Institute of Energy Process Engineering and Chemical Engineering

Chair of Energy Process Engineering and Thermal Waste Treatment

Institute of Energy Process Engineering and Chemical Engineering

n Efficient and sustainable use of fossil and renewable energy raw materials

n Leading in research for large-scale gasification pro-cesses based on comprehensive knowledge of ther-mo-chemical conversion processes

n Educating students in bachelor, master and diploma courses in process engineering, environmental engi- neering, industrial engineering and energy technology

n Internationally connected and promoting knowledge exchange and collaboration between science, industry and public/governmental agencies

n 90 employees from seven nations with interdisciplinary background (engineers, chemists, mathematicians, mineralogists, economists, lab and technical staff)

Research scientists, laboratory and technical staff of the Chair of Energy Process Engineering and Thermal Waste Treatment (EVT) at the slagging gasifier test plant located at IEC

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Content

History of the IEC 4

Introduction of the IEC 5

Energy Process Engineering and Thermal Waste Treatment (EVT) 6

Research Groups 7

Thermo-Chemical Conversion 8

Mineral Matter 9

Technology Assessment 10

Process Chain Development 11

CFD Modeling of High-Temperature Processes 12

Technologies for Solid Fuels Gasification 13

Syngas Technologies 14

Plant Operation 15

Equipment 16

Large-Scale Test Plants 16

Bench-Scale Test Facilities 19

Laboratory Equipment 20

Software Tools 21

Training Courses 22

Networking 23

International Freiberg Conference 23

ERN - Energy Raw Materials Network 24

Services 25

Contact Details 26

The history of the Institute of Energy Process Engineering and Chemical Engineering (IEC) dates back to 1918, when the Lignite Foundation of the State of Saxony was foun-ded to support and develop the upcoming Saxon lignite industry. Since then, significant milestones and develop-ments have been achieved. Building on that tradition, the IEC is the largest institute in the TU Bergakademie Freiberg today, both in terms of staff number and research funding.

Although the institute’s research and education topics and the focuses of the institute’s chairs have seen changes in recent decades, the IEC has maintained its close collabo-ration with the industry and broadened its research areas and competences in particular over the last years. The drive for excellence in theoretic and experimental research in the fields of energy process engineering, reaction engineering and numerical thermofluid dynamics remains the key focus of IEC‘s activities today.

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1918 Establishment of the “Lignite Foundation“ at the TU Bergakademie Freiberg financed by the Saxon Ministry of Finance and numerous industrial companies

1919 Foundation of the “Lignite Research Institute“ – with a heat-economical lab at the TU Bergakademie Freiberg which can be seen as the precursor of the IEC

1921 Construction of the technical test plant for the Heat-Economical Department of the Lignite Research Institute at the “Reiche Zeche“ site

1945 Transfer of the technical test facilities to the Institute for Technical Fuel Utilization, an independent institute from the Faculty of Mining at the university

1953 Establishment of the department “Processing“ with the focus on coal and oil; later subdivision of the department into the sections “Mechanical Processing“ and “Fuel Processing“

1954 Start of the wide expansion of the institute at the “Reiche Zeche“ site

1968 Assignment of the institute to the scientific field of “Reaction and Fuel Engineering“ within the section “Chemical and Silicate Engineering“; Establishment of the teaching area “Reaction Engineering“; Further specialisation of the department “Coal Upgrading“ in the field of “Fuel Engineering“

1991 Scientific reorganization of the IEC after the German reunification

1994 Assignment of the institute to the “Faculty of Mechanical, Process and Energy Engineering“

2003 Start-up of the large-scale test plant for the gasification of gaseous and liquid hydrocarbons through high-pressure partial oxidation (HP POX)

2009 Kick-off of the first research group of the “Center for Innovation Competence Virtuhcon“ (Virtual High Temperature Conversion)

2010 Establishment of the Chair of “Numerical Thermo-Fluid Dynamics“ (NTFD)

2010 First run of the Syngas-to-Fuel plant (STF)

2011 Inauguration of the new laboratory building at the IEC

2014 Commissioning of the fixed-bed slagging gasifier (SBV) large-scale test plant

2016 Start of phase II of the „Center for Innovation Competence Virtuhcon“

History of the IEC

Reiche Zeche, 2014(c) TU Bergakademie Freiberg / (Luftbildservice Dresden)

The Institute of Energy Process Engineering and Chemical Engineering (IEC) focuses on the comprehensive experi-mental investigation, theoretic description, modeling and simulation of material and energy conversion processes. Examples include syngas generation for the production of base chemicals or fuels, the beneficiation of carbonaceous feedstock for metallurgical and environmental applica-tions, and catalytic and non-catalytic flue gas treatment and syntheses.

The three chairs are responsible for fundamental lectures and multiple major subjects in the bachelor, master and diploma courses for “Process Engineering”. Additional-ly, the IEC is involved in the study courses for “Environ-mental Engineering”, “Energy Technology”, “Mechanical Engineering“ and “Industrial Engineering”. The chair NTFD also offers the master course “Computational Science and Engineering” which is jointly organized together with the TU Dresden.

The IEC is equipped with a wide range of experimental facilities ranging from laboratory to large-scale as well as comprehensive software packages for modeling and simulation of single processes and complete process chains. Due to its strong research background, the IEC is the institute with the highest third-party funding and the largest number of employees at the TU Bergakademie Freiberg. It is Germany’s leading research institute in the field of large-scale gasification processes.

Research activities of the chairs are focused on:

Energy Process Engineering and Thermal Waste Treatment (EVT): efficient and sustainab-le use of fossil and renewable energy raw materi-als such as coal, petroleum, natural gas, biomass and waste materials through thermo-chemical conversion processes (gasification, pyrolysis, co-king, etc.).

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Introduction of the IEC

Numerical Thermo-Fluid Dynamics (NTFD): modeling and numerical simula-tion of reactive flows and high-tempera-ture processes using sophisticated models combined with 3D Computational Fluid Dynamics (CFD), combining basic and ap-plied research of detailed flame structu-res for the simulation of industrial reactors.

