Technologien der Feststoff-Vergasung im Hause UHDE

DVV- Fachausschuss„Grundlagen und Anwendungen“

15.11.07 Umsicht in Oberhausen

Gasification PortfolioApplication defines Process

Shell SCGP / PRENFLO

Koppers-Totzek

Shell SGPHigh-Temperature Winkler(HTW)

TGP TCGP SGP SCGP Prenflo HTW

K-TDevelopment of Uhde‘s Gasification Portfolio

Winkler /HTW

Fluidized Bed

750-950 °C

< 30 bar

Dry Solid

1926 (Winkler)(Leuna)

WachtbergBerrenrath

Oulu Wesseling

40 Plants

Koppers-Totzek

Entrained Flow

1400-1600 °C

atm.

Dry Solid

1950 (Tippy Oy)

TalkhaNew Delhi

ModderfonteinMurphy Hill

77 Plants

Shell SCGP/PRENFLO

Entrained Flow

1500-1600 °C

25 - 45 bar

Dry Solid

1979(Hamburg)

FürstenhausenHouston

BuggenumPuertollano

5 Plants

Shell SGP

Entrained Flow

1300-1400 °C

35 - 65 bar

Liquid, Gas

Uhde‘s 1st: 1964(Belgium)

PernisLeunaHaldiaNangal

168 Plants

Process

Principle

Temp.

Pressure

Feeding

First Plants

Plants(Examples)

References

Uhde’s Gasification Portfolio

Verfahrenstechnische Kenngrößen 2

Winkler / HTW Shell SCGP/PRENFLO

Koppers-Totzek

CO : CO2 2 19 5,5 - 8

CO : H2 1,2 2 2 – 2,3

T Rohgas / °C 950 1500 (900) 1350 - 1600

P Rohgas / bar (abs.) 10 - 30 25 - 40 1.05 – 1, 2

Vergasungsmittel O2 / Luft O2 O2

Teergehalte. 500 ppm C6 H6 50 ppm C10H8, 5% CH4 CH4 <0,1 % CH4 <0,1 %

H2S ? ? ?

Leistungsgröße 200 t/h 170 - 220 t/h 40 t/h

HydrogenChemicals

CleanSyngas forRefinery Use

Synthesis ofHydrocarbons

IntegratedGasification

Combined Cycle

Gasification&

Gastreating

Feedstock

Oxygen

• Boilers• Furnaces• (Electricity)• (Steam)Clean

Syngas(CO + H2) • Liquid

TransportationFuels

• Electric Power• Steam

Gasification Applications

The Texaco Gasification Process

TGP / TCGP

(Liquid and Solid Feedstocks)

Texaco Gasification ProcessLiquids / Solids (Slurry)

OxygenCoal Slurry

Process GasQuench Water

Char Water

Slag

Lock Hopper

TEXACO Coal Gasification Plant SAROberhausen/Germany

The Shell Coal Gasification Process

SCGP

(Solid Feedstocks)

Shell Deer Park Refinery, Houston/USASCGP-I Demonstration Plant

Shell Coal GasificationSolid Feedstocks

DRY SOLIDSREMOVAL

WETSCRUBBING

Coal Feeding

MILLING/DRYING

MILLING AND DRYINGFLY ASH TO

HP STEAM

MP STEAM

Slag

COAL/PETCOKE FLY ASHRECIRC. QUENCH GAS

GASIFIER

SALTS SULPHUR

CLEANSYNGAS

WATERTREATMENT

900 °C

GAS TREATING

FLY ASH SYSTEM

Shell Coal/Coke Gasification SCGP

1600 °C

300 °C

Gasifier Form C/H Ratiowt

Sulphur% wt

Coal SCGP Solid 16.2 2.69Petroleum Coke SCGP Solid 27.7 7.0Brown Coal SCGP Solid 12.2 0.71

Visbreaker Residue SGP Liquid 9.7 5.0Liquid Coke (DTC®) SGP Liquid 11.9 8.0Asphalt SGP Liquid 9.5 6.0

SCGP – Shell Coal Gasification ProcessSGP – Shell Gasification Process

SCGP - Module Gasification Building

Shell Gasification Processes – Feedstock flexibility

Gasification feedstock flexibilityHeating Value (LHV) 16 - 40 MJ/kgAsh Content (< 1) - 40 % wtSulphur Content 0.5 - 7 % wtChlorine Content 100 - 2,000 ppm wt

SCGP-I HoustonGasification Performance with diverse feedstocks

CGE =HHV of sweet gas

HHV of coal feed

Carbon Conversion

CGE (%HHV)

Illinois #5 99.7 81.6Maple Creek 98.7 76.0Drayton 99.6 79.3Buckskin 99.7 78.0Blacksville #2 99.7 80.5Pyro #9 99.9 78.3Sufco 99.9 81.0Texas Lignite 99.4 80.3Pike County (washed) 99.9 80.9Pike County (ROM) 99.9 83.0Dotiki 99.9 80.1Newlands 99.7 80.3El Cerrejon 99.6 83.4Skyline 99.9 82.4Robinson Creek 99.7 82.2R&F 99.5 79.6Pocahontas #3 99.3 82.4Petroleum Coke 99.5 78.9

