Coking/Coal Gasification Using Indiana Coal for the Production of … · 2016-12-08 · 12 Coke Usage is Increasing 2005 forecasts indicate that the US will produce 11,500,000 net

Coking/Coal Gasification Using Coking/Coal Gasification Using Indiana Coal for the Production of Indiana Coal for the Production of

Metallurgical Coke, Liquid Metallurgical Coke, Liquid Transportation Fuels, and Electric Transportation Fuels, and Electric

PowerPower

Status ReportStatus Report8/30/20068/30/2006

Robert Kramer, Ph.D.Robert Kramer, Ph.D.Director, Energy Efficiency and Reliability CenterDirector, Energy Efficiency and Reliability Center

Purdue University CalumetPurdue University Calumet

22

Research TeamResearch TeamRobert KramerRobert Kramer (Ph.D.) is Director of the Purdue University Calumet Energy Eff(Ph.D.) is Director of the Purdue University Calumet Energy Efficiency and iciency and Reliability Center. Dr. Kramer serves as the Principal InvestigaReliability Center. Dr. Kramer serves as the Principal Investigator, coordinates the efforts, tor, coordinates the efforts, and maintains the overall program for this proposal. His areas oand maintains the overall program for this proposal. His areas of expertise include energy f expertise include energy research, electric system design and operation, engineering, phyresearch, electric system design and operation, engineering, physics, Combined Heat and sics, Combined Heat and Power system design and operation, environmental engineering, anPower system design and operation, environmental engineering, and project management. d project management. He has over 30 years of industrial experience in the energy fielHe has over 30 years of industrial experience in the energy field, most recently as the Chief d, most recently as the Chief Scientist for NiSource. He has previously served as principal inScientist for NiSource. He has previously served as principal investigator for three vestigator for three Department of Energy research contracts with budgets totaling ovDepartment of Energy research contracts with budgets totaling over $6.5M. He is currently er $6.5M. He is currently the principal investigator for projects with a value of ~$2M. Hethe principal investigator for projects with a value of ~$2M. He also teaches various courses also teaches various courses in Physics and Engineering. in Physics and Engineering. ChennChenn ZhouZhou (Ph.D.), Head of Mechanical Engineering Purdue University Calum(Ph.D.), Head of Mechanical Engineering Purdue University Calumet. Dr. Zhou et. Dr. Zhou is an expert in computational fluid dynamics. She is the principis an expert in computational fluid dynamics. She is the principal investigator for a $1.29M al investigator for a $1.29M 21st Century Grant to develop Computational Fluid Dynamic techni21st Century Grant to develop Computational Fluid Dynamic techniques for use in blast ques for use in blast furnace operations. She has modeled various industrial systems afurnace operations. She has modeled various industrial systems and has considered energy nd has considered energy and process optimization as part of the modeling effort. Recentland process optimization as part of the modeling effort. Recently, she was elected a Fellow y, she was elected a Fellow of the American Society of Mechanical Engineers.of the American Society of Mechanical Engineers.Harvey AbramowitzHarvey Abramowitz (Ph.D.), Professor(Ph.D.), Professor, , Department of Mechanical Engineering, Purdue Department of Mechanical Engineering, Purdue University Calumet. Dr. Abramowitz has had extensive experienceUniversity Calumet. Dr. Abramowitz has had extensive experience in metallurgy and steel in metallurgy and steel making processes in general. He has worked in the steel industrymaking processes in general. He has worked in the steel industry and is familiar with steel and is familiar with steel and iron quality and production issues. He has also worked on prand iron quality and production issues. He has also worked on process costing and ocess costing and economics.economics.Anita Anita KattiKatti (Ph.D.), Assistant Professor, Department of Chemistry and Physic(Ph.D.), Assistant Professor, Department of Chemistry and Physics, Purdue s, Purdue University Calumet. Dr. University Calumet. Dr. KattiKatti has a background in chemical engineering from the has a background in chemical engineering from the pharmaceutical industry. Her current interests include modeling pharmaceutical industry. Her current interests include modeling of chemical processes and of chemical processes and systems.systems.LibbieLibbie PelterPelter (Ph.D.), Assistant Professor, Department of Chemistry and Physi(Ph.D.), Assistant Professor, Department of Chemistry and Physics, Purdue cs, Purdue University Calumet. Dr. University Calumet. Dr. PelterPelter has a background in surface chemistry and catalysis from the has a background in surface chemistry and catalysis from the petroleum industry. Her current interests include development ofpetroleum industry. Her current interests include development of nanonano catalysis and surface catalysis and surface chemistry.chemistry.HardarshanHardarshan ValiaValia (Ph.D.),(Ph.D.), President, Coal Science, Inc. Dr. President, Coal Science, Inc. Dr. ValiaValia will serve as a team will serve as a team member and consultant to the project. He has extensive experiencmember and consultant to the project. He has extensive experience in the steel industry e in the steel industry and specifically in the utilization of coal and the coking proceand specifically in the utilization of coal and the coking process. He also has experience with ss. He also has experience with various production and economic aspects of both the coal and stevarious production and economic aspects of both the coal and steel industry.el industry.

