MEGAMEGA--GSP PROCESSGSP PROCESSEntrainedEntrained--FlowFlow GasificationGasification of of CoalCoal,, Biomass Biomass and and WasteWaste

FUTURE ENERGY GmbH, GermanyFUTURE ENERGY GmbH, Germany

International FreibergInternational Freiberg ConferenceConference on on IGCC & IGCC & XtL TechnologiesXtL Technologies

JuneJune 16 16 -- 18, 200518, 2005

Dr. Manfred Dr. Manfred SchingnitzSchingnitz, Friedemann Mehlhose, Friedemann Mehlhose

FUTURE ENERGY GmbH in Freiberg

3MW

5MWOffice

DBI

Freiberg city center

Advantages of GSP Entrained-Flow Gasifier with Cooling Screen

• high carbon conversion > 99 %

• raw synthesis gas without hydrocarbons, i.e. absolutely tarfree

• no dioxin/furan formation despite high chlorine content in the gasification feed

• no heed to be given to ash content and ash composition

• high gasifier performance

• high availability

• short startup and shutdown time (about one hour)

• multiple-fuel feeding

• cooling screen life time >10 years Granulated slag

Cooling screen

Pressur. water

Quenchwater

inlet

overflowWater

Gas outlet

Cooling jacket

Oxygen, SteamFuel

Pressur. wateroutlet

Burner

Particle Size Distribution of Pulverized Coalat a Carbon Conversion Rate of >99 %

in %

Sieve

Hard coal

High-re

active

Low-re

active

21

0.1

5

10

20

30

15

60

50

70

40

oversize

Pyrolysis char

Petcoke

10.50.30.2

Wood flour

0.10.05Particle diameter in mm

85

90

0.0295

0.01 0.03

Lignite,sewage sludge

80

Pneumatic Conveying and Feeding System for Pulverized Solid Materials

Material

N2

Depressu-rization

Storage bin

Waste air

Depressu-rization

Lock hopperLock hopper

Feeding vessel

Material togasifier

LIA PI

TI

LIC

PIC

H

L LLIC

H

PIC

M

M M

M

UC Q S

FIC

LIC

PI

M

2N

N2

N2

Burner for Coal Gasification

Cooling water

Oxygen/steam

Cooling water

Cooling water

Flame signal

Cooling water

Cooling water

Ignition voltage

Fuel gas to pilot

Cooling water

Pulverized coal

Pulverized Coal Burner

Oxygen

watercoalPulverized Cooling

3x

HP steamOxygen/

waterCooling

waterCooling

2x

Pilot burner gas

Cooling

Coolingwater

water

GSP Entrained-Flow Gasifier

Granulated slag

Cooling screen

Pressur. water

Quenchwater

inlet

overflowWater

Gas outlet

Cooling jacket

Oxygen, SteamFuel

Pressur. wateroutlet

Burner

Oxygen, SteamFuel

Raw gasSlag

Slag discharge unit

Views of the Cooling Screen after 10 Years in Service

Cooling Screen of the Gasification Reactor

Liquid slag

Solid slag

Membran wall

Pressurized water

Ramming mass

Pipe coil with studs

Anthracite

PetcokeLean coal

Forge coal

Fat coal

Medium-volatile coal

High-volatile coal

Hardbrown coal

Softbrown coal

95

90

85

80

75

70

65

60

55

Carbon content Cdaf

[wt.-%]

0 10 20 30 40 50 60 70

Volatile matter content Vdaf [wt.-%]

52

51 41

272621

28

232422

25

29

1401

02

15

13

12

04

11

03

Coals Gasified in theTest Facilities ofFUTURE ENERGY GmbH

SOFT BROWN COALS01 GERMANY Schwarze Pumpe02 GERMANY Braunsbedra03 BULGARIA Elhovo04 AUSTRALIA Mine Bowmans

HARD BROWN COALS11 SPAIN Teruel12 RUSSIA Kansk-Atschinsk13 CHINA Harbin14 CZECH REPUBLIC Most15 CZECH REPUBLIC Sokolov

HARD COALS21 GERMANY Ruhrgebiet22 POLAND Sosnica 2/123 POLAND Sosnica24 SPAIN Puertollano A (washed coal)25 SPAIN Puertollano (unwashed coal)26 AUSTRALIA Drayton27 AUSTRALIA Newlands28 SOUTH AFRICA Koornfontein29 COLOMBIA Cerrajon

41 Petcoke

ANTHRACITES51 GERMANY Doberlug52 GERMANY Ruhrgebiet

Ø2000

3500

5250

Ø2900

Ø3650

6700

Size Relation of Different Scale GSP Entrained-flow Gasifiers (2.5 MPa)

