Descriptor - include initials, /org#/date Coal Gasification as Alternative Fuel for Glass Industry Gasification Primer Presented By Donald L. Bonk Senior Technical Advisor National Energy Technology Laboratory U. S. Department of Energy Owens Corning Corporate Headquarters 1, Owens Corning Parkway, Toledo, OH July 27, 2005 10:00 – 4:00 Meeting Objective: Develop plans to obtain glass industry support for an investigation to determine the viability of using coal gasification "synfuel" as an economical alternative to natural gas for melting glass.
31
Embed
Descriptor - include initials, /org#/date Coal Gasification as Alternative Fuel for Glass Industry Gasification Primer Presented By Donald L. Bonk Senior.
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Descriptor - include initials, /org#/date
Coal Gasification as Alternative Fuel for Glass Industry
Gasification PrimerPresented By
Donald L. Bonk
Senior Technical Advisor
National Energy Technology Laboratory
U. S. Department of Energy
Owens Corning Corporate Headquarters
1, Owens Corning Parkway, Toledo, OH
July 27, 2005 10:00 – 4:00
Meeting Objective: Develop plans to obtain glass industry support for an investigation to determine the viability of using coal gasification "synfuel" as an economical alternative to natural gas for melting glass.
Descriptor - include initials, /org#/date
Gasification Chemistry
Gasification with OxygenC + 1/2 O2 CO
Combustion with OxygenC + O2 CO2
Gasification with Carbon DioxideC + CO2 2CO
Gasification with SteamC + H2O CO + H2
Gasification with HydrogenC + 2H2 CH4
Water-Gas ShiftCO + H2O H2 + CO2
MethanationCO + 3H2 CH4 + H2O
Coal
Oxygen
Steam
Gasifier Gas Composition
(Vol %)
H2 25 - 30CO 30 - 60CO2 5 - 15H2O 2 - 30CH4 0 - 5
H2S 0.2 - 1COS 0 - 0.1N2 0.5 - 4Ar 0.2 - 1
NH3 + HCN 0 -0.3
Ash/Slag/PM
Descriptor - include initials, /org#/date
History of GasificationTown Gas
First practical use of town gas in modern times was for street lighting
The first public street lighting with gas took place in Pall Mall, London on January 28, 1807
Town gas, a gaseous product manufactured from coal, supplies lighting and heating for America and Europe.
Town gas is approximately 50% hydrogen, with the rest comprised of mostly methane and carbon dioxide, with 3% to 6% carbon monoxide.
Baltimore, Maryland began the first commercial gas lighting of residences, streets, and businesses in 1816
Descriptor - include initials, /org#/date
History of Gasification
Used during World War II to convert coal into transportation fuels (Fischer – Tropsch)
Used extensively in the last 50+ years to convert coal and heavy oil into hydrogen – for the production of ammonia/urea fertilizer
Chemical industry (1960’s) Refinery industry (1980’s) Global power industry (Today)
Descriptor - include initials, /org#/date
Major Gasification Milestone1842 Baltimore Electric Town Gas1887 Lurgi Gasification Patent1910 Coal Gasification Common in U.S. / Europe for Town Gas1940 Gasification of Nature Gas for Hydrogen in the Chemical Industry
(Ammonia)1950 Gasification of Coal for Fischer-Tropsch (F-T) Liquids (Sasol-
Sasolburg)1960 Coal Tested as Fuel for Gas Turbines (Direct Firing)1970’s IGCC Studies by U.S. DOE1970 Gasification of Oil for Hydrogen in the Refining Industry1983 Gasification of Coal to Chemicals Plant (Eastman Chemical)1984 First Coal IGCC Demonstration (Coolwater Plant)1990’s First Non-Recourse Project Financed Oil IGCC Projects (Italy)1993 First Natural Gas Gasification F-T Project (Shell Bintulu)1994 NUON/Demkolec’s 253 MWe Buggenum Plant Begins Operation1995 PSI Walbash, Indiana Coal IGCC Begins Operation (DOE CCT IV)1996 Tampa Electric Polk Coal IGCC Begins Operation (DOE CCT III)1997 First Oil Hydrogen/IGCC Plant Begin Operations (Shell Pernis)1998 ELCOGAS 298 MWe Puertollano Plant2002 IGCC is now an Accepted Refinery and Coal Plant Option
Steam Req. High Low Moderate Moderate Low Moderate
Issues Fines and Hydrocarbon liquids
