Uhde Biomass and Coal Gasification
Applying Fluidized Bed and Entrained Flow Gasification
Karsten Radtke, Uhde GmbH, Germany
Uhde: 69 years of gasification experience
for coal, petcoke, biomass, oil, residues and wastes
[Basis goes back to 1909: Koppers Coal Gas Generators, a total of 536 built]
1941: Invention of Entrained-Flow Gasification:
Koppers-Totzek: dry-fed, membrane wall, multiple burners design
1973: Development of Pressurised Fluidised Bed Gasification:
High-Temperature Winkler (HTW)
Uhde has put over 100 gasifiers into successful operation:
PRENFLO Gasification for Coal, Petcoke, Biomass
HTW Gasification for Brown Coal, Biomass, MSW
Koppers-Totzek Gasification for Coal, Oil/Residues
Rummel-Otto Gasification for Coal
Saarberg-Otto Gasification for Coal
Texaco (GE) TGP Gasification for Oil/Residues
Texaco (GE) TCGP Gasification for Coal
Different Technologies for Different Applications: Uhdes Gasification History
TGP
TCGP
PRENFLO
1953
TGP-License
KoppersTotzek
1941
Koppers-Totzek
HTW
1926
Winkler Process
1960
Lisabon, Portugal
1971
Rhodes, Australia
1973
Start Developmt.
1978
Demoplant Holten
1986
Oberhausen, D
1974
Pressurised Entrained Flow:
Start of Development
1980
Demoplant, Hamburg
1982
E
Essen,
G
Germany
PSG
PDQ
1991
Oberhausen, D
2000
Wesseling, D
1973
Fluidised Bed Gasification:
Start of Development
1978
Frechen
1985
Berrenrath
1988
Kafue, Zambia
1988
Oulo, Finland
1989
Wesseling
1986
Frstenhausen
1998
Bharuch, India
77 Kopp
pers Totzek Reac
ctors
1959
Las Palmas,Spain
1993
KoBra
1997
Puertollano,Spain
2013
BioTfueL, France
2014
TransGas,
T
G
USA
2000
SHI, Japan
2002
Vresova, Cz.
2014
Vrmlands, S
PRENFLO
with Steam Generation
1200 MWth, 42 bar
PRENFLO PSG Features
dryy p
powder feeding
g
4 horizontal co-annular
burners
membrane wall
waste heat boiler (PSG)
PSG
Worlds largest single-train IGCC: PRENFLO Gasification
Elcogas, Puertollano, Spain
Feedstock: petcoke / coal with addition of biomass
New CO2 Capture Pilot Plant
PRENFLO
with Direct Quench
1200 MWth, 42 bar
PRENFLO PDQ Features
dry powder feeding
4h
horizontal
i
t l co-annular
l b
burners
membrane wall
direct water quench
operation pressure flexible to
requirements (25 - 42 bar)
raw gas temperature outlet of
quench (200 - 250 C)
C)
slag lock-hopper system
PDQ
TransGas Adams Fork Energy CTG Complex (18,000 bpd)
2 x PRENFLO PDQ Gasification to produce gasoline from coal
> Dec 2008: PDQ License Agreement signed & effective
> Feb 2010: Permit
Permit to Construct achieved
> 28 Oct 2010: EPC phase initiated
Mingo County,
County West Virginia
The images contained herein are the property of "TransGas Development Systems, LLC"
and are protected by intellectual property laws of the United States and other countries
Governor
J. Manchin III
Charleston, WV
28 Oct 2010
TransGas
EPC Ki
Kick-Off
k Off
Adams Fork
Energy Project
PRENFLO PDQ
for Clean Gasoline
MTG JAM project Shanxi, China
started-up in June 2009 as Chinas first Coal to Gasoline Plant
Picture courtesy of Shanxi Jincheng Anthracite Coal Mining Group
Market Trend: Biomass + X
PSG
PDQ
Entrained-Flow
Entrained
Flow
HTW
Fluidised Bed
Why BTL?
Biofuels Second Generation
Biomass
Bi
will
ill play
l a significant
i ifi
t role
l iin th
the energy mix,
i iirrelevant
l
t off th
the scenarios
i
For 2020 EU demands a minimum of 10 % renewables in the transportation sector
Biofuel Demand Growth
@ Reliable Biomass Gasification Technology is required
Source: IEA Energy Technology Perspectives 2008, 2010; BLUE Map scenario
BTL Challenges: Biomass based Feedstocks
High variety of biomass, availability varies seasonally
Decentralized production with low energy content (HHV: 10-15 MJ/kg)
Low storability,
storability high energy consumption for transportation and grinding
Agriculture
Forestry
Strohballen: Cool Deniboy, Strohballen, CC-Lizenz (BY 2.0), http://creativecommons.org/licenses/by/2.0/de/deed.de , Source: www.piqs.de
Holz: Josef Assmayr, Rohstoff Holz, CC-Lizenz (BY 2.0), http://creativecommons.org/licenses/by/2.0/de/deed.de , Source: www.piqs.de
Residues
Example 1:
Entrained-Flow
PRENFLO PDQ
Integrated Process Chain for the Production of Synthetic Biofuels
Feedstocks
Pretreatment
Gasification
Gas Treatment
Wood
Torrefaction
CO-Shift
Milling
AGR
Straw, etc.
