hydromax: breakthrough molten-metal coal gasification ... · ft synthesis reaction velocys f-t...

1DEC00352

HydroMax: Breakthrough Molten-Metal Coal Gasification Technology

Steven SchenkVice President, Special Programs

October 2007

GTC 2007 HydroMax Presentation 2DEC00352

Who is Diversified Energy?

• Alternative and renewable energy technology, project development, and services company

• Working in two alt-energy areas- Gasification (HydroMax, OMR)- Biofuels (CentiaTM, SimgaeTM)

• Focus on commercialization of technology• Headquartered in Gilbert, Arizona• Core team in place and key partnerships

established to support development• Strong State and Federal Gov’t relationships

“Develop and mature alternative energy technologies, systems, and projects to economically address

United States and World energy demand”

Core Strengths:Systems Engineering, Project Management, Project Development, and Finance


Overview of Gasification Areas of Expertise


HydroMax® Technology

Technically Sound, Economically Feasible, and Environmentally Friendly

• Patented breakthrough gasification technology developed by Alchemix Corp.– 5 years of private investment &

development work– 4 patents with 240 claims of inventions– Innovative chemical pathway to produce

syngas (CO+H2 & hydrogen (H2))– Laboratory & bench-scale demonstrations

have proven basic science– Technology and capital cost estimates

validated by independent, reputable third party evaluators (Aker Kvaerner)

• Diversified Energy has invested in, and holds a license to the HydroMax technology

• Major risk management program is currently underway

• Pursuing Government funding & support to accelerate technology development– 3 Government projects

awarded to date


HydroMax Technical Overview

Refractory Lined Hearth

Fe/Sn Melt(Fe Decreasing)

Slag (FeOIncreasing)

Steam Injection

Steam Injection

H2O + Fe H2 + FeO

Syngas(H2 Rich)

Oxidation Cycle

Water CooledLining

Fe/Sn Melt(Fe Increasing)

Slag (FeODecreasing)

Coal/AirInjection

Coal + FeO CO + Fe

Syngas(CO Rich)

Reduction Cycle

Coal/AirInjection

Coal + O2 CO2+ heat

0.000.501.001.502.002.503.003.50

0 5 10 15 20 25 30Time (minutes)

Feed

Rat

e (k

-mol

/sec

)

00.511.522.53

Syng

as

Rat

e(k

-mol

/sec

)

Steam

CoalHydrogen

Carbon Monoxide

Hydrogen

Carbon Monoxide

% FeO in Slag

% Fe in Melt

010203040506070

0 5 10 15 20 25 30Time (minutes)

%

%Fe in Melt

%FeO in Slag

Oxidation

Reduction

Refractory Lined Hearth

Fe/Sn Melt(Fe Decreasing)

Slag (FeOIncreasing)

Steam Injection

Steam Injection

H2O + Fe H2 + FeO

Syngas(H2 Rich)

Oxidation Cycle

Water CooledLining

Fe/Sn Melt(Fe Increasing)

Slag (FeODecreasing)

Coal/AirInjection

Coal + FeO CO + Fe

Syngas(CO Rich)

Reduction Cycle

Coal/AirInjection

Coal + O2 CO2+ heat

0.000.501.001.502.002.503.003.50

0 5 10 15 20 25 30Time (minutes)

Feed

Rat

e (k

-mol

/sec

)

00.511.522.53

Syng

as

Rat

e(k

-mol

/sec

)

Steam

CoalHydrogen

Carbon Monoxide

Hydrogen

Carbon Monoxide

% FeO in Slag

% Fe in Melt

010203040506070

0 5 10 15 20 25 30Time (minutes)

%

%Fe in Melt

%FeO in Slag

Oxidation

Reduction

• HydroMax uses a Two-Step Process for Creating H2 & Syngas that can be cyclic (separate cycles) or continuous:

Step 1: Oxidation. Steam reacts with molten iron to form iron-oxide & release H2

Chemistry: H20+Fe Fe0+H2

Step 2: Reduction: Carbon fuel reacts with iron-oxide to produce Syngas

Chemistry: FeO+C Fe+CO(endo)C+1/2O2 CO (exothermic)