200 MW

500 MW

1000 MW

Adverse Characteristics of Biomass

l low density, i.e. large volumes to be handled

l heterogeneous structure requiring high chopping expense

l low heating value compared with conventional fuels

l high oxygen content in the organic matrix

l high-alkaline fuel ash

l bad grindability

Effective Use of Biomassin cooperation between Karlsruhe research center (FZK) and FUTURE ENERGY

input energy plants harvest remains by-products / wastes

wood bark / forest residues wood shavingsmiscanthus straw / hay lignin / bagasse

napier grass wood remainders sewage sludgetriticale branches liquid manure

1. step

2. stepor a slurry from bio-oil & bio-char

at 1 bar (15 psi) & ~500°C (900 F) - capacity: ~50 MW each ~ 10 t/h (20,000 lb/hr)

3. step

gasification unit

4. step entrained-flow gasification process by FUTURE ENERGY~1400°C (2500 F); 40 - 60 bar (550 - 900 psi) capacity: op to 1000 MWth

generation of a tar free raw synthesis gas

5. step gas treatmentcleaning / conditioning

final use generation of generation of generation ofsynthetic motor fuels electrical energy fertilizers / chemicals

cent

ral s

yste

m /

plan

t

to a centralized large-scale

loca

l are

a

local fast pyrolysis to generate bio-oil / bio-char

rail transport of the products from different local units

biomass preparation: collecting / pre-drying / chopping / storage

solid fossil fuels

liquid fossil fuels

27

64

3

< 0.1

1.5 - 5.5

0.46

0.04

1.0

0.4

11.1

Composition of Raw Gas from Different Feedstocks

ComponentHardcoal

Unit Petcoke Domesticrefuse

Lignite Oil Biomass Sewagesludge

Heating value MJ/Nm3

Heatingvalue (dry) MJ/kg 25 - 32 34 - 36 18 - 25 39 - 42 17 - 19 12 - 15 10 - 13

H2

CO

CO2

CH4

N2

H2S

COS

HCN

NH3

vol.-%

vol.-%

vol.-%

vol.-%

vol.-%

vol.-%

vol.-%

mg/Nm3

mg/Nm3

22

65

5

< 0.1

1.0 - 6.5

1.3

0.16

0.8

0.3

10.9

31

55

8

< 0.1

3.5

0.20

0.02

1.0

0.24

10.3

45

48

4

< 0.1

0.5

0.1

0.01

0.2

0.4

11.2

27

50

14

< 0.1

4.0

0.12

< 0.1

0.3

0.4

9.3

29

49

16

< 0.1

4.0

0.36

0.02

0.01

0.25

9.4

32

49

12

< 0.1

4.5

0.28

0.02

2.0

0.3

9.7

GSP Gasification Test Facilities of FUTURE ENERGY GmbH in Freiberg

Sewage sludge drier500 kg/h

Pyrolysis unit500 kg/h

Inert gas plant1000 m3

i.N./h80 bar

Oxygen plantmax. 300 m3

i.N./h80 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 MWmax. 30 bar

Slurry feeding300 kg/h

5 MW

3 MW

Office

SulFerox desulfurization unitWaste water treatment

COS hydrolysisHCN hydrolysis

• optimize feedstock preparation• determine optimum gasification process

conditions

• allow optimization of reactor or burner design

• allow reliable scale-up

• test materials of construction and components

• gain information about products and wastes

Advantages for our Costumers

Granulated slag

Cooling screen

Pressur. water

Quenchwater

inlet

overflowWater

Gas outlet

Cooling jacket

Oxygen, SteamFuel

Pressur. wateroutlet

Burner

Autothermal Oil Conversion PlantClient Sokolovská uhelná, a.s.Location, country Vresová, Czech Republic

Commissioning 2005

Technical data

Type of reactor entrained-flow, cooling wall design

Capacity 140 MWth

Pressure 28 bar

Temperature 1400 °C

Reactor volume 15 m3

Type of quench system full quench

Equipment / subsystems

Feeding system liquid feeding

Gas cleaning spray scrubber

Slag discharge lock hopper

Soot water treatment depressurization and vapor condensation,sedimentation, chamber filter press

Feedstock Generator tar and other liquid by-products of 26 fixed bed gasifiers of a 440 MW IGCC

Products / by-products / effluent Raw gas to IGCC / slag, soot cake / waste water

Gasification Project in the Czech Republic

3D computer simulation

Thank you very muchThank you very much!!