On the Challenges of Coal Gasification Based Syngas ......• High efficiency: Slurry dry feed, ash...

On the Challenges of Coal Gasification Based Syngas Conversion Systems

Yong-Wang LiSynfuels Americas, Inc (Leesburg, VA )

Synfuels China LTD (Beijing) ywl@sxicc.ac.cn

Global Energy Supply System

Upstream resources: Coal/Minerals , Oil, Natural gas, Nuclear minerals, Biomass/wastesGeothermal, Winds, Sea wave, Solar

Down stream products:Electricity, Civil fuels, Motor fuels (gasoline/jet fuel/diesel)

Science & technology from resources to products large centered facilities: footprint controls

Status: China

Importing oil & gas Security, trade balance

Practical: coal conversion New energy technology

China has to find solutions to completely replace fossil fuels with new energy

resources within about 100 years.

Hydro/Nuclear/Wind 9.6%20% (?) Oil 17.8% (?) Natural gas 5.1% 10% (?) Coal 67.5% 60% (?)

Coal to oils：the strategic field

1938-1962 1997-2010

Scientifically hard topic: Experiences Germany/South AfricaLessons China and US

1980-1993

• Pilot 20b/d 2000-2008• Demon 5000b/d 2006-2009

Synfuels China

Synfuels China (founded 2006, Beijing)

Synfuels China R&D (Beijing)150 researchers 50 engineersLab R&DPilot testing

Synfuels China Engineering Design/EPC/commissioning500 engineers

Synfuels China Catalysts(Erdos) 200 staff12000 t/y F-T catalyst

Synfuels Americas (Leesburg)International projectDevelopment10 members

ChemEssen (Korea-based, Suoel)Chemical data base development applications

Syngas conversion: using “hard” materials

•Syngas conversion Development: New materials, reaction mechanisms, thermal data, new catalysts, unit technologies, new products and processes, integration of a process

• Engineering skills: Design and construction • Understanding Gasification: Improve gasifiers, integration, water handling……

Olefin (C2/C3)

Solvent

Gasoline

Lubricate

CH4 (CNG/LNG)

Product up-grading

Hydro-Pyrolysis Separation

H2/CO

Biomass

CatalyticGasification

GasificationPurification Conv. SG

Separation & Purification

H2/CO

CH4CH3OHOil

Chemicals

Jet fuels

Diesel

Others

CH4

Coal

Residue

Synfuels R&D EffortsMTFT technology formulation (1997-2015)

LAB1.0L

PPΦ 0.3m

DEMOΦ 5.Xm

IndustrializationΦ 10.Xm

1000 t syncrude /t Fe catalystCatalysis and catalyst Reactor and process

Synfuels China— R & Efforts： Catalysis technologiesSo far correct structure

• Research from fundamental (QM,CFD) to application (catalyst, reactors..)• Pilot plant testing, engineering design of plants, operation of plants

Fundamental research Application development Industrial operation

Seamless working environment for whole chain of R&D application ?

Catalyst related problems work but not the best

Synfuels China- IDL Projects overview

Shenhua Ningxia project• 100000b/d liquid • Dry feed gasifers (24)• Linda ASU (10)• SFC F-T 2 trains 8 reactors • Capital cost 58 billion RMB

• 85% construction completed• FT+ upgrading

design/construction services by SFC engineering

• 2016 commissioning

Synfuels China- IDL Projects overview

Luan project• 25000b/d liquids • 4 Shell gasifiers• Air products ASU• SFC F-T 1 trains 2 reactors • Capital cost 18 billion RMB

• 95% construction completed• SFC engineering overall design• FT+ upgrading

design/construction EPC by SFC engineering

• 2016 commissioning

Synfuels China- IDL Projects overview

Yitai HJQ project• 25000b/d liquids • 6 HTL gasifiers• Air products ASU• SFC F-T 1 trains 2 reactors • Capital cost 15 billion RMB

• 65% construction completed• SFC engineering overall design• FT+ upgrading

design/construction EPC by SFC engineering

• 2017 commissioning

Synfuels China- IDL Projects overview

Yitai Dalu /Guizhou projects• 50000b/d liquids • NM gasifers 10• SFC F-T 1 trains 4 reactors • Capital cost 29.5 billion RMB• With new version of design • 3 t water /t oil • Super-clean gasoline

Synfuels China– The Stepwise Process

Energy efficiencyProduct quality

Stepwise liquefaction

DieselProducts

up-grading

Gasification

O2/H2O

Gasoline

Kerosene

Solvent

…

ChemicalsResidues

DCL Process

Technology improvement

F-T synthesis

18-20MPa 3-5MPaStepwise liquefaction

SEP&HYDRO

Recycling solvent

H2Hydro-liquefaction

ICTL Process＋

Biomass

Younger coal

Synfuels China– The Stepwise Process

The hydropyrolysis test at capacity of 1t coal /h facility: Several low rank coals tested, ash contents limited to < 10% Two coals are successfully operated to increase the liquefaction efficiency from 44% (IDL) 60% (STWL)Estimated Capital cost 1 million liquids: from 16.0 billion RMB 12.0 billion RMB

Analysis instrument ESR, GC-MS, FTIR, NMR, XPS,XRD……

Conversion Processes

Syngas conversion• Fischer-Tropsch fuels straight chain based chemicals• MTO C2-C4 olefines• Lurgi gasifier SNG ( methanation ~ inefficient)

