waste gasification: key technology for closing the carbon ... · 2 content closing the carbon cycle...
TRANSCRIPT
R.P. Lee, A. Laugwitz, F. Mehlhose, B. Meyer Institute of Energy Process Engineering and Chemical Engineering (IEC)TU Bergakademie Freiberg
Berlin, Germany3-8 June 2018
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Waste gasification: Key technology for closing the carbon cycle
- Coupling the Energy, Chemical and Recycling Sectors-
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Content
Closing the Carbon Cycle
Key Global Challenges, Motivation
Gasification as Key Technology
Technological Needs for Closed Carbon Cycle
Key Global Challenges
Economic & population growth and
natural resource depletion
Reduce primary resource consumption;
Increase utilization of secondary resources
Growing waste problem; impacts for humans &
environment
Transform linear to circular economy
Key Factors: Sustainability, Competitiveness, Supply Security,
Societal Acceptance
Global warming &2°C Goal (Paris-Agreement)
Increase utilization of renewable energy;
GHG Neutrality
Emissions Reduction Goals for Diverse Sectors
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ActivitySector
1990 (in Mio.t CO2-Equi.)
2014(in Mio.t CO2-Equi.)
2030(in Mio.t CO2-Equi.)
2030(Reduction in % against 1990)
Energy 466 358 175 – 183 62 – 61%
Building 209 119 70 – 72 67 – 66%
Transport 163 160 95 – 98 42 – 40%
Industry 283 181 140 – 143 51 – 49%
Agriculture 88 72 58 – 61 34 – 31%
Subtotal 1209 890 538 – 557 56 – 54%Others 39 12 5 87%
Total 1248 902 543 – 562 56 – 55%Klim aschutzplan 2050, pp. 26-27
• Net zero emissions à not only for GHG emissions but also for rest
emissions (e.g. heavy metals, organic & inorganic traces, fine particles)
• Resource efficiency• Resource conservation• Minimize carbon leakage
LONG-TERM OBJECTIVES
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Motivation Closing the Carbon Cycle forDomestic Carbon Resources
ReduceGHG Emissions
Address Global Waste Problem
ConserveNatural Resources
Achieve a Circular Economy
Support Structural Change
Reduce Import Dependency
Reduce“Carbon Leakage”
Technology Leadership
Closing the
Carbon Cycle
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Content
Closing the Carbon Cycle
Key Global Challenges, Motivation
Gasification as Key Technology
Technological Needs for Closed Carbon Cycle
Waste Hierarchy:(Reduce, reuse,
recycle, incinerate,
landfill)
Sustainable utilization of primary & secondary
carbon resources
Stepwise release of coal from
power generation
Political Framework in Germany
Circular Carbon Economy=
Global undertakingfor the 21st Century
Energy Transition„Energiewende“
Circular Economy Law„Kreislaufwirtschaftgesetz“
Circular Carbon Economy„Kohlenstoffkreislaufwirtschaft“
From Linear to Circular Carbon Economy
Dom
estic
Car
bon
Res
ourc
esG arzw eiler M ine Pow erP lant N iederaußem
Spitte lau Incineration P lant, V ienna
Combustion to CO2
Pri
mar
yS
econ
dary
Combustion to CO2
C + O2 à CO2 Combustion
From Linear to Circular Carbon Economy
Dom
estic
Car
bon
Res
ourc
esN C PP 1 in N ingxia, C hina (S IEM EN S G asification, 5 x 500 M W )G arzw eiler M ine Pow erP lant N iederaußem
Spitte lau Incineration P lant, V ienna
Verbrennungzu CO2
Pri
mar
yS
econ
dary
Verbrennungzu CO2
Synthesis to Chemical Products
Synthesis to Chemical Products
(1) 2C+ 0,5 O2 + 2H2O à CO2 + CO + 2H2(Syngas)
(2) CO + 2H2 à -CH2- + H2O(Syngas) (Olefins)
Gasification
Synthesis
Show a D enko, Japan
Show a D enko, Japan
Proposed Concept: Closing the Carbon Cycle with Sector Coupling via Interface Technology Gasification
Minimum CO2 emissions & minimal demand on renewable energy to achieve net zero emissions
Lee, R .P ., W olfersdorf, C ., K eller, F ., M eyer, B . 2017. Tow ards a closed carbon cycle and achieving a circu lar econom y for carbonaceous resources. Erdöl, Erdgas, K ohle, H eft 6, 2017, S . 77 – 80
Sectors
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CO2-Reduction Potential by new Sector Coupling (in mill. t/a)
CO2
CO2
CO2CO2
Lignite
Carbon Waste 100 C
100 C
Electricity & Heat
Electricity & Heat
100 C100 C
Coal Power Plant
Sector coupling withreduced CO2
emissions
Carbon Waste 100 C
Lignite 100 C
96 C*
104 C*
Sector couplingWITHOUT CO2
emissions
0 C*
200 C*
“green” H2
Today: Combustion, w/o sector coupling, linear approach
Chemical products w/ 100%recycled carboncontent (Methanol to Olefin)
ETS* penaltyETS* allow ance *Em issions Trading System
Incinerator
2025+: Conventional Chemical Utilization with Sector Coupling
2050+: Future Chemical Utilization with Sector Coupling
Chemical products w/ ~ 50% recycled carbon content (Methanol to Olefin)
Carbon Waste 100 C
100 CLignite
* ow n process chain evaluation
* ow n process chain evaluation
Lee et al.. Chemie, Ingenieur, Technik, 6; 2017
Strategy for Sustainable Utilization of Domestic Carbon Resources
Chemical Utilizationof Waste
~13 Mio t/a C combusted
Closing the
Carbon Cycle
High Potential for Closing the Carbon Cycle: Example Plastic Waste in Germany
(Quelle: Consultic, 2015)
Only 1% chemically recycled.
