TU Bergakademie Freiberg I Institut für Energieverfahrenstechnik und Chemieingenieurwesen

Reiche Zeche I 09596 Freiberg I Tel. +49(0)3731/39 4511 I Fax +49(0)3731/39 4555

E-Mail evt@iec.tu-freiberg.de I Web www.iec.tu-freiberg.de

Institut für

Energieverfahrenstechnik und

Chemieingenieurwesen

Die Ressourcenuniversität. Seit 1765.

Gasification Process Research at the IEC – Lab investigations and large-scale research facilities

Prof. Dr.-Ing. Bernd Meyer

I General introduction to the IEC

II Lab-scale experimental research

III Large-scale experimental research and operating experiences

2

Outline

3

Fuel Research in Freiberg

3

GTI

1990

1949

1956

Institut für

Energieverfahrenstechnik und

Chemieingenieurwesen IEC

Department of Energy Process

Engineering and Chemical Engineering

Berufung Erich Rammler

Appointment Erich Rammler

BHT Coke Institut für technische

Brennstoffverwertung

Institute of Fuel Utilisation Braunkohlenforschungsinstitut

Lignite Research Institute

1947

1921 Sächsische Braunkohlenstiftung

Saxony State Lignite Research

Foundation 1918 L

iqu

id F

ue

ls

Co

ke

/To

wn

Ga

s

Syn

ga

s,

Fu

els

,

Ele

ctr

icit

y

1991

SIEMENS FGT

(CHOREN)

Deutsches

Brennstoffinstitut DBI

German Fuel Institute

Start-up

HP POX plant 2003

2008

2009

2011

Start-up

STF plant 2010

4

Organizational Chart of the IEC

4

Department of Energy Process Engineering and Chemical Engineering

Chair of Energy Process Engineering and Thermal Waste Treatment

Prof. Dr.-Ing. Bernd Meyer

Chair of Reaction Engineering Prof. Dr. rer. nat. Sven Kureti

Thermochemical Conversion/ Biomass

HP Gasification / POX

Gasifier Development

Flowsheet Simulation

Reaction Engineering

Refining/Hydrogenation

Esterification/Oxidation

Chair of Numerical Fluid Dynamics

Prof. Dr.-Ing. C. Hasse

Reacting Flow Systems

Interphase Phenomena

Multi Phase Systems

Mineral Matter Reactions

German Energy Raw Materials Centre

POX + ATR of gaseous and liquid fuels Slagging fixed bed + fluidized bed coal gasif.

5

Comprehensive Research on Fuel Utilization

Gasification

Gas Treatment

Synthesis or

Power Generation

Fuel Raw Gas Syngas Product

Macromolecule of hard coal and its decomposition

Distillation of the „mobile“ phase

Rupture of low bonds

Hydro-

genation

Coke

formation Gasification

Bonds between clusters

Aromatic-hydroaromatic complexes

Aliphatic bridges

Ether bridges

Experimental research at IEC:

Lab Scale

Large Scale

Dependent on: Fuel characteristics and conversion behaviour Process conditions Process technology

Low and high-temperature conversion of coal and biomass

Syngas-to-Fuels plant

CFD

Flow Sheet

Gaseous and liquid fuels: POX Coal: Fixed bed, entrained flow and fluidized bed

Modeling-based research at IEC:

Comprehensive stationary and dynamic modelling, concept development and technological, energetic, ecological and economic evaluation

Projects COORAMENT TEIMAB SFGT: dyn. modeling HotVeGas I & II

Industry Coop. Lurgi/Air Liquide Siemens (5 MW(th)) Choren, Phillips66

Test-Facilities HP POX® (5 MW(th) KIVAN

Projects COORIVA (PHTW) CCPP

Industry Coop. RWE (HTW:

150 MW(th), 10 bar 20 MW(th), 25 bar)

GTI (Students Exchange)

Test-Facilities INCI gasifier

Projects SBV

(10 MW(th))

Industry Coop. SVZ Schwarze

Pumpe (4 m FBDB)

Envirotherm (4 m SBG)

Test-Facilities RiFix

Background – Technical Know How in Gasification

6

Moving Bed Gasification

Feed

Raw gas

Gasifying agent (GA)

