technologien der feststoff-vergasung im hause uhde · technologien der feststoff-vergasung im hause...
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Technologien der Feststoff-Vergasung im Hause UHDE
DVV- Fachausschuss„Grundlagen und Anwendungen“
15.11.07 Umsicht in Oberhausen
Gasification PortfolioApplication defines Process
Shell SCGP / PRENFLO
Koppers-Totzek
Shell SGPHigh-Temperature Winkler(HTW)
TGP TCGP SGP SCGP Prenflo HTW
K-TDevelopment of Uhde‘s Gasification Portfolio
Winkler /HTW
Fluidized Bed
750-950 °C
< 30 bar
Dry Solid
1926 (Winkler)(Leuna)
WachtbergBerrenrath
Oulu Wesseling
40 Plants
Koppers-Totzek
Entrained Flow
1400-1600 °C
atm.
Dry Solid
1950 (Tippy Oy)
TalkhaNew Delhi
ModderfonteinMurphy Hill
77 Plants
Shell SCGP/PRENFLO
Entrained Flow
1500-1600 °C
25 - 45 bar
Dry Solid
1979(Hamburg)
FürstenhausenHouston
BuggenumPuertollano
5 Plants
Shell SGP
Entrained Flow
1300-1400 °C
35 - 65 bar
Liquid, Gas
Uhde‘s 1st: 1964(Belgium)
PernisLeunaHaldiaNangal
168 Plants
Process
Principle
Temp.
Pressure
Feeding
First Plants
Plants(Examples)
References
Uhde’s Gasification Portfolio
Verfahrenstechnische Kenngrößen 2
Winkler / HTW Shell SCGP/PRENFLO
Koppers-Totzek
CO : CO2 2 19 5,5 - 8
CO : H2 1,2 2 2 – 2,3
T Rohgas / °C 950 1500 (900) 1350 - 1600
P Rohgas / bar (abs.) 10 - 30 25 - 40 1.05 – 1, 2
Vergasungsmittel O2 / Luft O2 O2
Teergehalte. 500 ppm C6 H6 50 ppm C10H8, 5% CH4 CH4 <0,1 % CH4 <0,1 %
H2S ? ? ?
Leistungsgröße 200 t/h 170 - 220 t/h 40 t/h
HydrogenChemicals
CleanSyngas forRefinery Use
Synthesis ofHydrocarbons
IntegratedGasification
Combined Cycle
Gasification&
Gastreating
Feedstock
Oxygen
• Boilers• Furnaces• (Electricity)• (Steam)Clean
Syngas(CO + H2) • Liquid
TransportationFuels
• Electric Power• Steam
Gasification Applications
The Texaco Gasification Process
TGP / TCGP
(Liquid and Solid Feedstocks)
Texaco Gasification ProcessLiquids / Solids (Slurry)
OxygenCoal Slurry
Process GasQuench Water
Char Water
Slag
Lock Hopper
TEXACO Coal Gasification Plant SAROberhausen/Germany
The Shell Coal Gasification Process
SCGP
(Solid Feedstocks)
Shell Deer Park Refinery, Houston/USASCGP-I Demonstration Plant
Shell Coal GasificationSolid Feedstocks
DRY SOLIDSREMOVAL
WETSCRUBBING
Coal Feeding
MILLING/DRYING
MILLING AND DRYINGFLY ASH TO
HP STEAM
MP STEAM
Slag
COAL/PETCOKE FLY ASHRECIRC. QUENCH GAS
GASIFIER
SALTS SULPHUR
CLEANSYNGAS
WATERTREATMENT
900 °C
GAS TREATING
FLY ASH SYSTEM
Shell Coal/Coke Gasification SCGP
1600 °C
300 °C
Gasifier Form C/H Ratiowt
Sulphur% wt
Coal SCGP Solid 16.2 2.69Petroleum Coke SCGP Solid 27.7 7.0Brown Coal SCGP Solid 12.2 0.71
Visbreaker Residue SGP Liquid 9.7 5.0Liquid Coke (DTC®) SGP Liquid 11.9 8.0Asphalt SGP Liquid 9.5 6.0
SCGP – Shell Coal Gasification ProcessSGP – Shell Gasification Process
SCGP - Module Gasification Building
Shell Gasification Processes – Feedstock flexibility
Gasification feedstock flexibilityHeating Value (LHV) 16 - 40 MJ/kgAsh Content (< 1) - 40 % wtSulphur Content 0.5 - 7 % wtChlorine Content 100 - 2,000 ppm wt
SCGP-I HoustonGasification Performance with diverse feedstocks
CGE =HHV of sweet gas
HHV of coal feed
Carbon Conversion
CGE (%HHV)
Illinois #5 99.7 81.6Maple Creek 98.7 76.0Drayton 99.6 79.3Buckskin 99.7 78.0Blacksville #2 99.7 80.5Pyro #9 99.9 78.3Sufco 99.9 81.0Texas Lignite 99.4 80.3Pike County (washed) 99.9 80.9Pike County (ROM) 99.9 83.0Dotiki 99.9 80.1Newlands 99.7 80.3El Cerrejon 99.6 83.4Skyline 99.9 82.4Robinson Creek 99.7 82.2R&F 99.5 79.6Pocahontas #3 99.3 82.4Petroleum Coke 99.5 78.9
Shell Coal Gasification IGCC (253 MWe)Buggenum, The Netherlands
The PRENFLO Gasification Process
Development by Uhde (former Krupp Koppers)
