Day 2 Tuesday 16 October 2007 Session 8: FBC/ USC/ IGCC/ CCS

Speech 2 PR China
Two-stage Dry-fed Entrained Flow Coal Gasifier

Mr. Xu Shisen Chief Engineer Thermal Power Research Institute (TPRI) PR China

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A Two-stages Pressurized Entrained Flow Gasification with Dry Feed

Dr. Xu Shisen Thermal Power Research Institute Oct. 2007 Xian

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CONTENTS

The Conception of the Two-stages Entrained Flow Gasification with Dry Feed R&D on the Two-stages Entrained Flow Gasification with Dry Feed The Demonstration of TPRIs Gasification Process

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Fixed Bed

Lurgi BGL U.G.I. Slurry feed

Gasification

GE-Texaco E-Gas

Entrained Flow

Dry feed HTW KRW U-gas Transport

Fluidized Bed

Shell Prenflo GSP MHI TPRI

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ENTRAINED FLOW GASIFIER

It has high output, high efficiency and high carbon conversion efficiency than that of moving bed and fluidized bed. It has high availability verified by the large scale commercial gasifier. Main existing entrained flow gasifiers are: with slurry feed: Texaco, E-Gas, with dry feed: Shell, Prenflo, GSP,

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IGCC AND ENTRAINED FLOW GASIFIER

Tampa 250MW IGCC----2500t/d Texaco Wabash River 260MW IGCC----2500t/d E-Gas Buggenum 250MW IGCC----2000t/d Shell Purterllano 300MW IGCC----2500~3000t/d Prenflo

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ENTRAINED FLOW GASIFIER WITH DRY FEED

Advantages:

High cold gas efficiency, high carbon conversion efficiency, low oxygen consumption

Disadvantages:

For cooling and separating the molten slag in hot syngas at gasifier outlet, half part of cold syngas must be compressed to quench the hot syngas, that results the added energy loss, high auxiliary power consumption, large scale syngas cooler and much more cost.

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A TWO-STAGES GASIFIER WITH DRY FEED

Two stages reaction Mult-burners Water wall Molten slag No cold syngas quench Low auxiliary power consumption Small syngas cooler High cold efficiency Low oxygen consumption

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TPRIs Gasification

36 t/d (10MWth ) Funded by National 863 Program 2005

700kg/d,1996, funded by MOST and SPC

1000t/d2000t/d, 2009

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The change rate of second stage coal supply ratio to cold gas efficiency

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The change rate of second stage coal supply ratio to syngas temperature

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TEST RIG
Capacity : 700kg/d Pressure: 0~4.0MPa Temperature: 1300~1600 It was built funded by State Power Corporation of China in 1998 Research on pressured entrained flow gasification

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TEST RESULTS
Pressure3.0MPa First stage coal flow rate16kg/h First stage oxygen consumption0.55Nm3/kg First stage temperature1360~1400 Second stage coal flow rate4kg/h Second stage oxygen consumption0Nm3/kg Second stage temperature: 1100~1150

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TEST RESULTS

Syngas composition Outlet temperature: 1000~1050

CO 51.3% H235.1% CO2 6.3 % CH4 1.2 % N26.2% Carbon conversion rate95.9% Oxygen consumption294Nm3/1000Nm3 (CO+H2 Cold gas efficiency79.9%

Pilot Scale Facility for TPRIs Gasification

Cold efficiency >83% Carbon conversion>98% Oxygen consumption <320Nm3 /1000(CO+H2) Temperature: 1300~1400 Pressure: 3.04.0MPa Funded by MOST

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Control Center

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DCS of TPRIs Gasifier

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PILOT SCALE TEST FACILITY Capacity: 36-40t/d Pressure: 3.0MPa Temperature: 1400~1600 Funded by MOST and SPC To be built in 2004 Finished the tests of 13 Chinese coals

