FUTURE ENERGY GmbH, Germany CCT 2005
The GSP-PROCESS Entrained-Flow Gasification of different Types of CoalDr. Manfred Schingnitz; Friedemann Mehlhose
History of GSP Gasification TechnologyYear 1956 1977 Fixed-bed gasification 24 gasifiers constructed in the gas combine Schwarze Pumpe Entrained-flow gasification
DBI
Demonstration plants Freiberg1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 Lignite Saliferous lignite
Commercial plants
3 MW
DBI
130 MW42 lignite varieties 15 hard coal varieties (international) Pulverized hard coal and lignite Lignite Saliferous lignite
Schwarze Pumpe
Natural gas 15 municipal and industrial sewage sludges, MSW, waste oil, wood, straw Slurry, fly ash Industrial waste and residues Waste oil, tar oil Slurry Tar oil/solid sludges
Noell
5 MW
Chlorinated organics Nitrogen waste organics Black liquor
Nitrogen waste organics 13 t/h Seal Sands
BabcockBioslurry, coal Hard coal Tar oil
Vesov
FUTURE ENERGYFig. 4
Advantages of GSP Entrained-flow Gasifier with Cooling ScreenFuel Burner Pressur. water outlet Oxygen, Steam
- 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 compositionCooling jacket Gas outlet
Cooling screen
Pressur. water inlet Quench water
- High gasifier performance - High availability - Short start-up and shutdown time (about one hour) - Multipurpose feeding - Cooling screen life time >10 years
Water overflow
Granulated slag
Fuel Preparation Reference ValueFuels Petcoke Anthracite Hard coal(low reactivity, Vdaf > > > > > 99 % < 250 m 100 % < 500 m 94 % < 250 m 100 % < 500 m 94 % < 250 m 100 % < 500 m 55 % < 100 m 99 % < 500 m 94 % < 250 m 100 % < 500 m
Moisture Content
< 2 wt.-%
Pyrolysis coke Hard coal(high reactivity, Vdaf> 28 %)
< 2 wt.-% < 2 wt.-% < 8 wt.-% < 12 wt.-% < 10 wt.-%
Hard brown coal Soft brown coal Sewage sludge
Particle Size Distribution of Pulverized Coal at a Carbon Conversion Rate of >99 % Hard coal0.1 1 Sieve 2 oversize in % 5 10 15 20 30 40 50 60 70
Lo
w -re ac
ti v e
Petcoke
Pyrolysis char
80 85 90
Lignite, sewage sludge Wood flour
95 0.01
Hi gh
-re
ac
tiv e
0.02 0.03
0.1 0.05 0.2 Particle diameter in mm
0.3
0.5
1Fig. 12
Pneumatic Conveying and Feeding System for Pulverized Solid MaterialsMaterialLIA PI
Waste air
Storage binTI
N2
Depressurization
M
M
Depressurization
P IC
P IC
Lock hopperLIC
H LIC L
H L
Lock hopperM
N2
M
N2
FIC
UC LIC
Q
S
Material to gasifier
Feeding vesselPI
N2
M
Fig. 10
Burner for Coal GasificationIgnition voltage
Flame signal Fuel gas to pilot Cooling water Cooling water Oxygen/steam Cooling water Cooling water Pulverized coal
Cooling water Cooling water
Pulverized Coal Burner
Cooling water
Oxygen/ HP steam
Cooling water Cooling water
Pilot burner gas
2x
3x
Oxygen Pulverized Cooling coal water Cooling water
Cooling Screen of the Gasification ReactorLiquid slag
Membran wall Solid slag Pressurized water
Ramming mass
Pipe coil with studsFig. 6
GSP Entrained-flow GasifierFuel Oxygen, SteamBurner Pressur. water outlet Fuel Oxygen, Steam
Cooling screen
Pressur. water inlet Quench water Cooling jacket Gas outlet
Slag discharge unit
Water overflow
Raw gas Slag
Granulated slagFig. 5
Views of the Cooling Screen after 10 Years in Service