• Cyclic Operation Separates Syngas Streams

The Fundamental HydroMax Chemistry is Identical to Conventional Gasification, However, the Pathways are very Different


HydroMax Features and Benefits• CO and H2 Produced in Separate and Distinct Streams

– Reduced gas handling/cleaning equipment needed– Output flexibility – hydrogen, F-T, Electricity, process heat– Lower capital costs – Basis: A-K Report 10/02– Maximizes hydrogen production from coal

• Feedstock Flexibility– High thermal inertia enables use of everything from

coal to biomass and high moisture content MSW

• Sulfur Removal via Tin Sulfide– Ability to utilize high sulfur coals– More hydrogen available to be used

• Simple and Proven Reactor Design– Improved reliability– Lower capital costs– Robust economics– Easily Scalable – Industrial Applications

HydroMax Design Offers Output Flexibility, Robust Feedstock Accommodation and Attractive Economics in a Simple, Compact Design


Current HydroMax Funded Programs• DEC has been awarded 3 separate Government funded programs in the last

several months• Hardware Programs

– 1). U.S. Department of Energy Industrial Gasification Phase I SBIR• Objective: Reduce natural gas consumption through coal gasification• Project partner: CertainTeed• Scope:

– Bench-scale tests at PMET (~6” Diameter Reactor) using PRB and Ill#6 coals– System design for CertainTeed industrial application

– 2). State of California – Public Interest Energy Research (PIER)• Objective: Reduce CA natural gas consumption through biomass gasification• Project partners: Evergreen Pulp Inc., EERC• Scope: Design, build, and install a small HydroMax reactor at Evergreen Pulp to

offset the plant natural gas usage• Design/Analysis Programs

– 3). U.S. Department of Defense Alternative Fuels Phase I SBIR• Objective: Design a transportable gasification to liquid fuels system to support

forward deployed military operations• Project partner: Velocys• Scope: Feasibility and system design study for portable liquid fuel production using

HydroMax (gasification) and Velocys (FT) technologies


U.S. Department of Energy Industrial Gasification SBIR Project

Reactor #1

Reactor #2

Reactor #3

GasQuench

GasQuench

GasQuench

HeatExchanger

HeatExchanger

HeatExchanger

Valves

Filter

GasCleanup

Compressor

CoalPrep

SteamGenerator

Tin Roast

Tin Roast

TinRoast

Coal

Air

SnS

SnS

SnS

Sulfur

Sulfur

Sulfur

Syngas toDryer

Combustors

AshParticulate

Water

Water

Water

Water

Water

Water

Air Stream

Water/Steam Stream

Syngas Stream

Coal/Ash/Sulfur Stream

Notional System Plant Layout

• Two Small-Scale Bench HydroMax Tests at PMET using Ill#6 and PRB coals in the early 2008 timeframe

• Preliminary System level plant design for CertainTeed Application 0.1m Diameter

HydroMaxReactor

Furnace

SyngasOutlet

Steam/Pet CokeInlet Lances

0.1m DiameterHydroMaxReactor

Furnace

SyngasOutlet


Existing test set-up at PMET


HydroMax State of California Development Project


HydroMax State of California Development Project (Cont)

• HydroMax Demonstration Reactor size: ~ ø0.5m• HydroMax Reactor Process: Continuous due to high moisture content feedstock• HydroMax system on-site at EPI for a 12 month demonstration period starting

~November 2009

HeatExchanger

HydroMaxReactor

WaterQuench

Compressor

Dry SyngasStorage Tank

WoodHopper

Conveyor

Compressor

ThrottleValve

ThrottleValve

ThermalOxidizer

Steam

Air

Wood Fines(50% Moisture Content)

Water

NaturalGas

Air

AirWarm Moist Air

Slag

Air

Syngas

Steam

Water

Wood

Heat exchanger provides hot air for drying of wood prior to

injection into reactor

Syngas is input to Thermal Oxidizer to offset Natural Gas Consumption


U.S. Department of Defense Portable FT-Fuels SBIR Program

HydroMaxReactor 1

HydroMaxReactor 2

HydroMaxReactor 1

SnSRemoval

Sn Roaster

SnO2

SO2

ZnO GuardBedFilter

HeatEx

H2 (Ox. Cycle)

H2 (Ox.)

