7th international freiberg conferenceinternational...
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7th International Freiberg Conference7th International Freiberg Conference on IGCC & XtL TechnologiesCoal Conversion and Syngas7-11 June 2015, Huhhot, Inner Mongolia, China
CONCEPT OF DEMONSTRATION PLANT FOR ENERGY AND CHEMICA PRODUCTION BYENERGY AND CHEMICAL PRODUCTION BY
CO2 ENHANCED GASIFICATION OF COAL IN FLUIDIZED BED REACTOR
IChPW: M.Ściążko, T. Chmielniak, A. Sobolewski, P. Kolon, J. Popowicz, J. Bigda
FLUIDIZED BED REACTOR
p , gSUT: A. Ziębik, M. Liszka, T. Malik
Scope of the presentationScope of the presentation1. Introduction2. Main assumptions – the basis for the
conceptsp3. Plant characteristics for energy and
chemical applicationschemical applications Configuration
P d i l i l Process and simple economical parameters
4. Coal gasification development strategy in Poland – short and medium term goals
2/20
g
Introduction: GeneralIntroduction: General Strategic program of R&D: "Advanced energy generation technologies”
Task No 3: "Development of coal gasification technology for highp g gy gproduction of fuels and electricity"funded by the National Center for Research and Development
Main product of the project: Coal gasification in CFB reactor using CO2 asCoa gas cat o C eacto us g CO2 as
gasification agent see: session 8.4: Pilot scale studies on coal gasification in a circulating fluidized bed
reactor with CO2 addition as a gasifying agent (Aleksander Sobolewski Institute forreactor with CO2 addition as a gasifying agent (Aleksander Sobolewski, Institute forChemical Processing of Coal – Poland)
Technological project of the DEMO plant inPoland based on developed technology
Strategy of coal gasification development in
3/20Poland
Introduction: CO enhanced gasificationIntroduction: CO2 enhanced gasificationDecrease in specific emission
%
22056
19713
19930
81120
871
2010
9
20224
8345
20000220002400026000
Power consumptionDirect emission, hydrogen productionTotal emission
ca. 13% 178
17125
1671818
16819
16301
8000100001200014000160001800020000
kg CO2/Mg H2
‐1185
396
294
534
‐306
‐417
‐4000‐2000
02000400060008000
HCGEE/Texaco
Case 1
HCShell
Case 3
BC Shell
Case 5
HCCFB/CO2
Case 6
HCCFB‐CO2HTR/coalCase 7
HCCFB‐CO2
HTR/reactorCase 8
85
90
cy, %
74,3 75,777,3
70
75
80
ld gas efficien
c63,6
60
65
hard coall f di
hard coald f di
lignited f di
ligniteCFB IChPW
Co
Cold gas efficiency
4/20
slurry feeding dry feeding dry feeding CFB IChPWCold gas efficiency
Assumption (1): GeneralAssumption (1): General
Assumption for the concept of demonstration plant:p p p Results of tests in pilot scale 100 kg/h (pressure
gasification – strategic program)P i i t h i t f l Previous experiences – atmospheric reactor for coalpyrolysis/gasification in CFB reactor, scale 8 t/h
Atmospheric CFB Reactor 200 kg/h
Pressurized CFB Reactor1 5 MPa 100 kg/h
Atmospheric CFB Reactor 8 Mg/h
5/20
Reactor 200 kg/h 1.5 MPa, 100 kg/hReactor 8 Mg/h
Assumption (2): configuration / casesAssumption (2): configuration / cases
Coal conversion 80-85% Second product: charNeed for rational use CHP Oxy-IGCCNeed for rational use
Oxy combustionCh b ti
y CO2 enhanced CFB gasification Power and Heat production
Char combustion Power production
Chemical production integrated ith l ifi ti Raw gas partial
combustionCH4 reforming
with coal gasification CO2 enhanced CFB gasification Methanol4 g
Destruction of higher hydrocarbons
6/20
CHP Oxy-IGCC (1): technological block diagramdiagram
7/20
CHP integrated with Oxy-IGCC (2): operating parametersparameters
Cycle parametersParameter Unit Value P t U it V l
