Innovativeness and Development of Tsinghua Gasification Technology

Zhang Jiansheng

Email: zhang-jsh@tsinghua.edu.cn

Thermal Engineering Department, Tsinghua University

Beijing 100084, P.R.China

Gasification Technology Conference 2013Oct.13-16, Colorado Spring

Outline

1. Typical Entrained Flow Gasification Technology2. Research Abilities at Tsinghua University3. First Generation TU gasifier: Refractory structure4. Secondary Generation TU gasifier: Membrane Wall5. Conclusions and remarks

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

1.1 Typical Entrained Flow Gasification Technology

Shell

Prenflo PDQ

Siemens GSP E-Gas

Two stage dry feedMulti-burner HT-L

GE Texaco

Courtesy to: Henry Wang, Robert Rigdon, Harry Morehead, Phil Amick, Karsten Radtke, Zhou Zhijie, Jiang Congbin, Xu Shisen

All the O2 is injected into chamber at same level

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

1.2 Combination of section technology of entrained flow gasification

Dry Feed

slurry

Cooling Screen

Refractory Bricks

HRSG

Direct Quench

Feedstock Lining Heat Recovery

GE

GE, Multi-burnerGSP, HT-L

Shell, Prenflo, Two stage dry

feed？

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

2 Research facilities• Well established research and technology development method• Fundamental studies, gasification kinetics, simulation, cold and hot experimental facilities• Patent technology related to the whole gasification process, including feedstock preparation,

transportation, gasification, grey/black treatment, energy recovery• Successfully demoed two generation gasification technology

3D velocityLocal concentrationRTDNozzle evaluation……

Operation technologyOperation manualSafety……

Flow patternResistance Key parameters……

ProcessKey parametersCoal test……

Velocity fieldTemperature fieldConcentration fieldOptimization……

Support the application study and the successful of industrial application

3 First Generation TU gasifier: Refractory structure

Demo project: 500tons/day(Jan., 2006) The temperature near the process nozzle is about

50℃ lower than that of GE technology, double service life

1~2% higher of CO and H2, lower coal and oxygen consumption

Got the Appraisal Certificate of scientific and technological achievements in 2007

International advanced levelAwards and application2009, the support technology of industry revitalization by China

Nitrogen Fertilizer Industry Association (CNFA)2009, The Science and Technology progress award (First class)

of China Petroleum and Chemical Industry Association (CPCIA)2010, the Technology Progress Award(First Class) of China

Nitrogen Fertilizer Industry Association (CNFA)2009, Selected as one of the advanced gasification technology

with energy saving in the popularization list of the national key energy saving technology issued by NDRC

2010, Selected as one of the pressurized gasification technology in the popularization list clean of the clean production technology of nitrogenous fertilizer industry issued by Ministry of Industry and Information Technology of China

Key idea The concept of air staging wasintroduced into coal gasification Improve the temperature distributionand material mixing The only oxygen staging gasification process

Oxygen staging Tsinghua gasifier

Secondary oxygen nozzle after 88 days 6

4.1 Secondary Generation TU gasifier: Membrane Wall

Key idea The natural circulation

hydrodynamics and molten slagprotection are introduced into thedesign of membrane wall of gasifier

Better coal adaptability, low cost andfast startup

The world first slurry feedmembrane wall gasifier

Demo project: 600tons/day(Nov., 2011) With the advantage of slurry feed gasifier

and membrane wall gasifier Outstanding overall performance Got the Appraisal Certificate of scientific

and technological achievements in 2012 International leading level

Advantages Successful gasification of coal with 1520℃, coal

covers from lignite to anthracite 140 days operation in the first startup Only 2 hours from normal status to full load

(which is 3 days of GE technology), save 90% energy during startup

Long life membrane, low capital cost and maintenance cost

Lower pressurized shell temperature, domestic steel can be used instead of imported steel

Slurry feed membrane wall gasifier 7

4.2 Structure of TU membrane wall

Vertical pipe, hanging from top flange

Free expansion down Natural circulation water

system No superheated steam

generation

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

4.3 Features of TU membrane wall gasifier

The water circulation is designed based on natural circulation, which is intrinsic safe even without forced circulating pump.

Even distribution of cooling water, low resistanceNo stratified flow in the pipe

4.3.1 Intrinsically safe water circulation system

The water flow rate during the period of power loss of the whole plantGasification Technology Conference 2013, Oct.13-16, Colorado Spring

As membrane wall is used and the water screen is cooled by cooling water, the temperature in the gasification is no longer limited by the refractory bricks. The coal with high ash fusion point can be used.There is no change of the original SiC layer after 2 years operation.

