Entrained Flow Gasifier R&Dat CanmetENERGY

May 6, 2010Robin Hughes

CanmetENERGY

• Canadian Federal energy R&D organization• All aspects of energy production excluding nuclear• Employs over 450 scientists, engineers, and technicians• Laboratories:

• Ottawa, ON – fossil fuel and hydro power generation, industrial, commercial, residential, catalysis, explosives

• Varennes, QC – wind, solar, system integration and optimization, smart grid• Devon, AB – oil and gas

• Project arrangements• Fee for service• Cost shared• Task shared

2

Clean Electrical Power Generation

• Focus areas – fossil fuel power generation• Carbon capture and storage• High efficiency• Emissions reduction

• Groups• Fluidized Bed Combustion & Gasification

• Entrained flow gasification• Air and oxygen fired circulating fluidized bed combustion• Solid looping cycles for carbon capture (pre & post combustion)

• Zero Emissions Technologies• Oxygen fired pulverized coal combustion

• Combustion Optimization• Combustion Kinetics• Emissions• CO2 Storage

3

4

EF Coal Gasification R&D Scope

5

Operating Parameters• Pmax = 1500 kPa • Tmax = 1700 oC• Capable of gasifying pulverized fuel, fuel-water slurry, or liquids• Dry coal feed rate: 10-20 kg/h• Slurry or liquid feed rate: 100 kg/h• 1 or 2 stage operation• Full or partial quench•Tie ins for syngas treating and optical access available

Pressurized Entrained Flow Gasifier

6

Canmet EF Gasification Facility

CARBON CAPTURE & STORAGE

COALASPHALT

HEAVY OIL

PETROLUEMCOKEBIOMASSWASTES

IGCC HYDROGEN HIGH VALUE CHEMICALS

CLEAN LIQUIDFUELS OIL SANDS

FUELS APPLICATIONS NEAR ZERO EMISSIONS

STEAM

SLURRIED OR LIQUID FUEL

DRY FUEL

OXYGEN

ENTRAINED FLOW

SLAGGING GASIFIER

HOT GAS FILTRATION

WET SCRUBBER

SYNGAS

SLAG&

WATER

FINE PARTICULATE

CAPTURE1.5 metre

Sample#2

Sample#3

Sample #6

Sample#4

Sample #5

Sample#1

7

Gasification Applications Research

• CO2 separation• Solid looping cycles

• Hot gas clean-up• Hg• Alkali

• IGCC and oil sands upgrader modelling• With and without CO2 capture• With Advanced technologies

• Integration of slurry hydrocracking technology with gasification and CO2 capture for oil sands upgrading

8

Gasification Characteristics

• Working with the Canadian Clean Power Coalition to characterize both raw and beneficiated Canadian & US fuels• Bituminous, sub-bituminous, lignite coals• Petroleum coke

• CCPC includes Canadian and US organizations• Members: Basin Electric, Capital Power , Nova Scotia Power, SaskPower, TransAlta, and

Sherritt (metallurgical and thermal coal)• Associate member : Electric Power Research Institute• Additional research and funding NRCan, Alberta, Saskatchewan, Nova Scotia

• Fuel Properties• Proximate, ultimate, major oxides, trace elements, Hg, halides• Reactivity via thermogravimetric analysis• Surface area and pore size determination

• Nitrogen porosymmetry and Hg pycnometry• Density• Slurryability

9

Gasification Characteristics

• In Situ Sampling • Provide validation data for computational fluid

dynamics task shared project to create advanced modelling tools and code for slagging gasification

• Characterize gasification products• Syngas majors (H2, CO, CO2, N2, CH4, H2S)• Minors (COS, NH3)• Trace• Characterization of coarse and fine fractions

• >10 micron• 8 size fractions between 0.2 and 10 micron• Toxics leachability (TCLP), micro XRD to determine

local composition

Slag and char from liquids bag filter

Sample Probes

• Sample Probes are used for extracting gases, tar, slag and char from the gasifier

• Fixed point testing winter 2010• Radial traversing using servo

motors fall 2010• Axial traversing under design• Servo motors have been

successfully used in the past to position actively cooled test samples for materials testing and heat transfer analysis

10

11

Fixed Point Sampling System

12

Impingers for Wet Chemistry

• Used winter 2010 for Hg speciation and fate• Oxidized via KCl solution• Elemental via activated carbon• Results being analyzed now• Results will be reported at IPCC in

