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© CSIR 2010 Slide 1 www.csir.co.za
Fluidised bed gasification of high-ash South African coals: An experimental and modelling
study
A.D. Engelbrecht, B.C. North, B.O. Oboirien, R.C. Evers on and H.W.P.J. Neomagus
MAY 2012
© CSIR 2010 Slide 2
Outline of presentation
�Coal gasification reactors
�Fluidised bed coal gasification
�Fluidised bed pilot plant at CSIR
�Pilot-scale coal gasification tests results
�Fluidised bed gasifier modelling
� 15 MW FB gasifier design
�Summary and conclusions
© CSIR 2010 Slide 3
Coal gasification reactors
Entrained flow gasifierEntrained flow gasifierAdvantages:•Very low tar and CH 4 conc.•Caking coals•High pressure operation
Disadvantages:•Reduced refractory life•Short residence times•High oxygen consumption
Moving bed gasifierAdvantages:•High gasification efficiency•Long residence time•High ash coals
Disadvantages:•Coal 8 – 50 mm•Produces tar and CH 4
•Rotating grate
Fluidised bed gasifierAdvantages:•Coal 0 - 5 mm•High ash coal•Low tar and CH 4 conc.
Disadvantages:•Lower gasification efficiency•Mixed flow reactor•Bed agglomeration
© CSIR 2010 Slide 4
GTI U-gas® fluidised bed gasifier
Projects:
� Shadong, China, 28 000 Nm3/h syngas for methanol, start-up 2008, high-ash coal wash plant waste.
� Henan, China, 45 000 Nm3/h syngas for ammonia, start-up 2014, high-ash sub-bituminous coal
Gas
char
Oxygen + steam
Oxygen + steam
char
coal
High pressuresteam
steam
© CSIR 2010 Slide 5
KBR TRIGTM transport gasifier
Standpipe
J-Leg
Riser
Upper
Mixing
Zone
Lower
Mixing
Zone
Startup
Burner
Second
Separation
Device
Seal
Leg
First
Separation
Device
Syngas
Syngas
CoalAir
SteamOxygen
Projects:
� Kemper County, USA, 550 MW IGCC, start-up 2014, lignite
� Dongguan, China ,120 MW IGCC, start-up 2014, high-ash bituminous coal
� Inner Mongolia, China, 35 000 Nm3/h syngas for ethylene glycol, start-up 2015, high-ash lignite
© CSIR 2010 Slide 6
Coal properties important for fluidised bed gasific ation
Coal properties
Requiredfor FBG
SA coalin future
Fit
Moisture < 7.5 % < 6 %
Ash 15 - 50 % 25-50 %
AFT > 1400 °C > 1400 °C
Caking index <1 <1
Reactivity high med-low
Size 1- 4 mm Fines
Volatiles >20 % ± 25 %
© CSIR 2010 Slide 7
Proximate and ultimate analysis of New Vaal and Groote geluk coals
New Vaal Grootegeluk
Proximate analysis:
Calorific value (MJ/kg) 14.8 21.4
Ash content (%) 40.7 31.7
Moisture (%) 5.7 1.9
Volatile matter (%) 20.5 28.3
Fixed carbon (%) 33.1 38.1
Total sulphur (%) 0.84 1.17
Ultimate analysis:
Carbon (%) 39.25 52.93
Hydrogen (%) 3.45 4.11
Nitrogen (%) 0.90 1.19
Sulphur (%) 0.84 1.17
Oxygen (%) 9.16 7.00
Reflectance analysis:
Vitrinite reflectance (%) 0.55 0.71
© CSIR 2010 Slide 8
Fluidised bed gasifier pilot plant
Bed area: 200mm X 200mmFurnace height: 4000mmRating: 140 kWCoal feedrate: 20 -30 kg/h
© CSIR 2010 Slide 9
Experimental Program
� Twelve pilot-scale fluidised bed (FBG) gasification tests were carried out on two high-ash South African coals (six test on each coal) using oxygen enriched air and steam as the gasification agents.