Major issues• Fischer-Tropsch catalysts and integration philosophy

Syncrude processing Fe gasoline and diesel Co diesel

• MTO catalysts • SNG economics & waste water management

Synfuels China/US EffortsSynfuels Americas- Initializing International activities

Atom

ic le

vel r

esea

rch

to u

nit d

evel

opm

ent

Pilo

t sca

le (2

0b/d

) to

com

erci

alsc

ale

(110

000/

d)

50000b/d virtual Plant based on mathematic models

Industrialized Gasifiers in China

GasifiersTerms Moving Bed Shell HTL GSP Choren NM SE Water

slurry ECUST

Feed PelletsDry

powder

Dry

powder

Dry

powder

Dry

powder

Dry

powder

Dry

powderSlurry Slurry

Hydrodyn

-amic

Moving

beds G-up

Entrained

G-up

Entrained

G-down

Entrained

G-down

Entrained

G-down

Entrained

G-down

Entrained

G-up

Entrained

G-down

Entrained

G-down

Major

points

Waste water

Steam comsup.

Capacity

Cost

Complex

H2/CO low

Black water

Carbon eff.

Flowing ash

H2/CO low

Black water

Carbon eff.

Flowing ash

H2/CO low

Black water

Carbon eff.

Flowing ash

H2/CO low

Black water

Carbon eff.

Flowing ash

H2/CO low

Black water

H2/CO low

Black water

Efficiency

Flowing ash

Black water

Efficiency

Flowing ash

Existing gasification technologies have not optimized for a whole syngas production processes. It works, and it can be much better……

Moving bed: Success and Failure

Coal

OxygenSteam

LP steam

Ash

Recyclingwater

Raw gas300-520oC

Gas water Gas water

BFW

Gas water

BFW

BFW

Dewater gas

BFWBFW

Coal lock

Gasifer

Ash lock

Lock gas

SteamWater jacket

Rich in CH4Only reasonfor CNG

• CH4 12-14% in cleaned gas, some tar recovered SNG• H2/CO=1.8-2.5, avoiding WGS in most cases

• Coal balances coal powder usage• Steam consumption is large water saving challenges• Waste water with complicated organic contaminates • Capacity low

Pulverized Coal stack

Mill

Hot flue gas

Coal

Coal powder lock

Coal powderFeeding tank

Carrying gasCO2

Flue gas

Slag quench

Slag lock

Oxy

gen

Oxy

gen

Coal + CO2

BoilerBl

ack

wat

er

Slag

Flying ash

Wet ashBFW

Steam

Flying ash filters

Quenching gas recycle ~ 250oC

Dust

y ga

s str

eam

~ 3

00o C

Dust

y ga

s str

eam

~ 3

00o C

Wet

was

hing

tow

er

Clean water

Black water

Wet ash

Dust free raw gas

Dry Feed Shell

• Dry feed with higher efficiency, less oxygen consumption, steam recovery• Much less black water treatment

• Cost is high, low H2/CO = 0.3, water system optimization, Steam for WGS section

Syngas conditioning

Shell SCGP Siemens/GSP HTL ECUST GE-Energy Lurgi (Mark IV)

(CO+H2) Basis : 100000 Nm3/h

CH4: 15000 Nm3/h

H2: 23500CO: 76500CO2 : 6000N2 +H2S: <1000H2O: ~3000

H2: 23500CO: 76500CO2 : 6000N2 +H2S: <1000H2O: > 100000

H2: 23500CO: 76500CO2 : 6000N2 +H2S: <1000H2O: > 100000

H2: 43000CO: 57000CO2 : 28000N2 +H2S: <1000H2O: > 100000

H2: 65000CO: 35000CO2 : 28000N2 +H2S: <1000H2O: > 30000

Coal tar

Purification

H2: 65000CO: 35000

WGS: 22000 COSimple scheme

WGS: 41500 COComplicated scheme

WGS: 41500 COAdding steam: > 60000Complicated scheme

Black water: 1Black water: 3 Black water : 3

Waste water : 5Very difficult water

• High efficiency: Slurry dry feed, ash dust remove, new structure, coal powder delivery

• Water handling: Desalting and recycling (2000t/d: black water 30-100t/h2-5t/h)

• Syngas quality: Increase H2/CO from 0.3 to 0.7-1.0, partial water quenching system

• Safety and availability: Hydrodynamic understanding, more clever design

Gasification: some points to think

The Funny Cycle

650k years ago

How long we need for the complete sustainable system formulation?

Our destination is where we started, with much harder sustainability

Tech

nica

l bar

riers

Electricity Clean fuelsChemicals

Ancient FutureNow

Future for Energy Science

Research: Fischer-Tropsch

Future for Energy Science

Would it work at the large capacity?

Remarks

1.Syngas conversion: better catalysts smart reactor and process technologies

2.Effort here in China a unique platform advanced clean coal technologies

contribution to the world

3.Advanced gasification technologies coal to clean fuels CTL/SNG projects;

gasification technologies have to be upgraded with consideration of not only gasifier

itself, but also the whole integrated system covering coal delivery to syngas cleaning

units

4.Next step very clean and efficient use of coal

5.Long term thinking: bridging what being done today and what to be done tomorrow

essential development in SCIENCE highly demanded