Turkey

• Test method for NH3developed and tested winter 2010• Dilute sulphuric acid• Test campaign fall 2010

• Other minors to follow

13

Gasifier CFD Modelling

Entrained flow slagging gasifier computational fluid dynamics (CFD)

• Models are being validated using pilot plant data

• Our models include the gasifier and the quench section

• Working with National Research Council to characterize slurry sprays at high pressure

• Task shared agreement expected shortly to develop next generation gasification CFD code

CFDModel

3D SolidModel

DetailedEngineering

Drawings

Coal slurry droplets

coloured by temperature

Cross-section

colouredby CO molar fraction (wet)

Winter 2010experimental

data set

Traversingpoints to be

added fall 2010

Gasifier CFD Model Validation

Winter 2010experimental

data set

Selected raw plant data available to aid validation

15

Slag Viscosity Measurements• Measure the viscosity of slags derived from Canadian coal,

petroleum coke and hydrocracker residue• Study blending and fluxing, effect of vanadium• Compare neutral and reducing atmospheres

16

Slag Viscosity Modelling• Apply artificial neural networks to model viscosity• Compare with other available models• Apply FactSage thermodynamic equilibrium predictions• Combine models with process simulation and computational fluid

dynamics models• Rotational viscometer• Mo spindle and

crucibles• Alumina chamber for

gas containment (Ar or Ar/H2)

• 1700 C Furnace• Method standardized

with CSIRO, Australia

17

Pilot Plant Slag Tests• Generate gasifier slags

from a variety of sources• Removable samples

• Slag thickness• Slag - component

bonding mechanisms• Viscosity• Rate of slag build-up at

various locations• Varying fuel, fluxant,

O2:fuel ratio and wall heat flux

Probes inserted• Metal and ceramic• Ambient and actively cooled

18

Slurry Hydrocracker and Gasification

• Slurry hydrocracker technology uses an Fe additive to produce high yields and high quality oil from bitumen

• Removing the Fe additive can be problematic in many applications, but when combined with gasification the additive greatly reduces the temperature required for slagging operation

• Combination of technologies:• Low operating temperature for gasifier

while allowing slagging operation• Inert slag produced rather than soot • High oil yield technology enabled• Gasifier can meet hydrogen, power, and

steam needs of hydrocracker• Carbon dioxide capture easily

performed

Coke Ash

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Dense Phase Conveying

• Allow us to more closely approach commercial gasifier gas:solid ratio

• Design feed rate 25-75 kg/hr fuel

• Using hot gas filtration vessel as coal hopper to finalize design and operating procedures prior to purchase of final feed vessel

• A variety of fuels will be tested to determine variability and operating limitations

N2-003.05

N2-700.01

FSH51

PT51

PIC61A1

HV

-51A

PCV-61A1

N2-092.01N2-092.02 S

G-0

91.?

?

DC-013.01

SG-093.01

PS

E-51

From PSE-401

DPT-54 HIGH

201-T28SG-93.01

201-B34DC-013.01

201-O31N2-003.05

VENT

204-B10SG-088.02

SG-088.02

WT51

WIC51

202-S34N2-003.03

202-R34N2-700.02

WE51C

WE51B

WE51A

SG-093.02

YV-52

Transport Gas

To BurnerYIC52

Vent

Coal In

Fluidizing Gas

Vent

Pre-heat using 21A heaers?

Vent

20

Dense Phase Conveying

Coal OutTransport

Gas

FluidizingGas

PressurizingGas

21

CO2 Capture with Solid Looping Cycles

• Solid looping cycles can be used to remove C and S species at high temperature

• Allow process simplification for H2production by combining removal of multiple contaminants and WGS

• Reduce capital cost• Improve efficiency• Working with many

partners worldwideOther cycles under study:• Fe looping• CaS/CaSO4 looping

22

ConocoPhillips

• Objective: Tar formation and control in 2nd stage of CoP gasifier

• Fee for service work• CanmetENERGY gasifier can operate

with 2 stages• Stage 1

• Additional 6 ft reactor section• Oxy-fuel burner

• Stage 2• Slurry atomization • In situ sampling and analysis of

gas, tars, and solids

Multi Stage Gasification

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Process Simulation

• Process simulations• Power, oil sands, polygen• Built-in fluxant optimization routines• Integration of advanced technologies• Carbon dioxide capture technologies