� FBG operating conditions:
� Bed temperature (875 - 975 °C)� Residence time (15 - 55 min)� Fluidising velocity (1.5 - 2.0 ms-1)� Oxygen enrichment level (32 - 37 %)
© CSIR 2010 Slide 10
Experimental results
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Experimental results
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Experimental results
Air
Oxygen enriched air
H2 - 22.7CO - 17.6CH4 - 1.2
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FBG syngas flare
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Fluidised bed gasifier modelling
O2
Steam
Coal
Bottom ash
Air
Fly ash
Syngas
FBG
© CSIR 2010 Slide 15
Fluidised bed gasifier modelling
Fluidised bed gasifier models can be used for:
� Design, optimisation and scale-up
� Accessing start-up and shut-down conditions
� Adaptive control
� Trouble shooting
© CSIR 2010 Slide 16
Fluidised bed gasifier modelling
1. Mass and energy balance models
� Conservation of mass and energy� More unknowns than equations� Assumptions regarding unknowns are required:
� Fixed carbon conversion� CH4 and CO in the gas
2. Equilibrium models
� Equilibrium relationships are added � Only fixed carbon conversion assumption is required� Reactions are assumed to have reached equilibrium
3. Kinetic models
� Conservation of mass and energy� Bubbling fluidised bed hydrodynamics � Kinetics of gas-phase reaction (homogenous)� Kinetics of char-gas reactions (heterogeneous)� Heat and mass transfer rates in the gasifier� Coal pyrolysis
© CSIR 2010 Slide 17
Comprehensive Simulator of Fluidised and Moving Beds (CeSFaMB)
� Development of CeSFaMB started in 1989 at the University of Sheffield (UK) by Professor Mario De-Souza Santos
� CeSFaMB can be used for the simulation of :
� Fluidised bed combustors, gasifiers and dryers� Moving bed gasifiers (updraft and downdraft)� Entrained flow gasifiers and combustors
� CeSFaMB was obtained by North West University and the CSIR under an academic license
© CSIR 2010 Slide 18
CeSFaMB sub-models and correlations
Sub-model Correlation used by CeSFaMB
Hydrodynamics:Minimum fluidising velocity (Umf)Bubble diameter (db)Bubble rise velocity (m/s)Bubble fraction (-)
Wen and Yu Mori and Wen Davidson and Harrison Davidson and Harrison
Reaction rates:Gas-solid (combustion and gasification)Gas combustionWater gas shift
Yoon et al , Johnson Villenski and Hezeman Franks
Mass transfer coefficientsBubble - emulsionEmulsion- solid
Sit and Grace La Nauze et al
Heat transfer coefficientsBubble - emulsionEmulsion- solid
Kunii and Levenspiel Kunii and Levenspiel
Devolatilisation Loison and Chauvin
Elutriation Wen and Chen
© CSIR 2010 Slide 19
CeSFaMB inputs
Gasifier design inputs:
� Gasifier diameter, height and thermal conductivity of insulation in the bed
� Gasifier diameter, height and thermal conductivity of insulation in the freeboard
� Height at which coal is fed into the gasifier
� Height at which reactants (air, oxygen and steam) are injected into the gasifier
� Height of syngas withdrawal from the gasifier
� Number and diameter of holes in the distributor for reactant injection
Operation inputs:
� Coal feedrate and analysis (proximate, ultimate, CV, size, sphericity, density)
� Feedrate of air, oxygen and steam
� Temperature of air, oxygen and steam
� Gasifier pressure
� Fluidised bed height (dynamic)
© CSIR 2010 Slide 20
CeSFaMB outputs
� Bed and freeboard temperatures ( i.e. temperature profile through the
gasifier)
� Fixed and total carbon conversions
� Syngas output flow and composition
� Concentration of all gasses as a function of height in the gasifier
� Superficial gas velocity as a function of height in the gasifier
� Bubble diameter and bubble velocities as a function of bed height
� Rate of all reactions as function of height in the gasifier
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CeSFaMB model parameters
Model parameters
� Pre-exponential factor (ko3) for the steam- char reaction ( C + H2O => CO + H2 )
� Pre-exponential factor (ko4) for the the carbon dioxide – char reaction ( C + CO2 => 2 CO )
� Pre-exponential factor (ko5) for the the hydrogen-char reaction ( C + 2H2 => CH4 )
� Pre-exponential factor (ko41) for the water-gas shift reaction ( CO + H2O => CO2 + H2 )
Rate equationRate equation
nj
ioi PXF
RT
Ek
dt
dX)()exp(
−=
© CSIR 2010 Slide 22
CeSFaMB model parameters
Rate equationParameter New Vaal Grootegeluk
Pre-exponential factors (s -1)
C+H2O ���� CO + H2: k03 13 600 49
C + CO2 ���� 2CO: k04 210 6
C + H2 ���� CH4: k05 3.1E-07 4.0E-07
CO + H2O ���� CO2 + H2: k41 78 25
© CSIR 2010 Slide 23
CeSFaMB predictive capability
Rate equationDeviation between measured and predicted output variables (%)
New Vaal Grootegeluk
Mid bed temperature 2.1 2.4
Fixed carbon conversion 3.6 3.4
Gasifier exit temperature 3.0 13.4
CO 6.3 11.0
H2 11.7 39.5
CH4 38.5 27.1
CO2 4.6 8.6
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15 MW FBG design
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15 MW FBG output variables
Rate equationOutput variables New Vaal
Mid bed temperature (°°°°C) 948
Gasifier exit temperature (°°°°C) 931
CO (%) 19.80
H2 (%) 24.3
CH4 (%) 1.2
CO2 (%) 18.62
Calorific value (MJ/Nm 3) 6.2
Fixed carbon conversion (%) 93.2
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Gas concentration profiles in the gasifier
Concentration of gasses in the gasifier as a functi on of height
0
5
10
15
20
25
30
35
40
45
50
0 1 2 3 4 5 6 7 8 9 10
Gasifier heigh t (m )
Gas
con
cent
ratio
n (%
)
O 2
H2O
CO 2
CO
H2
CH4
C+H2O ----> H2+CO
C+CO2 ----> 2COCO+H2O ---->H2+CO2
H2+O2---> H2O
CO+O2---> CO2
C+O2--->CO+CO2
CH4+O2--->H2+CO2
© CSIR 2010 Slide 27
Bubble velocity and bubble diameter in the bed
Rate equation
© CSIR 2010 Slide 28
Summary and conclusions
� Two high-ash South African coals were successfully gasified in a pilot-scale fluidised bed gasifier
� The fixed carbon conversion in the fluidised bed gasifier increases with an increase in coal reactivity, temperature and residence time of char particles in the gasifier
� The deviation between measured values and values predicted by the model can partially be attributed to the elemental mass balance non-closures produced by CeSFaMB
� For a scaled-up 15 MW fluidised bed gasifier CeSFaMB predicts a significant increases in fixed carbon conversion
� A higher fixed carbon conversion is possible due to due to the increase in residence time and the absence of bed slugging
© CSIR 2010 Slide 29
Thank You