Ash/Slag

Fluidized Bed Gasification

Raw gas

Ash

GA Feed

6

Entrained Flow Gasification

Feed + GA

Slag

Raw gas

Slag

Raw gas

Feed + GAFeed + GA

Projects COORVED

Industry Coop. EDL Pörner

Test-Facilities COORVED/INCI

gasifier (100 kW, 5 bar)

3rd Generation Gasification

I General introduction to the IEC

II Lab-scale experimental research

III Large-scale experimental research and operating experiences

7

Outline

8

Common fuel characterization (mainly ambient pressure):

High importance of process neutral analysis and characterization of fuels, conversion behaviour and products

Minimum 4 persons (skilled and experienced lab. staff)

Appropriate building infrastructure

Requirement for approx. 2 Mio. EUR initial investment into standard lab equipment

Fuel characterization under realistic conditions :

Need for tailored lab-equipment: - elevated pressures - process specific analysis

Investigation of: - petrography - drying and particle defragmentation - pyrolysis of carbonaceous feedstock - gasification of pyrolysis products - ash/slag behaviour

Specialized and experienced scientists and technicians

1–2 years for design, construction, installation

1–2 years learning curve for each equipment use and optimization

Lab Facilities for Fuel Characterization – Introduction

Experience/ qualification

low inter-

mediate high

Infrastructural requirement

Equipment on offer

Operating costs

Effort for equip. acquisition

Experience/ qualification

low inter-

mediate high

Infrastructural requirement

Equipment on offer

Operating costs

Effort for equip. acquisition

9

Typical Fuel Test Program

Process-neutral lab-scale analysis of fuel properties and conversion

behavior

Proximate, ultimate and sulphur analysis

LHV-determination

Characteristic ash temperatures

Pyrolysis balances

Pyrolysis product characterization

Char gasification reactivity

Petrography

etc.

Gasification process

selection

Specific lab-scale analysis

Dependent on process – analysis of fuel properties and conversion behavior

Ash composition and vaporization

Ash viscosity

Gasification kinetics

Particle defragmentation

etc.

Broad properties and conversion characteristics database for process modeling, design and engineering

Modeling

CFD

Flow sheet simulation

Thermodynamic equilibrium (multiphase systems)

Optional: Large-scale

testing

Fundamental/Common Lab Facilities

Multi Element Analysis with XRF High Pressure Thermo-

gravimetric Analysis High-temperature/high-

pressure XRD chamber

(1.000 °C, 20bar)

10

High-temperature XRD

Fuel analysis

Standard fuel analysis laboratory (e.g. elemental analysis, LHV analysis etc.)

Chromatography (GC, HPLC)

Mass spectrometry (MS, GC-MS-coupling)

Atomic absorption spectrometry (AAS)

X-ray diffractometry (high temperature and high temperature and high pressure)

Multi element analysis with XRF and trace component analysis

Online gas analysis (IR, FTIR, FID)

Thermo-analysis (TG/DTA/DSC)

Rotating viscosimetry

Mercury porosimetry

BET surface area determination

11

Advanced fundamental (process neutral) test facilities

Amb. press. Elev. press.

Analysis of feed and product structure

Pressurized pyrolysis Drop tube/ fixed bed

Closure of elemental and heat balance possible

Atm.: Ar, H2, CO2, H2O, CH4 up to 30 bar/ 800 °C

xpart: 0,04–1 mm

Coal pyrolysis Drop tube

Closure of elemental and heat balance possible

Atm.: Ar, H2, CO2, H2O, CH4 up to 100 bar/ 800 °C

xpart: 0,04–1 mm

Lab-scale pyrolysis Fixed bed

Closure of elemental and heat balance possible

Atm.: Ar up to 1.000 °C

xpart up to 10 mm

Rotating kiln reactor Rotating kiln

Char production and tar production

Atm.: Ar or N2 up to 800 °C (large amounts)

