7th International Freiberg Conference7th International Freiberg Conference on IGCC & XtL TechnologiesCoal Conversion and Syngas7-11 June 2015, Huhhot, Inner Mongolia, China

CONCEPT OF DEMONSTRATION PLANT FOR ENERGY AND CHEMICA PRODUCTION BYENERGY AND CHEMICAL PRODUCTION BY

CO2 ENHANCED GASIFICATION OF COAL IN FLUIDIZED BED REACTOR

IChPW: M.Ściążko, T. Chmielniak, A. Sobolewski, P. Kolon, J. Popowicz, J. Bigda

FLUIDIZED BED REACTOR

p , gSUT: A. Ziębik, M. Liszka, T. Malik

Scope of the presentationScope of the presentation1. Introduction2. Main assumptions – the basis for the

conceptsp3. Plant characteristics for energy and

chemical applicationschemical applications Configuration

P d i l i l Process and simple economical parameters

4. Coal gasification development strategy in Poland – short and medium term goals

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g

Introduction: GeneralIntroduction: General Strategic program of R&D: "Advanced energy generation technologies”

Task No 3: "Development of coal gasification technology for highp g gy gproduction of fuels and electricity"funded by the National Center for Research and Development

Main product of the project: Coal gasification in CFB reactor using CO2 asCoa gas cat o C eacto us g CO2 as

gasification agent see: session 8.4: Pilot scale studies on coal gasification in a circulating fluidized bed

reactor with CO2 addition as a gasifying agent (Aleksander Sobolewski Institute forreactor with CO2 addition as a gasifying agent (Aleksander Sobolewski, Institute forChemical Processing of Coal – Poland)

Technological project of the DEMO plant inPoland based on developed technology

Strategy of coal gasification development in

3/20Poland

Introduction: CO enhanced gasificationIntroduction: CO2 enhanced gasificationDecrease in specific emission

%

22056

19713

19930

81120

871

2010

9

20224

8345

20000220002400026000

Power consumptionDirect emission, hydrogen productionTotal emission

ca. 13% 178

17125

1671818

16819

16301

8000100001200014000160001800020000

kg CO2/Mg H2

‐1185

396

294

534

‐306

‐417

‐4000‐2000

02000400060008000

HCGEE/Texaco

Case 1

HCShell

Case 3

BC Shell

Case 5

HCCFB/CO2

Case 6

HCCFB‐CO2HTR/coalCase 7

HCCFB‐CO2

HTR/reactorCase 8

85

90

cy, %

74,3 75,777,3

70

75

80

ld gas efficien

c63,6

60

65

hard coall f di

hard coald f di

lignited f di

ligniteCFB IChPW

Co

Cold gas efficiency

4/20

slurry feeding dry feeding dry feeding CFB IChPWCold gas efficiency

Assumption (1): GeneralAssumption (1): General

Assumption for the concept of demonstration plant:p p p Results of tests in pilot scale 100 kg/h (pressure

gasification – strategic program)P i i t h i t f l Previous experiences – atmospheric reactor for coalpyrolysis/gasification in CFB reactor, scale 8 t/h

Atmospheric CFB Reactor 200 kg/h

Pressurized CFB Reactor1 5 MPa 100 kg/h

Atmospheric CFB Reactor 8 Mg/h

5/20

Reactor 200 kg/h 1.5 MPa, 100 kg/hReactor 8 Mg/h

Assumption (2): configuration / casesAssumption (2): configuration / cases

Coal conversion 80-85% Second product: charNeed for rational use CHP Oxy-IGCCNeed for rational use

Oxy combustionCh b ti

y CO2 enhanced CFB gasification Power and Heat production

Char combustion Power production

Chemical production integrated ith l ifi ti Raw gas partial

combustionCH4 reforming

with coal gasification CO2 enhanced CFB gasification Methanol4 g

Destruction of higher hydrocarbons

6/20

CHP Oxy-IGCC (1): technological block diagramdiagram

7/20

CHP integrated with Oxy-IGCC (2): operating parametersparameters

Cycle parametersParameter Unit Value P t U it V l

Low temperature heat sourcesParameter Unit ValueGross Electric Power MWe 111,2Net Electric Power MWe 73,7

Parameter Unit ValueInterstage cooling in the process of O2 MW 9 51

Thermal Power MW 44,2Gas turbine MWe 45,5

and N2compression (ASU)