Approx. 11 Mio. t CO2 /year
Material
Recycling
3,14 Mio. t (53%)Combusted
Combusted
Incineration of plastic waste generates approx. 11 Mio. t CO2/year à High potential for chemical utilization & emission reduction(PLUS untapped potential of all other types of waste e.g. industry and biomass waste)
Total EBS (Substitute Fuel)~ 5 Mio t/year
(in 30 coal power plants)
Over 2200 incinerationplants worldwide
Treatment of around 225 Mio t per year
Strategy for Sustainable Utilization of Domestic Carbon Resources
Chemical Utilizationof Coal
Chemical Utilizationof Waste
~46 Mio t/a C combusted
~13 Mio t/a C combusted
Closing the
Carbon Cycle
Domestic Coal as Partner for Waste in Closing the Carbon Cycle
Not all chemical products re-enter
carbon cycle as waste materials
after utilization
“Top up” this gap with domestic
coal to maintain quantity of
chemical production
Carbon Losses
Demand for stable process for
syngas production and reliable
operation
Coal as co-feedstock with waste to
support formation of solid carbon
required for a stable process
Technological Requirement
Strong market competition for waste
as feedstock (e.g. incinerator, as
substitute fuel in power plants, …)
Gap in waste resources to be met
with domestic coal resources
Market Competition
Lee et al., IRRC 2017
Strategy for Sustainable Utilization of Domestic Carbon Resources
Chemical Utilizationof Coal
Chemical Utilizationof Waste
New Technologies especially Gasification
~46 Mio t/a C combusted
~13 Mio t/a C combusted
Closing the
Carbon Cycle
Overview of International Coal Gasification Technologies
Entrained Flow coal gasification technologies increasingly dominating the market, HOWEVER, also not suitable for waste gasification & closing the carbon cycle
R-Gas(GTI)
GE Energy (Texaco)
Prenflo(Thyssen
Krupp)Shell
CB&I(E-Gas)
BGL(Enviro-
therm)
TRIG (KBR)
OMB (ECUST)
Mitsu-bishi(MHI)
U-Gas (GTI)
HTW(Thyssen
Krupp)ash-free
Conventional fuels
Reactor with cooling screen
ash-containing
Industrial andchemical wastes
ash-containing
Reactor with specialcooling screen and quench
Industrial and chemical wastes
Fuel gas
PowerHeat
high-salt ash-free
Reactor with cooling wall
FertilizersOxoalcohols
Recovered resources
Syngas
HydrogenMethanol Raw syngas
Siemens (GSP)
Clean Coal Gasifier
(Choren)
Tsinghua 2-stage-oxygen
HT-L
(CECO)
TPRI2-stage-
coal
MCSG(NRI)
Lurgi FBDB
AirLiquide
2nd generationFluidized BedFixed Bed Entrained Flow
Strategy for Sustainable Utilization of Domestic Carbon Resources
Chemical Utilizationof Coal
Chemical Utilizationof Waste
~46 Mio t/a C combusted
~13 Mio t/a C combusted
Closing the
Carbon Cycle
“Green” H2 from Renewable Electricity
New Technologies esp. Gasification
Chemical Products from Domestic Carbon
Resources
Demand:~20 Mio t/a C
75%
18%5%
2%
Net Zero Emissions Olefins Production with Gasification Technology
Renewable H2 Demand: 0.235 kg/kg C
19(Source: own calculation)
Gasification
Auxiliaries & Electrolysis
Syngas cleaning
Renewable electricity
H2
Waste & Coal
MeOH & MTO-Synthesis Olefins
Diffuse CO2 recovery
Net Zero Emissions
O2
Diffuse CO2
Concentrated CO2
Renewable electricity
Legend
Raw gas/Syngas
11.1
GW
(10 Mio. t/a)
SyngasComposition
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Content
Closing the Carbon Cycle
Key Global Challenges, Motivation
Gasification as Key Technology
Technological Needs for Closed Carbon Cycle
Gasification enhances Recycling Rates
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+ a wide range of plastics cannot be recycled for material utilisation
+ Parts of waste are not suitable for combustionè Such waste streams can be a useful, high energy feedstock for gasification after a pre-treatment
(extraction of metals and glass )
Environmental benefits:§ Decreases GHG emissions§ Reduces use of imported fossil fuels§ Reduces use of virgin materials § Enhances recycling rates§ Changes waste to value feedstock§ Reduces waste deposits and problems of ocean wastes
Alternative Forms of Chemical Waste Recycling
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• Produce fuels - BUT: chlorine contamination of products• No technical solutions at present to prevent chlorine contamination
à Pre-selected polyolefin required as feedstock• Example: SYNTROL® facility in Mannheim; further development of
BASF‘s patented process; under construction since 2012 (??)