Low temperature heat sourcesParameter Unit ValueGross Electric Power MWe 111,2Net Electric Power MWe 73,7
Parameter Unit ValueInterstage cooling in the process of O2 MW 9 51
Thermal Power MW 44,2Gas turbine MWe 45,5
and N2compression (ASU)
MW 9,51
Interstage cooling Steam Turbine MWe 65,7Gross Electrical Efficiency % 43,7
g gin the process of CO2 compression
MW 5,43
Syngas cooling MW 25 55Net Electrical Efficiency % 29
System efficiency: % 46
Syngas cooling MW 25,55Total MW 40,49
y yNel. +Q % 46
Typical capacity for the average urban agglomeration in Poland
8/20
Typical capacity for the average urban agglomeration in Poland
CHP Oxy IGCC (3): PESCHP Oxy-IGCC (3): PES
Index of Primary Energy Savings
Ech cog - consumptions of the chemicalenergy of fuels in CHP
Ech hp - consumptions of the chemicalenergy of fuels in referenceheating plant (replaced process)
Ech pp - consumptions of the chemicalenergy of fuels in reference powerenergy of fuels in reference powerplant (replaced process)
-Ech - savings of the chemical energyof fuels
E ti f th h i lEch sep - consumption of the chemicalenergy of fuels concerningseparate production of heat andelectricity
9/20
electricity
CHP integrated with Oxy-IGCC (4): IC – first estimatesestimates
Investment Costs: 300 mln $$
2500 $/kW (Net Heat and Power)( )
Feasibility study – in progressy y p g
10/20
Methanol productions (1): technological block diagramtechnological block diagram
11/20
Methanol productions (2): process modelingprocess modeling
Subf l ow sheet
69CW S
CO2 k o m p .
74
71 CWR79
2CWS6
CWR
7BFW NP
8BFW SP
ASU
Azot vent .
93
1
powiet rze
224
258
9
279
280 281232
82
CO2
198
70 174
221woda
M h l d iSubfl ow sheet
2
Subf l ow sheet3
15
23
W oda pr ocesowa
Que nc h Subf l owsheet
5
CO Shi ftSubf l ow sheet
6
Ch łod z e nie 1
Subf l ow s heet7
Chł odzeni e2
27
G az CLAUS
3738
39
25
32
Subf l owsheet9
Se le x o l33
48
49
50
51
Subf l owsheet14
56
42 Cla us
65
Subf l ow sheet16
5954
53
CO 2 1. 5
CO 2 11
CO 2 17
Subf l ow sheet17
PSA
20
36
76
21
66
27
62
64
58
43Subf l ow sheet
53
Sp a la n ie
73
Spaliny
Subf l owsheet2 6
132
109
Par a W P
110 41
Par a SPPar a NP
28
63
45 Cl aus 2
HRSG
141
60
18
G az procesowy164Par a
Węgiel suchy
ścieki166
170
110
O2
11
Azot reakt or
O2
G az reszt kowy
22
169
175
67
179
26
65
21
Para shif t
177
34
Woda pr ocesowa
181
19
20
72
55 186
112
G az kwaśny
Powiet rze
111
72 H2254
61108 Spaliny
261
180
40
41
153
88
326
154
327 328
187
12
138
73
OXY
17
16
165
2595
196
329
151
335
140 139
CHAR
342
345
CFB IChPW
349
81
178
204
173
222
52
CO 2 21
347
220
SkraplaczGa z procesowypo konw ersj i i chłodz eniu
Rozpręż aczsolwentuws tępniezregenerowanego
Usuwanie H2S i CO2 z gazu procesowego w technologii Rectisol
Przegrz ewac zRozpręż acza
Do SRU Claus
Koncentrator H2S
11 3 6
USUWANIE H2S USUWANIE CO2
26Turboge nera tor
CO2do kompres ji
8
18
39
4
12
218
110
Gaz s iarkowodorowydo węz ła SRU Claus
16
52
12 5251
41
46
62
48
70
55
51
33
16
200
1609Uklad zieb niczy
1613
17
111641
1602
1603
107
47
61
50
34
29 13
1621
1622
16241625
1653
1627
1628
55
1655
16571659
1660
74
1661
1658
1662
1621
1651
1632
1602
54
OCZYSZCZANIE WSTĘPNE GAZU
1645
1671
1600 22
1601
1603
20
16231620
1801
3000
1630
76 3003
48
49
47
50
16461663
C-1609C‐1617
E‐1616
T‐1618
1665
1666
T 1619
T‐1605 T‐1622
C‐1623
E‐1630
E‐1631
Methanol production
CW S
Subf l ow sheet15
68
CWS
CW R
CWR
77
67
Subf l ow sheet
4 0
T P
114Par a SP
CW S
BD
38
CWR
116
118
106111
117
Cl aus 2
120
115
BD
BFW WP
31
Par a I P
19
75
61
176BFW shif t
Para SP69
182
181
G az Claus
183
71
184
185
44
62
14192
Powiet rze
Woda uzup.