Reaction Engineering (RT): heterogeneous catalysis and chemical reaction engineering, the removal of pollutants from flue and exhaust gases, CO2 abatement, syngas chemistry and biogenic fuels, optimization of existing and development of new processing methods for petroleum and petrochemicals, biofuels and synthetic fuels.

Prof. Dr.-Ing. Bernd Meyer(Institute Director)

Phone: +49 3731 39-4511Web: evt.tu-freiberg.de

Prof. Dr.-Ing. Christian Hasse

Phone: +49 3731 39-4830Web: ntfd.tu-freiberg.de

Prof. Dr. rer. nat. habil.Sven Kureti

Phone: +49 3731 39-4551Web: rt.tu-freiberg.de

The educational and research profile of the chair of Energy Process Engineering and Thermal Waste Treatment (EVT) is focused on the efficient and sustainable use of fossil and re-newable energy raw materials by thermo-chemical conver-sion processes. A wide variety of products can be obtained from these processes such as electricity, heat, synthetic pro-ducts for the chemical industry or transportation fuels as well as metallurgical coke or adsorbents for environmental applications.

Numerous facilities and sophisticated equipment ranging from lab analysis equipment to large-scale test plants are applied to investigate and develop related processes and products. In addition, manifold experimental work, mathematical and scientific modeling and simulation of conversion processes, e.g. by means of conventional or high-performance computing, are of high importance to EVT‘s research. Not only single processes but whole pro-cess chains are being addressed. In this way, not only is it possible to evaluate, optimize and improve existing tech-nologies, it furthermore supports the development of new approaches with reduced experimental efforts and in a shorter amount of time.

The fields of research are reflected in the educational pro-file of EVT. The chair is responsible for student education in the study course “Process Engineering“ with its specia-lization in “Energy Process Engineering“. Besides that, a large number of lectures and seminars related to energy and fuel conversion processes are being offered to other study courses. In this context, practical relevance of the lec-ture content is of high importance. In addition to student

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Energy Process Engineering and Thermal Waste Treatment

education, EVT offers qualification courses to industry. The-se are held in English and focus on synthesis gas generati-on and thermo-chemical conversion processes.

In terms of research, the chair EVT belongs to the stron-gest in Germany with respect to third-party research funds. A large number of small and large research projects in the fields of fundamental and applied research are often being initiated and performed in collaboration with part-ners from scientific institutions and industry. Besides that, the chair actively fosters a network involving its scientific and industrial partners, e.g. ERN or DBI:bergakademie. One of the highlights is its “International Freiberg Con-ference on IGCC & XtL Technologies“, an internationally renowned conference organized biennially and attracting a well-mixed international audience from science and industry.

The chair EVT is structured into eight research groups. Each group focuses on a distinct field related to fuel conversi-on, placing emphasis on syngas generation technologies.

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Research Groups

Thermo-Chemical ConversionDr.-Ing. Steffen Krzack

Chair EVT Prof. Dr.-Ing. Bernd Meyer

Research Groups EVT

Mineral MatterDr.-Ing. Stefan Guhl

Technology AssessmentDr. rer. pol. Roh Pin Lee

Process Chain DevelopmentDr. rer. nat. Felix Baitalow

CFD Modeling of High-Temperature ProcessesDr.-Ing. Andreas Richter

Technologies for Solid Fuels GasificationDipl.-Wi.-Ing. Alexander Laugwitz

Syngas TechnologiesDr.-Ing. Peter Seifert

Plant OperationDipl.-Ing. Olaf Schulze

They cover a wide range of activities ranging from the-oretic and modeling-based research, experimental work, process demonstration to large-scale operations.

Left to right: O. Schulze, U. Böhning, S. Guhl, R.P. Lee, A. Laugwitz, B. Meyer, A. Richter, J. Tanneberger, P. Seifert, S. Krzack, F. Baitalow, M. Schreiner, S. Bauersfeld

Laboratory Dr. rer. nat. Marcus SchreinerMechanical Workshop Tom Mader

Conversion processes at elevated or high temperatures can be applied to produce higher value products from fossil and renewable energy raw materials, e.g. coke, hydrocarbons or combustible gases which are then further processed for energetic or non-energetic use. Typical pro-cess routes include the efficient and clean generation of electricity, heat, transportation fuels, base chemicals or the production of coke for metallurgical processes or as adsor-bent for environmental applications. The focus is placed on beneficiation and conversion of biomass, coal, wastes or residues by pyrolysis, gasification or related processes. The “Thermo-Chemical Conversion“ research group aims for a better understanding and improvement of conversion processes as well as for the development and realization of new applications and variants of conversion processes for alternative feedstock and new products.

Research tasks:n Fuel technological evaluation of energy raw materialsn Characterization of thermochemical behavior of coal,

biomass, wastes or residuesn Investigation of mechanism, kinetics, energy and mate-

rial balances of pyrolysis processesn Investigation of reactivity of fuels and kinetics of gasifi-

cation reactions

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Thermo-Chemical Conversion

n Production and characterization of coke and chars for various applications including the development and optimization of carbon-based adsorbents

n Investigation of the influence of feed properties and operating conditions on the product quality of conver-sion processes

Current projects and references:n Demonstration of the gasification of high-ash coals

applying internal-circulating fluidized-bed gasification concept (COORVED, BMWi-funded)

n Agglomeration behavior of coal ash under gasification conditions (BWWi-funded)

n Co-conversion of coal and biomass n Suitability of various feedstock for the production of

adsorbents for flue gas cleaning and waste water treat-ment (AiF-funded)

n Influence of ash-forming components and additives on pyrolysis product distribution and kinetics of gasificati-on

n Tar formation under conditions of pressurized fixed bed gasification (BGL, BMWi-funded)

n Rotary kiln pyrolysis of digestates and other biomass residues (Industry- and BMWi-funded)

n Pyrolysis behavior of industrial residues in different at-mospheres (Industry-funded)

Dr.-Ing. Steffen Krzack

Phone: +49 3731 39-4524E-mail: Steffen.Krzack@iec.tu-freiberg.de

The mineral matter behavior observed in high-temperatureconversion processes such as gasification and combustion is of special interest as process disturbances and wear and tear of plant components are often linked to the ash/slag properties of the feedstock. The objectives of the “Mineral Matter“research group are the chemical and physical characteriz-ation of these mineral components. Based on this informa-tion, the understanding of the processes and the influence of the ash/slag behavior is extended to the development of new approaches. Besides analytical and experimental investigations, chemical equilibrium calculations are used to estimate the behavior of mineral components in high temperature processes.