xpart up to 10 mm

Retort oven Fixed bed

Char preparation for gasification Atm.: Ar, N2, H2, CO up to 1.100 °C

Retort: 200x200x400 mm

Pyrolysis GC-MS/FID Micro fixed bed

Analysis of liquid pyrolysis products

Atm.: Ar up to 34 bar/ 1.400 °C

xpart: 0.4–1 mm

Investigation of gasification and pyrolysis kinetics

RIFix Fixed bed

Determination of reactivity of char/coke

Atm.: Ar, CO2, H2O, CO, H2 up to 5 bar/ 1.450 °C

xpart up to 20 mm

HTR Drop tube

Determination of char gasification kinetics

Atm.: Ar, CO2, H2O, CO, H2 up to 1.359 °C

xpart up to 0,5 mm

Magnetic suspension balance TGA-MS

Fixed bed

Determination of pyrolysis and gasification kinetics

Atm.: Ar, N2, CO2, H2O, H2, O2 up to 40 bar/ 1.100 °C

xpart up to 10 mm

KIVAN Drop tube

Determination of hetrogeneous gasification kinetics and particle defragm.

Atm.: Ar, N2, CO2, H2O, H2, O2, CO up to 100 bar/1.600 °C

xpart up to 0,5 mm

12

Typical Test Program

Amb. press. Elev. press.

Investigation of ash/slag behavior

Furnaces Fixed bed Preparation of ash samples from carbon feedstock

Atm.: Ar, air, H2, CO, CO2, H2O up to 30 bar/ 1.800 °C

Atm.: Ar, N2, CO, H2 up to 1.800 °C

Viscosimeter Atm.: N2, Ar, (H2/CO) up to 1.800 °C

Special furnaces (TOM-AC, TOM-I)

Measurement of dimensional changes (shrinkage, sintering,…), option for in-situ FTIR

Atm.: Ar, N2, Ar/N2 up to 2.100 °C

Double-chamber TGA Determination of devolatilization and condensation of mineral compounds

Atm.: N2/H2 or Ar/H2 possible up to 1.500 °C (ΔTmax = 700 K)

Particle defragmentation

KIVAN Option for laser based measurement

See slide 12

See slide 12 See slide 12

PSD analyzer

DPA: Pressurized pyrolysis reactor Operation as drop tube or fixed bed Tube diameter d = 20 mm

heated length: 1.1 m p ≤ 30 bar T ≤ 800 °C Atmosphere: Ar, H2, H2O, CO2, CH4 (400 l(STP)/h)

PDO: Rotating kiln reactor (continuous mode) ambient pressure T ≤ 800 °C Feed rate: 3 kg/h

PYMEQ – Pressurized drop tube Tube diameter d = 20 mm

heated length: 2,2 m p ≤ 100 bar T ≤ 800 °C Atmosphere: Ar, H2, H2O, CO2, CH4 (400 l(STP)/h) 2 sampling points over heated length (tar, gas) Optical port between feeding system and

heated zone

Lab Facilities – Small-scale Pyrolysis Equipment (selection)

13

14

Feeds

Coal / biomass

Particle size: 40…500 µm

Moisture: < 10 wt.%

Feed rate: up to 10 g/min

Equipment Heated length: 1,100 mm Reactor ID: 20 mm 3-stage condensing system (-20 °C ethylene glycol/H2O) Online micro GC

Process conditions

Temperature: ≤ 800 °C

Pressure: ≤ 30 bar (g)

Gas atmosphere: Argon

Volume flow rate argon:

≤ 130 l/h (STP)

Coal feeding

Coalparticle

Partiallypyrolysedparticle

Coke particle

Electricalfurnace

Argon feeding

Argon feeding

Electric traceheating

Pyrolysis gas + argon

Coke collectorwith electrictrace heating

Reactor tube

Zufluss Argon

Pyrolysegas

+ Argon

Biomasse-

schüttung

Zufluss Argon

Pyrolysegas

+ Argon

Biomasse-

partikel

Biomasse-

zufuhr

Koks-

partikel

Zufluss Argon

Tw. pyro-

lysierte

Partikel

Schüttung aus

Kokspartikeln

Argon

Pyrolysegas

Reaktorbeheizung

Metallisches

Innenrohr

Begleitheizung

Begleitheizung

Koksauffang-

behälter

Begleitheizung

b) Fallrohra) Festbett

Pyrolysis gas

Pressurised drop tube reactor – experimental results

15

0

10

20

30

40

50

60

70

80

0 5 10 15 20 25 30 35

Pro

du

ct y

ield

s in

wt.

% (

d)

Pressure in bar

0

10

20

30

40

50

60

70

80

0 5 10 15 20 25 30 35

Pro

du

ct y

ield

s in

wt.

