solid materials

13


Bogie Hearth Furnace ENVIROTHERM



Bogie Hearth Furnace – Selected References

Bogie Heart Furnace Technology

• Base technology for incineration of toxic and hazardous waste

• High temperature post incineration and extensive flue gas cleaning

• Process applied to thermally destroy residual materials from chemical weapons destruction

• one plant in Germany, four plants in Russia

Exit of bogie hearth furnace Plant arrangement Potschep

14

ENVIROTHERM



Rotary Kiln (under license of Doosan Lentjes GmbH)

Rotary kiln incineration technology is the most secure method to eliminate and to dispose of

hazardous waste, such as industrial and chemical as well as hospital waste, in an ecologically

compatible manner

• Incineration at high temperatures (around 1,200 °C), i.e. toxic components are

thermally destroyed

• Waste volume is significantly reduced

• Energy from waste is recovered and utilized

• Ash is recovered as non-leachable slag and can easily be disposed of or utilized

• Capacities up to 50,000 t/a have been realized in 25 installations worldwide

15

ENVIROTHERM



Rotary Kiln – Selected References

Start-up in 1996; solid and liquid waste incineration, capacity

35.000 t/a

Process chain

• Waste reception and pre-treatment

• Waste charging

• Rotary kiln incineration

• Post combustion

• Heat recovery section with steam production

(27 t/h, 40 bar, 350°C) and generation of

electricity (5.2 MW)

• Flue gas cleaning

• Scrubber effluent and waste water treatment

16

Izmit, Turkey

Hazardous Waste Treatment Plant

ENVIROTHERM



Rotary Kiln – Selected References

Izmit, Turkey: Hazardous Waste Treatment Plant

ENVIROTHERM


Clean Energy

- Modern Gasification Technologies -

18

ENVIROTHERM


Modern Gasification Technologies

The BGL Slagging Gasifier: Development

• Developed by British Gas and Lurgi (hence BGL) to improve Lurgi’s dry bottom fixed bed

gasification process

• Demonstrated with various feedstock in Westfield, Scotland

• Highest efficiency, lowest oxygen consumption

• First commercial installation at “Schwarze Pumpe” Site (East Germany) in 2000

• Technology acquired from Lurgi in 2003

• 14 BGL under engineering/construction (12 in China, 2 in India), commissioning planned

from 2011 onwards

19

ENVIROTHERM



The BGL Slagging Gasifier: Process Applications

BGL

Gasifier

Air Separation

Unit

Alternative

Feedstock

Input Gasification

Shift Reactor Gas Clean-Up

Methanol

Synthesis

Methanation

Fischer Tropsch Synthesis

Chemicals/ Gasoline

Synthetic natural gas

Fuels

Oxygen

Coal

Power

Products Additional Processing Conversion

CO2 IGCC

Ammonia Synthesis

Fertilizers

Typical BGL Gas Composition

for bituminous coal

H2 33 %

CO 56 %

CO2 4 %

CH4 7 %

• BGL Process has clear investment and operational

advantages in a wide range of application.

• According to gas composition BGL is well suited to SNG

production because of its high efficiency and the presence of

CH4 in product gas

20

ENVIROTHERM



BGL Slagging Gasification

• Commercial plant for the gasification of

mixtures of coal and waste as feedstock to

generate electricity and to produce methanol

• Site location: Secondary Raw Materials

Utilization Centre, SVZ Schwarze Pumpe,

Germany

• Start-up in 2000, commercial operation until

mid 2007

• Modular pressurized fixed bed gasification,

gas output equivalent to 120–140 MWel

• Currently 14 BGL gasifiers are under

engineering/construction in China and India

21

ENVIROTHERM


• Increase in reactor diameter to 4m higher throughput

• Increase in operation pressure (up to 40bar) higher CH4 content, less tar and oil

• Stirrer implementation for caking coals

BGL Gasifier

Current Development

22

0

1

2

3

4

5

200 400 600 800 1000 1200 1400 1600 1800 2000

Gasif

ier

inn

er

dia

mete

r in

m

Fuel throughput in t/d

Plant Start up Feedstock

BGL 1 1975 Coal

BGL 2 1981 Coal

BGL 3 SVZ 2000 Waste & up to 80% waste

BGL 3 Hulunbeier 2011 Lignite

BGL 3 Yituo 2012 Hard coal

BGL 3 Shriram 2013 High ash hard coal

BGL 3 China National 2013 Bituminous coal

BGL 4 Project Lignite

BGL 1

BGL 2

BGL 3

Yituo BGL 3

SVZ

BGL 3

Shriram

BGL 3

Hulunbeier

BGL 4 BGL 3

China Nat.