1. Development StepsGerman patent for Koppers-Totzek process
1. Development StepsKoppers-Totzek gasifier
Koppers-Totzek Gasification Plant in India(Capacity: 900 t/d ammonia)
1978-1981 Construction and operation of the Shell-Koppers plant in Hamburg
1985 Construction of the PRENFLO demonstration plant in Fürstenhausen
1986 Commissioning of the PRENFLO plant in Fürstenhausen
1992 First order for commercial-size PRENFLO plantin Spain (300 MWe net)
1999 Again cooperation with Shell promoting the Shell coalgasification process (SCGP)
Development of entrained-flow coal gasification
Development Steps
Shell-Koppers plant inHamburg / Germany150 t/d coal
22
Development Steps
PRENFLO Burner Test RigEssen / Germany5 t/d coal
PRENFLO plant inFürstenhausen / Germany48 t/d coal
Development Steps
PRENFLO Gasifier and Syngas Cooler
IGCC 318 MWel, netPuertollano, SpanienKohle und Petrolkoks2400 t/d
Post Weld Heat Treatment - Gasifier Vessel
Post Weld Heat Treatment - HP-Vessel
Membrane Wall
Gasifier - Erection of Internals
Erection of Gasifier/Turning
HP-Boiler/Internals
HP-Boiler/Heating Coils
Lifting of Gasifier/HP-Boiler
Lifting of Gasifier/HP-Boiler
- Membrane Wall protected by the slag layer
BFW, 40-70 bar
Water Tube
Gasifier space
> 1500 °C
molten slag flows downwards
solid slag
Shell Coal/Coke Gasification SCGP
.
Membrane wall for gasifier(test piece)
Raw synthesis gas
Coal in 100%
83%
0.8 % Steam fromreactor wall
14.0 % HP Steam fromSyngas cooler
0.2% Unconvertedcarbon
2.0% Low level heat
- Energy Balance
Energy Balance SCGP/ PRENFLO
IGCC Puertollano 318 MWel, net(feedstock: petcoke / coal)
The High-Temperature Winkler Process
HTW
(Lignite, Waste)
0
5
10
15
20
25
30
0 5 10 15 20 25 30
Gasifier pressure in bar
Spec
ific
thro
ughp
utin
t/m
²hDemonstration PlantDesigned (not realized)Realized
Winkler (10 t/h)
Vresova 2 (81,5 t/h)
Oulu/SF (26.7 t/h)
Vresova 1 (247.2 t/h)
KoBra, Air (160 t/h)
Sumitomo (0.6 t/h)
KoBra, O 2 (205 t/h)
Deggendorf (16.1 t/h)Kawasaki 2 (41.6 t/h)
Kawasaki 1 (82.4 t/h)RESH (7.1 t/h)
Elsterwerda (5.4 t/h)
HTW: Development and Commercialization
Classification of Coals Processed in HTW
PDUScale
PilotScale
IndustrialScale
Low-rank coalBrown coalHigh-S browncoalLigniteSubbituminouscoalHard coal
Ensdorf-Saar
Pittsburgh No.8
Other low-rank fuels (biomass and energy crops)
Peat
Wood
Grasses
Waste materials
Sewage sludge
Loaded coke
Used plastics
HTW: Operating Experience
Bottom Product
FireTubeDried Brown
CoalGasifier
WaterScrubber
Shift-Conversion Synthesis Gas
CO2LockHopperSystem Ceramic
Candle Filter
Filter Dust
GasificationAgents
Cooling Screws Sulphur
SulphurRecoveryDesulphurisation
toWaste Water Treatment
Syngas CoolerWaterTube
HTW Process: Typical Process Flow
HTW Demonstrationsanlage
Berrenrath/Deutschland30 t/h Braunkohle≈ 300 t/d Methanol
HTW Syngas AnlageKemira OyOulu / Finnland30 t/h Torf≈ 300 t/d NH3
Sumitomo Heavy Industries Ltd.
HTWGasifier
Cyclone
Steamturbine Generator
Shortkiln
Off-Gas
Slag
MSW
Sumitomo Heavy Industries Ltd.
HTW-Precon plant inNiihama / Japan48 t/d MSW
Das NuOn-Magnum Projekt(ohne CO2-Abscheidung)
1200-MW-Kohle- / Biomasse-Kraftwerk
Basistechnologie: IGCC
El. Leistung: 1200 MW netto
Nettowirkungsgrad: 46 -48 %
Einsatz von Importkohle undBiomasse (bis 30 %)
3 x SCGP- Vergasung (3 x 85 t/h)3 x Gasturbinen (noch nicht bestimmt)
Inbetriebnahme: Ende 2010
Budget: ca. 2,5 Mrd. €
Das RWE-Projekt des CO2-freien450-MW-Kohlekraftwerks mit CO2-Speicherung
Basistechnologie: IGCC
El. Leistung: 450 MWbrutto
360 MWnetto
Nettowirkungsgrad: 40 %
CO2-Speicherung: 2,3 Mio. t/a
CO2-Speicher in alter Gaslager-stätte oder in salinem Aquifer
Inbetriebnahme: 2014
RWE-Budget: ca. 1 Mrd. €