New PHTW Gasifier Design for Multi Fuel IGCC Application. Gasification Technologies Conference October 3-6, 2004 JW Marriott Hotel, Washington, DC

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1 New PHTW Gasifier Design for Multi Fuel IGCC Application Gasification Technologies Conference October 3-6, 2004 JW Marriott Hotel, Washington, DC Prof. Dr.-Ing. B. Meyer, Dipl.-Ing. S. Ogriseck, Dr.-Ing. D. Korobov TU Bergakademie Freiberg Dipl.-Ing. K. Radtke Uhde GmbH Dortmund Dr.-Ing. J. Ewers RWE Power AG Essen - 1 -

2 Concepts for Coal Power Plants with Integrated CO 2 -Removal ASU air O 2 coal gasification gas cleaning CO shift IGCC: gasification with oxygen/steam, gas cleaning and CO shift, CO 2 separation, and compression, H 2 combined cycle ASU air O 2 coal steam generation water-steam cycle with turbine CO 2 air CO 2 2 separation gas turbine steam turbine water Oxyfuel: combustion with Oxygen/CO 2, steam generation, CO 2 recycling, flue gas cleaning, CO 2 compression CO 2 water flue gas desulphurization CO 2-2 -

3 Pros and Cons IGCC vs. Oxyfuel IGCC Oxyfuel pros + IGCC without CO 2 separation under demonstration, gas cleaning and conditioning in industrial scale available 2015 commercially available + non regret technology, highest efficiencies independent of CO 2 separation + multi fuel ability + multi product ability (syngas, hydrogen) + lab scale, concept studies 2015 pilot scale + low complexity? + higher time availability? cons high complexity lower time availability high CAPEX regret technology, makes sense only in case of life long CO 2 separation limited fuel ability no multi product ability high CAPEX - 3 -

4 COORETEC German`s R&D Program for CO 2 -Reduction-Technologies for fossil fuelled Power Plants ( Initiated by German Ministery BMWA Intended R&D key projects for coal power plants (COORETEC WG 3: short and mid term power plant technologies") R&D Oxyfuel: 1) Design study MW el Plant (Universities Dresden, Hamburg / Companies Vattenfall, RWE, E.ON, Alstom) 2) Future OXYFUEL ; PROJECT OXYCOAL (University Aachen / Companies RWE, E.ON, ) R&D IGCC: Design study MW el IGCC without / with CO 2 separation (University Freiberg / Companies RWE, Vattenfall, E.ON, SIEMENS, LINDE, UHDE, LURGI) - 4 -

5 R&D IGCC Design study MW el IGCC (2015) without / with CO 2 separation Participants Universities: Freiberg/Saxony Companies: RWE, Vattenfall, E.ON, SIEMENS, LINDE, UHDE, LURGI Project duration

6 Objectivs Design study MWel IGCC (2015) without / with CO 2 separation state of the art analysis improved design of MW el IGCC without / with CO 2 separation (HTW gasification) future design 2015 of MW el IGCC with integrated CO 2 separation (PHTW gasification) PHTW = HTW + Slagging gasifier (related to BGL) - 6 -

7 HTW gasification (1) Berrenrath demonstration plant: methanol synthesis gas from brown coal - 7 -

8 HTW gasification (2) Principle of HTW gasification process - 8 -

9 HTW gasification (3) Operation results Berrenrath 140 MW th 10 bar methanol synthesis gas production in operation from 1986 to 1997 smooth, viable gasifier operation successful component test program (CTP) for IGCC application 67,000 h of operation syngas output 2,130 Mm³ methanol production 800,000 t average availability of the last 10 years approx. 85 % proven technology for power and syngas generation from brown coal - 9 -

10 HTW gasification (4) Component test program (CTP) til `

11 HTW gasification (5) CTP: Proven plant equipment improved coal feeding system water-tube cooler for high availability reliability increase and cost reduction

12 HTW gasification (6) CTP: Improved three-stage hot gas filter temperature 270 C (max. 400 C in a precursor filter) 50,000 m 3 N/h raw gas (30 g/m 3 N dust) 450 candles (3 stages) after total operation time of 15,500 h candles in a proper condition clean gas < 2 mg/m 3 N alkalis and heavy metals almost completely adsorbed proven technology

13 HTW gasification (7) HTW lessons learned commercially available for IGCC without and with CO 2 - removal (KoBra) preferable for low rank coals 95 % C conversion enhancement due to multi fuel ability, process simplification and operational reliability new approach: PHTW

14 New PHTW Gasifier Design (1) PHTW = HTW + slagging gasifier (related to BGL) basic process: HTW fluidized bed gasification supplementary process: slagging gasification according BGL gasification SVZ Schwarze Pumpe (Germ.) for wastes BGL gasifier in commercial operation since

15 New PHTW Gasifier Design (2) British Gas Lurgi slagging gasifier in Schwarze Pumpe (methanol and electricity)

16 New PHTW Gasifier Design (3) BGL slagging gasifier SVZ (Slagger) inner diameter 3,6 m, inner heigth ca. 10 m 200 MWth, 30 t/h waste feed 40,000 m 3 st/a raw synthesis gas for methanol synthesis 6,000 h operation

17 New PHTW Gasifier Design (4) PHTW-gasifier BGL-gasifier

18 New PHTW Gasifier Design (5) PHTW-gasifier low CH 4 -content ~ 5 % vol high cyclone temperature 1000 C multiple feedstocks: lignite & hard coal & biomass high gasification temperature 1000 C non leachable slag

19 New PHTW Gasifier Design (6) HTW gasifier upper part from HTW gasifier MWth PHTW gasifier MW th BGL gasifier Schwarze Pumpe lower part from BGL 200 MWth

20 Summary Power plant gasifier PHTW promising gasification concept for coal fuelled IGCC low and high grade fuels (ash, grain size, rank, ) lower CAPEX utilizable, disposible residues (slag)

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