Coal
Synthesis
GaselTM
FischerTropsch
Synthesis
and product
upgrading
Bio-diesel,
Bio-kerosene
Petcoke
Liquid
Residues
PRENFLOTM
PDQ
BXTL Project BioTfueL, France
applying PRENFLO PDQ and Fischer-Tropsch Technologies
Overview BioTfueL Project (B-XTL process chain)
Total
Target:
Development and commercialisation
of integrated process chain for the
production of 2nd generation biofuels
via thermochemical conversion
Projectbudget and timeline:
112.7
112 7 million over 7 years
Uhde contribution
Provider of PRENFLO PDQ
gasification process as well as
general know-how on CTL
and engineering capabilities
Uhde
Sofiproteol
Axens
IFP
CEA
Germany
France
Torrefaction
Process Conditions
Temperature: 200 - 300 C
Residence time: 15 - 90 min
atmospheric pressure
Improvement of feedstock
properties for
enhanced energy
gy content
grindability with less energy
storage behaviour
fluidization behavior
pneumatic transportation
behaviour
Kaffeebohnen: viewsion, Kaffeebohnen, CC-Lizenz (BY 2.0), http://creativecommons.org/licenses/by/2.0/de/deed.de , Source: www.piqs.de
Rstkaffee: Knipsermann, Rstkaffee, CC-Lizenz (BY 2.0), http://creativecommons.org/licenses/by/2.0/de/deed.de , Source: www.piqs.de
Example 2:
Fluidised Bed
HTW
Integrated Process Chain for the Production of Bio-Methanol
Feedstock
Pretreatment
Gasification
Gas Treatment
Synthesis
CO-Shift
Domestic
Forest
Residues
Methanol
Synthesis
Grinding,
Grinding
Drying
fuel grade
methanol
AGR
HTW
Biomass to Methanol, VrmlandsMetanol, Sweden
applying HTW Fluidised Bed Gasification
VrmlandsMetanol, Sweden
HTW Biomass to Methanol Project
Uhde selected as technology
supplier and EPC contractor
Plant Capacity:
100,000 t/a of fuel grade
methanol + district-heating 15 MWth
Feedstock:
Domestic forest residue, ~25 t/h
P
Process:
Fluidized bed gasification (HTW)
(eq. 111 MWth)
HTW
Cyclone
HTW Gasification
Refractory
Lined
Gasification
Chamber
Pressurised,, fluidised bed
Temperature: 800 - 1000 C
Pressure: 10 - 30 bar
Recycle
y
Line
stationary
Fluidized
Bed
Operates below ash melting
point (ideal for coals with
high ash melting point,
biomass, lignite, waste)
Requirements for
VrmlandsMetanol Project
Feedstock:
Domestic forest residue
Grain size:
< 4mm for biomass
HTW Gasifier
G ifi
Commercial-Scale HTW Coal to Methanol Plant
Berrenrath, Germany
Operating results
Capacity: 140 MWth; 10 bar
smooth, reliable gasifier
f
operation
successful component test
program (CTP) for IGCC
application
67,000 h of operation
methanol production
800,000 t
average plant availability
over 10 years:
~ 85 %
best year:
> 91 % (>8,000 h)
Feeds operated in HTW Fluidized Bed Gasification
hard coal
brown coal
wood
peat
waste
Key Project Differentiators
BioTfueL Project:
Project target: to develop a complete B-XTL chain, converting
biomass into renewables-based fuels
Th
The PRENFLO
PRENF O PDQ entrained-flow
i d fl
gasifier
ifi iis d
designed
i
d as multi
li
feedstock gasifier with the ability to simultaneously gasify biomass,
coal, petcoke, liquid vacuum residues and Fischer-Tropsch recycle
gases
VrmlandsMetanol Project:
P
Project
j t target:
t
t to
t produce
d
f l grade
fuel
d bio-methanol
bi
th
l used
d as liliquid
id
motor fuel substituting fossil fuels
The HTW fluidized bed gasification has a capacity of 111 MWth and
uses domestic forest residue to produce 100
100,000
000 t/a of fuel grade
methanol
Process Wrap
From feed-in to product-out, Uhde provides a wrap for the entire process chain.
Diesel
MTO
Naphtha
Methanol
Gas
Gasoline
MTG
LPG
Naphtha
Biomass
Steam Reformer
Coal
PRENFLO /
HTW
Gasification
Urea
Ammonia
Uhde
FischerTropsch
Syngas
Diesel
Naphtha
Waxes
Lubes
H2
Refinery
Resid.
SNG
Fuel gas
Execution Wrap
Uhde is licensor, technology provider and engineering contractor from a single source.
Feasibility
Study
Basic
engineering
Detail
engineering
Procurement
Erection
and
commissioning
Services
Uhde: Our Wrap Offers
combining process chains and EPC from a single source
Summary
Over 100 gasifiers designed, built and put into successful operation by Uhde, which
include:
Feeding principles:
Dry powder feeding
Water-slurry feeding
Screw conveyor and gravity pipe (fluidised-bed applications)
Syngas Cooling with
Gas Quench
Water Quench
Q
All these gasifiers went into
successful operation and
Waste Heat Boiler
are fully proven in
Radiant Cooler
commercial scale by Uhde
Gasifier Insulation with
Refractory lining
Membrane Wall
Uhde is an integrated licensor and EPC contractor from a single source
A number of new projects have selected Uhde Gasification technologies, including:
TransGas, CTL / MTG Complex, USA
BioTfueL, B-XTL, France
V l d M t
l BTL ((methanol),
th
l) S
d
VrmlandsMetanol,
Sweden
Thank you for your attention
PRENFLO IGCC, Puertollano, Spain
November 2010
www.prenflo.com
p
prenflo.uhde@thyssenkrupp.com
@ y
pp