112
Siarka
255
278
107
39
HPS
167
Slag
333 332
13 334
N2 LPS
336 337
N2 LPS
CO2 DRY
CO2 DRY
104202
203
I PS I PS
205
204
227
Gaz procesowy odsiarczony
Metanolzregenerowany
Reboiler
9
Turbogenerator
13
10
24
34
37
2719
28
38
19
12
109
31
35 40
80
8
89
103
17
22
25
15
201
1607 1629
1612
431604
43
24
3441650
1637
1614
5
1626
1630
35 1636
1609
2116101640
1633
16111634
1616 1615
1601
1622
1617
1619
1643
1654
1656
1618
1632
39
16491605
1021627
49
1652
1631
95
1629
1635
1642
16341636
1635
16441639
1604
1672
1647
1674
1682
Turbina
1608
104
1628
15
56
27
1501
1675
1638
1618
14
84
1802108
1816
323001
1626
3002
1623
1606
21161615
1664
E-1601
V-1602 E-1607
V-1608
P-1610
E-1606
T-1604
E-1624
V‐1614
P-1615
E‐1613
E‐1625
E‐1612
T‐1619
E‐1621
E‐1629
P‐1640
P‐1641
1631 1625
3004
16331648
3005
BFW NP
Par a SP
kondensatBFW NP
190
28 Par a NP ( 4, 5bar )
T 117 C
9730
BFW SP ( 17 bar )
35
99
Par a SP ( 17 bar )Par a SP ( 60/ 30 bar )
Par a NP
37
45
25
131
134
BFW SP338
LPS O XY189
MPS O XY
207
209 Gasifier 300. Wsad - zgazowanie
P RODUKTY GAZOWE P IROLIZY8
9
30103113009
Węgiel
1001
147
4. 5
60
40
W 515547 kg/ h
BFW SP
29
47
36
Par a NP 4. 5
46
42
10096
Subf l owsheet46
8998
119
57
92
122
30
60
123
124
Z a s ila n ie
44
136
133
105
3
Para NP
4
Para SP
29
95 190
59
163
103 102 225
64
121
128
50213
125
144
172130200
156
201
20694
219
24
Piroliza
Para zgaz.
300Import danychz modelu pirolizy węgladr hab. M. Ściążko
310
320
301
340
311
322
314
Tlen
307
308
350
1
309
2
341
3001
3
3000
3003
321
3403002
3004
5
E nt. tw. W r
Q pirol.
E nt. Karb.
KARBONIZAT Z P IROLIZY
WILGOĆ I W ODA P IROGE NE TY CZNA
S MOŁY I HCULE GAJĄCE ZGAZOW ANIU
GAZ DO OCZY S ZCZANIA
3006
E FE KTY CIE P LNE UWZGLĘDNIONE W RE AKTORZE ZGAZOWANIA:
- 27,428 MW - Ciepło pirolizy - 2,200 MW - S traty cieplne
- 29,628 MW - S UMA
27,428 MW
7
312
30103113009
36 74 5
tarBTXGAZwilg. H2O
1,000 C
0,612 C
0,388 C 0,388 C
0,044 C0,203 C
0,141 C
8,951E -3 C etan28,152E -3 C m etan30,800E -3 C btx142,1E -3 C sm oła
S UMA: 0,210 C
0,388 C
0,178 C
0,354 C
0,999 C
0,645 C
0,645 C
0,178 C
1,177 C
E nt. tw. Gaz
310
301
Gaz sur .
312
1101
202
WChP
200
2145 WChZ
1620
1146
2161
155
101
193
Methanol production –t i
Gaz surowy
300340
302 342
330
332
307 309
CO2 DO RE AKTORA
ZAŁOŻENIA PROCESOWE:
całkowity stopień konwersji C:ilość C ulegająca r. Boudouarda: ilość pirogenet. smół i HC ulegających zgazowaniu: ciepło do produkcji pary: straty cieplne,
%%%% LHV węgla (st. rob.):MW% LHV węgla (st. rob.):MW
77,715,0 60 0 0 1 2,2
0,389 C
0,223 C
0,400 C
0,599 C
0,485 C
8Karb. piro.