MW 9,51

Interstage cooling Steam Turbine MWe 65,7Gross Electrical Efficiency % 43,7

g gin the process of CO2 compression

MW 5,43

Syngas cooling MW 25 55Net Electrical Efficiency % 29

System efficiency: % 46

Syngas cooling MW 25,55Total MW 40,49

y yNel. +Q % 46

Typical capacity for the average urban agglomeration in Poland

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Typical capacity for the average urban agglomeration in Poland

CHP Oxy IGCC (3): PESCHP Oxy-IGCC (3): PES

Index of Primary Energy Savings

Ech cog - consumptions of the chemicalenergy of fuels in CHP

Ech hp - consumptions of the chemicalenergy of fuels in referenceheating plant (replaced process)

Ech pp - consumptions of the chemicalenergy of fuels in reference powerenergy of fuels in reference powerplant (replaced process)

-Ech - savings of the chemical energyof fuels

E ti f th h i lEch sep - consumption of the chemicalenergy of fuels concerningseparate production of heat andelectricity

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electricity

CHP integrated with Oxy-IGCC (4): IC – first estimatesestimates

Investment Costs: 300 mln $$

2500 $/kW (Net Heat and Power)( )

Feasibility study – in progressy y p g

10/20

Methanol productions (1): technological block diagramtechnological block diagram

11/20

Methanol productions (2): process modelingprocess modeling

Subf l ow sheet

69CW S

CO2 k o m p .

74

71 CWR79

2CWS6

CWR

7BFW NP

8BFW SP

ASU

Azot vent .

93

1

powiet rze

224

258

9

279

280 281232

82

CO2

198

70 174

221woda

M h l d iSubfl ow sheet

2

Subf l ow sheet3

15

23

W oda pr ocesowa

Que nc h Subf l owsheet

5

CO Shi ftSubf l ow sheet

6

Ch łod z e nie 1

Subf l ow s heet7

Chł odzeni e2

27

G az CLAUS

3738

39

25

32

Subf l owsheet9

Se le x o l33

48

49

50

51

Subf l owsheet14

56

42 Cla us

65

Subf l ow sheet16

5954

53

CO 2 1. 5

CO 2 11

CO 2 17

Subf l ow sheet17

PSA

20

36

76

21

66

27

62

64

58

43Subf l ow sheet

53

Sp a la n ie

73

Spaliny

Subf l owsheet2 6

132

109

Par a W P

110 41

Par a SPPar a NP

28

63

45 Cl aus 2

HRSG

141

60

18

G az procesowy164Par a

Węgiel suchy

ścieki166

170

110

O2

11

Azot reakt or

O2

G az reszt kowy

22

169

175

67

179

26

65

21

Para shif t

177

34

Woda pr ocesowa

181

19

20

72

55 186

112

G az kwaśny

Powiet rze

111

72 H2254

61108 Spaliny

261

180

40

41

153

88

326

154

327 328

187

12

138

73

OXY

17

16

165

2595

196

329

151

335

140 139

CHAR

342

345

CFB IChPW

349

81

178

204

173

222

52

CO 2 21

347

220

SkraplaczGa z procesowypo konw ersj i i chłodz eniu

Rozpręż aczsolwentuws tępniezregenerowanego 

Usuwanie H2S i CO2 z gazu procesowego w technologii Rectisol

Przegrz ewac zRozpręż acza

Do SRU  Claus

Koncentrator H2S

11 3 6

USUWANIE H2S USUWANIE CO2

26Turboge nera tor

      CO2do kompres ji

8

18

39

4

12

218

110

Gaz s iarkowodorowydo węz ła SRU  Claus

16

52

12 5251

41

46

62

48

70

55

51

33

16

200

1609Uklad zieb niczy

1613

17

111641

1602

1603

107

47

61

50

34

29 13

1621

1622

16241625

1653

1627

1628

55

1655

16571659

1660

74

1661

1658

1662

1621

1651

1632

1602

54

OCZYSZCZANIE WSTĘPNE GAZU

1645

1671

1600 22

1601

1603

20

16231620

1801

3000

1630

76 3003

48

49

47

50

16461663

C-1609C‐1617

E‐1616

T‐1618

1665

1666

T 1619

T‐1605 T‐1622

C‐1623

E‐1630

E‐1631

Methanol production

CW S

Subf l ow sheet15

68

CWS

CW R

CWR

77

67

Subf l ow sheet

4 0

T P

114Par a SP

CW S

BD

38

CWR

116

118

106111

117

Cl aus 2

120

115

BD

BFW WP

31

Par a I P

19

75

61

176BFW shif t

Para SP69

182

181

G az Claus

183

71

184

185

44

62

14192

Powiet rze

Woda uzup.