Carbon Conversion Raw gas cooling
Control carbon inventory and carryover
Descriptor - include initials, /org#/date
Gasifiers
Oxygen BlownOxygen Blown Entrained Flow
Texaco E-GAS Shell Prenflo Noell
Fluidized Bed HT Winkler Foster Wheeler
Moving Bed British Gas Lurgi Sasol Lurgi
Transport Reactor Kellogg
Air BlownAir Blown Fluidized Bed
HT Winkler IGT “Ugas” KRW Foster Wheeler
Spouting Bed British Coal Foster Wheeler
Entrained Flow Mitsubishi
Transport Reactor Kellogg
Hybrid Foster Wheeler British Coal ENERCON FERCO/Silva
Descriptor - include initials, /org#/date
Gasification-Based Energy Production System Concepts
Sulfur By-Product
Sulfur By-Product
Fly Ash By-Product
Fly Ash By-Product
Slag By-Product
Slag By-Product
Descriptor - include initials, /org#/date
Gasification-Based Industrial Concept
Descriptor - include initials, /org#/date
Moving Bed Gasifier – Lurgi, BGC
Counter current flow of reactants, products: gases and solids
Separate zones for coal processing
Products: top gases, hc’s, tars; bottom dry ash or slag
Issues: uniform flow of solids and gases
Design: bottom temperature determines H2O/O2
Effects of dry or slagging bottom
High cold gas efficiency, low O2
Descriptor - include initials, /org#/date
Mixed Bed Gasifier – Winkler, KRW, IGT Fluidized bed, mixed flow of
reactants, products Mixed zones of heating, drying,
devolatilization, gasification, combustion; dependent on feed location
Process conditions: temperature limited by ash fusion; high temperatures promote gasification, limit desulfurization; flow velocity determined by fluidization requirements
Products: top gases, no hc’s tars, potentially desulfurized, particulates (C, ash); bottom, ash perhaps agglomerated
Issues: reactant feed means, locations; ash removal means
Design: bed volume, by gasification requirements; cross section, velocity
Moderate cold gas efficiency; O2 H2O requirements; broad range of coals
Descriptor - include initials, /org#/date
Co Current Gasifier – Krupp Koppers, Texaco, Shell
Entrained flow of coal in O2 + H2O, reactants
Widely dispersed particles heated by radiation, gas mixing
Process conditions: high temperature for ash fusion, rapid gasification
Products: CO, H2 (no CH4, hc’s, oils tars); ash slag
Issues: uniform feed of pulverized coal, slurry, dry; separation of gases and ash; heat recovery from high temperature product fuel gases
Design: required volume is the time weighted average of reactant and product gas volumes/wt coal * the coal flow rate * the coal conversion time
devolatilization; char, particulates introduced to fluid bed, combustion, gasification
Process conditions: nearly uniform temperature limited by ash agglomeration
Products: CO, H2, devol products, ash fines
Issues: coal particle size, flow conditions for rapid devol; recycle for char combustion, gasification; recirculation particulates
Design: riser entrains particulates, coal; devolatilizes, cracks oils, tars; delivers char for gasification, combustion. Stand pipe, particulates from cyclones, delivers to fluid bed. Fluid bed combustion, gasification of char; product gases, particles enter riser
Moderate efficiency, O2 demand, control of devolatilization S team ,
O xygenor A ir
P roductG as ,Ash
R ecycle DriveG as
C oal,Sorbent o r
Inert
Independence does not come cheap for
the
small utility
Descriptor - include initials, /org#/date
Based on NETL StudiesRepowered Total Plant Cost vs. Original Size of Steam Plant
Cedar Lane Farms FGR-FBC
A Study
of
Small Project
Success & Cost
Descriptor - include initials, /org#/date
Cedar Lane Coal-Fired Flue Gas Recirculating Fluidized Bed Boiler
Unit achieved ~7 months of continuous computer control operation
96.9% availability over the 193 day heating season
$200,000+ Saved over Natural Gas this season (2 of 5 Acres)
20% reduction in coal usage compared to old under-grate stokers
2 types of computer controlled operation demonstrated; demand and slumping