33

Initial Scoping Study Initial Scoping Study CompletedCompleted

Results indicated a significant potential to use Results indicated a significant potential to use Indiana coal for the production of coke and Indiana coal for the production of coke and electricityelectricityPreliminary investigation indicates that pyrolysis Preliminary investigation indicates that pyrolysis gas can be used for a Fischergas can be used for a Fischer--Tropsch process Tropsch process to produce liquid transportation fuels. Also to produce liquid transportation fuels. Also investigating production of fertilizer and investigating production of fertilizer and hydrogenhydrogen

44

Current EffortsCurrent Efforts

Process development effortsProcess development effortsComputer modelsComputer modelsSimulation studiesSimulation studies

Assembling data for Indiana coalAssembling data for Indiana coalConducting testing of composition of Conducting testing of composition of pyrolysis gas from Indiana coal samplespyrolysis gas from Indiana coal samplesDeveloping process conceptsDeveloping process conceptsCFD studies to increase usage %CFD studies to increase usage %Blending considerationsBlending considerationsConsider methods to optimize various Consider methods to optimize various value streamsvalue streams

55

Coke Ovens at Redstone, COCoke Ovens at Redstone, CO

66

Process Value StreamsProcess Value Streams

77

Coke is an Essential Part of Iron Coke is an Essential Part of Iron Making and Foundry ProcessesMaking and Foundry Processes

Currently there is a shortfall of 5.50 million Currently there is a shortfall of 5.50 million tons of coke per year in the United States. tons of coke per year in the United States. Shortfall is being filled by imports, mainly Shortfall is being filled by imports, mainly from China and, to a lesser extent, from from China and, to a lesser extent, from Japan. Japan. The result is high volatility in coke prices and The result is high volatility in coke prices and a general trend to dramatic price increases. a general trend to dramatic price increases.

Coke FOB to a Chinese port in January Coke FOB to a Chinese port in January 2004 was priced at $60/ton, but rose to 2004 was priced at $60/ton, but rose to $420/ton in March 2004 and in September $420/ton in March 2004 and in September 2004 was $220/ton. 2004 was $220/ton.

88

Zones of a blast furnaceZones of a blast furnace

Source: Modern Blast Furnace Ironmaking, Verlag Stahleisen GmbH, 2004

99Source: Modern Blast Furnace Ironmaking, Verlag Stahleisen GmbH, 2004

1010

Temperature ProfileTemperature Profile

Source: Modern Blast Furnace Ironmaking, Verlag Stahleisen GmbH, 2004

1111

Preliminary CFD ResultsPreliminary CFD Results

Streamlines

Velocity Vectors

Pressure

1212

Coke Usage is IncreasingCoke Usage is Increasing

2005 forecasts indicate that the US will 2005 forecasts indicate that the US will produce 11,500,000 net tons of coke, but produce 11,500,000 net tons of coke, but will require 17,000,000 net tons for blast will require 17,000,000 net tons for blast furnace, foundry, and related uses.furnace, foundry, and related uses.

At present, essentially no Indiana coal is being At present, essentially no Indiana coal is being used for coke production. used for coke production. In 2002, IndianaIn 2002, Indiana’’s steel industry used an s steel industry used an estimated 10.7 million tons of coal. estimated 10.7 million tons of coal.

8.1 million tons was used for coke production. 8.1 million tons was used for coke production. Most from West Virginia and Virginia. Most from West Virginia and Virginia.