Shell Coal Gasification IGCC (253 MWe)Buggenum, The Netherlands

The PRENFLO Gasification Process

Development by Uhde (former Krupp Koppers)

1. Development StepsGerman patent for Koppers-Totzek process

1. Development StepsKoppers-Totzek gasifier

Koppers-Totzek Gasification Plant in India(Capacity: 900 t/d ammonia)

1978-1981 Construction and operation of the Shell-Koppers plant in Hamburg

1985 Construction of the PRENFLO demonstration plant in Fürstenhausen

1986 Commissioning of the PRENFLO plant in Fürstenhausen

1992 First order for commercial-size PRENFLO plantin Spain (300 MWe net)

1999 Again cooperation with Shell promoting the Shell coalgasification process (SCGP)

Development of entrained-flow coal gasification

Development Steps

Shell-Koppers plant inHamburg / Germany150 t/d coal

22

Development Steps

PRENFLO Burner Test RigEssen / Germany5 t/d coal

PRENFLO plant inFürstenhausen / Germany48 t/d coal

Development Steps

PRENFLO Gasifier and Syngas Cooler

IGCC 318 MWel, netPuertollano, SpanienKohle und Petrolkoks2400 t/d

Post Weld Heat Treatment - Gasifier Vessel

Post Weld Heat Treatment - HP-Vessel

Membrane Wall

Gasifier - Erection of Internals

Erection of Gasifier/Turning

HP-Boiler/Internals

HP-Boiler/Heating Coils

Lifting of Gasifier/HP-Boiler

Lifting of Gasifier/HP-Boiler

- Membrane Wall protected by the slag layer

BFW, 40-70 bar

Water Tube

Gasifier space

> 1500 °C

molten slag flows downwards

solid slag

Shell Coal/Coke Gasification SCGP

.

Membrane wall for gasifier(test piece)

Raw synthesis gas

Coal in 100%

83%

0.8 % Steam fromreactor wall

14.0 % HP Steam fromSyngas cooler

0.2% Unconvertedcarbon

2.0% Low level heat

- Energy Balance

Energy Balance SCGP/ PRENFLO

IGCC Puertollano 318 MWel, net(feedstock: petcoke / coal)

The High-Temperature Winkler Process

HTW

(Lignite, Waste)

0

5

10

15

20

25

30

0 5 10 15 20 25 30

Gasifier pressure in bar

Spec

ific

thro

ughp

utin

t/m

²hDemonstration PlantDesigned (not realized)Realized

Winkler (10 t/h)

Vresova 2 (81,5 t/h)

Oulu/SF (26.7 t/h)

Vresova 1 (247.2 t/h)

KoBra, Air (160 t/h)

Sumitomo (0.6 t/h)

KoBra, O 2 (205 t/h)

Deggendorf (16.1 t/h)Kawasaki 2 (41.6 t/h)

Kawasaki 1 (82.4 t/h)RESH (7.1 t/h)

Elsterwerda (5.4 t/h)

HTW: Development and Commercialization

Classification of Coals Processed in HTW

PDUScale

PilotScale

IndustrialScale

Low-rank coalBrown coalHigh-S browncoalLigniteSubbituminouscoalHard coal

Ensdorf-Saar

Pittsburgh No.8

Other low-rank fuels (biomass and energy crops)

Peat

Wood

Grasses

Waste materials

Sewage sludge

Loaded coke

Used plastics

HTW: Operating Experience

Bottom Product

FireTubeDried Brown

CoalGasifier

WaterScrubber

Shift-Conversion Synthesis Gas

CO2LockHopperSystem Ceramic

Candle Filter

Filter Dust

GasificationAgents

Cooling Screws Sulphur

SulphurRecoveryDesulphurisation

toWaste Water Treatment

Syngas CoolerWaterTube

HTW Process: Typical Process Flow

HTW Demonstrationsanlage

Berrenrath/Deutschland30 t/h Braunkohle≈ 300 t/d Methanol

HTW Syngas AnlageKemira OyOulu / Finnland30 t/h Torf≈ 300 t/d NH3

Sumitomo Heavy Industries Ltd.

HTWGasifier

Cyclone

Steamturbine Generator

Shortkiln

Off-Gas

Slag

MSW

Sumitomo Heavy Industries Ltd.

HTW-Precon plant inNiihama / Japan48 t/d MSW

Das NuOn-Magnum Projekt(ohne CO2-Abscheidung)

1200-MW-Kohle- / Biomasse-Kraftwerk

Basistechnologie: IGCC

El. Leistung: 1200 MW netto

Nettowirkungsgrad: 46 -48 %

Einsatz von Importkohle undBiomasse (bis 30 %)

3 x SCGP- Vergasung (3 x 85 t/h)3 x Gasturbinen (noch nicht bestimmt)

Inbetriebnahme: Ende 2010

Budget: ca. 2,5 Mrd. €

Das RWE-Projekt des CO2-freien450-MW-Kohlekraftwerks mit CO2-Speicherung

Basistechnologie: IGCC

El. Leistung: 450 MWbrutto

360 MWnetto

Nettowirkungsgrad: 40 %

CO2-Speicherung: 2,3 Mio. t/a

CO2-Speicher in alter Gaslager-stätte oder in salinem Aquifer

Inbetriebnahme: 2014

RWE-Budget: ca. 1 Mrd. €