markets, technology, developments. - tu …gtc database, 2013 and higman ... houston 2008 . 11...

H.Tautz, Linde AG, Div. Linde Engineering

D. Korobov, Linde AG, Clean Energy/Innovation Management

82049 Pullach, Germany,

6th International Freiberg Conference on IGCC & XtL Technologies,

19 – 22 May 2014, Radebeul, Germany

Gasification.

Markets, Technology, Developments.

2

Contents

Actual market situation and trends

Evaluation of existing gasification technology

Design tools and development facilities at Linde

Trends in technology development

Potential future markets and feedstocks

Summary

3

Actual market situation and trends

for gasification downstream processes

Compounded annual

Growth Rate (CAGR)

Methanol: 8,5%1)

Ammonia: 2,7 % 2)

GTL: ? %

Source:

1) http://press.ihs.com,March,11, 2013

2) www.prweb.com, Nov. 21,2013, Syngas

market.

Source:

GTC Database, 2013 and Higman Consulting Gmbh

Gasification Technologies Conference Colorado Springs, 16th October, 2013

2010

http://www.prweb.com/

4


Typical production capacities

Commercial gasification plants are

typically linked with large production

capacities and high investment costs

Know How & special design tools and

methods are necessary

for process optimization

mitigation of technical risks

avoidance of overdesign

Chemicals: 0,1- 0,5 Mio. Nm³/h Syngas

GTL: 1- 5 Mio. Nm³/h Syngas

5


Specific technical challenges for gasification

Insufficient reaction performance

High temperature control

Evaluation of effective reaction zone

Refractory design and installation

Burner design and fabrication

6


Solid gasification

Fixed/Moving Bed Gasification Fluidized Bed Gasification Entrained Flow Gasification

coal

Syngas,tar

ash

O2,

Steam

500-

600 °C

1400 °C

1000 °Ccoal

Syngas

ash free

ash

O2,

Steam

Fine coal,

Ash recycle

900-

1000 °C

Water

Quench

slag

Syngas

Ash free

Coal, O2,

steam feed

1400-

1600 °C

Fixed/Moving bed Fluidised bed Entrained flow

Temperature (°C) 1000-1400 900-1000 1400-1600

Av. conv. rate (t/m².h) 5 22 (CIT 64, Vol.5,1992) variable

Ash Dry/molten Dry Molten

Energy demand low medium high

7


Process simulation and CFD modeling

Design tools

Dynamic process simulation program with

Linde property database

CFD modeling

Reduced kinetic model in CFD calculation

8

CFD with equi-

librium model

T max. > 2000 °C

CFD with

kinetic model

T max. < 2000 °C

Swirl Burner

Example: Calculation of max. flame temperature with reduced kinetic model


Reduced kinetic model

9


Scale up from lab to technical scale

Lab scale: 10 Nm³/h; 30 bar

Pilot scale: 600 Nm³/h; atm pressure

Technical scale: > 200.000 Nm³/h; > 70 bar

10


Levers for future optimization

Cost reduction:

High pressure

More compact design

Standardisation

Extended prefabrication

Reduction of CO2 emissions:

Increase of energy efficiency

Co-gasification of biomass

Source:

Siemens Global Gasification update

Houston 2008

11


Reduction of CO2 production and O2 consumption

Investigation of theoretical potentials for reduction of specific CO2 production

and specific O2 consumption by reduction of gasification temperature,

feedstock preheating and biomass co-gasification

Feed Coal Coal Coal Wood Mix *

Preheat temp °C 25 25 300 300 300

Reactor temp. °C 1400 1000 1000 1000 1000

O2 supply % *** 100 84 71 11- 40 41- 55

CO2 release % *** 100 94 84 0 ** 42 **

Cold gas eff. % LHV daf 78.4 84.0 88.1 88.4 88.3

* Mix: 50 % wt coal/50 % wt wood ** CO2 of wood not counted *** Nm³ Gas/Nm³ Syngas

12


More compact design: POX with horizontal catalyst bed

XXL ATR: > 1 Mio. Nm³/h Syngas

Potential invest cost reduction

Controlled conditions for catalyst

POX & Catalyst bed = ATR POX

Gas

conditioning

several small POX Single

POX

Alternative

13


More compact design: Horizontal coal gasification

Potential Invest cost reduction

Theoretical cold gas efficiency > 85 %

Capacity 22 t/m².h or 100 MW/m² in HTW pilot plant at 25 bara 3)

Syngas

Horizontal

gasification reactor

R1

Circulating

fluidised bed

Coal

pressurization

to 80 bara in

liquid phase

Preheating

up to 300

°C

Feed Solid

content >

70-80 %

Fine coke

gasification

& ash

melting

Product gas

Steam & oxygen supply

Heat

recovery

3) CIT 64, Vol.5,1992

14

Potential future markets and feedstocks

Decentralized gasification of NG, coal, waste, biomass

Potential products: Power, District Heating, SNG, H2, FT-fuel, CO2

Gasification &

down stream process

Power

District heating

H2

SNG

CO2

Fuels

Chemicals

Ammonia

Foam

Natural gas

Coal

Biomass

Waste

15

Summary

Commercial gasification plants are typically linked with large

production capacities and high investment costs.

Gasification technology has significant optimization potential → but

special tools & methods are required for optimized design.

More compact design can help to reduce CAPEX and increase

competition of gasification.

Local feedstock and product demand provide additional opportunity

for gasification technology.

Thank you for your attention.

markets, technology, developments. - tu …gtc database, 2013 and higman ... houston 2008 . 11...

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