Production of hydrogen for the hydrogenation of heavy oil and coal

European Commission Directorate-General For The Information Society And Media Directorate-General For Energy

Description

Energy research
Coal - hydrocarbons

Informations

• Publié par: EUROPEAN-COMMISSION-DIRECTORATE-GENERAL-FOR-THE-INFORMATION-SOCIETY-AND-MEDIA-DI
• Nombre de lectures: 16
• Langue: English
• Poids de l'ouvrage: 1 Mo

Extrait

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Commission of the European Communities
energy
Production of hydrogen for the
hydrogenation of heavy oil and coal
Demonstration project Commission of the European Communities
Production of hydrogen for the
hydrogenation of heavy oil and coal
Demonstration project
VEBAOLAG
Alexander-von-Humboldt Straße
D-4650 Gelsenkirchen
Contract No LG 01/10/80
Technical report
:"i,tk r h ,
Directorate-General
Energy
EUR 12412 EN 1989 Published by the
COMMISSION OF THE EUROPEAN COMMUNITIES
Directorate-General
Telecommunications, Information Industries and Innovation
L-2920 Luxembourg
LEGAL NOTICE
Neither the Commission of the European Communities nor any person acting on
behalf of then is responsible for the use which might be made of the
following information
Cataloguing data can be found at the end of this publication
Luxembourg: Office for Official Publications of the European Communities, 1989
ISBN 92-826-0921 -9 Catalogue number: CD-NA-12412-EN-C
© ECSC-EEC-EAEC, Brussels • Luxembourg, 1989
Printed in Belgium CONTENTS
Page
1. ABSTRACT 1
2. PROJECT DESCRIPTION
2.1. Objective of the project
2.2. Scope of work
2.3. Framework conditions
PILOT PLANT TESTS
3.1. Description of the pilot plant 9
3.2. Operating parameters of the extruder feeding-system 14
3.2.1 Conveyance behaviour of the extruder 14
3.2.2 Binding agent content 15
3.2.3 Throughput, specific energy and attrition 16
3.2.4 Atomizer head of the extruder 17
3.2.5 Gasification burner 17
3.3. Gasification tests 18
3.3.1. Gas composition and carbon conversion 18
3.3.2. Gasification waste water 20
CONCEPT STUDIES FOR THE DEMONSTRATION PLANT 24
4.1. Integrated gasification train 24
4.1.1. Grinding 24
25 4.1.2. Reactor, waste heat boiler, ash lock
4.1.2.1. Reactor with integrated radiant cooler 25
28 4.1.2.2. Reactor with partial quench
4.1.3. Solids separation from waste water 29
4.1.4. I-LS scrubber 30
4.2. Separate gasification train 36
4.2.1. Grinding 36
4.2.2. Reactor, ash lock 36
4.2.3. Solids separation from waste water 37
4.2.4. HLS/C0? scrubber 37
4.3. Results of concept studies 39
ill — 5. APPLICATION FOR APPROVAL OF THE DEMONSTRATION PLANT 41
6. ENGINEERING FOR THE DEMONSTRATION PLANT 44
6.1. Main design data 45
6.2. Detailedengineering formainequipment46
6.2.1.Extruderfeeding-system47
6.2.2.Gasification burner48
6.2.3.n reactor49
6.3. Process description53
6.4. Consumption and production data 59
6.5. Investment 60
6.6. Economic viability61
PROSPECTS63
■IV — 1. Abstract
The objectives of the overall project were the planning, construction
and industrial testing of a commercial-size plant for the entrained-
flow gasification of solid fuels under high pressure.
This project served to examine the technical feasibility, the possibi­
lities for official approval and the economic viability of the demon­
stration plant before the final decision on its construction was taken.
The main equipment of the gasification plant is an extruder feeding-
system developed by VEBA OEL AG and Werner & Pfleiderer which enables
solid fuels, e.g. hard coal or pyrolysis coke from hydrogenation resi­
dues, to be fed to the pressurized gasification reactors.
A preplanning phase served to investigate different concepts with re­
spect to process flow, the technical design of the main parts and the
integration of the demonstration plant into the RUHR OEL refinery in
Gelsenkirchen-Scholven.
Parallel to the planning of the demonstration plant, gasification
tests were made in an existing pilot plant. The aims of these tests
were to improve and test the extruder feeding-system and the gasifica­
tion burner, as well as to determine the design data for the demon­
stration plant.
For two process variants the basic engineering was carried out for the
main process steps; a pre-basic was worked out for the conventional
units of the plant, i.e. grinding, crude gas shift conversion and
HpS/CCL scrubbing. Detailed documents including construction drawings were produced for
the main parts e.g. the extruder feeding-system, the burner and the
