M. Kuschel at International Freiberg Conference, Leipzig 2012 Update on STF technology – Freiberg test plant for the production of high octane gasoline from synthesis gas Dr. Mario Kuschel, May 2012
M. Kuschel at International Freiberg Conference, Leipzig 2012
Update on STF technology –Freiberg test plant for the production of high octane gasoline from synthesis gas
Dr. Mario Kuschel, May 2012
M. Kuschel at International Freiberg Conference, Leipzig 2012
2 First Results
3 Outlook
1 Review STF technology
M. Kuschel at International Freiberg Conference, Leipzig 2012
Natural gasNatural gas
Crude oil associated gas
Crude oil associated gas
CoalCoal
BiomassBiomass
……
Gasoline
Gasoline
Raw MaterialSynthesis gasgeneration
Production ofgasoline
Syngas to Methanol
Syngas to Methanol
Methanol to Fuel
Methanol to Fuel
Partial non catalytic oxidation
Partial non catalytic oxidation
Catalytic auto thermal reforming
Catalytic auto thermal reforming
M. Kuschel at International Freiberg Conference, Leipzig 2012
Fresh synthesis
gas
Methanol synthesis reactor
Fuel synthesis reactor
Cooling and separation
Circulation compressor
Fuel
stabilization column
Flare
Overhead product
Stable fuel
Produkt -
Lager
Instable fuel
Recycle gas
Process waste water
Steam condensate system
Boiler feed water
Steam
Steam
Absorption refri-gerating machine
Recooling plant
Nitrogen supply
Feed water buffer vessel
Control room
Power supply
Analytics
Instrument and compressed air
supply
Electric energy
Instrument & compressed
air
Feed water Catalytic waste water purification
CO + H2 gas
Purifed water
Cooling and separation
Circulation compressor
Heavy fuel
Recycle gas
Methanol separation column
Methanol
M. Kuschel at International Freiberg Conference, Leipzig 2012
STF plantSTF plant
Technical University Bergakademie Freiberg,
Department of Energy Process Engineering and Chemical Engineering,
“Reiche Zeche“
Synthesis gas plant
Synthesis gas plant
M. Kuschel at International Freiberg Conference, Leipzig 2012
Novelties of Technology:
� Employment of new isothermal reactorsAdvantage: more stabile and better product quality
� Employment of new developed catalysts in section of gasoline production and treatment of process water (formed in process)Advantage: higher product yields and better product quality
� Lower rate of circulation gases in combination with isothermal plant operation
Advantage: Lower rates of circulation gases are necessary in comparison toadiabatic operation mode.
M. Kuschel at International Freiberg Conference, Leipzig 2012
1 Die Chemieanlagenbau Chemnitz GmbH stellt sich vor
2 First results
1 Review STF technology
2.2 Results of full load mode
2.3 Results of partial load mode
3 Outlook
2.1 Test campaigns
M. Kuschel at International Freiberg Conference, Leipzig 2012
Test campaigns:
1. June 2010 2 weeks2.1 December 2010 2 weeks2.2 Feb./March 2011 4 weeks3. Aug./Sept. 2011 4 weeks
total 12 weeks
forecast:5. May/June 2012 6 weeks
M. Kuschel at International Freiberg Conference, Leipzig 2012
1st campaign:15.06.2010Feed of synthesis gas and Start-up of main process units in test mode17.06.2010Sampling of first STF fuel produced in test facility
2nd campaign:(Febr./March 2011)Supply Syngas 95 hMethanol, pure 9,170 kgGasoline, instable 4,000 kg
3rd campaign:(Aug./Sept. 2011)Supply Syngas 240 hMethanol, pure 12,850 kgGasoline, instable 8,800 kg
M. Kuschel at International Freiberg Conference, Leipzig 2012
°C-40 – 186Boiling range
kPa
% vol.
% vol.
wt%
wt%
wt%
wt%
kg/kmol
kg/m³
max. 10066,7Steam pressure
min. 82,584 – 85Motor octane number
min. 9193 – 95Research octane number
max. 3Durene
max. 10,2 – 0,4Benzene
max. 3534 – 36Aromatic compounds
7 – 9Naphthenes
max. 184 – 6Olefins
30 – 40Paraffins
95 – 96Molecular mass
720 – 775750 – 760Density (15°C)
DIN EN 228:2004-03
gasoline, regular
STF fuel
Properties of STF fuel
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M. Kuschel at International Freiberg Conference, Leipzig 2012
Drehzahl [1/min]
1000 2000 3000 4000 5000 6000
Be
ff [
g/k
Wh
]250
275
300
325
350
375
400
pm
e [
ba
r]
12
14
16
18
20
22
24
26 STF Benzin Charge 2 Basis Benzin ROZ95
Zü
nd
win
ke
l [-
]
-12
-8
-4
0
4
8
12
16
in cooperation with:
First results of „full load“ mode:
• tests with a modern fuel injection motor (Downsizing Concept)
• Comparative fuel: Gasoline RON 95 („Super E10“with 5.1% Ethanol)
Valuation of Results:
• With STF gasoline nearly same results under full load at constant charging pressure
• Ignition angle with STF gasoline minimal later (ca. 1°KW), this means knocking behavior slightly higher
• Specific fuel demand Beff until 4000 1/min for both fuels identical, at higher speed (number of revolutions) slightly higher
Speed [1/min]
Ign
itio
n A
ng
le [
-]
M. Kuschel at International Freiberg Conference, Leipzig 2012
in cooperation with:
First results of „partial load“ mode:
• fuel consumption for STF similar to commercial gasoline, with ethanol addition increasing value due to decreasing cross value
• with STF increased HC emissions at higher loads, slight decrease through E10
• NOx with STF at level of commercial gasoline, STF E20 as expected at lowest level
HC
[p
pm
]
0
250
500
750
1000
1250
1500
NO
x [
pp
m]
050010001500200025003000350040004500
pme [bar]
0 2 4 6 8 10 12 14 16
Be
ff [
g/k
Wh
]
200
280
360
440
520
600
ROZ 95
ROZ98
STF1
STF3
STF3 E10
STF3 E20
M. Kuschel at International Freiberg Conference, Leipzig 2012
2 First Results
3 Outlook
1 Review STF technology
M. Kuschel at International Freiberg Conference, Leipzig 2012
Open points:
• Constant operation with all units• Optimization of process parameters of gasoline synthesis
• especially heat transfer• Development of improved reactor for gasoline synthesis• Variation in methanol quality and investigation of impurities due to different sources of methanol• Improvement of sampling
• e.g. Sampling under high pressure
Target:• First commercial plant in Engineering Phase
latest end of 2013
M. Kuschel at International Freiberg Conference, Leipzig 2012
The project is supported with public funding by the Saxon State Ministry for Economic Affairs and Labour (SMWA) represented by the Sächsische AufbauBank (SAB) financed by the European Regional Development Fund (ERDF)
as well as by private investors.
European Union – European Regional Development Fund
Acknowledgement
M. Kuschel at International Freiberg Conference, Leipzig 2012
Chemieanlagenbau Chemnitz GmbHAugustusburger Str. 34
09111 ChemnitzGermany
Phone: +49 371 68 99 0Fax: +49 371 6899 342
Internet: www.cac-chem.deEmail: [email protected]