% (

d)

Pressure in bar

Char Liquid product Gas

0

4

8

12

16

20

0 5 10 15 20 25 30 35

Pro

du

ct y

ield

s in

wt.

% (

d)

Pressure in bar

Liquid product Reaction water Tar/oil

0

4

8

12

16

20

0 5 10 15 20 25 30 35

Pro

du

ct y

ield

s in

wt.

% (

d)

Pressure in bar 60

0 °

C

80

0 °

C

Pressure ↑

Main effect on product yields up to about 10 bar

Decrease of char and liquid product yield

Increase of pyrolysis gas yield

Tar yield shows minimum at 5 bar

Temperature ↑

slightly decreasing char and liquid product yield

strong rise in gas yields

Pressurised drop tube reactor - Pressure influence on product yields

Rubotherm – Magnetic Suspension Balance p ≤ 40 bar T ≤ 1.100 °C Pyrolysis: determination of kinetics and pressure

influence Gasification: CO2 and H2Od kinetics Atmosphere: Ar, N2, CO2, O2, H2, CO, H2Od

RIFix – Fixed bed gasification Reaction chamber: d = 20 mm p ≤ 5 bar T ≤ 1.450 °C Sample ≤ 5 g Atmosphere: CO2, H2O, CO, H2, Ar

HTR – Drop tube reactor

Tube diameter: d = 30 mm heated length: 1,75 m

Ambient pressure T ≤ 1300 °C Atmosphere: CO2, H2O, CO, H2, Ar

16

Lab Facilities – Small-scale Pyrolysis and Gasification Equipm.

17

Rubotherm TGA … magnetic suspension balance with various gases

and MS gas analysis

Weight loss of different coals at 10 bar

40

50

60

70

80

90

100

200 400 600 800 1000 1200

m/m

0in

wt.

-% (

d)

Temperature in °C

K3-3

K2-1

K2-2

K2-4

K2-5

K2-3

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

0 200 400 600 800 1000 1200

gas

yiel

d in

(m

l/m

in)/

g co

al

Temperature in °C

Sum PyGas

H2

CO

CO2

N2

CH4

COS

H2S

H2O

Gas release of K2-4 (Colombian hard coal)

Thermo-gravimetric analysis of coal pyrolysis – Rubotherm TGA

Influence of pressure and coal rank on: Decomposition behavior Mass loss curves Char yields Conversion rates Shift of conversion temperatures Gas release Composition of pyrolysis gas Temperatures of gas specie formation Yields of total gas and single species Experimental conditions: up to 1100 °C 5 K/min inert atmosphere (Ar) 1, 5, and 10 bar (40 bar in preparation)

KiVan = Kinetische Versuchsanlage (pressurized drop tube) High pressure heterogeneous

kinetic data Investigation of diffusion controlled

reaction regime Investigation of inhibition effects Feed: Coal and coke dust (≤ 1 mm) < 28 g/min Heated length: 2,8 m (d=70 mm) Atmosphere : O2, H2O, CO2, CH4,

Ar, H2, CO 4 levels of gas sampling points and optical

ports over heated length

18

Lab Facilities – Investigation of Gasification (KIVAN)

Pressurized Furnace p ≤ 30 bar T ≤ 1.800 °C Atmosphere: Ar, H2, Air, CO, CO2, H2O(g)

Large Sample Furnace T ≤ 1800 °C Ar, N2, CO, H2

Sample space: 500 x 600 mm E.g. testing of refractory linings

TOM-AC = Thermooptical measuring device with controlled atmosphere Non-contact measuring of dimensional changes

(shrinkage, sintering, …) Weight measuring device Option for In-situ FT-IR Ambient pressure T ≤ 2.100 °C Atmospheres: Ar, N2, Ar/N2

Lab Facilities – Small-scale Pyrolysis Equipment (selection)

19

20

Investigation of wedding behavior New developed refractories of different

ceramic systems Test with different ashes/slags

(acid, intermediate, basic) Experimental conditions: Up to 1450 °C 10 K/min Reducing atmosphere

(5 vol.-% H2 in Ar) Results: Images of sample at each

temperature Automatic shape detection

(height, width, area, contact angle etc.)