Research tasks:n Chemical characterization of feedstock and process

samples (slags, agglomerates, fouling layers)n Determination of viscosity, density, surface tension and

wetting behavior of slagsn Experimental investigation of slag formation and the

interactions between solid, liquid and gaseous phases at high temperatures and under different gas atmos- pheres

n Modeling of the ash/slag behavior on the basis of che-mical equilibrium considering experimental data e.g. slag formation and solidification, mobilizing of trace elements and extraneous materials (sulphur and alka-lis), deposit formation/fouling, refractory corrosion etc.

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Mineral Matter

Current projects and references:n Further development of the slagging fixed-bed

gasification process (BMWi-funded)n General investigations of selected process steps (ki-

netics, slag formation and slag properties) inside gasi-fiers (HotVeGas I - III, BMWi-funded)

n Investigations on flux dosing and slag discharge (SBV, SMWA-funded)

n Support of material property data acquisition for ash-slag systems (CIC Virtuhcon, Group Multiphase Sys-tems, BMBF-funded)

n Development of a heat recovery system for the Siemens gasification process (TEIMAB, BMWi-funded)

n Fouling and slagging models for coal-fired boilers ba-sed on experimental investigations and thermochemi-cal calculations (SIMEX, RWE Power AG-funded)

n Fouling inside a pressurized coal-fired boiler of the combined heat and power plant Cottbus

n Experimental investigation of single-particle reactions at high pressure and temperature in cooperation with Friedrich-Schiller-Universität Jena, Institute of Applied Physics (HITECOM I & II, BMBF-funded)

n Investigation of fouling in coal fired power plants (Co-firing founded by RWE; KORRISTENT in cooperati-on with Vattenfall founded by BMWi)

Dr.-Ing. Stefan Guhl

Phone: +49 3731 39-4485E-mail: Stefan.Guhl@iec.tu-freiberg.de

The Technology Assessment (TA) research group focuses on deepening the understanding of the interaction between science, technology and society. Drawing on concepts and methods from both social sciences and technical disciplines ranging from engineering, decision sciences to resource management, it utilizes a systemic approach to investigate technological and scientific developments that will pave the path for a low-carbon economy and support a sustainable transition in the energy and resource systems.

The tasks of the research group include the assessment of “STEEP” (social-technological-economic-environmen-tal-political) impacts along technological and resource chains representing viable alternatives for the energy and resource economies. Both direct impacts as well as systemic and indirect effects are considered so as to facilitate a bet-ter understanding of the energy and raw materials systems as large-scale social-technical systems which are made up of interrelated components and stakeholders connected in complex networks and infrastructures. The objective is to provide decision-makers with a holistic overview of the strengths, weakness, opportunities and threats which are associated with promoting existing and future technologies, in integrating them into the existing structure and the wider society and in supporting an identification of R&D and pub-lic engagement needs. Research insights support the gene-ration of specific recommendations to support sound and grounded decision-making as well as measures develop-ment for a transition to a competitive, low-carbon, secure and sustainable energy and/or raw materials system.

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Technology Assessment

Research tasks:n “STEEP” evaluations to support decision-making for a

transition from: i) fossil to renewable energy sources (energy transition), ii) primary to secondary/renewable substances (raw material transition), iii) a predominant energetic use of primary and secondary resources to a non-energetic application through an innovative integ-ration of renewable energies (resource transition)

n Comparative eco-efficiency evaluations of the entire value chain for existing and promising technologies for the production of carbon-based products and fuels

n Life-cycle assessments for the conventional and alter-native utilization of carbon resources as well as con-cepts integrating renewable energy and CO2 in pro-duction pathways

n Identification of systemic factors in the social and institutional environments that are barriers to the societal acceptance of alternative utilization of natural resources and the social uptake of innovative tech- nologies and associated infrastructures

Current projects and references:n German Center for Energy Resources (BMBF-funded,

co-financed by industry partners)n Zwanzig20-Forum (BMBF-funded) n Collaboration with the Saxon Academy of Sciences in

Leipzig to establish a technology assessment working group

Dr. rer. pol. Roh Pin Lee

Phone: +49 3731 39-4423E-mail: Roh-Pin.Lee@iec.tu-freiberg.de

n Investigation of dynamic process behavior, e.g. the mo-deling of partial load states at load change processes

n Scaling of plants and processesn Evaluation of economics (identification of advanta-

geous routes)

Current projects and references:n Fundamental studies of future high-temperature gasifi-

cation and gas treatment processes for dynamic power generation and production of chemicals (HotVeGas I, II & III, BMWi-funded)

n Evaluation of Annex-concepts for the integration of coal-based synthesis routes and conventional electricity generation (Polygeneration-Annex, BMWi-funded)

n CO2-conversion in dynamic methanol synthesis (CODY, BMWi-funded)

n Technological and economical assessment of innovati-ve routes for the utilization of associated petroleum gas in Russia (Erdoelbegleitgas, BMBF-funded)

n Evaluation of load flexible polygeneration concepts (BMWi-funded)

n Evaluation of concepts for staged coal to liquids con-version (BMBF-funded)

n Industry-funded projects, e.g.:- SNG and H2 production from German lignite- CO2 conversion integrated with renewable energy

utilization- Substitution of coal/coke by natural gas in a metal-

lurgical process

Today’s technologies to use fossil and biogenic energy raw materials need continuous development and adaptation to meet the requirements of improved efficiency, minimal environmental impact (CO2 and pollutant emissions) and optimal economic performance. In addition, the steady in-crease in the contribution of fluctuating renewable energy to the electricity market leads to new requirements concer-ning the operation flexibility of energy generation plants.

