TU Bergakademie Freiberg I Institute of Energy Process Engineering and Chemical Engineering Reiche Zeche I 09596 Freiberg I Tel. +49(0)3731/39 4511 I Fax +49(0)3731/39 4555

Email evt@iec.tu-freiberg.de I Web www.iec.tu-freiberg.de

The University of Resources. Since 1765.

R&D Packages

of the DBI:bergakademie

Prof. Dr.-Ing. Bernd Meyer

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Organic Petrology – Fundamentals for Chemical Coal Utilization

TASKS Investigation of coal generation and the connection

between sedimentation and maturation of organic substances

Micro- and macropetrographical characterisation of coal components

Microscopic investigation of solid and liquid substances under natural or vacuum conditions

Analysis of process residuals from thermal-destructive conversion of rare materials

APPROACH/TOOLS Stereomicroscope (binocular macroscopical equipment)

and additional colour camera Research microscope (DM 4000) for conventional &

ultraviolet light including spectrometer and adaptable automatic point counter

Incident light microscope (DM 2500) with hot stage (Linkam TS 1500) and colour high speed camera

Microhardness tester (Vickers)

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Deep Chemical Analysis of Fuels

TASKS Structural analysis of thousands of organic compounds

in fuels Element speciation analysis in solid fuel samples APPROACH/TOOLS Hyphenation of one and two dimensional separation methods and ultra-high resolution mass spectrometry enable analysis of the totality of organic and inorganic compounds to be analyzed in solid coal/biomass and extracts or pyrolysis products of fuels. Infrared spectrometry (FTIR) Nuclear magnetic resonance (NMR) analysis Separation methods (GC, GC×GC, HPLC, SEC, extraction) Mass spectrometry (TOF-MS, FT-ICR-MS) also coupled to

GC, LC Plasma atomic emission spectrometry (ICP OES) with

electrothermal vaporization (ETV)

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Deep Chemical Analysis of Fuels

ESI-FT-ICR-MS of Coal/Biomass Pyrolysis Oil

C16 H13 O4

? ?

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Deep Chemical Analysis of Fuels

0 20 40 60 80 100 120 140 160

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1000

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2400

dI/

dt

time [s]

tem

pe

ratu

re [

°C]

sulphur

sodium

potassium

calcium

ETV-ICP-OES Multi-Element Analysis by ETV-ICP OES Temperature profile: programmable Temperature range: 25 °C – 2400 °C Heating rate: up to 800 K/s Analysis:

• qualitative/quantitative results • element speciation • temperature related release

of element species

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CFD Modeling of Gasification

TASKS 3D-CFD modeling and simulation of large scale gasifiers Flamelet modeling of partial oxidation processes Chemical kinetic mechanism reduction for CFD simulation APPROACH/TOOLS Coupling of advanced particle and turbulence-chemistry interaction models (flamelet) to CFD solvers Flamelet model development in laminar and turbulent flames and partial oxidation processes RANS and LES of pulverized coal flames Volume-of-fluid (VOF) simulations of liquid slag flows Flamelet Look-up Table Generator (FLUG) for non-premixed, premixed and partially premixed flames Matlab based chemical kinetic mechanism reduction toolbox HPC cluster with Infiniband network for large simulation with more than 2000 cores (Intel)

Large Eddy Simulation of coal flames CDF coal gasifier

Carbon Particle Chemically Reating in Hot Gas The Temperature scaled with Tin

The mass fraction of CO Calculated isocontours of temperature scaled with Tin and the CO mass fraction near the char-particle surface for different ambient temperature:(left) –Tin= 800 K, (center) – Tin = 1000 K, (right) – Tin = 1200 K. Here Re = 5.

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Particulate Interphase Phenomena in Gasification

TASKS Particulate flows including the heat and mass transfer

applications. Fixed bed systems including heterogeneous and

homogeneous chemical reactions. Solidification of slags, metals and alloys, Crystal growth. Heat and energy storage systems.

APPROACH/TOOLS Development of mathematical and numerical models. Performance of numerical simulations - optimization of

processes. ADDE-cluster with more than 1000 core-processors

(Intel) commercial software (academic licenses): 30 (long life)

licenses + 351 HPC parallel licences of ANSYS(Fluent/CFX) own CFD- and DPM-source codes (2D and 3D)

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Mechanical and Physical Low-temperature Conversion Processes for Coal and Biomass

TASKS Development of innovative methods for efficient crushing and

agglomeration (pelletizing, granulation, briquetting) of raw materials

Energy efficient drying of fine grain and agglomerates Development of a solid feeding systems for gasification reactors

(DER) Direct use of coal and its attendant materials New technologies for the processing of oil shale and tar sands New methods for solid-liquid separation Hybrid and reactive separation techniques APPROACH/TOOLS Pellet press, Hydraulic punch press, Roller press Extruder, Double-screw-extruder Jaw crusher, Roll Crusher Hammer mill Mixer Screening machine Devices for tests of the agglomerates mechanical stability Pulsed counter current extraction test facility (liquid-liquid-

extraction) Membranes e.g.reverse osmosis- , Nano- and ultra-filtration

facility

ITUN

Roller press Mixer

Pellet press Extraction

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Evaluation and Optimization of Processes and Concepts by Flow sheet simulation

