Post on 22-Mar-2020
transcript
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PRENFLO PSG and PDQ Latest Developments based on
Decades of Gasification Experience
Fourth International Conference on Clean Coal Technologies CCT 2009 3rd International Freiberg Conference on IGCC & XtL Technologies
Dresden, Germany 18-21 May 2009
Dr. Stefan Hamel, Uhde GmbH, Germany
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Does Gasification make any sense @ ~50 US$/bbl?
Yes, because
• Gasification feedstock is unrelated to short-term oil price volatility
• Gasification is a poly-generation technology
• Gasification enables power generation with CCS
• Gasification is clean, efficient, and well-proven
• and...
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Uhde‘s Gasification Highlights – SUMMARY:
Development, Design and Construction of
first Koppers-Totzek Coal Gasification Plant
first Texaco Coal Gasification Plant
first HTW Coal Gasification Plant
first Shell-Koppers Coal Gasification Plant
first PRENFLO Coal Gasification Plant
Over 100 Gasifiers designed, built and put into successful operation by Uhde
Invention of Entrained-Flow Gasification:
Koppers-Totzek: dry-fed, membrane wall, multiple burners (1941)
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Uhde‘s proprietary Koppers-Totzek Gasification Process First Entrained-Flow Gasification Technology
Koppers-Totzek gasification plant Modderfontein, South Africa
1,000 t/d of ammonia
Koppers-Totzek gasification plant Ramagundam, India 900 t/d of ammonia
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HTW coal gasification plant Berrenrath, Germany
1,000 t/d of ammonia
GE (Texaco) coal gasification plant Oberhausen, Germany hydrogen, oxochemicals
First GE (Texaco) Coal Gasification Plant with radiant cooler First HTW Coal Gasification Plant in commercial-scale
8World‘s largest single-train IGCC: PRENFLO Gasification Elcogas, Puertollano, Spain
Feedstock: petcoke / coal with addition of biomass
PRENFLO Gasifier
Gas Treatment
Coal PreparationASU
Combined Cycle
New CO2 capture Pilot Plant under implementation
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PRENFLO gasifier and waste heat boiler (PSG)
• dry coal/petcoke powder feed• 4 horizontal co-annular burners• membrane wall• waste heat boiler (PSG)
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PRENFLO Membrane Wall protected by the slag layer
BFW, 40-70 bar
Water Tube(membrane wall)
Gasification Reactor
> 1500 °C
molten slag flows downwards
solidified slagmolten slag
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PRENFLO Gasifier Membrane Wall
View to gasifier membrane wall after operation (PRENFLO burner)
View to gasifier membrane wall before 1st operation (PRENFLO burner)
Perfect slag layer protecting membrane wall
14Puertollano IGCC: Operating Experience
General
Gasification is flexible with broad range of solid fuelshigh-ash hard coal and petroleum coke
addition of biomass successully demonstrated
Flexible load change behaviour
Nearly constant gas heating value irrespective of fuel
No formation of higher hydrocarbons, methane < 0.1 vol. %
Non-leachable slag production
Fly ash sold to cement industry
Elcogas statistics show that the vast majority of down-times was caused by non-gasifier related issues
16The PRENFLO process with Direct Quench (PDQ)
TargetsIntegrate Lessons Learned from >10 years operation of Puertollano IGCC
Optimize PRENFLO technology for chemical and hydrogen applications
Identify areas of significant Capital Cost Reduction
Water Quench instead of Gas Quench and Waste Heat Boiler
Keep commercially proven elements of PRENFLO technology
Design of a robust system
17The PRENFLO process with Direct Quench (PDQ)
Process characteristicsPressurized entrained-flow gasification
Dry coal dust feeding
Multiple co-annular burners (horizontal, tangential arrangement)
Membrane Wall, no refractory
Operation pressure flexible to requirementsapprox. 25 - 40 bar
Raw gas temperature outlet of quenchapprox. 200 - 250 °C
Slag lock-hopper system
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Slag
Feed,oxygen
Waste heat boilers
Raw gas(incl. fly ash)
Raw gas
Slag
Feed,oxygen
PRENFLO gasifier with Direct Quench (PDQ)
PRENFLO gasifier with Steam Generation (PSG)
Direct Quench
Feed,oxygen
Raw gas
Samegasifier design
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Raw Gas
S/G=1.3
PSG Gasifier Gas
QuenchWaste H.
BoilerFA
FilterScrubber
CO-Shift
Saturator H2 Gas
Steam
Raw gas
S/G=1.3
PDQ Gasifier Direct
QuenchScrubber CO-
ShiftH2 Gas
Steam
PSG:
PDQ:
PRENFLO PSG vs. PRENFLO PDQ Impact on Cost: Process Configuration (e.g. H2 plant)
substituted by Direct Quench
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PRENFLO PSG vs. PRENFLO PDQ Impact on Cost: Plant Layout
PRENFLO (PDQ)
PRENFLO (PSG)
EPC cost savings: ~30 %
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-4,0%
-3,5%
-3,0%
-2,5%
-2,0%
-1,5%
-1,0%
-0,5%
0,0%
0% 20% 40% 60% 80% 100%
shifted gas fraction
Δ o
f ele
ctric
effi
cien
cy [%
-poi
nts]
• CTC• CTL • IGCC-CCS
PRENFLO PSG vs. PRENFLO PDQ Impact on Efficiency
IGCC H2
In the targeted applications, PDQ is -1.0 to -1.8 %-points lower than PSGthis low impact does notjustify the higher capital costof a waste heat boiler design
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February 2009:New Co-operation Agreement Elcogas ~ Uhde
• Extensive integration of Operating Experience with technology and engineering know-how
• Joint implementation of R&D projects• Platform for plant reliability, operator training,
operating and maintenance services• Regular exchange and presence on site
24One of the latest projects: TransGas Coal-to-Liquids Complex (18,000 bpd)
2 x PRENFLO Gasification with MTG based on Coal
Mingo County, West Virginia
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Summary
Gasification will play an increasingly important role in our future. Oil and gas supply and demand do not match any longer.
February 2009: Co-operation Agreement signed between Elcogas and Uhde: Operating experience and engineering fully integrated into PRENFLO
Lessons Learned from >10 years operation of the Puertollano plant and decades of experience in coal gasification and all related down-stream processes provide full benefit to successful future projects
As a technology-driven engineering company, Uhde can act as integrated Licensor, E, EP or EPCM contractor – PRENFLO is a product
Depending on the application, PRENFLO is available with conventional steam generation (PSG) or direct quench mode (PDQ) with significant cost savings