Siemens IGCC and Gasification Technology - tu-freiberg.de · pressurisation, fluidisation and coal...

Copyright ® Siemens Power Generation, Inc. 2007All rights reserved

Siemens IGCC and GasificationTechnology –Today’s Solution and DevelopmentsFrank Hannemann, Manfred Schingnitz, Gerhard ZimmermannSiemens Power Generation

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Power Generation / FG, EIPCopyright ® Siemens Power Generation, Inc. 2007

All rights reserved

• Competitive terms & economics

• Compliance with tightening environ-mental standards

• Continuation of coal use

• Multi-pollutant emissions legislation

• CO2 mitigation efforts

• Coal price stability and availability

• High natural gas price

• Security of supply

Market drivers and challenges for clean coal

• Material enhancements

• Experience from IGCC demon-stration plants

• Gas turbine development

• Single source IGCC product

• Carbon capture and storage technologies (CCS)

Innovation

Clean Coal

Customer Requirements

Energy Sources -

Fuels

Government Influence

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Siemens PG FG (Fuel Gasification):Origins and focus of new PG entity

Sustec Holding AG

FUTURE ENERGYGmbH Sustec AG Sustec

Industries AG

Sustec GSP China Corp. Ltd.

SustecSchwarze Pumpe

GmbH

Scope of acquisition Not included

100% 100% 100%

50% (50% Shenhua Ningxia Coal Group)

Siemens acquired Sustec

Holding with subsidiaries

FUTURE ENERGY GmbH

(Freiberg, Saxony),

entrained-flow gasifier

technology company

(~ 60 employees)

Sustec GSP China Corp. Ltd.,

50% of the Joint Venture

(Beijing)

(~ 20 employees)

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Gasifier –Current SFG Design with Full Water Quench

Attributes☺ Flexible feedstock ☺ World class gasification test facility☺ Cooling screen for high availability☺ Dry feed for high efficiency☺ Quench technology for simplicity &

improved reliability☺ High water content in rawgas

partial CO shiftbenefit for chemical synthesesand IGCC with CO2 capture

Coal/Feedstock

Oxygen Steam

QuenchWater

Raw Gas

LP Steam

VenturiWash

Partial Condenser

to gas cleaning

Reaction 1300 to 1800°C

Quench

170 to 230°C

Black Water Treatment

Water

Sludge

LP Steam

Slag

Current designCooling of the raw gas to about 200°C by direct water quench and subsequent mechanical cleaning (water wash) for downstream gas treatment and synthesis

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Gasifier –NCPP: Largest Coal to Chemical Plant in China

Recent Success: 5 x 500 MWth (Ningxia Coal Based Polypropylen Project ) Contract signed Q1/2007; Start commissioning Q1/2009

NCPP Project:Province Ningxia

Distance to federal capital appr. 40 km

Customer:SNCG - Shenhua Ningxia Coal Industry

Group Co., Ltd.IPMT - Integrated Project Management Team

consisting of SNCG and AMEC

SFGT Scope:Engineering Contract (PDP)Engineering Supply Contract (Training, TFA ..)Equipment Supply Contract (Reactor, Burner ..)

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Gasifier –Determination of Parameters / First Project Phase

Anthracite

Petcoke

Lean coal

Forge coal

Fatcoal

Medium

-volatile coal

High-

volatile coal

Hard

brown coal

Soft

brown coal

95

90

85

80

75

70

65

60

55

Carboncontent Cdaf

[wt.-%]

0 10 20 30 40 50 60 70

Volatile matter content Vdaf [wt.-%]

5251 41

272621

282324 22

25

29

14 01

0215

1312

04

11

03

Coal known

Ultimate / Proximate AnalysisDetermination of Ash Fusion Temperature

Coal and Ash properties

known

Determination of Moisture Leveland Particel Size Distribution

Fluidisation Tests

Slag Viscosity and Deeper Coal Analysis

(e.g. Petrological)

Gasification Tests for high Ash Containing Coals or critical

Fusion Temperature

Basic Engineering Package and Project Execution

yes

yes

no

no

Costumer Inquiry

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Objective:• Measurements of slag melting behaviour up to 1800°C under

reducing atmosphere and with 2 different viscometers

Rotational viscometer

Falling body viscometer

Target:• Optimization of gasification temperature

• Systematic analysis of different slag compositions produced under both oxidised and reduced conditions

Correlation in melting behaviour

Set up of database

Gasifier -High Temperature Viscometer

0

5

10

15

20

25

30

35

40

1150 1200 1250 1300 1350 1400 1450 1500

Temperature [°C]

Visc

osity

[Pa

s]

T25 =1206°C

- Example of a short coal ash slag● Measurement with rotational viscometer

of Australien lignite

Viscosity Temperature Diagram

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Gasifier -High Pressure Test Rig for Coal Feeding

VV5000 M

ATMOSPHERE

FEED

ING LI

NE

INERT GAScontinuous40 bar

INERT GASdiscontinuous40 bar

DRUM DISCHARGE

WEIGHINGVESSEL

PULVERIZED

PNEUMATICCONVEYOR

ROTARYFEEDER

LOCKHOPPER

ATMOSPHERE

ROTARYFEEDER

FEEDERVESSEL

PULVERIZED

INERT GAS6 bar

DRUM STATION

COAL BIN

COAL BIN

LOCKHOPPER

ObjectiveTest of coal dust flow measurement and monitoring devices Comparison of different velocity measurements(capacity, frictional electricity .. .)

