Numerical Simulation of Coal Gasification in Entrained Flow Gasifiers With CoalFoam

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Numerical simulations of coal gasification in

entrained flow gasifiers with coalFoam

Danny Messig, Konrad Uebel, Martin Grbner, Bernd Meyer

Institute of Energy Process Engineering and Chemical EngineeringFreiberg, Germany

Fifth OpenFOAM WorkshopGothenburg


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Contents

1 Introduction

2 Research project HotVeGas

3 Solver-package coalFoam

4 Preliminary results

5 Future work

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Contents

1 Introduction




5 Future work

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Introduction

Scope:

Numerical simulation of an industrial coal gasifier with respectto the influence of mineral matter

What is gasification?

Gasification is a thermo-chemical process that convertscarbonaceous materials (e.g. coal, biomass) into a combustiblegas, yielding mainly CO and H2.

Typical conditions: 10001500 C, 30 bar, < 1,O2, CO2, H2O as gasifying agents

Why gasification?

Gaseous fuels are better to handle than solid ones

Syngas may be burned in combined cycles for powerproduction, used to produce methanol and hydrogen orconverted via the Fischer-Tropsch process into synthetic fuel

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Introduction

Software used for numerical simulation:

OpenFOAM-1.5.x [1]:Open-source software for CFD calculations

ChemApp [2]:

Commercial software for calculation of complexmulticomponent and multiphase chemical equilibrium

Cantera [3]:Open-source software package for kinetic controlled reactionrates and equilibrium calculations

alternateChemistryModel [4],[5]:Coupling of chemistry packages with OpenFOAM

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Contents

1 Introduction




5 Future work

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Research project HotVeGas

Tasks:

Fundamental investigations in development of futurehigh-temperature gasification and gas cleaning processes forIGCC power plants and for production of synthetic energysources

Basic analysis of the behaviour of coals and otherheterogeneous energy sources with mineral content and traceelements at highest temperatures and pressures under reducingatmosphere

Numerical simulation of a large scale coal gasifier(POI for now)

Project period:

01.09.2007 till 31.08.2011

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Research project HotVeGas

Project partners:

Department for Energy Process Engineering and ChemicalEngineering - TU Freiberg

Chair of Energy Systems [project coordinator] - TU MunichInstitute of Energy Research - Forschungszentrum Jlich

GTT-Technologies - Herzogenrath

Siemens (Fuel Gasification Technology) - Freiberg

Energy companies (E.ON, RWE, EnBW, Vattenfall)

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Contents

1 Introduction




5 Future work

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Contents

1 Introduction




5 Future work

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Preliminary results

Actual proceedings in calculation/simulation:

1 2D-Case (tube reactor) for plausibilty tests

[evaporation and devolatilization (pyrolysis)]2 2D-Case (dualInlet) for testing of transport-equations in

OpenFOAM

3 3D-Case of a large scale coal gasifier [INCI-Principle]

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Tube reactor

Case settings:

Inert gas phase: YN2 = 1.0, v 3ms

,

TGAS {800, 1300, 1700} K, p = 5 bar

Tube idealised as 2D-domain:

xmax = 1 m, ymax = 0.1 m, 100 10 cells

coal-parcels:mGASmCOAL

= 3, d = 0.1 mm, YP,Solid = 0.8 (ash),TCOAL = 298 K

Evaporation: YP,Liquid = 0.2 (H2O)Devolatilization: YP,Gas = 0.2 (CH4)

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T b


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Tube reactor

Evaporation

Conclusion:

massflow at outlet correct (error < 0.1%)

tendency of evaporation rate is correct

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d lI l


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dualInlet

Case settings:

Operating conditions: T = 1700 K, p = 5 bar

XInlet: YN2 = 1.0, v = (2 0 0)ms

YInlet: YH2O = 1.0, v = (0 -2 0)ms

Grid: xmax = 0.07 m, ymax = 0.04 m, 1500 cells

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d lI l t


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dualInlet

Results of dieselFoam-1.5.x:

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d lI l t


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dualInlet

Results of dieselFoam-1.6.x:

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dualInlet


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dualInlet

Bug removal in solvers:

YEqn.H:

old: ( Yi) ((Chem + t) Yi) = SYi

new: ( Yi)

ChemLe

+ tSct

Yi

= SYi

HEqn.H:old: ( h) ((Chem + t) h) = Sh

new: ( h)

Chem +tPrt

h

= Sh

Dimensionless numbers:

Le = aD

, Lewis number

P r = a

, Prandtl number

Sc = D

, Schmidt number

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dualInlet


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dualInlet

Results of coalSteadyFoam:

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Coal gasifier


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Coal gasifier

INCI-Principle:

Internal Circulation Gasifier allowshigh-ash/low-rank coal feed and combine:

entrained flow gasifier (e.g. SCGP)(POI for the following simulation)

fluidised bed gasifier (e.g. HTW)

new principle of post-gasification

Some advantages of INCI:

Fouling free HRSG operation due tohigh dust carbon content

High flame temperatures partialash melting with agglomeration

complete carbon and mineralsoxidation

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Coal gasifier


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Coal gasifier

First results:

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Contents


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Contents

1 Introduction




5 Future work

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Acknowledgement


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Acknowledgement

The results described above were obtainedin the research project HotVeGas.

The project was supported with public funding by the

German Federal Ministry of Economics and Technology(Project ID 0327773B)

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Literatur I


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Literatur I

[1] OpenFOAM, www.opencfd.co.uk/openfoam/.

[2] http://www.gtt-technologies.de/chemapp.[3] DG Goodwin.

Cantera: Object-oriented software for reacting flows.Technical report, California Institute of Technology, 2002.

[4] Gschaider B., Rehm M., Seifert P., Meyer B.Implementation of an alternative chemistry library intoopenfoam.In Open Source CFD International Conference 2008, Berlin,2008.

[5] Messig D., Rehm M., Meyer B.Coupling of ChemApp and OpenFOAM.In CCT2009, Dresden, 2009.

[6] Strmungsforschungs GmbH, http://www.ice-sf.at/cfd.shtml.

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Literatur II


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Literatur II

[7] Messig D., Uebel K., Gschaider B., Grbner M., Meyer B.Coal gasification solver coalfoam.In Open Source CFD International Conference 2009, Barcelona,2009.

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Numerical Simulation of Coal Gasification in Entrained Flow Gasifiers With CoalFoam

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