112

Siarka

255

278

107

39

HPS

167

Slag

333 332

13 334

N2 LPS

336 337

N2 LPS

CO2 DRY

CO2 DRY

104202

203

I PS I PS

205

204

227

Gaz procesowy odsiarczony

Metanolzregenerowany

Reboiler

9

Turbogenerator

13

10

24

34

37

2719

28

38

19

12

109

31

35 40

80

8

89

103

17

22

25

15

201

1607 1629

1612

431604

43

24

3441650

1637

1614

5

1626

1630

35 1636

1609

2116101640

1633

16111634

1616 1615

1601

1622

1617

1619

1643

1654

1656

1618

1632

39

16491605

1021627

49

1652

1631

95

1629

1635

1642

16341636

1635

16441639

1604

1672

1647

1674

1682

Turbina

1608

104

1628

15

56

27

1501

1675

1638

1618

14

84

1802108

1816

323001

1626

3002

1623

1606

21161615

1664

E-1601

V-1602 E-1607

V-1608

P-1610

E-1606

T-1604

E-1624

V‐1614

P-1615

E‐1613

E‐1625

E‐1612

T‐1619

E‐1621

E‐1629

P‐1640

P‐1641

1631 1625

3004

16331648

3005

BFW NP

Par a SP

kondensatBFW NP

190

28 Par a NP ( 4, 5bar )

T 117 C

9730

BFW SP ( 17 bar )

35

99

Par a SP ( 17 bar )Par a SP ( 60/ 30 bar )

Par a NP

37

45

25

131

134

BFW SP338

LPS O XY189

MPS O XY

207

209 Gasifier 300. Wsad - zgazowanie

P RODUKTY GAZOWE P IROLIZY8

9

30103113009

Węgiel

1001

147

4. 5

60

40

W 515547 kg/ h

BFW SP

29

47

36

Par a NP 4. 5

46

42

10096

Subf l owsheet46

8998

119

57

92

122

30

60

123

124

Z a s ila n ie

44

136

133

105

3

Para NP

4

Para SP

29

95 190

59

163

103 102 225

64

121

128

50213

125

144

172130200

156

201

20694

219

24

Piroliza

Para zgaz.

300Import danychz modelu pirolizy węgladr hab. M. Ściążko

310

320

301

340

311

322

314

Tlen

307

308

350

1

309

2

341

3001

3

3000

3003

321

3403002

3004

5

E nt. tw. W r

Q pirol.

E nt. Karb.

KARBONIZAT Z P IROLIZY

WILGOĆ I W ODA P IROGE NE TY CZNA

S MOŁY I HCULE GAJĄCE ZGAZOW ANIU

GAZ DO OCZY S ZCZANIA

3006

E FE KTY CIE P LNE UWZGLĘDNIONE W RE AKTORZE ZGAZOWANIA:

- 27,428 MW - Ciepło pirolizy - 2,200 MW - S traty cieplne

- 29,628 MW - S UMA

27,428 MW

7

312

30103113009

36 74 5

tarBTXGAZwilg. H2O

1,000 C

0,612 C

0,388 C 0,388 C

0,044 C0,203 C

0,141 C

8,951E -3 C etan28,152E -3 C m etan30,800E -3 C btx142,1E -3 C sm oła

S UMA: 0,210 C

0,388 C

0,178 C

0,354 C

0,999 C

0,645 C

0,645 C

0,178 C

1,177 C

E nt. tw. Gaz

310

301

Gaz sur .

312

1101

202

WChP

200

2145 WChZ

1620

1146

2161

155

101

193

Methanol production –t i

Gaz surowy

300340

302 342

330

332

307 309

CO2 DO RE AKTORA

ZAŁOŻENIA PROCESOWE:

całkowity stopień konwersji C:ilość C ulegająca r. Boudouarda: ilość pirogenet. smół i HC ulegających zgazowaniu: ciepło do produkcji pary: straty cieplne,

%%%% LHV węgla (st. rob.):MW% LHV węgla (st. rob.):MW

77,715,0 60 0 0 1 2,2

0,389 C

0,223 C

0,400 C

0,599 C

0,485 C

8Karb. piro.