Test of alternative coal flow measurement technologies

Investigation of CO2 and other feeding gases for pressurisation, fluidisation and coal feeding

Optimisation of lock hopper cycle and de-pressurisationwith different throttling devices (silencer plates or ceramic valves)

Long term test of different dust flow valves

Investigation of fluidisation behaviour under elevated pressure condition

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Own gasification technology allows to optimize the complete system and offer competitive IGCC solutions

Transportation fuelsMethanolAmmoniaHydrogen

Air Separation Unit

Oxygen

Raw syngas

CO2 disposal or Enhanced Oil Recovery

(EOR)

Gasifier

Gas Island

Co-Production of Chemicals

Synthesis

Power Island

CCPP(Combined Cycle

Power Plant)

Siemens PG scope of delivery

Gasifier-Island

Raw GasShift

Coal Preparation

Coal

SulfurRemoval

Air

Slag and Filter cake

Sulfur

CO2Removal

Electricity

N2

H2 rich Syngas

Plant Design -Siemens Gasification Combined Cycle (SGCC)

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Gasifier –Partial Quench with Heat Recovery as Future Option

Future design for IGCCCombination of

Water quench of raw gas and slag down to 700 to 900°C(below ash melting point)Efficient use of the high temperature heat in the steam generator for HP steam generation (optional: IP steam)

Mid-term R&D project together with partnersSFG optimized for IGCC applications.

Optimization of the reactor similar to current designReliability

Optimization and design of the partial quench system by investigation of mass and heat transfer (supported by CFD)Development of a waste heat recovery steam generatorConstructional aspectsExperimental testing on pilot plant

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500 MW~120.000 Nm3/h

(H2+CO)

1000 MW~246.000 Nm3/h

(H2+CO)

Objective :Optimized IGCC concept consisting of one gasifier and single shaft power train configuration

Advanced F Class SGCC Design with CO2 Capture

Plant Design -Optimized Concept between Gas Turbine and Gasifier

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Plant Design -Gas Conditioning as a Parameter for Optimization

Dilution with nitrogenHumidification

Mitigation of combustion conditions (reactivity, NOxformation)Enhancement of overall plant performance (increase mass flow, use of low temperature heat)

Linde Engineering

Integration of Air Separation Unitair- and nitrogen-side

Evaluation of integration concepts needs to look at the complete IGCC plant performance.

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Plant Design –Integration of Air Separation Unit

Linde Engineering

Nitrogen-side partial or non-integrated systems☺ Advanced premix combustion systems do

not need high dilution (and H2O moreeffective)

☺ Lower N2 compressor mass flow

Air-side partial or non-integrated systems☺ Operational behavior☺ ASU as separate plant unit for

independent gas supply ("over thefence") in case of non-integration

100 %

0 % 0 % 100 %

N2

Inte

grat

ion

Air-side Integration

100 %

0 % 0 % 100 %

N2

Inte

grat

ion


IGCC net power output IGCC net efficiency

GT power output limit

Compressormass flowreduced

Guide vanesfully open

Net power

Air-side integration

Thermodynamic study of effect of ASU on power output and efficiency –Typical trends

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Linde Engineering





independent gas supply ("over thefence")

100 %

0 % 0 % 100 %

N2

Inte

grat

ion


100 %

0 % 0 % 100 %

N2

Inte

grat

ion


air inlet pressurewaste N2 productpressurepower demand

ASU concepts differregarding

IGCC net power output IGCC net efficiency

16.5 bar air inlet5 bar N2

3 columns

6 bar air inlet1 bar N2

2 columns

11 bar air inlet3 bar N2

2 columns

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Linde Engineering





independent gas supply ("over thefence")

Integration defined by burner & turbine, plant layout, operational & economical aspects.For optimal performance optimum ASU configuration is needed.

100 %

0 % 0 % 100 %

N2

Inte

grat

ion


100 %

0 % 0 % 100 %

N2

Inte

grat

ion


Restriction bysyngas burner(combustability,geometry of gaspassages, etc.)

IGCC net power output IGCC net efficiencyH

eatin

gVa

lue

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Conclusion / Summary

Coal based ZEIGCC application are ready for demonstration and

subsequent commercialisation

Siemens offers both IGCC key components and provides integrated

and cost effective IGCC solutions

Siemens Gasification Combined Cycle (SGCC) Technology is

optimised for concepts with CO2 capture

Siemens gasification technology is well accepted and several

gasification projects are under consideration

High R&D investment into Freiberg facility ensures further

technology development

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Disclaimer

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