The “Process Chain Development” research group focuses on the investigation of process chains for: n Energetic fuel utilization (e.g. for conventional plants

and IGCC plants with and without CO2 capture), n Production of chemicals from fuels (XtY routes), n Polygeneration concepts for combined energetic and

non-energetic fuel conversion, n CO2 utilization,n New concepts integrating renewable energies.

All relevant steps (including fuel treatment, gasification, air separation, gas treatment, syntheses, power block etc.) are modeled in detail in order to allow a realistic simulation of complex process chains. Based on its extensive experience, a large number of validated process models are readily available at the chair EVT.

Research tasks:n Concept development and modeling using suitable

software tools (stationary and dynamic) n Detailed material and energy balancing and optimiza-

tion of processesn Technological and ecological evaluation of process

chains

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Process Chain Development

Dr. rer. nat. Felix Baitalow

Phone: +49 3731 39-4702E-mail: Felix.Baitalow@iec.tu-freiberg.de

The tasks of the “CFD Modeling of High-Temperature Processes“ research group focus on the modeling of high-temperature processes across the entire spectrum ranging from chemically reacting particles to the comple-te reactor. One key aspect is the development of models and strategies for the simulation of high-temperature re-actors such as fixed-bed, fluidized-bed, and entrained-flow systems in metallurgy and chemical engineering. Funda-mental research on subsystems is incorporated into the development of advanced sub-models. These sub-models are then integrated into reactor models for an improved simulation of fluid-solid systems. Based on insights gained through such advanced modeling, optimization strategies can be developed for an accelerated adaption of existing technologies as well as for the development of new tech-nologies.

Research tasks:n CFD Modeling of catalytic and non-catalytic reforming

of natural gasn CFD Modeling of coal gasification processes (entrained-

flow gasification, fluidized-bed gasification, slag-bed gasification)

n CFD Modeling of metallurgical processes (roasting, bed smelting, blast furnaces)

n Design and modeling of high-temperature test reactorsn Studies of isolated particles in high-temperature en-

vironments (heat and mass transfer, pyrolysis, gasifica-tion, particle shape development)

n Heat and mass transfer in porous median Sub-model development (e.g. slag film, carbon con-

version, pore growth)

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CFD Modeling of High-Temperature Processes

Current projects and references:n Numerical simulation of bed smelting processes

(ProVirt, founded by the European Social Fund and the Free State of Saxony)

n Numerical modeling of fluidized-bed roasting (ProVirt, founded by the European Social Fund and the Free Sta-te of Saxony)

n Model development for fluidized-bed gasification (ProVirt, founded by the European Social Fund and the Free State of Saxony)

n Model development for slag-bed gasification (ProVirt, founded by the European Social Fund and the Free Sta-te of Saxony)

n CFD-based improvement of high-temperature experi-ments (ProVirt, founded by the European Social Fund and the Free State of Saxony)

n Single-particle studies in high-temperature environ-ment (HITECOM, BMBF-funded)

n Numerical studies and design improvements of high- temperature test reactors (HITECOM, BMBF-funded)

n Modeling entrained-flow gasifiers (industry)n CFD studies of blast furnaces (industry)n Model development for coal combustion (KORRISTENT

in cooperation with Vattenfall founded by BMWi)n Modeling and optimization of entrained-flow gasifiers,

slag-flow modeling (HotVeGas III, BMWi-funded)n CFD-based optimization of HP POX and ATR processes

(internal project)n Model development for heat and mass transfer in pa-

cked beds (internal project)

Dr.-Ing. Andreas Richter

Phone: +49 3731 39-4801E-mail: A.Richter@vtc.tu-freiberg.de

The evaluation and comparison of commercial coal gasifiers of the so-called second generation as well as their sugge-sted improvements and EVT in-house gasifier development activities are conducted by the “Technologies for Solid Fuels Gasification“ research group. Accordingly, the influence of the type and quality of the feedstock and process parame-ters such as temperature and pressure on the operation suc-cess are analyzed. Addressed processes are investigated by applying various computer-based simulation tools as well as empirical non-dimensional correlations. Calcu-lation results are presented as thermodynamic indices, exergy analyses and multidimensional maps (ternary diagrams). Additional topics include the gasification of low-quality (low-grade and/or high-ash) coal and the development of suitable gasification concepts as well as the optimization of established commercial gasifiers.

Research tasks: n Evaluation and comparison of commercial coal

gasifiers:- Thermodynamic efficiency under different

operation conditions - Investment and operational costs

n Development of advanced gasifiers and raw gas cooling concepts:- Reactor design- Gas-solid flow pattern- Fuel blending - Water quench chambers

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Technologies for Solid Fuels Gasification

Current projects and references:n Concept studies on production routes applying a slag-

ging fixed-bed gasifier: market analyses, technologi-cal & economic evaluations as well as operation of a 10 MW(th), 40 bar gasifier and its simulation in flow sheets

n Development of full water quench and partial water quench designs for entrained-flow gasifiers using cou-pled flow sheet and CFD simulations in ASPEN Plus and ANSYS Fluent

n Numerical simulation of an entrained-flow gasifier in OpenFOAM

n Development of the patented INCI gasifier including CFD simulation of the reactive fast fluidized bed in a 100 kW(th) input reactor, balancing various loads and feedstock

n Flow sheet simulation of a process chain for a material-based production of various products from Central German lignite, development of a reactor network model for fuel blend gasification kinetics

n Detailed numerical simulation of the slag flow behavior under changing material properties using VOF method in OpenFOAM

n Slag behavior simulation of different operating condi-tions including slag tapping under varying process pa-rameters of the slagging fixed-bed gasifier large-scale test plant at “Reiche Zeche“

n Improvement of gasifier components using optimizati-on algorithms via coupling of modeFRONTIER, ICEM-CFD and ANSYS Fluent

Dipl.-Wi.-Ing. Alexander Laugwitz

Phone: +49 3731 39-4558E-mail: Alexander.Laugwitz@iec.tu-freiberg.de

The generation of synthesis gas through high-pressure partial oxidation and the synthesis of high-quality fuels are impor- tant process steps of modern XtL routes. The IEC operates a high-pressure synthesis gas plant for the gasification of li-quid and gaseous feedstock (HP POX – High Pressure Parti-al Oxidation) that is connected to a gasoline synthesis plant for the generation of high-octane gasoline out of synthesis gas (Syngas To Fuel – STF). The “Syngas Technologies“ re-search group focuses on pre-calculation, planning, evalua-tion and test activities which are jointly carried out with the plant operation group.

