Innovative Energy Solution
Innovative Energy Solution
Charge Induced Gasification: A Hybrid Plasma-Partial Oxidation Process
Brad Culbertson, PhDChief Operations Officer
Innovative Energy Solution
Disclaimer: We would like to apologize in advance for only presenting results of the charge induced gasification process and not the reactor itself or methods of how to reduce the device to practice.
Innovative Energy Solution
BackgroundEnergy technology development founded in 2004.
• 7 Employees: 6 engineers and 1 technician. • Growing and constantly pushing the limit.• In the process of spinning off first technology.
Mission Statement: • Innovative Energy Solution is dedicated to developing
innovative, robust, and cost efficient solutions for the global energy sector.
Goals: • Provide our customers with a single yet simple solution for
solving multiple problems.
Innovative Energy Solution
Business PositionFocused portfolio of unique thermal-based solutions in renewable and non-renewable hydrogen generation
• Superadiabatic Auto-Thermal Reformer (SuperATR).• Charge Induced Gasification (CIG).
Combined Heat & Power
CIG
Glycerin(biodiesel wastes)
Hydrogen Sulfide(petroleum wastes)
SuperATR
HYDROGEN & SULFUR(carbon-free)
SYNTHETIC GAS(CO & H2 )
Biomass(renewable)
Municipal Solid Wastes(renewable)
Coal (250 years worth)
SYNTHETIC GAS(CO & H2 )
Synthetic Natural Gas
Fischer-Tropsch Diesel
Combined Heat & Power
Innovative Energy Solution
SuperATRThe cheapest and cleanest cogeneration plants from a toxic gas (hydrogen sulfide):
• Carbon-free hydrogen (and sulfur).• Less expensive than Claus-based sulfur recovery units (present
day method than only recuperates sulfur and wastes the hydrogen).• Decrease overall emissions: greenhouse and acid rain.
Ignition PilotU-Shape Cyclic Flow Reactor
Incinerator
Sulfur Condenser3-Way Valves (x2) Inlet/Outlet Piping
Flanges with Gasket (x7)
Reactor
Stand
Three-Way
Valve
Igniter
Auxiliary
Ignition
Port
Exhaust
Pipe
Igniter
Reactor
Body
Three-Way
Valve
Innovative Energy Solution
Motivation for a New Gasification ProcessTraditional gasification processes (entrained flow, fluidized/fixed beds) are characterized by:
• High capital cost (especially entrained flow): − Cryogenic air separation for oxygen generation.− Large reactors with expensive refractories (chrome bricks).
• High operating cost: − Refractory maintenance.− Oxygen generation (efficiency penalty).− High temperatures (heat losses / expensive heat exchangers).
C. Higman and M. van der Burgt, Gasification, Elsevier 2008.
Operating Cost Breakdown
2%
82%
4%
5%2%5%
ASU
Coal Handling
Gasification Block
Gas Cleanup
Balance of Plant
Power Generation
Innovative Energy Solution
Charge Induced Gasification
Hybridization of partial oxidation (ultra-substoichiometric) with gliding-arc plasma:
• Ultra-substoichiometric partial oxidation: − Less oxygen than normal partial oxidation of present system: small
and cheaper oxygen generation units.− Lower temperatures: less expensive refractories.
• Gliding arc plasma discharge (very different from normal plasma): − Electro-catalyst: energetic ions and charged particles.− Low temperature and low electric power.
Innovative Energy Solution
Use of Gliding Arc Plasma DischargeUsed only for catalytic effect and stabilization of ultra-substoichiometric partial oxidation:
• Generation of charged particles: − Ions: create catalytic surfaces.− Electrons: generation of strong radical pool.
• Produce synthetic gas with high hydrogen and methane content.
CH4
H
C
C
O
H
CO
H2
i
e-
O2
H2O
C
O
OH
CCharged Particles
Radicals
Radicals
(Catalytic Surfaces)
O
O
i
e-
i
e-
Innovative Energy Solution
Bench-scale reactor (1 foot tall)• Initial configuration with coal and natural gas.• Electrode design with biomass, coal, natural gas.
Laboratory scale reactor (5 feet tall)• Updraft configuration with biomass, coal.• Downdraft configuration with coal, biomass/coal blend.
Proof-of-Concept Project
Innovative Energy Solution
Bench-scale reactor (1 foot tall)
• Initial configuration with coal and natural gas.
• Electrode design with biomass, coal, natural gas.
Proof-of-Concept Project
Laboratory scale reactor (5 feet tall)
• Updraft configuration with biomass, coal.
• Downdraft configuration with coal, biomass/coal blend.
Reactant
InletQuartz
Plates
Exhaust
Ceramic
Sealant
Electrodes
Steam
Inlets
Innovative Energy Solution
Experimental Set-up
Tank
Carrier Gas Outlet (Solids, Nitrogen, Air)
Pneumatic Conveying Fluid
Gas Inlet (Nitrogen, Air)
Feeding Screw
Control valve
Carrier Gas Tube
Feeding Motor
In addition to the reactor:
• Steam maker• Steam flow meter• Solid fuel feeder• Gas chromatograph
Biomass Coal
Steam Maker Gas Chromatograph Solid Fuel Screwfeeder
Innovative Energy Solution
Bench-scale Reactor“Up-draft” configuration
• Methane/oxygen-enriched air.• Biomass + methane.