H2 (Ox.)

SteamGenerator

CO/H2(Red. Cycle)

Feedstock/O2 or Air

Steam

Syngas Stream Combiner

(2:1 H2/CO ratio)

Water Re-Feed

Partial Boiling

Sat.Steam

CO/H2

FT Synthesis Reaction

VELOCYS F-T PLANT

Heat Heat

CO + 2H2

HYDROMAX PLANT

OUTPUT:-(CH2)n- + H2O

SyngasCooler

CO + 2H2

Water

GasCleanup

- AGR- Scrub- Misc

WaterCO2

Other

SyngasCompressor

Pump

Pump

DistillationC1 – C5

C5 +HydrocrackerDistillationJP-8

Power Generation ForCompressor/Pumps/Other

Gasoline/Naptha

Pump

H2

H2

HydroMax Feedstock & Output Flexibility due to High Thermal Inertia of the Molten Metal Bath Ideal for Portable F-T Plant

3-1.75m ReactorsProvide split syngas stream of H2 and H2/CO mix

Control valves blend stream to desired 2/1 H2:CO ratio

Reactors sized to meet all system power and heating needs in addition to providing syngas for FT backend

Waste heat from FT backend preheats water to reactor for better system performance


HydroMax Development/Testing History

PMET 0.1m Reactor Test• Hydrogen Stream

Production Demonstration• Blew Steam in FeSn Bath

CSIRO 0.3m Reactor Test• Proof-of-Concept Test• Cyclic Process

Demonstrated

PMET 0.1m Reactor Test• Continuous Cycle Test

Demonstration• Carbon & Steam Injection

PMET 0.1m Reactor Test• Steam Injection Rate

Demonstration• Ideal Flow Rate ~Mach 0.49


Furnace

SyngasOutlet



Furnace

SyngasOutlet


PMET 0.1m Reactor Test• Lock Cycle Test• Carbon & Steam Injection

DOE SBIR (Early 2008)

CA PIER (2009-2010)

Future HydroMax Testing

2002 2003 2004 2005 2006 2007

Systematic Approach to Engineering Bench Testing Results in a Well Understood Process Backed by

Analysis Correlation


HydroMax AspenPlus Analysis Model Set

OXYGEN2

MELT

CHNS

SYNGAS

REDALLOYOUT

RETURN

CFEED

REDUCTN

B4

RYIELD

STEAM

OXYGEN

MOLTEN GAS

MELT

ALLOY

FLUX MIX

OXIDTNB3 B1

ReductionOxidation

STEAM

OXYGEN

MOLTEN GAS

MELT

PETCOKE

OXYGEN2

WATER

SYNGAS

REDALLOY

ALLOY

FLUX

RETURN

MIX

OUT

OXIDTNREDUCTN

B3

B4

B1

Lock Cycle

Lock-cycle defined as repeatable cycle where slag and alloy conditions are the same for the end of oxidation as the beginning of reduction. Lock-cycle model inputs water in fuel as separate stream

A HydroMax AspenPlus Model Exists for Accurate Prediction of HydroMax Operations, Test Correlation and Optimization


HydroMax Model Correlation to Test Data

Predicted Performance vs Test Data

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

H2 -Ox. H2O - Ox. H2 - Red. H2O - Red. CO - Red. CO2 - Red.

Volu

me

%

Test Analysis

Initial Comparison of AspenPlus/FactSage Model with Test Data Shows Good Correlation During Oxidation, and Fair Correlation During Reduction


HydroMax Analysis Results - Wood Feedstock Output Versus Reactor Diameter -

• Optimum slag/melt depth is a function of reactor diameter based on lessons-learned from the smelting industry

• H2 and CO output doubles (1000-2000 kmols/hr) while reactor diameter only increases 43% (from ø3.0m to ø4.3m)

Wood Feedstock

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5Reactor Diameter (m)

H2

+ C

O O

utpu

t (km

ols/

hrs)

0

10

20

30

40

50

60

70

80

90

100

Dry

Woo

d Fe

ed R

ate

(mt/h

r)