HP POX related research tasks:n Generation and evaluation of experimental data sets

obtained from HP POX plantn Material and enthalpy balances, thermodynamical

pre- and recalculation, and modeling of synthesis gas production

n Studies on formation of trace components relevant for gas cleaning and utilization, e.g. HCN, NH3, COS and organic acids

n Optimization of the gasification process for different feedstock

n Flame visualization by an optical probe system and in-vestigation of flame geometries

n Development and testing of advanced burners

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Syngas Technologies

Gasoline synthesis related research tasks:n Generation and evaluation of experimental data sets

obtained from the STF plantn Material and enthalpy balances, thermodynamical

modeling of gasoline synthesisn Optimization of operating parametersn Overall system analysis in terms of process efficiency

and economy

Current projects and references:n Gasification tests for the generation of reference data

sets for the CFD Modeling of non-catalytic gas refor-ming and for practical tests of new burner concepts

n Gasification of hydrocarbons and slurries by high- pressure partial oxidation (HP-POX, funded by BMWi/ SMWK and mg engineering (third-party funding) as well as Lurgi AG (sub-contractor))

n Further development of IGCC power plant technolo-gy with CO2 capture (COORAMENT, funded by BMWi, SMWK (EFRE) and Air Liquide Group)

n Oxygen reforming (R&D, funded by Air Liquide Group)n Development of a new technology for the production

of high-octane gasoline from synthesis gas (funded by SMWK (EFRE) and Chemieanlagenbau Chemnitz GmbH)

n Test campaigns at the STF plant (funded by Chemie- anlagenbau Chemnitz GmbH)

Dr.-Ing. Peter Seifert

Phone: +49 3731 39-4552E-mail: Peter.Seifert@iec.tu-freiberg.de

The “Plant Operation“ group is involved in the design, construction and operation of bench-scale and large-scale research plants. These plants enable investigation, process development, equipment performance assessment and optimization under realistic operating conditions. Diverse experimental activities are contributing to the realization of innovative process concepts and process chains.

Research tasks:n Designing, planning, construction and operation of

bench-scale and large-scale research plantsn Assessment of process design parameters for

industrial-scale plant designn Optimization of process design and equipmentn Sampling under process conditions (high pressure and

temperature)n Development, implementation and operation of com-

plex measurement equipment n Provision of synthesis gas products for external

analyses

Plants operated by the group “Plant Operation“ include:n HP POX plant: (5 MW(th), 100 bar, up to 1500 °C):

large-scale high pressure partial gasification test plant for liquid and gaseous hydrocarbon feedstock

n STF gasoline plant: (Input: 700 m³(STP)/h syngas): large-scale test plant for the production of gasoline from methanol or syngas

n SBV plant: (10 MW(th), 40 bar, up to 2000 °C): large-scale moving-bed gasification test plant for ana-lysis of “difficult” feedstock

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Plant Operation

n KIVAN reactor (10 kW(th), 100 bar, up to 1600 °C): bench-scale drop tube reactor for kinetic analyses

n COORVED reactor (60 kW(th), 0.4 bar, up to 1600 °C): bench-scale gasifier for analysis of flame development in gasification systems

Current projects and references:n Further development of moving-bed slagging gasifier

to a polygeneration process, test of two technology routes (BMWi-funded)

n Construction and operation of a moving-bed slagging gasifier to obtain design specifications for “difficult” feedstock, development of measurement methods for slag behavior and gas flow in the moving bed under high-pressure conditions (SBV, SMWA-funded)

n Investigation of reaction kinetics up to 100 bar un-der different gas atmospheres (Virtuhcon, BMBF/ SMWK-funded)

n Commissioning, operation and optimization of a fluidized-bed gasifier including the optical measure-ment of the particle flow under operating conditions (COORVED, BMWi-funded)

n Investigation of syngas production from gaseous and liquid hydrocarbons for different operation modes ap-plying the HP-POX plant (industrial R&D, Air Liquide Group-funded; COORAMENT, BMWi/SMWK (EFRE)and Air Liquide Group-funded)

n Demonstration and performance of test programs to prove and optimize a new gasoline synthesis technology (Syngas-to-Fuel)

Dipl.-Ing. Olaf Schulze

Phone: +49 3731 39-2691E-mail: Olaf.Schulze@iec.tu-freiberg.de

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Equipment – Large-Scale Test Plants

Large-scale test plant for gasification of gaseous and liquid hydrocarbons by high-pressure partial oxidation – HP POX (start-up in 2003)

Process applications: n Autothermal catalytic reforming (ATR) of gaseous

feedstock at pressures of up to 70 bar(g)n Autothermal non-catalytic partial oxidation of gaseous

feedstock (Gas POX) at pressures of up to 100 bar(g)n Autothermal non-catalytic gasification of liquid hy-

drocarbons (Oil POX) at pressures of up to 100 bar(g)

Feedstock:n Natural gasn Light and heavy oilsn Heavy residues from crude oil processing

Operating parameters:n Temperature: up to 1450 °Cn Pressure: up to 100 bar(g)n Input: up to 500 m³(STP)/h natural gas or 500 kg/h

liquid feedstockn Syngas output: up to 1500 m³(STP)/h

Objectives:n Variation of steam-to-feed ration Investigation of influence of pressure and temperaturen Analysis of product streams including trace

componentsn Energy, exergy and material balancing

Scientific topics:n Gasification process design and modeling n Reactor and burner design and modeling n Modeling and understanding of trace component

behavior (mechanisms of formation and distribution of technologically relevant trace components)