gasification reactor.
In order to determine whether the gasification plant would qualify for
approval by the authorities a preliminary application in accordance
with § 9 of the Federal Environmental Protection (Immission) Act was
prepared and submitted. After a thorough examination of the applica­
tion and a discussion on the objections the preliminary approval was
granted.
To conclude the investigations, the investment cost were determined
and the economic viability was examined for both process alternatives.
The economic viability study showed that due to the change in the
energy price situation since the end of 1985 a cost-covering operation
of the gasification plant will not be possible, even when using the
cheapest types of fuel, i.e. petrol-coke and vacuum residues. A deci­
sion on the construction of the gasification plant had, therefore, to
be postponed.
2 -Project description
For the hydrogenation of coal or heavy oil, a major conside­
ration is the economical and environment-friendly utilization
of then residues containing heavy metals which
become available as unavoidable byproducts. This was demon­
strated by intensive work carried out i.a. by VEBA OEL to de­
termine the best overall concept for coal and heavy oil hy­
drogenation plants. As against possible combustion, the gasi­
fication of the hydrogenation residues provides the advantage
that, in addition to environmentally safe disposal of the re­
sidues, it is also possible to produce the hydrogen required
for the hydrogenation units.
The solids-containing, high-melting residues from coal and
heavy oil hydrogenation plants become available in the liquid
state at temperatures of approx. 300° C. For energetic rea­
sons, the direct feeding of the hot hydrogenation residues to
the gasification seems to be the most appropriate solution.
The hydrogenation residues are, however, not stable in sto­
rage and their intermediate storage is, moreover, only pos­
sible in very limited quantities in stirred and heated tanks.
Because of the interconnection of the gasification and the
hydrogenation the availability (and consequently also the
economy) of hydrogenation plants is, therefore, largely de­
pendent on the availability of the residue gasification. In
order to avoid this it is necessary to provide for the dis­
connection of the two processes. This disconnection requires
the solidification of the liquid residues and the interme­
diate storage of the solidifieds as well as a standby
reserve in the H„ supply of the hydrogenation unit. Solidi­
fication can be effected by pyrolysis of the hydrogenation
residues in indirectly heated rotary drums. This process was
already used on an industrial scale during World War II for
the processing of coal hydrogenation residues. Because of the
production of pyrolysis oil, the residue pyrolysis enables an
increase of the total oil yield of hydrogenation plants. The coke from the pyrolysis can be stored intermediary with­
out any problems and can be used for hydrogen generation.
The dosage of the solid fuels to the pressurized gasification
reactor would be carried out with an extruder feeding-system
developed on pilot plant scale by VEBA OEL AG and Maschinen-
fabrik Werner & Pfleiderer. This feeding system consists es­
sentially of a twin-screw extruder.
The finely ground fuel and a small portion of a liquid bin­
ding-agent are metered pressure-free into the extruder. Hy­
drocarbons (heavy oils, used oils) as well as water can be
used as binding agents. In the extruder, the solid fuel and
the binding agent are first mixed, whereupon the mixture is
compressed to a pressure above the reactor pressure. The op­
timum liquid content for the operation of the extruder de­
pends greatly on the type and granulation of the solid fuel.
The compacted fuel leaves the extruder via a nozzle atomized
by means of a gas and conveyed to the burner in the top of
the gasification reactor.
This feeding system was developed as an alternative to the
pneumatic and water/slurry feeding of solids and offers the
following advantages:
as against slurry feeding: reduction of the liquid
(water) content by approx. 50 %, which results in a
higher specific gas yield and a lower consumption of
oxygen
as against pneumatic feeding: forgoing of a lockhopper
system used to pressurize the solid fuels up to the ga­
sification pressure; this leads to lower costs for in­
vestment and energy.
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