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Test Coals
Mt Mad Aar Vdaf FCdaf Mt Mad Aar Vdaf FCdaf Qnet,ar Qgr,ar DT ST FT % % % % % % % % % % MJ/kg MJ/kg lignite 26.5 6.08 9.92 44.95 55.05 47.43 3.13 0.55 12.25 0.22 18.80 17.55 1140 1160 1190 Shenmu 4.9 4.86 10.68 36.09 63.91 66.71 4.09 0.78 11.97 0.87 26.57 25.61 1150 1190 1250 Huating 12.5 7.52 17.24 38.10 61.90 55.16 3.57 0.57 10.42 0.54 21.80 20.78 1300 1370 1410 Huangling 8.2 1.21 22.15 35.17 58.03 58.03 3.58 0.83 6.66 0.55 23.46 22.53 1400 1470 >1500 Jincheng anthracite 6.8 1.34 13.76 8.88 91.12 72.39 2.63 1.00 3.08 0.34 27.73 27.03 1390 >1500 >1500

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Test Results
coals
CO% H2% CH4% CO2% H2S+COS% N2%

lignite
61.9 27.84 0.05 3.59 0.11 6.51

Shenmu
62.38 29.36 0.26 2.76 0.37 4.87

Huating
62.79 28.46 0.17 3.41 0.25 4.92

Huangling
60.36 26.98 0.04 7.39 0.24 4.99

Jincheng anthracite
59.93 25.78 0.02 9.18 0.14 4.95

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Test Results
Carbon conversion rate98.9% Oxygen consumption: 298.6Nm3/1000Nm3CO+H2 Specific coal consumption 518.2kg/1000Nm3(CO+H2) Cold gas efficiency 83.2% CO+H2: 91.74%

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Test Results
Gas components Shenmu First stage CO% H2% CH4% CO2% H2S+COS% N2% 62.38 29.38 0.26 2.76 0.37 4.85 Two stage 60.63 32.64 0.72 1.07 0.35 4.59 Huating

First stages 62.79 28.46 0.17 3.41 0.25 4.92

Two stages 60.50 31.93 0.77 2.81 0.25 3.74

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Shenmu Coal Slag

Huangling Coal Slag

Lignite Slag

Jincheng Coal Slag

Entrained Flow Gasification

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TPRI Comparison with the Existing Gasifier

A(Slurry Feed) Cold syngas eff.% CO+H2% Carbon conversion% Thermal eff.% O2 consumption Nm3/1000Nm3(CO+H2) Auxiliary power, % Coals flexibility % Burners life Inner shirt life, y Start time, hr Cost , 70~75 74~80 96 80~85 380~410 85 70 3 months 1 26 70 B(Dry Feed) 78~81 87~90 98 90 350 100 95 2y 20 2 100 TPRI 83 90~93 98~99 90~95 310 80 100 2y 20 2 6070

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TPRIs Gasification Process with Syngas Cooler

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2000t/d TPRIs Gasifier for 250MW IGCC

Huaneng Tianjin 250MW IGCC Demonstration Project of CHNG With syngas cooler Capacity: 2000t/d Pressure: 3.0~3.5MPa Temperature: 1400~1500 Syngas flow rate: 165000Nm3/h O2 consumption310 Nm3O2/1000Nm3CO+H2 Cold syngas eff.83% CO+H291% Net power: 250MW Start to operate in 2009

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TPRIs Gasifier with Syngas Cooler

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TPRIs Gasification Process with Quenching

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1000t/d TPRIs Gasifier for Chemical Project

300kt/a Methanol Demonstration Project of Shilin Chemical Ltd. With quenching Capacity: 1000t/d Pressure: 4.0MPa Temperature: 1400 Syngas flow rate: 82000Nm3/h O2 consumption310 Nm3O2/1000Nm3CO+H2 Cold syngas eff.82% CO+H290% Production: 250kt/a Methanol Start to operate in 2009

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TPRIs Gasifier with Quenching

Thank you for your attention.

xushisen@tpri.com.cn www.tpri.com.cn