1313

Recovery Recovery vsvs Non Recovery Non Recovery OvensOvens

Source:Valia, H., “Coke Production for Blast Furnace Ironmaking”, AISI

Source:SunCoke Company, Knoxville, Tennessee, http://www.suncoke.com.

1414

Battery AgeBattery Age

Age (years)

Num

ber

Battery Age - Mittal Steel

Source;Ludkovsky, G., “Coke Overview at Mittal Steel – Issues and Opportunities”, 3rd ChinaInternational Coking Technology and Coke Market Congress 2005, Beijing, China, Sept. 2005.

1515

Coke Oven GasCoke Oven Gas

In a recovery coke oven, typically the coke In a recovery coke oven, typically the coke oven gas has a composition of 58% hydrogen, oven gas has a composition of 58% hydrogen, 26% methane, 5.5% nitrogen, 2.25% 26% methane, 5.5% nitrogen, 2.25% acetylene, 2% carbon dioxide, 6% carbon acetylene, 2% carbon dioxide, 6% carbon monoxide, and .25% oxygen. monoxide, and .25% oxygen. One metric ton of coal typically produces 600One metric ton of coal typically produces 600--800 kg of blast800 kg of blast--furnace coke and 296furnace coke and 296--358 m358 m33

of coke oven gas.of coke oven gas.

Source:Coke Oven Flow Gas Measurement, General Electric Industrial Sensing, Application Note 930-095B, March, 2005.The Making Shaping and Treating of Steel, Association of Iron and Steel Engineers, Herbick & Held, Pittsburgh, 1985.

1616

Slow Slow PyrolysisPyrolysis Gas Composition Gas Composition vsvs TemperatureTemperature

Source:Coal Conversion Technology, Wen,C., Lee, E.

1717

Test FurnaceTest Furnace

1818

TGATGA

1919

GC for Gas AnalysisGC for Gas Analysis

2020

2121

Next Phase IssueNext Phase Issue

There is an opportunity to There is an opportunity to significantly accelerate the testing significantly accelerate the testing program and the development of program and the development of test capability for the production test capability for the production of liquid transportation fuels of liquid transportation fuels This will also facilitate blending This will also facilitate blending tests leading to increased usage of tests leading to increased usage of Indiana CoalIndiana Coal

2222

CCRI Conventional coke ovenCCRI Conventional coke oven

Finished coke cycle & coke ready to push

CSL Conventional Coke Oven

2323

CSL Non Recovery Coke Simulator

Door lifting mechanism and exposed interior of non recovery oven

2424

CSL non recovery pilot ovenExisting Gas port

Proposed Gas port sites in the sole flue

Proposed gas port site in down comer

2525

Slow Slow PyrolysisPyrolysis Gas Production RateGas Production Rate

20

0 0

0

1 0'

' h e a t i n g r a t e =

v o l u m e o f a n y p a r t i c u l a r g a s r e l e a s e d a t t i m e t ( n o t t o t a l v o l a t i l e s )K r a t e c o n s t a n t f o r r e l e a s e o f a p a r t i c u l a r c o m p

ERTK RTE e

RT mEK Vd Vd t m

dTmd t

V

⎛ ⎞− ⎜ ⎟⎝ ⎠

⎡ ⎤⎢ ⎥− −⎢ ⎥⎣ ⎦=

=

=

=- 1

o

o n e n t , i n c l u d i n g t a r , s e c a c t i v a t i o n e n e r g y k J / m o l

R g a s c o n s t a n t , k J / m o l Km o r d e r o f r e a c t i o n

E =

==

18.018.05555COCO

19.519.5550550COCO22

31.031.01.67x101.67x1055CHCH44

22.322.32020HH22

EEKK00GasGas

Source:Coal Conversion Technology, Wen,C., Lee, E.

(1975 data)

2626

Phase 2 IssuesPhase 2 Issues

Phase 2 can be started in 2007.Phase 2 can be started in 2007.Additional funding required (~$950,000) Additional funding required (~$950,000) Duct work, piping, controls, expanded Duct work, piping, controls, expanded monitoring equipment, monitoring equipment, FischerFischer--TropschTropsch unit design, construction, and unit design, construction, and installation.installation.Expanded environmental licensing required.Expanded environmental licensing required.

2727

Process Value StreamsProcess Value Streams

2828

Robert Kramer, Ph.D.Director, Energy Efficiency and Reliability [email protected]

www.calumet.purdue.edu/energycenter