1000
331
1003
1000 1005Karbonizat
CO2
1102
201
1604
1621
12/20
steering program
Methanol productions (3): GasifierMethanol productions (3): Gasifier 40 t/h of dryed coal (20% W ar)
90
CO2 gasification agent: 0,27 kg/kg Coal dry; 0,15 kmol /
kmol C in coal
74,3 75,777,3
75
80
85
efficiency, %
kmol C in coal
Cold gas efficiency (HHV): 64% (referring to total amount
63,6
60
65
70
Cold gas 64% (referring to total amount
of AR coal, HHV) 80% (referring to coal converted)
84% ( id i th 60hard coal
slurry feedinghard coaldry feeding
lignitedry feeding
ligniteCFB IChPW
84% (considering as the products gas and char)
Cold gas efficiency LHV base coal fed to the reactor Cold gas efficiency referring to gas after POX: 72%
Cold gas efficiency, LHV base, coal fed to the reactor
13/20 Lost in efficiency 8 % point
Methanol production (4): operating parametersMethanol production (4): operating parameters
Methanol efficiency: 41,4% (referring to total
amount of AR coal, HHV), ) 52% (referring to coal
converted, HHV)
Methanol and Power efficiency 54,1 %,
Loss in enthalpy (Referring to coal converted)( g ) Gasification ca. 20% Reforming 8%
14/20
Methanol production (5): economics – first estimatesestimates
Coal handling and
preparation;
Methanol synthesis; 162,8; 15% Total Investment costs:
178,2; 16%
Gasifier and char oxy‐
b
ASU; 163,4; 15%
310 mln $ Cost of production
365 €/Mg combustion; 345; 31%
Gas processing; 151,1; 13%
Power Island, ST; 115,4; 10%
365 €/Mg 340 €/Mg without EUA
(European Union Allowances)
450 450 450450
500Methanex European Posted Contract Price (MEPCP)
MEPCP
Cost of production, Demo plant
412 412 412
322 322 322
354 354 354 354339 339
365
350
400
Euro/M
g
Cost of production, Demo plant without UEA
Cost of production, commercial technology, dry feeding
200
250
300
15/20
01.14 02.14 03.14 04.14 05.14 06.14 07.14 08.14 09.14 10.14 11.14 12.14 01.15 02.15 03.15 04.15
Scenarios for gasification technology development in Poland (1)development in Poland (1)
Two Targets
1. Short term activities beyond 2020 Development of industrial scale plant based onDevelopment of industrial scale plant based on
selected commercial available technology
2. Medium and long term activities beyond 2030 Development of industrial scale plant based on
d l d ifi ti t h l i CFB tdeveloped gasification technology in CFB reactor(Demo stage needed)
16/20
Scenarios for gasification technology development in Poland (2)development in Poland (2)
Configuration and production directions
1. Medium scale CHP plants integrated withcoal gasificationg
2. Substitution of NG for hydrogeny gproduction and ammonia synthesis
3. Methanol synthesis and olefin productions
17/20
Scenarios for gasification technology development in Poland (3)development in Poland (3)
C t ti itCurrent activity
1. Chemical Industry is interested in implementationof coal gasification for chemical production
2. Economical screening (prefeasibility studies) ofdifferent technological options show promisingd e e t tec o og ca opt o s s o p o s gresults
3. Next decisions expected in 2 months
18/20
ConclusionConclusion Two potential application of the developed technology of
CO2 enhanced coal gasification in CFB reactor
Further development of the technology is related to the construction of demonstration plants
Especially attractive is the application of technology in a p y pp gyCHP Oxy-Combustion plant High Index of Primary Energy Savings Process scale (single reactor) is appropriate for energetic
needs of average urban agglomeration in Poland
At present technical and economic studies and analyses are performed for determination of economics of demonstration and industrial scale plants
19/20
demonstration and industrial scale plants
Acknowledgments
Thank you for your attention
The task of research, "Development of coal gasification technology forhigh production of fuels and electricity" funded by the National Centerhigh production of fuels and electricity funded by the National Centerfor Research and Development within the strategic programof research and development: "Advanced energy generationt h l i "technologies".
20/20