ENVIROTHERM


Client China National Coal Development Co. Ltd., Beijing, PRC

China National Coal Corp., Beijing, PRC

Location of facility Ordos Tuke, Inner Mongolia, PRC

Application Syngas for the production of 1,000,000 t/a Ammonia

(1,750,000 t/a urea)

Feedstock Weakly caking bituminous coal (210 t/h, 5,000 t/d as received)

Features Five (5) + two (2) BGL gasifiers (40 bar operating pressure) with

stirrers

Synthesis gas production 295,000 Nm³/h

Scope of Supply Process Design Package for gasification and gas liquor separation

Process performance guarantees

Plant erection and commissioning assistance

Start-up 2013

Progress Process Design Package finished October 2011


BGL – Selected References: China National Coal

23

ENVIROTHERM


Client Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC

Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier,

Inner Mongolia, PRC

Location of facility Hulunbeier, Inner Mongolia, PRC

Application Syngas for the production of 500,000 t/a ammonia

(800,000 t/a urea)

Feedstock Domestic dried and briquetted lignite (130 t/h, 3,100 t/d as received)

Features Two (2) + one (1) BGL gasifiers (40 bar operating pressure)

Raw gas production (CO+ H2) 119,000 mN³/h

Scope of Supply PDP (Process Design Package) for gasification island including

tar/oil separation

Proprietary equipment supply



Start-up Summer 2011


BGL – Selected References: Hulunbeier, China

24

ENVIROTHERM


Progress May 2008 site clearance and civil work commenced

Process Design Package delivered 4th Quarter 2008

Detailed Design completed 3rd Quarter 2009

Gasifier installations on site 2009-2010

Class room staff training, August 2010

25

Cou

rte

sy o

f H

ulu

nb

eie

r N

ew

Go

ld C

he

mic

al C

o.

Ltd

.


BGL – Selected References: Hulunbeier, China ENVIROTHERM


Yuntianhua: Gasifier Reactor Transport over more than 1,000 km Distance

26


BGL – Selected References: Hulunbeier, China ENVIROTHERM


Client China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC

Location of Facility Luoyang, Henan Province, PRC

Application Fuel gas

Feedstock Local hard coal (30t/h, 720 t/d)

Features One (1) + one (1) BGL gasifiers

Raw gas production 43,000 mN³/h

Scope of Supply PDP for gasification, gas cooling and tar/oil separation

Proprietary equipment supply



Start-up Mid 2013

27


BGL – Selected References: Yituo, China ENVIROTHERM


Client Shriram EPC Ltd., Chennai, India

Location of Facility Paradeep, Orissa, India

Application Syngas for the production of synthetic ammonia

Feedstock High ash domestic hard coal (132 t/h, 3,200 t/d)

Features Two (2) BGL gasifiers, one relocated from Germany, the second

built identical to the relocated one

Raw syngas production 150,000 mN³/h

Scope of Supply Relocation and reengineering as far as required for gasification,

gas cooling, tar/oil separation and phenol recovery

Basic engineering for new BGL

Plant erection and commissioning assistance on request

Start-up 1st Quarter 2015

28


BGL – Selected References: Shriram EPC, India ENVIROTHERM



The CFB Gasification Process: Development and References

• Fluid bed technology was developed in the early 1920s (original Winkler fluid process)

• Lurgi developed the circulating fluid bed (CFB) applying high “slip velocity”, introduced CFB to

power plants and applied the process to gasification of various feedstock

• Fluid beds are operated at temperatures below ash softening point (i.e. 800-950 °C) with an

even temperature profile in the reactor and excellent heat and mass transport

• Proven technology with numberless references

• Envirotherm acquired the CFB gasification process from Lurgi/Lentjes in 2003

• Envirotherm’s commercial reference plants include

- first CFB gasification in the cement industry – Ruedersdorf, Germany

- CFB gasification of demolition wood – Geertruidenberg, The Netherlands

- CFB gasification of high ash Indian coal – Barbil, India

29

ENVIROTHERM


Client N.V. Elektriciteits-Produktiemaatschappij, Zuid-Nederland (EPZ),

Eindhoven, The Netherlands (today RWE-essent)

Location of Facility Amercentrale, Geertruidenberg, The Netherlands

Application Gasification of demolition wood, gas is dedusted and injected into

coal fired boiler for the generation of electricity (CO2-neutral)

Feedstock Crushed demolition wood (21 t/h, 500 t/d)