Fig. 7
GSP Gasification Test Facilities of FUTURE ENERGY GmbH in Freiberg
5 MW 3 MW Office
Gasifier VV100 Reactor with cooling wall 2-3 MW max. 30 bar Gasifier Reactor with cooling screen 3-5 MW max. 30 bar
Pulverized fuel dosing and feeding system up to 10 t/h
Inert gas plant 1000 m3i.N./h 80 bar
Oxygen plant max. 300 m3i.N./h 80 bar
Slurry feeding 300 kg/h
Sewage sludge drier 500 kg/h Pyrolysis unit 500 kg/h
SulFerox desulfurization unit Waste water treatment COS hydrolysis HCN hydrolysisFig. 3
Schematic Flow Diagram of the Test Facility (NKV)Pulverized fuel feedingPulverized fuel Vent gas
GasificationOxygen/Steam
Quenching/ Scrubbing
SulFerox Raw gas COS cooling Hydrolysis Unit
Inert gas
el
Syngas
Inert gas Slurry
Granulate discharge system Slurry feedingWaste water treatment Feed water Air
Sulfur
Feed water
SlagS3
Anthracite
Forge coal Fat coal
Mediumvolatile coal Highvolatile coal
Hard brown coal Soft brown coal
Petcoke Lean coal 95 52 51 90 Carbon content Cdaf [wt.-%] 85 41
Coals Gasified in the Test Facilities of FUTURE ENERGY GmbH
27 21 28 24 23 22 25 13 12 15 02 29 26
SOFT BROWN COALS 01 GERMANY Schwarze Pumpe 02 GERMANY Braunsbedra 03 BULGARIA Elhovo 04 AUSTRALIA Mine Bowmans HARD BROWN COALS 11 SPAIN Teruel 12 RUSSIA Kansk-Atschinsk 13 CHINA Harbin 14 CZECH REPUBLIC Most 15 CZECH REPUBLIC Sokolov HARD COALS 21 GERMANY Ruhrgebiet 22 POLAND Sosnica 2/1 23 POLAND Sosnica 24 SPAIN Puertollano A (washed coal) 25 SPAIN Puertollano (unwashed coal) 26 AUSTRALIA Drayton 27 AUSTRALIA Newlands 28 SOUTH AFRICA Koornfontein 29 COLOMBIA Cerrajon 41 Petcoke ANTHRACITES 51 GERMANY Doberlug 52 GERMANY Ruhrgebiet 70
80
75
70 14 04 65 11 60 01
03 55 0 10 20 30 40 [wt.-%] 50 60
Volatile matter content Vdaf
Fig. 13
Fuel Burner
Gas to pilot burner Oxygen
Advantages for our customers : optimize feedstock preparation
Pressur. water outlet
Cooling screen
determine optimum gasification processPressur. water inlet Quench water Cooling jacket
conditions allow optimization of reactor or burner design allow reliable scale-up test materials of construction and components gain information about products and wastes
Gas outlet
Water overflow
Granulated slag
Gasification Project in the Czech RepublicAutothermal Oil Conversion PlantClient Location, country Commissioning Technical data
Sokolovsk uheln, a.s. Vesov, Czech Republic planned 2005 entrained-flow, cooling wall 140 MWth 28 bar 1400 C 15 m3 full quench liquid feeding spray scrubber lock hopper depressurization and vapor condensation, sedimentation, chamber filter press Generator tar and other liquid by-products of 26 fixed bed gasifiers for 440 MW IGCC3D computer simulation
Type of reactor Capacity thermal Pressure Temperature Reactor volume Type of quench system Equipment / subsystemes Feeding system Gas cleaning Slag discharge Soot water treatmentFeedstock
Products / by-products / effluent Raw gas to IGCC / slag, soot cake / waste waterFig. 20
Size Relation of Different Scale GSP Entrained-flow Gasifiers (2.5 MPa)1000 MW
500 MW 150 MW
5250
3500
3650 2900
2000
6700
Thank you very much!
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