Construction and Commissioning of an HTW TM Pilot Plant

Energy Systems and Technology Prof. Dr.-Ing. B. Epple

Otto-Berndt-Straße 2 64287 Darmstadt / Germany Phone: +49 6151 16 23002 www.est.tu-darmstadt.de

Construction and Commissioning of an HTWTM Pilot Plant

Philipp Herdel, Jochen Ströhle, Bernd Epple (TU Darmstadt) Brigga Kolmorgen (thyssenkrupp Industrial Solutions AG) 8th International Freiberg Conference on IGCC & XtL Technologies 12-16 June 2016, Cologne, Germany

Outline

HTWTM Process

Description of the pilot plant

- Fuel feeding System

- HTWTM-Gasifier

- Syngas cooling unit

- Syngas burning unit

Commissioning of the pilot plant

Summary and Outlook

8th International Freiberg Conference on IGCC & XtL Technologies 1

High Temperature Winkler (HTWTM) Process


Gasification in 2 zones

Bubbling fluidized bed: T < ash softening point (850 – 950 °C)

Post-gasification zone: high T conversion of heavy hydrocarbons (up to 1200 °C)

Recirculation of particles separated in cyclone to the fluidized bed

Continuous extraction of bed material by cooling screw

Cyclone

Recycle Line

Bubbling Fluidized Bed

Post Gasification

Zone

Nozzles Source: thyssenkrupp Industrial Solutions AG

High Temperature Winkler (HTWTM) Process

1970s: first activities in process development Rheinbraun (today: RWE Power AG) Uhde (today: thyssenkrupp Industrial Solutions AG)

Goal: Production of methanol from lignite

Main difference to Winkler process (1920s): increase in gasifier pressure (10-25 bar(g))

1990s: feasibility demonstrated in commercial scale Pilot plant Frechen (1978 – 1985; 3.100 m³ i. N./h) Demo plant Berrenrath (1986 – 1997; 53.000 m³ i. N./h)

Since 2010: thyssenkrupp Industrial Solutions (TKIS) is licensor of HTWTM process


Berrenrath demo plant (Source: RWE)

HTWTM Pilot Plant

Since 2013: cooperation between TKIS and EST (TU-Darmstadt)

Erection pilot plant to carry on development of HTWTM gasification technology to: 1. Explore gasification of new feedstocks (biogenic residues, hardcoals, high ash coals)

2. Study gasification parameters to meet requirements for different syngas applications (XtL, methanol synthesis, SNG, etc.)

3. Validation of existing reaction models

4. Test customer-specific feedstocks to gain base data for the technical design of a customized commercial HTWTM-Plant

Modification of a existing fluidized bed reactor

Construction of pilot plant finished in 1st quarter 2015

Commissioning and first test runs conducted in 2nd quarter 2015


Description of Pilot-Plant


feed HTWTM-gasifier

feed entry

tubular fume cooler

combustor

bag filter

stackinduced draft fan

bottom product

fly ash

gasification mediums

combustion air

Fuel Feeding System


Storage Vessel

Weighing Vessel

Container docking Station

1.5 m³ Storage Vessel

0.5 m³ Weighing Vessel

Cooled Screw Conveyor

Fluidized Bed

HTWTM Gasifier


Refractory lined steel casing

Fluidization with CO2, steam or synth. air

Gasification agent (O2/steam) added by special nozzles

Nozzles are located at different heights of the gasifier

Total height ~ 11 m Outer diameter 1000 mm Inner diameter 400 mm Therm. capacity 0.5 MWth

Max. gas quantity 250 kg/h

HTWTM-Gasifier


Entrained particles separated by cyclone and returned to fluidized bed

Product gas leaves cyclone with reduced dust load and is analyzed with regard to its composition

Ash is removed continuously/discontinuously at bottom of gasifier by cooled screw conveyor

Removed ash is fed into storage vessel

Syngas Cooling Unit


Rawgas is cooled to 350 – 400 °C

Cooling with pressurized water - forced circulation - System pressure: 28 bar a - Inlet temperature: 205 °C - Max. heat quantity: 90 kW

No production of steam

Heat removed is discharged to environment

Schmidt‘sches

Doppelrohr-/Ovalsammlerdesign

Sou

rce:

ALS

TOM

Pow

er E

nerg

y R

ecov

ery

Syngas Combustion Unit


Top fired combustion chamber - Total height: 7 m - Outer diameter: 1.3 m - Inner diameter: 0.75 m

Syngas combustion with low btu-gas-burner

Auxiliary firing with natural gas

Flame monitoring with 3 independent flame guards

Water cooled membrane wall in the radiation part

Tube bundle heat exchanger in the convective part

Flue gas leaves combustion chamber at 180 °C

CAD Modell of HTWTM Pilot Plant


Tubular fume Cooler

Combustion Chamber

Bag Filter

Ash removal Unit

To ID Fan

HTWTM-Gasifier

Commissioning of Pilot Plant


Commissioning of the HTWTM pilot plant (2nd quarter 2015) - ca. 500 armatures (valves etc.) - ca. 650 m of pipes - ca. 250 measuring points (p, T, flow etc.) - ca. 6 km of wire

First commissioning of different sub-systems - Cooling system - Combustion chamber - Fuel feeding system - Gas preheating units

Testing of interaction between sub-systems and safety shut down system

May 2015: First ignition of gasifier with dried lignite (TBK 12) and hearth furnace coke (HOK)

Temperature and Pressure during first Ignition of Gasifier


Differential Pressures & Gasifier Temperature at stat. operating Point


8 h stationary operating Δpges = 70 – 80 mbar

TBed ≈ 750 °C TNVZ ≈ 900 – 920 °C

0

200

400

600

800

1000

1200

0

50

100

150

200

7:24 8:24 9:24 10:24 11:24 12:24 13:24 14:24 15:24

Gas

ifie

r Te

mp

erat

ure

[°C

]

Dif

fere

nti

al P

ress

ure

Δp

[m

bar

]

TNVZ

TBed

Δpges

Nozzles stage 1

Nozzles stage 2

Gas Composition and Gasifier Temperature


Gasifier performance of 0.42 MWth

Summary of Results


Coal mass flow kg/h 70 Water content wt.-% 13 Ash content wt.-% 4

Raw gas quantity kg/h 225

Gas composition (dry) CO2 Vol.-% 30 CO Vol.-% 31 CH4 Vol.-% 1 H2 Vol.-% 30

Heating value raw gas (dry) MJ/m³ 7.5

Syngas combustion

Summary and Outlook


Construction of HTWTM pilot plant finished in 1st quarter of 2015

Commissioning with German lignite successful

First run: 13 t German lignite gasified, analyzed and burned

Continuous, stationary gasification successful over a period of 8 days

In 2016: further gasification tests planned

Before next test campaign parts will be improved to increase plant efficiency

- New design of cyclone

- Removal of the loop seal

- Improvement of gas pre heating

Polygeneration of power/fuels (Fischer-Tropsch, methane, methanol) from lignite

Project FABIENE


Catalysis test rig of RWE New gas treatment unit

Existing HTW gasifier

Acknowledgements


Documents

Construction and Commissioning of an HTW TM Pilot Plant