Accomplished projects and funding:n Funded by the Federal Ministry of Economic Affairs and

Energy (BMWi) and Saxon State Ministry of Science and Fine Arts (SMWK) with funds provided by the European Fund for Regional Development (EFRE) under the rese-arch projects HP POX and COORAMENT

n Funded by the Saxon State Ministry of Science and Fine Arts (SMWK) with funds provided by the European Fund for Regional Development (EFRE) under the research project ”Development of a new technology for produ-cing high-octane gasoline from syngas”

n Plant operation under industrial-funded research projects

Plant construction funded by:

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Equipment – Large-Scale Test Plants

Syngas-to-Fuel (STF) – Large-scale test plant for the synthesis of high-octane gasoline from syngas (start-up in 2010)

STF plant characteristics:n Large-scale synthesis test plant for demonstrating the

production of high-octane gasoline from synthesis gasn Input: 700 m3(STP)/h of syngas (provided by the

HP POX)n Two-stage reactor concept: 1st stage: methanol synthe-

sis at 50 bar, 2nd stage: gasoline synthesisn Output: 120 l/h of stabilized gasoline

STF process innovations:n New heat exchanger concept and reactor design

allowing for isothermal operation of the gasoline synthesis reactor

n Selective yield of isomeric hydrocarbons instead of aro-mats during gasoline synthesis

n New catalytic waste water treatment for minimization of process waste water production

STF gasoline quality:n Gasoline quality meeting DIN standard and achieving

an octane number higher than 93n Substitution of aromats by isomers (Aromatic content

<35 %)

Accomplished projects and funding:n Demonstration and performance of test programs

proving and optimizing a new gasoline synthesis technology (Syngas-to-Fuel)

n Funded by the European Fund for Regional Develop-ment (EFRE) and the State of Saxony (Saxon Develop-ment Bank) and co-financed by Chemieanlagenbau Chemnitz GmbH and partners

STF project partners:n Chemieanlagenbau Chemnitz GmbH jointly with

- SAPR Neftechim- Techno Trading Ltd

n TU Bergakademie Freiberg with - Institute of Energy Process Engineering and

Chemical Engineering (IEC) - Institute of Technical Chemistry (ITC)

Plant construction funded by:

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Equipment – Large-Scale Test Plants

Slagging Gasifier – fixed-bed slagging gasifier for difficult solid feedstock (start-up in 2013)

Characteristics of the slagging gasifier:n Large-scale test gasifier for solid feedstockn Operating pressure: 40 bar(g)n Input:

- 1.38 t/h hard coal (equivalent to 10 MW(th))- Up to 430 m³(STP)/h of oxygen and up to

450 kg/h of steamn Output: ca. 2300 m³(STP)/h raw gas

Plant infrastructure: n Coal hoppern Lock hopper system for coal feeding and slag

extractionn Gasification reactor with slag tap and quenchn Gas cooling and gas water storage n Gasifier steel structure (12 x 12 x 22 m)

Research topics:n Investigation of fuel influence and fluxing agents on

ash/slag behaviorn Generation of material property data for application

oriented modelingn Characterization of ash/slag systems under real

process conditions

Accomplished and current projects:n Further development of moving-bed slagging gasifier

to a polygeneration process, test of two technology routes (BMWi-funded)

n Construction and operation of a moving-bed slagging gasifier to obtain design specifications for “difficult” feedstock, development of measurement methods for slag behavior and gas flow in the moving bed under high-pressure conditions (SBV, SMWA-funded)

Plant construction funded by:

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Equipment – Bench-Scale Test Facilities

List of bench-scale and larger test facilities:n COORVED gasification reactor for low-rank high-ash

coaln High-temperature drop tube reactor: HTRn Pressurized gasification measurement equipment

(drop tube): GMEQn Kinetic test reactor (High-pressure high-temperature

drop tube reactor): KIVAN reactorn Laboratory pyrolysis facility: LPAn Advanced laboratory pyrolysis facility: ALPAn Pressurized pyrolysis reactor (fixed-bed and drop tube

mode): DPAn High-pressure pyrolysis measurement equipment

(drop tube reactor): PYMEQ

Furnaces: n Muffle furnaces (6) n High-pressure furnace n Large sample furnace n Ashing furnaces (2)

COORVED reactor

n Pyrolysis furnaces (3) n Rotary kiln furnaces (2) n Vertical tube furnaces (2)n QTF (quenching test facility, in-house development) n Horizontal tube furnace

Solid fuels characterization facilities: n Ruhr dilatometer n High-temperature dilatometern Gieseler plastometer n Facility to determine the coke reactivity index (CRI) and

coke strength after reaction (CSR)n Facility to determine reactivity in fixed bed: RiFixn Quartz glass reactors to determine reactivity with

CO2 (7)n Camsizers (Determination of particle size

distribution) (2)n Simple particle disintegrator: SPaltorn Ambient pressure thermo-analysis (thermo-gravime-

try: TG, differential thermo-analysis: DTA, differenti-al-scanning calorimetry: DSC, all with optional mass spectrometer (MS) coupling)

n High-pressure thermo-analysis (TG, DTA, DSC)n High-pressure magnetic-coupling thermo-balance

Mechanical fuel preparation equipment:n Sieve analysisn Mills (cutting mill, impact mill, ultracentrifugal mill,

freezer mill)n Tablet/pellet presses (2)

PYMEQ

Large sample furnace

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Equipment – Laboratory Equipment

Fuel technological laboratory: n Leitz heated microscope (LEM) for investigations of

ash melting behaviorn Elemental (ultimate) analyzers (3)n Combustion calorimeters (2)n Karl-Fischer titrations (2)n Mercury analyzern Microwave pressure pulpingn surface area measurement (N2 or CO2 isotherme)n Mercury porosimetryn Helium pycnometry