HydroMax Analysis- Various Feedstock -

Shows decreasing utility for stand-alone oxidation cycle for Feedstock with moisture contents (mc) greater than ~25% (reduction cycle cannot convert FeO back to Fe to balance lock-cycle)

Model predicts very high H2/H20 and CO/CO2 ratios during reduction

2.3 to 2.9 for H2/H2O6.9 to 8.6 for CO/CO2)

Reduction Cycle Performance

0

10

20

30

40

50

60

Petcoke Dry Wood 25% mcWood

PRB Coal Illinois Coal

Out

put (

kmol

s/cy

cle)

H2 H2O O2 CO CO2

Analysis for a ø1.0 meter Reactor

Oxidation Cycle Performance

0

5

10

15

20

25

Petcoke Dry Wood 25% mcWood

PRB Coal(High MC)

Illinois Coal(High Sulfur)

Inpu

t (km

ols/

cycl

e)

H2 H2O O2 Steam


HydroMax as a Hydrogen Producer- Advantages -

Comm. Gas

HydroMax vs Commercial Gasifier(PRB Coal)

23.77

35.26

10.08

5.07

21.78

26.7724.9

13.37

0

5

10

15

20

25

30

35

40

Output H2 Output CO Output H2O Output CO2

Out

put (

kmol

s/cy

cle)

HydroMax(theoretical)

Comm. Gasifier(proven)

Used 1.0 mt/hr of PRB coal as basis for comparison.

Predicted HydroMax Performance versus commercial gasifier

performance with PRB coal

Comm. Gas

Comm. Gas

HydroMax Requires Less Input Products (“Consumables”) while Producing Output Products Comparable to Existing and Proven Gasifiers

HydroMax vs. E-Gas(PRB Coal)

0

200

400

600

800

1000

1200

Inlet Feedstock Inlet Water Inlet Oxygen

Inpu

t (m

etric

tonn

es)

HydroMax - 100 kW(theoretical)

E-Gas(proven)

HydroMax vs Commercial Gasifier

Comm. GasHydroMax(theoretical)

Comm. Gasifier(proven)


HydroMax Analysis Results- Wood Feedstock Performance -

HydroMax Performance Using Wood Feedstock

0.55

0.91

0.33

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

1.00

H2/wood CO/wood O2/wood

Perf

orm

ance

Rat

io (k

mol

s/km

ols

woo

d)

Prod

uced

Prod

uced

Con

sum

ed


HydroMax Analysis Results- Output Sensitivity to Slag Concentration -

Continuous Mode Operating “Sweet Spot”

Output Variation with Slag Concentration

0

20

40

60

80

100

120

140

160

180

30.00% 35.00% 40.00% 45.00% 50.00% 55.00% 60.00% 65.00% 70.00%FeO Concentration in Slag (%)

Out

put (

kmol

s/hr

)

300

320

340

360

380

400

420

440

460

480

500

Air

Con

sum

ptio

n (k

mol

s/hr

)

H2 CO Air

SiO2 Precipitation RegionSiO2 Precipitation

Region

Syngas Output (H2 and CO) and Consumption (Air) for Continuous Mode is Constant When HydroMax Operated Within “Sweet Spot” (40% - 60% FeO Concentration)


HydroMax Summary• HydroMax is a breakthrough technology that offers an efficient, less costly,

feedstock flexible carbon gasification process• Previous HydroMax tests have successfully demonstrated the fundamental

science and molten-metal (FeSn) process• Three funded contracts being executed by Diversified Energy

– U.S. Department of Energy– U.S. Department of Defense– State of California

• HydroMax interest spans multiple applications– Industrial scale natural gas replacement– Distributed liquid fuels production

• Modeling and analyses indicate key technology discriminators (water consumption, CO2 emissions, etc.)

• HydroMax appears to be ideally suited for industrial scale applications– Low-cost at small scales– High temperature (1300C) operations results in very clean syngas output

• Next steps include contract execution of currently funded programs, system scale-up, system integration, and commercialization

hydromax: breakthrough molten-metal coal gasification ... · ft synthesis reaction velocys f-t...

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