1) Pyrolysis
Costs & Chlorine
Contamination
• Produce fuels – BUT: chlorine contamination of products (as per pyrolysis)
• No technical solutions at present to prevent chlorine contamination
• Example: Kohleölanlage Bottrop (1990’s – 2000)
2) Direct Liquefaction Costs & Chlorine
Contamination
Overview of Waste Gasification Projects – Germany
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Rheinbraun, Berrenrath
SVZ, Schwarze Pumpe
1985-1997700 tpd coal-waste-mixture à 350 tpd MeOHHTW fluidized-bed gasifier
1991-20071300 tpd coal-waste-mixture à 300 tpd MeOHFBDB® gasifier, BGL gasifier, GSP gasifier
• Extended technological experience in Germany• Various waste mixtures tested• Different waste preparation technologies developed
è BUT not placed on the marked
• SVZ: 1991 – 2007 in East Germany• Processed 3.6 million tons of waste• Co-gasification of up to 75% waste with coal
- Shredder pellets (from cars) - Municipal waste- Dried sewage sludge- Used plastics- Contaminated wood- Tars & other liquid waste
• Uneconomic after changes to the German waste management regulations
• Key operation issues:- Chloride condensation- Low raw gas quality, fluctuating quantity- Extensive tar/oil-extraction and gasification
Experience from Schwarze Pumpe in Germany (SVZ)
Insights from IEC collaboration with SVZ
Source: IEC Internal SVZ Report
Overview of Waste Gasification Projects - International
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Showa Denko, Kawasaki, JPN
Since 2003, expansion in 2015
2 x 195 tpd waste à hydrogen for ammonia synthesis
EBARA PTFIG fluidized-bed gasifier
Enerkem, Edmonton, CAN
Since 2015
300 tpd waste à 80 tpd MeOH or Ethanol
Enerkem fluidized-bed gasifier
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Content
Closing the Carbon Cycle
Key Global Challenges, Motivation
Gasification as Key Technology
Technological Needs for Closed Carbon Cycle
Fixed Bed
FluidizedBed
EntrainedFlow
Net Zero Emissions
Synthesis Gas Quality
Synthesis Gas Yield low (C H 4, tars, o ils) moderate (C H 4) high
Carbon-free Ash yes no yes
Suitability forco-gasificationFeedstock coarse fine to coarse pulverized
Demands on Gasification Technologies for Closing the Carbon Cycle
R&D required to further develop fixed-bed and fluidized bed-technologies for closing the carbon cycle
R&DR&D
The Way Forward for Gasification Technology Development to Close the Carbon Cycle – Carbon Balance (1)
Internal Circulation Gasifier(INCI)
Circulating Fluidized Bed Gasifier(HTW)
Fludized-Bed Technology Further R&D
• High concentration of carbon in ash• No direct ash melting
• Lower concentration of carbon in ash• Improved gas quality• No direct ash melting
Test gasifier at IEC in Freiberg:• Improvement of Design• Testing of waste mixture• Improvement of gas quality
Fixed Bed Slagging Gasifier (BGL Gasifier)
Fixed Bed Dry Bottom Gasifier (FBDB)
The Way Forward for Gasification Technology Development to Close the Carbon Cycle – Carbon Balance (2)
Fixed-Bed Technology
• High concentration of carbon in ash• No direct ash melting• Low Gas Quality & Gas fluctuations
• Vitrified ash – unleachable slag• Low Gas Quality (Tar)• Gas fluctuations
Test gasifier plantat IEC in Freiberg:• for testing of design changes
and application of waste gasification
• Optimisation of gas quality• Test of different waste qualities
and mixtures
Further R&D
Planned Demonstration Project CARBONTRANS
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Start Engineering2021
Start Demonstration2024
Demonstration of closed carbon technology by using secondary sources implemented in a chemical plant site
IEC
Friedemann MehlhoseInstitute for Energy Process Engineeringand Chemical Engineering (IEC)TU Bergakademie Freiberg
Email: [email protected]: 0049 3731 39 4126
Thank You& Glück Auf!