Liquids and gas analysis: n Gas chromatography (various micro gas chromato-

graphs, gas chromatographs with different columns and detectors)

n Ion chromatography (3)n High-performance liquid chromatography: HPLCn Pyrolysis facility coupled with gas chromatograph and

mass spectrometer (Pyrolysis-GC-MS)n Viscometers for oil and watern Total-reflection X-ray fluorescence analysis (XRF)

Ash/slag analysis: n Plasma ashing devicen X-ray analysis (X-ray fluorescence analysis: XRF (2),

X-ray diffractometrical analysis - also under high tem-perature and pressure: XRD (2))

n Electron microscopy (SEM, FIB-SEM)n Thermo-optical measurement systems for surface ten-

sion and characteristic ash melting temperatures (with atmosphere control: TOM-AC, without atmosphere control: TOMMI)

n High-temperature viscometers (2)n Two-chamber double thermo-balancen Calorimeter AlexSys (drop-in melting calorimetry) n ETV-ICP OES – electrothermal vaporization - inductive

coupled plasma – atomic emission spectroscopy for multielement-analysis, temperature dependent ele-ment release in combination with elemental speciation

Pyrolysis-GC-MS

SEM

FIB-SEM

Dr. rer. nat. Marcus Schreiner

Phone: +49 3731 39-4520E-mail: Marcus.Schreiner@iec.tu-freiberg.de

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Equipment – Software Tools

Various software tools are available for different research and development activities including in-house code (ih), commercial (c) and open source (os) codes.

CAD: n AutoCAD (c), AutoCAD P&ID (c)n Autodesk Inventor (c)

CFD:n ANSYS CFD (c)

- Fluent, CFX, ICEM, Workbench, etc. (c) - ANSYS Mechanical (c) - Fluent-UDFs (ih): for the coupling of stand-alone tools (drying, pyrolysis, gasification, slag layer) with Fluent

n OpenFOAM (os, ih): reactor and slag flow modelingn PBS – Perić Based Solver (ih): in-house solver (2D and

3D, reactive and non-reactive flows, flows in porous media)

DEM:n FB-DEM (ih): simulation of polydisperse packed beds

Flow sheet simulation:n Aspen Engineering Suite (c): Aspen Plus, Aspen

Dynamic, Aspen Custom Modeler, Aspen HYSYSn EBSILON® Professional (c)n SimuSage (c)

CFD/DEM

Mathematical tools:n Matlab (c), Origin 9 (c)

Optimization:n modeFRONTIER 4 (c)

Particle simulation:n Pyrolysis simulator (ih)n RPG – Resolved Pore Growth (ih): modeling of the

growth of macro-pores for different feedstockn Drying simulator (ih): particle drying n Gasification simulator (ih): analysis of single particle

gasification

Process control:n LabView (c)

Slag analysis:n Slag Simulator (ih): prediction of slag layer thickness in

entrained flow gasifiers

Thermodynamics: n FactSage (c), SimuSage (c)

Visualization:n e!Sankey (c), MathType (c), MS Visio (c), Paraview (os),

Tecplot (c)Aspen

Reactor simulation

SEM Micrograph of crystalline slag

The IEC offers intensive courses in the field of gasification technologies (carried out in English). The courses aim to provide a detailed introduction to the scientific fundamen-tals and technologies of:n Gasificationn Synthesis gas productionn Synthesis gas purificationn IGCC power plants

Leading large-scale gasification technologies such as those from Shell, GE, Siemens etc. are presented in detail. Furthermore, the course program covers introductions to various simulation software tools and visits to lab facilities and large-scale test plants.

Training Courses

The courses cater to:n Process and development engineersn Plant engineersn Executives of companies in the fields of plant construc-

tion and energy supplyn Development companies in the fields of thermal fuel

technology, power plant technology, waste manage-ment etc. who would like to update and expand their knowledge on gasification processes and technologies

The restricted number of participants allows for an inten-sive and comprehensive presentation of this scientific field which is tailored to individual participants. By request, spe-cial courses for different audiences or participants can be arranged to meet specific needs. To ensure a high level of quality, experienced specialists from the industry are invited to present special topics in the courses.

Since 2006, the IEC has regularly offered two to three cour-ses per year. Representatives from leading national and international companies have participated in the courses for example Shell, Linde, Alstom, RWE, Haldor Topsoe, Sie-mens, BASF, E.ON, Total, Hydro Oil and Energy, GSP China Technology, MAN and Lurgi.

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Dr.-Ing. Sindy Bauersfeld

Phone: +49 3731 39-4536E-mail: gasification-course@tu-freiberg.deWeb: http://tu-freiberg.de/en/iec/evt/events/ compact-courses

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Networking – International Freiberg Conferencewww.gasifi cation-freiberg.com

Since 2005, the IEC has organized the „International Frei-berg Conference on IGCC & XtL Technologes“ – a leading international conference addressing a wide range of to-pics relating to the thermo-chemical conversion of carbo-naceous feedstock and related process chains. The event focuses on innovative carbon value chains and the scope of the conference spans the entire value chain from mining to conversion and chemical utilization.

The conference provides a high-level discussion forum to facilitate the exchange of information and expertise bet-ween political, industry and scientific stakeholders. Parti-cipants come from diverse fields and industrial branches ranging from researchers and specialists engaged in fun-damental and applied R&D to policymakers, industry ex-perts from mining companies as well as equipment and technology providers/manufacturers. Previous conferences have been held in various locations in Germany as well as in Inner Mongolia in China. During the conference, studies and new developments by researchers and technology de-velopers as well as current or planned projects and opera-tional experiences by plant operators related to innovative carbon value chains are presented.