• Objectives• Compare efficiency and environmental performance• Technology screening• Pilot facility planning and analysis

• Recently completed simulation for typical IGCC with Canadian fuels• Sub-bit, lignite, pet coke

• Typical IGCC with CO2 capture to be completed this spring• Advanced CO2 capture technologies

• In-house• In conjunction with CCPC and Electric Power Research Institute (EPRI)

Fuel Preparation

5

ASU

4

SteamTurbine

10

CombustionTurbine

9

Humidifier

8

AGR And WGS

7

CoalGasifier

6

Sour WaterStripper

11

Claus

12

TGTU

13

O2 4152.01

COL 4205.01 SYN 4312.01 SYN 4419.01 SYN 4503.01 FLG 4621.01

SLG 4341.01

ACD 4821.01

H2O 4811.01

ACD 4912.01

ACD 5020.01

ACD 5053.01

SUL 4936.01

SYN 4500.01

COL 4200.01

AIR 4230.01

AIR 4610.01

Sink

Source

Sink

Sink AIR 4101.01

FLX 4240.01Sink

Source

Source

Sink

SourceFLG 4220.01

SourceCOL 4250.01

Source

FLG 4791.01

N2 4149.01 Source CO2 Compression

14

ACD 4475.01

# Source

#

ACD 4474.01

O2 4153.01

ACD 4476.01

H2O 4512.01

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Process Flow Diagrams for Simulation

REV. DESCRIPTION DATE BY1 Pre-Scope FEB 2010 RWH

DRAWN BY:

ISSUED:

R. Hughes

FEB 2010 REVISION NO

1DRAWING NO

TBDSHEET NO

6

APPROVED BY: D. Lu

IGCC EMISSIONS Dry Gasifier w/ Cooling

A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

SCALE: NONE

A

B

C

D

E

F

G

H

I

J

K

L

M

N

O

P

Q

R

S

T

U

Key Assumptions- Gasification modelled using conversion reactor followed by Gibbs reactor- Gasification temperature 1427°C at 42 bar- Overall carbon conversion 99.5%- Radiant syngas cooler outlet temperature 316°C- Scrubber modelled by flash followed by 4 stage distillation (SOUR1 method) - For Illinois case no fluxant added – insufficient information in DOE report

E-4301

O2 4152.01

COL 4205.01

HPC 3641.01

SLG 4341.01

HPS 4337.01

SYN 4306.01

V-4300

H2O 4332.01

V-4306

H2O 4331.01

P-4313

H2O 4330.01

SYN 4307.01

Coal / SlagOxygenWater / SteamSyngas

SYN 4300.01

E-4302V-4303

V-4304SYN 4301.01

SYN 4302.01

SYN 4303.01

C-4305

SYN 4304.01

SYN 4305.01

CandleFilter

Cyclone

COL 4342.01COL 4343.01

COL 4344.01

COL 4340.01H2O 4512.01

HUMIDIFIER

H2O 4335.01

H2O 4333.01

HPS 4746.01

E-4312LPC 4338.01LPC 4767.01

Source

HRSG

HRSG

HP STEAM

OXYGEN

E-4309E-4308E-4307

SYN 4309.01SYN 4308.01 SYN 4310.01

H2O 4326.01H2O 4324.01

H2O 4325.01 H2O 4327.01

CWS

CWR

V-4310

H2O 4328.01

KNOCK OUT

SYN 4311.01

V-4311Hg

Removal

SYN 4312.01

H2O 4320.01

H2O 4322.01

LPC 3668.01

DEAERATOR

SULPHURREMOVAL

H2O 4329.01

SOUR WATERSTRIPPER

H2O 3510.01

H2O 4336.01

H2O 4323.01

10-5A

10-11A

10-13A

10-30G

10-33H10-21M

10-21N

7-2I

8-26J

4-32H

FUEL

5-25L

DEAERATORCONDENSER

11-12G

25

Topics of Interest

• Gasification databank of feedstocks

• Mechanisms of entrained flow gasification

• Process efficiency improvement of high ash feedstocks• Feedstock beneficiation• Partial quench• Multi-stage gasification

• High temperature syngas treating

• Synthesis gas conversion• Gasifier materials testing• Gasification by-products• Hydrogen production

technologies for gasification systems

• High pressure H2/CO2separation technologies