Reactant Inlet
ThermalPlasma
Non-thermal(non-equilibrium)Zone
TransitionZone
Methane/airFlame
Exhaust
Reactant Inlet
ThermalPlasma
Non-thermalPlasma
Biomass/Oxygen-enriched air Flame
Exhaust
Innovative Energy Solution
Efficiency Determination
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
Hydrogen Carbon Monoxide
Methane Reformation
Flame Only
With Plasma
Pro
du
ct
Str
ea
m C
on
cn
etr
ati
on
(%
)Natural gas reforming
• Hydrogen produced by reforming rather than water-gas shift.• Concept proven.
Determination of power (thus efficiency)• Chemical power (ultra-substoichiometric partial oxidation): at least 91%.• Electrical power: 9% and can be lowered to ~2.5%.
Gliding Arc Plasma
(Electrical Power)
Methane Flame
(Chemical Power)
0
200
400
600
800
1000
1200
1400
1600
1800
0 500 1000 1500 2000
Total Power (W)
Ele
ctri
cal
& C
hem
ica
l P
ow
er (
W)
Innovative Energy Solution
CIG In Operation
Innovative Energy Solution
Innovative Energy Solution
Solid Fuel Gasification (High Volatile)
0
1
2
3
4
5
6
Hydrogen Carbon Monoxide Methane
No Plasma
With Plasma
Pro
du
ct S
trea
m C
on
cnet
rati
on
(%
)
Biomass Gasification• Syngas produced by steam-carbon reaction mechanism.• Both hydrogen and carbon monoxide production is
almost doubled.• Methane production increase by over 300%.
Innovative Energy Solution
Solid Fuel Gasification (Low Volatile)
Coal Gasification
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
Hydrogen CO Methane
Flame Only
With Plasma
Pro
du
ct S
trea
m C
on
cnet
rati
on
(%
)
Coal Gasification
0%
20%
40%
60%
80%
100%
120%
Hydrogen
CO
Methane
In
crea
se o
f Y
ield
wit
h P
lasm
a (
%)
Coal Gasification• Hydrogen production increased by over 100%• Carbon monoxide production increased by 25%• Methane production increased marginally
Innovative Energy Solution
Solid Fuel Gasification (Combination)
Coal/Biomass Mix Gasification
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
Hydrogen CO Methane
Flame Only
With Plasma
Pro
du
ct S
trea
m C
on
cnet
rati
on
(%
)
Coal/Biomass Mix Gasification
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
HydrogenCOMethane
Increa
se o
f Y
ield
wit
h P
lasm
a (
%)
Coal/Biomass Blend Gasification• Hydrogen production increased by 20%• Carbon monoxide increased by 40%• Methane production increase by 25%
Innovative Energy Solution
Optimization
• Optimum electrical power
• Argon lowers electrical breakdown energy
0
0.5
1
1.5
2
2.5
3
3.5
4
0 250 500 750 1000
Total Power (W)
Hyd
rog
en P
rod
uct
ion
(%
)
Poly. (Biomass)
Poly. (Coal/N2)
Poly. (Coal/Ar)
Poly. (Coal/Biomass)
Biomass
Coal/N2
Coal/Ar
Coal/Biomass
• Optimum C/O ratio depends on fuel type
0
1
2
3
4
5
6
7
8
0 1 2 3 4
Carbon/Oxygen Ratio
Hyd
rog
en P
rod
ucti
on
(%
)
Poly. (Biomass)
Poly. (Coal)
Poly. (Coal/Biomass)
Biomass
Coal
Coal/Biomass
Innovative Energy Solution
Summary & Comparative AnalysisEfficiency
• 10-15% higher efficiency than commercially available technology− Lower temperatures (higher methane production).− Higher C/O ratios hydrogen from water.
• Electrical power can be further reduced with− Higher partial oxidation temperatures.− Better insulation to improve heat losses.
Capital Costs are 25 to 50% lower than the Shell process.
0102030405060708090
100
Fixed
Bed
Fluidized
Bed
Entrained
Flow
Charge
Induced
Cold Gas Efficiency
Thermal Efficiency
Eff
icie
ncie
s (%
)
0
500
1,000
1,500
2,000
2,500
Shell
Coal
CIG
Coal
Shell
MSW
CIG
MSW
Balance of PlantOxygen UnitGasification BlockAcid Gas RemovalPower Generation Block
Cap
ital C
ost
($/k
W)
Innovative Energy Solution
CIG Commercial PotentialHeat & power (small to large)
• Refuse from large military installations• Agricultural residue from farm communities
and forest residue• Dust from saw mills
Synthetic natural gas• Coal• Municipal solid wastes
Fischer-Tropsch Liquids:• Coal• Municipal solid wastes• Biomass
Innovative Energy Solution
Next StepMore testing at the small scale
• Blends of coal municipal solid wastes.• Blends of coal and more varieties or biomass.
Scaling: 1 ton/hour process development unit• Small pilot plant with “real world reactor”: steel shell,
refractory, feeder, etc.
Financing: $3 million for 2 years• US Army.• Department of Energy.• State Agencies: Indiana, Illinois, California, New York, etc.• Private partners (cash and in-kind).
Innovative Energy Solution
Acknowledgments
• Center for Coal Technology Research
• Department of Defense
• Department of Energy
• Hoosier Energy
• Indiana 21st Century Fund