Calculation of surface tension Microscopic examination of the contact

surface refractory/slag (after experiment)

TOM-AC … Thermo Optical Measuring System with Atmosphere Control

10

15

20

25

30

35

800 900 1000 1100 1200 1300 1400 1500

Wid

th in

mm

Temperature in °C

Slag A

Slag B

start of sintering (shrinking)

different slags on same refractory

1204 °C 1309 °C 1355 °C 1383 °C

Slag A (short melting interval)

Slag-refractory interactions – TOM-AC

I General introduction to the IEC

II Lab-scale experimental research

III Large-scale experimental research and operating experiences

21

Outline

22

Semi-scale and Large Test Facilities – Introduction

Installation and operation of 3 large-scale test plants and 1 semi-scale test plants:

Since 2003: HP POX unit - 5 MW(th) gasifier for gaseous and liquid hydrocarbons

Since 2010/11: Syngas-to-fuels plant – 2 t/d capacity gasoline synthesis

Under construction: Slagging fixed-bed gasifier – 10 MW(th)

Under commissioning: Internal Circulating Mild Transport Gasifier (INCI) – 100 kW (beginning of construction: 2010)

Objectives:

Demonstration and optimization of new process technologies at an up-scalable capacity

Investigation of particular fuel conversion phenomena and processes

Needs:

Highly trained technical and scientific staff for operation and research (sufficient for research campaigns lasting several weeks)

2–3 years for design and construction plus 2 – 3 years for 1st research period

High-level infrastructure (oxygen supply, steam generation, flares etc.)

Experience/ qualification

low inter-

mediate high

Infrastructural requirement

Equipment on offer

Operating costs

Effort for equip. acquisition

23

Semi-scale and Large Test Facilities – Introduction

HP POX© plant

STF plant

Construction site Fixed-bed slagging gasifier

COORVED/INCI gasifier

Demonstration of the INCI Gasifier Concept = Internal Circulating mild transport gasifier Funded by the German Federal Ministry of Economics and Technology (BMWi) Design and demonstration of a 100 kW mild

transport gasifier (standard pressure) Gasification of coals of different grades Prove superior performance for processing

low grade coals Gasifier modeling (flow sheet & CFD) Plant features: Ambient pressure

T ≤ 1.100 °C (resistively heated, flame ≈ 1.800 °C) Atmosphere: H2O, O2, CO2, H2, CO, Ar, N2 Feed: coal and coke dust (≤ 0,5 mm, ≤ 15kg/h) Measurement equipment: - Online-GC

- Online-FTIR - Radiometric densitometry - Particle Image Velocimetry - Thermography (visible light range)

9 levels of gas sampling , 3 levels with optical ports

24

Coal Gasification Projects – COORVED

Under commissioning

Fixed bed slagging (slag bath) gasifier for the utilization of low-grade fuels Funded by the European Development Fund and the Federal State of Saxony (Sächsische Aufbaubank – SAB) Ground breaking: 05/2012 Comissioning planned for 05/2013 IEC activities/project objectives: Operation of a 10 MW(th)

slagging fixed-bed gasifier at 40 bar

Investigating of slag formation and behavior at high pressures: Studies on fuel influence Collecting material property

data Application-oriented slag

modeling

Coal Gasification Projects – SBV

25

Status: 9/5/2012

26

HP POX® test plant

Gasification modes ATR (autothermal catalytic reforming of natural gas) Gas-POX (autothermal non-catalytic reforming of natural gas) MPG (autothermal gasification of liquid feeds)

Feedstock Natural gas Light or heavy fuel oils Residues of oil processing

System specifications Max. pressure: 100 bar Temperature:

1200 – 1500 °C Thermal power: 5 MW

≈ 500 m³(STP)/h NG ≈ 500 l/h liquid fuels

Adjustable reactor volume

technology First test runs: 2004

Partial Oxidation of Gaseous and Liquid Hydrocarbons

27

water treatment

storage

compressor and

heater

pump and

vaporiser

fresh water

liquid feeds

natural gas

liquid O2

high pressure

steam generator

reactor and quench

quench water

cooler soot water

droplet separator

flue gas

flue gas chimney

desulphurisation

reactor

soot water flasher

control roominstrumentation air

supplypower supply measuring stationnitrogen supply

syngas

HP steam: 380 °C, 115 bar

Oxygen: 280 °C, 110 bar

Reactor design: max. 1.500 °C, 100 bar

HP natural gas: 650 °C, 113 bar

Liquid fuels storage, max. 160 °C

HP POX® Plant Layout

28

Head

Free space

Quench

HP POX project

10/01 01/02 04/02 07/02 10/02 01/03 04/03 07/03 10/03 01/04 04/04 07/04 10/04 01/05 04/05 07/05 10/05 01/06