4.3.2 High coal adaptability

The water flow rate during the period of power loss of the whole plant

4.3 Features of TU membrane wall gasifier

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

Only one combined nozzle is used for heating up and normal operation, less than 3 hours is necessary from normal temperature to full load.

Auto ignition of fuel gas → heating up → slurry feed and ignition → fuel gas switching → normal operation

SOE recorder Ignition: 6:20 Slurry feed: 8:49

4.3.3 High flexibility, fast startup

The water flow rate during the period of power loss of the whole plant

4.3 Features of TU membrane wall gasifier

As the gasifier can be startup fast, also there no refractory bricks change which need two months at least.

The service life of the process nozzle is much longer than that of refractory gasifier.

The running hours of single gasifier is expected to 8000 hours.

4.3.4 High availability

The combined process nozzle after 140 days operation, the service life is expected as long as 180 days

4.3 Features of TU membrane wall gasifier

The out surface temperature of pressure shell is 120℃ lower than that of refractory gasifier, 15CrMoR is used instead of SA387)

Membrane wall with simple structure instead of refractory bricks(saved several millions RMB)

100% domestic deviceHigher operation pressure, the capital cost for downstream shift

unit, cleanup unit and synthesis unit decrease.

4.3.6 low capital cost and low operation cost

4.3 Features of TU membrane wall gasifier

The out surface temperature of pressure shell is 120℃ lower than that of refractory gasifier, 15CrMoR is used instead of SA387)

Membrane wall with simple structure instead of refractory bricks(saved several millions RMB)

100% domestic deviceHigher operation pressure, the capital cost for downstream shift

unit, cleanup unit and synthesis unit decrease.

4.3.6 low capital cost and low operation cost

4.3 Features of TU membrane wall gasifier

4.4 TU-licensed gasification plant(water cooled)

Description of the contents

Describe a vision of company or

strategic contents.

Describe a vision of company or

strategic contents.

New projects of 2013

Retrofitting projects:Change existing refractory gasifier to TU membrane wall gasifier

No. Customer Parameters of gasifier Coal type CO+H2 rate Final product

1 China Offshore Oil Tianye Chemical Co., Ltd φ2800mm/6.5MPa Bituminous 159000 Ammonia,Methanol

2 Hebei Yangmei Zhengyuan Chemical Co. Ltd(Pingshan) φ2800mm/3.5MPa Bituminous,

Anthracite 90000 Ammonia

3 Xinjiang Tianzhi Chenye Chemical Co. Ltd. φ2800mm/6.5MPa Bituminous,Anthracite

120000 ethylene glycol,Mechanol

4 Xinganmeng Wulan Taian Energy Chemical Co.Ltd.

φ3200mm/6.5MPa Lignite 193900 Ammonia

5 Yangquan Coal Industry (Group) Co. Ltd.(Pingding)

φ2800mm/4.5MPa Bituminous 69000 ethylene glycol

6 Xinjiang Guotai Xinhua Mining Co. Ltd. φ2800mm/4.0MPa Bituminous 85000 Methanol

7 Jinmen oil refining plant φ2800mm/6.5MPa Bituminous 200000 H2

8 Jishan sub-company of Shanxi YangmeiFengxi Fertilizer Industry (Group) Co., Ltd

φ2800mm/4.0MPa Bituminous 50000 Ammonia

9 Hebei Qian’an Fertilizer Co., Ltd. φ2800mm/6.5MPa bituminous 110000 Ammonia

1. Guizhou Xincheng Coal chemistry Co. (NWRICI technology) 2. Hilongjiang Beidahuang AgricultureCo. (GE technology)

From Sep. 2012 to now, total licensing project is 16, more than the total number of all the other gasification technology providers

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

5. Conclusions and remarks

R&D of coal gasification are very active in China because of market driven.

It looks like original gasification technologies invented by advanced country still have space to improve.

The contribution of Tsinghua on gasification is somehow engineering innovation but not science invention. While such innovation is welcomed by Chinese industry or by the world.

Gasification Technology Conference 2013, Oct.13-16, Colorado Spring

Welcome to Tsingua ParkZhang Jiansheng

Tel: +86-10-62795930Fax: 86-10-62795930

Email: zhag-jsh@tsinghua.edu.cn