Topics for presentations include:n Fuel preparation and upgrading (e.g. drying, feeding

and deashing)n Low temperature conversion processes (e.g. extracti-

on, torrefaction and pyrolysis)n Upgrading of low-temperature conversion products

(e.g. tar reforming)n Coal conversion (e.g. characterization, reaction ki-

netics)n Gasification/co-gasification (for solid, liquid and ga-

seous feedstock)n Underground coal gasificationn Mineral matter characterization and behaviorn Synthesis gas treatment and synthesis technologiesn Carbon dioxide capture, storage and utilization

n Combined cycle and gas turbine developments for IGCC and polygeneration

n Coke productionn Direct liquefaction of coaln Integration of coal and renewables for chemical

storagen Concept evaluations and flow sheet simulationn Numerical modeling of conversion processesn Perspectives from industry (e.g. coal mining organiza-

tions, technology developers)n Public acceptance, trends and global boundary con-

ditions (economic, regulatory and political) for fuel conversion to chemicals/fuels and electricity

n ...

In addition to a stimulating scientific conference program, the event also includes exciting technical tours such as vi-sits to lignite mines, innovative and modern R&D facilities, power plants, CtL facilities and chemical plants etc. During the tours, participants not only obtain first-hand experience of the facilities, they also have the opportunity to engage experts and industry specialists on-site in intensive discus-sion about their activities. Last but not least, the conferen-ce program also consists of interesting social events (e.g. welcome reception, conference dinner, walking tours etc.) which are dedicated to facilitating networking and interac-tion between conference participants.

Dr.-Ing. Sindy BauersfeldDr. rer. pol. Roh Pin Lee

Phone: +49 3731 39-4536/-4423E-mail: gasification@iec.tu-freiberg.deWeb: http://www.gasification-freiberg.com

Partners are:

Networking – Energy Raw Materials Network (ERN)

The Energy Raw Materials Network (ERN) continues the activities of the former information platform “German Centre for Gasification Technologies” (DeZeV). Current-ly, ten partners from science and industry in the fields of energy and resource conversion are active in the ERN.

The network provides a platform for collaboration, knowledge transfer and exchange through regular meetings, courses, workshops and conferences.

Topics addressed by the ERN include new developments, current projects and operational experiences linked to:n The efficient, sustainable and economical utilization of

fossil fuels, biomass and waste, in particular for the provision of base chemicals, fuels, coke, other carbo-naceous products and hydrogen

n Strategies, approaches and technologies for reduc- tion of carbon dioxide emissions, e.g. carbon dioxide capture and utilization

The network activities strive for the promotion of scientific exchange along the whole innovation and value chain from fundamental research to commercial applications. The ERN is initiated and based in Freiberg at the Institute of Ener-gy Process Engineering and Chemical Engineering at the TU Bergakademie Freiberg.

Dr.-Ing. Sindy Bauersfeld

Phone: +49 3731 39-4536E-mail: ern@iec.tu-freiberg.deWeb: http://tu-freiberg.de/en/projekt/ern

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BASF SE

Envirotherm GmbH

German Biomass Research Center

Linde Engineering Dresden GmbH

Mibrag mbH

Romonta GmbH

RWE Power AG

TAF Thermische Apparate Freiberg GmbH

TU Bergakademie Freiberg - Institute of Energy Process Engineering and Chemical Engineering

UTF GmbH

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Services

The Chair of Energy Process Engineering and Ther-mal Waste Treatment offers a full spectrum of ser-vices to companies, organizations and individuals (tailored to your business) in the following areas:

1. Scientific consulting:n Identification and evaluation of advantageous conver-

sion routes for carbonaceous fuels, especially solids (biomass and coal)

n Technological evaluation (for example gas to syngas processes, pyrolysis etc.)

2. Lab services and interpretation of analy-sis data:

n Fuel analyses and evaluationn Thermal analyses and characterization of fuelsn Pore structure analysesn Mineral matter analyses and characterizationn Pyrolysis and gasification behavior (kinetics), charac-

terization of feedstock and products

3. Process routes evaluation:n Development and modeling-based energy and materi-

al balancing of process chains for syngas-based utiliz-ation of carbonaceous fuels (XtY)

n Energetic, environmental and technology evaluationn Estimation of CAPEX and OPEX (pre-feasibility study) n Support of feasibility studies, technology selection and

economical evaluationn Independent technology consulting for companies acti-

ve in the field of XtY technologiesn Supporting different phases of project development

and realization

4. Utilization of large-scale test plants:n Use existing IEC plant equipment for specific fuels or

research topicsn Determination of fuel suitability or process applicability

5. Joint technology development through collaborative research projects.

6. Utilization/transfer of patents owned by TU Bergakademie Freiberg for commerci-alization by interested companies.

Prof. Dr.-Ing. Bernd Meyer

Phone: +49 3731 39-4511E-mail: info-evt@iec.tu-freiberg.deWeb: evt.tu-freiberg.de

Directions to IEC: n Leave A4 at the “Siebenlehn“ exit and travel along the B101 towards Freibergn In Freiberg, turn left at the second set of traffic lights towards Dresdenn At the next traffic lights, go straight aheadn Turn left towards “Silberbergwerke/Reiche Zeche“ in front of the churchn Follow the signs “Silberbergwerke/Reiche Zeche“, “IEC/Energiepark“ to our institute

26

Contact Details

GPS: Latitude: 50.92918, Longitude: 13.35831

Postal address and contact data:

TU Bergakademie FreibergInstitute of Energy Process Engineering and Chemical Engineering Fuchsmuehlenweg 9, 09599 Freiberg, Germany

Phone: +49 3731 39-4511 Fax: +49 3731 39-4555E-mail: info-evt@iec.tu-freiberg.deWeb: www.iec.tu-freiberg.de

Imprint

Editor:Prof. Dr.-Ing. Bernd Meyer

TU Bergakademie FreibergInstitute of Energy Process Engineering and Chemical Engineering

Fuchsmuehlenweg 9, 09599 Freiberg/Germany

Phone: +49 3731 39-4511Fax: +49 3731 39-4555

E-mail: info-evt@iec.tu-freiberg.de

Design and Photos: IEC

Status:05/2016

Institute of Energy Process Engineering and Chemical EngineeringChair of Energy Process Engineering and Thermal Waste Treatment