Features One (1) CFB gasifier

Raw gas production 50,000 mN³/h

Scope of Supply EPC contract

Start-up 2000


CFB – Selected References: Geertruidenberg, The Netherlands

30

ENVIROTHERM




EPZ, Amercentrale: Process Scheme

31

ENVIROTHERM




EPZ, Amercentrale: Plant View

ENVIROTHERM



CFB – Selected References: Ruedersdorf, Germany

• First industrial application of the near

atmospheric circulating fluidized bed (CFB)

gasification process in the cement industry,

Ruedersdorf, Germany

• Start-up and in full commercial operation since

1996

• Two follow-up CFB gasifiers in early

commissioning for the Indian steel industry

Key Data

Thermal Capacity 100 MW

Fuels: Carbon containing ash 5 - 15 t/h

Pulverised coal max. 6 t/h

or

Secondary fuels 20 - 25 t/h

Produced Gas: Flow rate 50,000 m3N/h

Heating value 3,000 – 5,000 kJ/m3N

Gas exit temperature 950 °C

33

ENVIROTHERM


Client Jindal Steel and Power Co. Ltd., New Delhi, India

Location of Facility Barbil, Orissa, India

Application Production of clean fuel gas for the steel industry

Feedstock Domestic Indian high ash (27%) coal (23 t/h, 550 t/d per gasifier)

Features Two (2) CFB gasifiers

Raw fuel gas production 50,000 mN³/h per gasifier

Scope of Supply Basic engineering


Start-up First Quarter 2011

34


CFB – Selected References: Jindal Steel, India ENVIROTHERM



CFB – Selected References: Jindal Steel, India

Barbil / Orissa, India:

• two CFB gasifiers in parallel

• fuel: domestic Indian coal with 27% ash, 8% moisture

• per gasifier: 23t/h coal, 50,000 m³n/h syngas

35

ENVIROTHERM



CFB – Selected References: Jindal Steel, India

Solid

Fuel

Bed

Material

Bed Ash

Air

Air

Air

Air C.W.

C.W.

Cyclone CFB

Gasifier

Radiation

Pass

Turbine / Generator

Steam Drum

Deaerator

Su

pe

rhe

ate

r

Eva

po

rato

r Quench

Wet ESP

Clean Fuel Gas

Recirculation Pump

Ash Tar

Dust

Water

Prim. Air

Sec. Air

C.W.

Seal Pot

Water

36

Barbil / Orissa, India: Process Flow Diagram

ENVIROTHERM


Clean Air

- Air Pollution Control Technologies -

ENVIROTHERM


APC - Technologies

38

• Dust removal

• SCR-Process

• Production and distribution of honeycomb catalysts

ENVIROTHERM


• Dust removal

– Wet & dry electrostatic precipitators

– Fabric filters (standard design)

– Proprietary low pressure fabric filters

– Tar filters

– Ceramic filters

(high temperature application)

• More than 13,000 reference plants worldwide

APC Technologies

Dust Removal

ESP Wachtberg 200 MW CFB Powerplant Retrofit 350 MW – Powerplant Fynsvaerket, Denmark

ENVIROTHERM


• NOx reduction (DeNOx) process, based on Selective Catalytic Reduction (SCR)

• Manufacture of honeycomb SCR catalysts in China

(joint venture with Dongfang Boiler Group)

APC Technologies

SCR Process

Power Plant Hoosier, 2x540 MW

ENVIROTHERM


Chengdu Dongfang KWH Environmental

Protection Catalysts Co., Ltd. (DKC)

Since the 60’s Envirotherm (former KWH) developed

honeycomb SCR catalysts and their application for

NOx reduction.

Envirotherm/KWH became one of the top five

manufacturers worldwide.

The former German catalyst production plant was

relocated in 2006 from Marl to China for cost

reasons and forms part of the joint venture company

between Envirotherm and Dongfang Boiler Group.

This plant is in commercial operation and delivers

low-cost, high quality honeycomb catalysts accepted

by reputed utilities. A second plant with a capacity

twice as high as the relocated plant has been put

into operation in July 2010.

APC Technologies

SCR Catalyst Production in China

41

ENVIROTHERM


DKC: 2nd Plant

APC Technologies

SCR Catalyst Production in China

42

ENVIROTHERM


Contact

Envirotherm GmbH

Ruhrallee 185 D – 45136 Essen

[email protected] www.envirotherm.de

Tel: +49 / 201 / 6346 – 400

Envirotherm GmbH - ООО Инвайро / Enviro Co....

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