TASKS

Process modeling/”model toolbox” development

Concept development for energetic and non-energetic fuel utilization

Energetic, technological, and economic process/concept evaluation

Process design and optimization APPROACH/TOOLS

General technological process evaluation Comprehensive process modeling and

simulation validated with published, experimental or customer data

Optional investigation of dynamic or stationary process behavior at part and full load conditions

Determination of energy and mass balances forming the basis for ecological, energetic and economic process assessment

Estimation of capital and operating costs for the derivation of specific product costs

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3rd Generation Coal Gasification

TASKS

Evaluation and comparison of different gasification technologies depending on feedstock and product

Optimization of gasifier operation Development of new gasification concepts for

low-grade coals (high ash content, low rank) Design of gasification reactors Influence of fuel (e.g.blending) on gasifier

performance RAM analysis of gasification systems APPROACH/TOOLS

Generic thermodynamic modelling of coal gasification

Potential studies and exergy analyses One-dimensional kinetic modelling of coal

gasification Numerical Simulation of coal gasifiers Phenomenological description of fluid-particle-

systems ASPEN PLUS®, ChemCAD®, ANSYS Fluent®,

modeFrontier

Ternary diagram – visualization of operation windows

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Gasification in Test and Pilot Scale

TASKS

Gasification of organic feedstocks (coal, oil, natural gas) Influence of fuel on synthesis gas quality and gasifier

performance Influence of residence time, pressure, temperature, fuel-

steam or fuel-oxygen ratio, and reactor geometry on fuel conversion and raw gas composition

Material and energy balances Mechanisms of formation and distribution of by-

products (trace components) Reactor and process modeling APPROACH/TOOLS

The Department of Energy Process Engineering and Chemical Engineering operates gasification plants in test and pilot scale. High pressure entrained flow gasification of liquid and

gaseous hydrocarbons New INCI type of coal gasification Laboratory analysis of fuel, raw gas, trace components

and gasification residues In-situ optical measurements (flame diagnostics, thermo

analysis)

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Conversion of Coal & Biomass for Conventional and Advanced Applications

TASKS Fuel characterization of coal, biomass & alternative fuels Characterization of pyrolysis & gasification behavior of coal & biomass Analysis of mechanisms, material & energy balances & kinetics of pyrolysis processes Analysis of the reactivity of fuels & kinetics of gasification processes Development & characterization of coke & carbonaceous materials for different use (carbonaceous adsorbens,

reducing coke, …)

APPROACH/TOOLS Modern equipment for standard and applied fuel characterization Thermal analysis equipment for ambient and pressurized TG, DSC, TG-DTA, TG-DSC- MS, TG-GC-MS as well as high

temperature dilatometry Small-scale pyrolysis reactors with fixed bed, drop tube (PYMEC) and rotary kiln up to 1100 °C and 100 bar

(depending on reactor type) Small-scale gasification reactors with fixed bed, drop tube (KIVAN) and fluidized bed (COORVED) up to 1600 °C and

100 bar (depending on reactor type) Equipment for pore structure and adsorption investigation

KIVAN – Gasification Drop tube reactor: < 100 bar, < 1,600 °C flow gas: H2O, O2/air, CO2, H2, CO, Ar, N2

feedstock < 1 mm, < 1,2 kg/h

Conversion of Coal & Biomass for Conventional and Advanced Applications

Equipment in start-up:

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COORVED - Gasification Internally circulating fluidized bed: < 1,5 bar, < 1,100 °C flow gas: H2O, O2/air, CO2, H2, CO, Ar, N2

feedstock < 1 mm, < 15 kg/h

PYMEC - Pyrolysis Drop tube reactor: < 100 bar, < 800 °C flow gas: H2O, CO2, H2, CH4, Ar feedstock < 1 mm, < 0,5 kg/h

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Ash-Slag-Behaviour A Challenge in Gasification Processes

TASKS Acquisition of chemical and physical property data Modelling of Ash-Slag-Behaviour (Fouling and deposit formation , Element partitioning and mobilisation )

Thermal analyses up to 2100 ºC (heat capacity,

phase transitions, mass loss) Furnaces with oxidising/reducing atmosphere

(exposure tests, interaction refractory/slag/gas) Thermochemical calculations (FactSage®,

SimuSage®) Modelling of surface tension and viscosity

APPROACH/TOOLS Phase Analysis (Reflected and transmitted light

microscopy, X-ray diffractometry ) Viscosimetry with reducing/oxidising atmosphere up

to 1700 ºC Thermo-optical measurement system with

atmosphere control (surface tension, wetting behaviour, mechanical tests, thermogravimetry with optical observation)

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Advanced Refractory Materials and Composities

TASKS Thermal shock Corrosion, Erosion Clogging, Anti-Clogging High temperature mechanical properties APPROACH/TOOLS Technical facilities for manufacturing pilot components

due to casting, pressing, extrusion and firing in different conditions

High temperature creep, refractoriness under load High temperature Young’s modulus, thermal expansion DTA, DSC, TG High temperature thermal conductivity High temperature modulus of rupture Slag-metal casting simulator Corrosion facilities, Clogging facilities SEM with EBSD, ESEM Computer tomography

Steel teeming from a leedle in a steel mill

Tundish stopper

Metal-casting simulator

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Thank you for your attention. Bernd.Meyer@iec.tu-freiberg.de

Reiche Zeche - Freiberg, Germany

For detailed Information: Technical Tour 2 to Freiberg on Thuesday