Slim POX Design for Gasification -...

H. Tautz,Dept. EV, Linde Engineering

Slim POX Design for Gasification4th International Freiberg Conferenceon IGCC & XtL Technologies3-5. May 2010

2 R&D activities Linde LE, Dept. EV.pptLinde AG Engineering Division

— Introduction

— Kinetic modeling

— Reactor design

— Experimental results

— Summary

Contents


Operation conditions and requirements

— Coal components and operation conditions can have strong impact on the life cycle time of refractories.

— High availability of gasifiers is an issue for chemical and especially IGCC plants.

Technical approach

— Short maintenance periods for refractory repair or exchange are required.

— A new reactor design will be presented, which is based on advanced kinetic modeling and new insulation concepts.

Introduction


HOMogeneous REActions

(HOMREA)

tool for simulation of homogeneous reaction

kinetics on the basis of elementary reactions

and ideal mixing

Computational Fluid Dynamics

(CFD)

tool for simulation of fluid dynamics

and reactions

Link of

tailored kinetics model and CFD

Kinetic modelingPrinciple


Oxidation (exotherm):CH4 + ½ O2 CO + 2 H22 H2 + O2 2 H2O2 CO + O2 2 CO2

Reforming (endotherm):CH4 + H2O CO + 3 H2C2H2 + 2 H2O 2 CO + 3 H2

Shift Reaction (exotherm):CO + H2O H2 + CO2

Acetylene production (endotherm):2 CH4 C2H2 + 3 H2

Kinetic modelingBasic reactions


C2H2

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0 10 20 30 40 50t (m s)

y (k

g/kg

)

C2H2-Detailed C2H2-Tailored

Calculated mass fraction and temperature with tailored model and detailed model

CH4

0

0.006

0.012

0.018

0.024

0.03

0 10 20 30 40 50t (ms)

y (k

g/kg

)

CH4-Detail CH4-Tailored

Kinetic modelingBasic of calculation


CO2

0

0.02

0.04

0.06

0.08

0.1

0.12

0.14

0 10 20 30 40 50

t (ms)

y (k

g/kg

)

CO2-Detailed CO2-Tailored

Temperature

0

500

1000

1500

2000

2500

0 10 20 30 40 50t (ms)

T (K

)

T-Detailed T-Tailored

Calculated mass fraction and temperature with tailored model and detailed model

Kinetic modelingBasic of calculation


CFD with Equi-librium modellT max. 2500 °C

CFD withKinetic modellT max. 1700 °C

Jet Burner Swirl Burner

Kinetic modelingMax. flame temperature


BackgroundConventional reactor design characterized by:

— major recirculation zones

— increased potential for soot formation

— complex refractory design

Advanced Reactor (AR) Concept— new refractory material with design temperatures up to

1800°C and closed cylinder building blocks

— reduced reactor diameter resulting in reduced recirculation, higher reaction temperature & higher conversion

— Advantages— lower oxygen demand

— reduced potential for soot formation

— substantially higher specific capacity

— preassembly of reactor with refractorywith substantially reduced installation & start-up time

— for ATR applications: separation of combustion & catalyst zoneconventional

reactor designAdvanced Reactor

(AR)

Reactor designBackground, Concept & Advantages


— Reaction chamber dimensions:

Length: 4 m, Inner Diameter: 0.3 m

— Installation time for

insulation with 2 layers: 8 h

— Tested preheating gradient: 100-150°C/h

— Max. theoretical flame temperature: 1800 °C

— Theory of reduced flame temperature could be proved.

— Operated syngas production at atmospheric pressure 600 Nm³/h.

— Syngas production extrapolated to 30 bar:50000 Nm³/ h / m³reactor

Experimental resultsNew insulation concept in pilot plant


Status:

— Kinetic model with reduced flame temperature could be proved.

— New insulation concept with short installation time could be verified.

— New reactor design with reduced diameter and specific high production capacity could be qualified in pilot test runs for about 50 h.

Follow up:

— Long term test and validation in pilot application

Potential applications:

— Gas to Liquid (GTL)

— Integrated Gasification Combined Cycle (IGCC)

— Direct Reduction (DR) of iron ore.

Summary

Thank youfor your attention.

Slim POX Design for Gasification -...

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