Design Installation Cold tests ATR tests Gas-POX MPG

COORAMENT project

01/06 04/06 07/06 10/06 01/07 04/07 07/07 10/07 01/08 04/08 07/08 10/08 01/09 04/09 07/09 10/09 01/10 04/10 07/10

ATR + Gas-POX MPG (bio-tar and oil) MPG (different heavy feeds)

European Union – European Regional

Development Fund – ‘Investing in your future‘

(Air Liquide Group)

Project funding since 2001 by:

Industry research

HP POX® Project Schedule

29

Research scopes: Reactor and process modelling : - autothermal non-catalytic reforming of NG up to 100 bar

- autothermal catalytic reforming of NG of up to 70 bar Reduction of reaction mechanisms – „simplification“ of models for implementation into fluid

dynamic simulations Trace elements – mechanisms of formation and distribution of trace components at highest

pressures Atomisation behaviour of liquid feeds

Test runs since 2004 (including gas supply for STF plant since 2010): ATR mode: 19 runs MPG mode: 33 runs

Gas POX mode: 11 runs

Typical test run schedule (24/7 operation):

Staff requirement per shift (2 working shifts): - 2 laboratory workers - 2 operators in the control room - 1 plant operator on the site - 1 technician for process measuring and control devices - 1 operator for sample taking

In total approx. 25 permanent employees

1,5 days for start-up

6–7 days for steady state test runs

1,5 days for shut-down

2–3weeks of maintenance and plant preparation

HP POX® Operating Experiences

30

time

tem

pera

ture

[°C

]

1) free space 2) catalyst bed

1)

2)

end of

pre-heating

nitrogen flushing

start of steam

and natural gas feed

oxygen feed,

ignition: start of ATR

HP POX® Operating Experiences – Typical Start-up Curve

31

CFD model validation by: - Process data - Residence time measurements (tracer tests) - Optical observation of flame size, structure and temperature

Steady state CFD simulations including elementary kinetics are performed to study: - Flame structure - Recirculation behaviour - Temperature and species distribution inside the reactor

Example – CFD modelling of oil gasification (MPG): Simulation of 3D-model of the nozzle and comparison with 2D

Extension of model nozzle to MPG nozzle Simulation in OpenFOAM using lesInterFoam (large eddy simulations) Characterization of quality and propriety of results; search for adequate parameters

to compare results with experimental data

HP POX® – Selected Research Results

32

0,00

0,02

0,04

0,06

0,08

0,10

0,12

0,14

0,16

0,18

0,20

0,22

0,24

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0

relative Verweilzeit t/tm0

Wa

hrs

ch

ein

lic

hk

eit

sd

ich

te E

(t) Signal: OGasR (2)

Signal: Austritt (6)

Anpassung durch Faltung

1

4

5

6

2

3

Example 2: Investigation of the residence to validate assumptions for CFD modelling and to derive a model formed by standard/ideal reactor types for complex CFD modelling

Method: detection of radio-activated argon at multiple levels along the reactor height

Introduction of the tracer material at the top measuring

Derivation of a reactor model based on ideal models (Plug Flow, CSR, DCSR)

HP POX® – Selected Research Results

33

Temperature distribution as modelled in K

Reactions: 113

Species : 28

Example 3: Optical observation of the flame under process conditions to validate CFD simulation results for the different gasifcation modes

Introduction of OPTISOS probe (camera device) into the reactor through the start-up-burner hole

Option for measurement of the whole flame length and

Still need for improved measurement techniques to gain data about concentration and velocity distribution in reducing flames (Problem: limited optical accessibility to high pressure, high temperature gasification reactors for common laser techniques)

HP POX® - Selected Research Results

Feed and products: Feed: 700 m³/h (STP)

syngas from HP POX plant

Main product: Gasoline: 90 kg/h (approx. 120 l/h) meeting the Euro IV standard

By-products – Fuel gas – Feed water

New STF technology – process characteristics:

Funded by CAC Chemitz GmbH, the European Development Fund and the Federal State of Saxony (Sächsische Aufbaubank – SAB)

Conversion in two steps: 1. Syngas Methanol 2. Methanol Gasoline

Novel reactors for isothermal operation

European Union – European Regional Development Fund – ‘Investing in your future‘

STF (Syngas-to-Fuel) Gasoline Synthesis

35

Test campaigns: June 2010 2 weeks December 2010 4 weeks Feb./March 2011 4 weeks Aug./Sept. 2011 4 weeks May/June 2012 6 weeks All runs with HP POX operation too! Results: 15 June 2012 first run on syngas

17 June 2010 first STF gasoline produced Feb./March 2011: - 95 h of operation

- 9.170 kg of produced methanol - 4.000 kg of non-stabilized gasoline

Aug./Sept. 2011: - 240 h of operation - 12.850 kg of produced methanol - 8.800 kg of non-stabilized gasoline

Current activity: Replacement of the gasoline reactor to test another cooling concept

STF (Syngas-to-Fuel) Gasoline Synthesis – Project experiences

36

Thank you for your attention!

Prof. Dr.-Ing. C. Hasse

Chair of Numerical Fluid Dynamics

3D CFD Modelling of chemically reacting flows

Multi-Scale Modelling of turbulence-chemistry interaction

Chemistry modelling for combustion and partial oxidation conditions

Modeling and simulation of turbulence

Multi-phase systems

Professorships at IEC

37

Prof. Dr.-Ing. B. Meyer

Chair of Energy Process Engineering and Thermal Waste Treatment

Prof. Dr. rer nat. S. Kureti

Chair of Reaction Engineering

Solid fuels (coal, biomass, waste), gaseous fuels (natural gas, fuel gas)

Technologies of pyrolysis, gasification, combustion

IGCC and XtL technologies

Fuel gas cleaning and gas treatment

Thermal waste treatment

Development of carbonaceous adsorbents

Liquid fuels (oil, biofuels), chemicals

Kinetics and modelling of processes and reactors

Technologies of industrial organic chemistry

Technologies of biofuels

Technologies of oil processing

Co-processing/hydrogenation of crude oil residues and synthetic materials

38

Research Focus & Partners

Coal

Stranded Gas

Biomass

Waste

Electricity/Heat

Gasoline/Diesel

Basic Chemicals

(Synthetics,

Plastics)

Fertilizers

Hydrogen

SNG CO2-capture

Research on sustainable conversion routes including the key processes…

jointly with our partners (selection):

Gasification Synthesis Refinery

Residuals

Background – Technical Know How – Power/Chemical Plants

39

Stationary modeling of IGCC, chemical & polygeneration plants Dynamic modeling of gasifiers and IGCC plants Projects

55+ IGCC COORIVA Polygeneration ibi Studies for industry

Industry Cooperation RWE, Vattenfall, E.ON, Alstom, Sharyngol, …

Software Know How – Flow Sheet Simulation

40

Validated flow sheet models are available for:

Gasification Processes:

Entrained flow: Shell/Prenflo, Siemens, GE, CoP, Carbo-V, MHI

Fluidized Bed: HTW, Güssing, KBR, U-Gas, KRW

Air Separation Unit:

LP-ASU

HP-ASU

Gas Processing:

Gas cleaning: Water wash, Rectisol, Genosorb/Selexol*, MEA

Gas conversion: sweet/sour CO-Shift, HCN/COS-Hydrolysis

Sulfur recovery: Claus + Tail gas treatment

Pressure swing adsorption

Synthesis Processes:

Methanol

MtG MtO* DME (indirect)

Fischer-Tropsch

DME (direct)

Methanation (SNG)

Ammonia*

Power Block:

Gas turbine (E-class, also part load)

Bottoming cycle

Large tool box of models available:

Complex heat integration and integrated concept development possible (CCS-IGCC, IGCC, Polygeneration, BtL, CtL)

Coupling of all models from several environments possible (Aspen Plus, EBSILON, EES, ChemCAD)

* currently under development, dynamic modelling in Dymola/Modelica

Software Know How – CFD Simulation

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