1000

331

1003

1000 1005Karbonizat

CO2

1102

201

1604

1621

12/20

steering program

Methanol productions (3): GasifierMethanol productions (3): Gasifier 40 t/h of dryed coal (20% W ar)

90

CO2 gasification agent: 0,27 kg/kg Coal dry; 0,15 kmol /

kmol C in coal

74,3 75,777,3

75

80

85

efficiency, %

kmol C in coal

Cold gas efficiency (HHV): 64% (referring to total amount

63,6

60

65

70

Cold gas  64% (referring to total amount

of AR coal, HHV) 80% (referring to coal converted)

84% ( id i th 60hard coal

slurry feedinghard coaldry feeding

lignitedry feeding

ligniteCFB IChPW

84% (considering as the products gas and char)

Cold gas efficiency LHV base coal fed to the reactor Cold gas efficiency referring to gas after POX: 72%

Cold gas efficiency, LHV base, coal fed to the reactor

13/20 Lost in efficiency 8 % point

Methanol production (4): operating parametersMethanol production (4): operating parameters

Methanol efficiency: 41,4% (referring to total

amount of AR coal, HHV), ) 52% (referring to coal

converted, HHV)

Methanol and Power efficiency 54,1 %,

Loss in enthalpy (Referring to coal converted)( g ) Gasification ca. 20% Reforming 8%

14/20

Methanol production (5): economics – first estimatesestimates

Coal handling and 

preparation; 

Methanol synthesis; 162,8; 15% Total Investment costs:

178,2; 16%

Gasifier and char oxy‐

b

ASU; 163,4; 15%

310 mln $ Cost of production

365 €/Mg combustion; 345; 31%

Gas processing; 151,1; 13%

Power Island, ST; 115,4; 10%

365 €/Mg 340 €/Mg without EUA

(European Union Allowances)

450 450 450450

500Methanex European Posted Contract Price (MEPCP)

MEPCP

Cost of production, Demo plant

412 412 412

322 322 322

354 354 354 354339 339

365

350

400

Euro/M

g

Cost of production, Demo plant without UEA

Cost of production, commercial technology, dry feeding

200

250

300

15/20

01.14 02.14 03.14 04.14 05.14 06.14 07.14 08.14 09.14 10.14 11.14 12.14 01.15 02.15 03.15 04.15

Scenarios for gasification technology development in Poland (1)development in Poland (1)

Two Targets

1. Short term activities beyond 2020 Development of industrial scale plant based onDevelopment of industrial scale plant based on

selected commercial available technology

2. Medium and long term activities beyond 2030 Development of industrial scale plant based on

d l d ifi ti t h l i CFB tdeveloped gasification technology in CFB reactor(Demo stage needed)

16/20

Scenarios for gasification technology development in Poland (2)development in Poland (2)

Configuration and production directions

1. Medium scale CHP plants integrated withcoal gasificationg

2. Substitution of NG for hydrogeny gproduction and ammonia synthesis

3. Methanol synthesis and olefin productions

17/20

Scenarios for gasification technology development in Poland (3)development in Poland (3)

C t ti itCurrent activity

1. Chemical Industry is interested in implementationof coal gasification for chemical production

2. Economical screening (prefeasibility studies) ofdifferent technological options show promisingd e e t tec o og ca opt o s s o p o s gresults

3. Next decisions expected in 2 months

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ConclusionConclusion Two potential application of the developed technology of

CO2 enhanced coal gasification in CFB reactor

Further development of the technology is related to the construction of demonstration plants

Especially attractive is the application of technology in a p y pp gyCHP Oxy-Combustion plant High Index of Primary Energy Savings Process scale (single reactor) is appropriate for energetic

needs of average urban agglomeration in Poland

At present technical and economic studies and analyses are performed for determination of economics of demonstration and industrial scale plants

19/20

demonstration and industrial scale plants

Acknowledgments

Thank you for your attention

The task of research, "Development of coal gasification technology forhigh production of fuels and electricity" funded by the National Centerhigh production of fuels and electricity funded by the National Centerfor Research and Development within the strategic programof research and development: "Advanced energy generationt h l i "technologies".

20/20