evolution of black liquor gasifier designswhitty/blackliquor/colloquium2003/pdfs_color_sl… ·...
TRANSCRIPT
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Evolution of Black Liquor Gasifier Designs
Shamelessly based on Kevin Whitty’s“State of the Art in Black Liquor Gasification Technology”
presentation for theIEA Annex XV Meeting
20-21 August 2002Piteå, Sweden
Chris VerrillIPST
Kevin WhittyUniversity of Utah
May 14, 2003
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Outline
• Introduction• History of BLG development• Current BLG technologies• Future of BLG• Conclusions
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Introduction – Future Industry Needs
•Eliminate Smelt-water Explosions•Lower Capital Cost•Lower Energy Use•Lower Emissions•Less Downtime•Less Deadload•Less Raw Material
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Black Liquor Gasification
• Promising Advantages– More electricity per lb steam co-generated– New chemical recovery options– Higher availability
• Development & demonstration issues– Competitive system cost– Materials lifetime– Overall mill impact
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Prehistory…
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The First Black Liquor Gasifier?(From a patent application by G.A. Richter, 1927)
Gas Scrubber
Reducing smelter
Char residue removal
Use of gas?
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First Chemicals Production from BL Syngas?(From a patent by E.G Goodell, 1945)
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First Application of Split Sulfidity?(From a patent by W.L. Savell, 1951)
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"Recent" BLG Development Efforts
• Low temperature– St. Regis* – SCA-Billerud*– Weyerhaeuser – Texaco*– Owens-Illinois – VTT– ABB* – B&W*– KBR* – MTCI*– Copeland – DARS
• High temperature– NSP* – Champion/Rockwell*– U. California* – SKF– Paprican – Ahlstrom– Tampella* – Noell– B&W – Chemrec*
(Underline = built pilot or demo facility, Bold = currently active)
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Gasifier Design Categories
• High-pressure, hydro-thermal reactors• Deconstructed/reengineered Tomlinson• Molten salt reactors• Bubbling beds• Circulating fluidized beds• Entrained flow reactors
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St. Regis Hydropyrolysis Process
Blackliquor Pump HP
pump
Hydropyrolysisreactor
Flashtank
Heatexchanger Heater
Cooler
H2O
Char
Scrubber
Fluegas
Filtrate
(~1967-1980)
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Texaco Black Liquor Coking Process(~1967-1974)
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U. California PGC Process
Air
Fluegas
Smelt tank
Scrubber
Water
Char bed
Boiler
Black liquor
Primarypyrolyzer
Secondarypyrolyzer Air
(~1967-1980)
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NSP Cyclone Gasifier
Air
Blackliquor
Air
Smelt
Fluegas
(~1973-1985)
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Champion/Rockwell Pilot Gasifier(~1982-1988)
Black liquor
Productgas outlet
Fuse castalumina bricks
Castablerefractory
Upper airnozzles (x6)
Lower airnozzles (x2)
Air nozzle andliquor drain port
Air nozzle andoil gun port
Smeltwithdrawal
port
Insulation
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B&W Bubbling-Bed Gasifier(~1993-1998)
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State of the Art: Bubbling Bed Design
Manufacturing Technology and Conversion International (MTCI)
Steam Reforming Process
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State of the Art — MTCI
• Fluidized bed (bubbling)• Low temperature (~600°C)• Low pressure• Steam for reaction / fluidizing• Medium heating value fuel gas
– 73% H2
– Approx. 13.3 MJ/Nm3
• Essentially all sulfur to gas as H2S
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MTCI Steam Reformer
Product Gas + Air
Black Liquor
Product Gas
Flue Gas
Fluidizing SteamBed Solids
PulsedCombustors
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MTCI System Configuration
Green liquor
Dregs
Steam
Productgas
Black liquor
Superheater
Boiler
Stack
Fluegas
Mixtank
Filter
Venturi
HRSG
Fuelgas
Gascooler
H2Sscrubber
Steam
Steam
Bedsolids
Source: MTCI
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ABB CFB BLG PDU(~1989-1997)
Cyclones
Bag house
Gas cooler
Scrubber
Blower Airpreheater
Black liquor
Weak wash Green liquor
AirBedsolids
Mixtank
Circulatingfluidized bed
gasifier
Fuel gas
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State of the Art: Circulating Fluidized Bed
Kellogg, Brown and Root (KBR)
Transport and Spouting Bed Gasifiers
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State of the Art — KBR
• Two fluidized bed reactor concepts– Transport reactor– Spouting bed
• Enriched air-blown• Pressurized (>20 bar)• "Medium temperature" (800–1000°C)• Titanate addition
– Allow operation at higher temperature– Effect direct causticization
• Medium heating value fuel gas (7–12 MJ/Nm3)• Novel sulfur removal and recovery processes
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KBR Transport Reactor
PressurizedSyngas
Solids toChemical Recovery
Black Liquor,Enriched Air
And Steam
Riser
Disengager Cyclone
Standpipe
J-leg
Dipleg
Source: KBR
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KBR Conceptual Gasification Process
VenturiWHB
Hydrolysisreactor
Black liquor,enriched air Titanate
separator
Na2O·3TiO2 and Na2O·6TiO2
H2O
Pressurizedgasifier
DSRPBed
solids
HRSG
GT
HTDS/TC
Auxiliaryfuel gas
Polysulfidecooking liquor
Sulfur-leanwhite liquor
4Na2O·5TiO2
Air
Rawfuelgas
Sulfur-freefuel gas
SO2 in N2
Liquid sulfur
Flue gas
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KBR Development Status
• Conceptual studies completed• Initial pilot studies completed
– 0.15 tds/day transport reactor test unit– Proof of concept successful
• Next stage of pilot testing planned– 2.4 tds/day transport reactor unit at UNDEERC– Verification of scale-up issues
• Titanate studies– Integrity and reactivity of low-attrition titanate– Leaching of Na from bed solids at high pressure
• Demonstration targeted for 2005-2008
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SCA-Billerud Process
Blackliquor
Air
Oil
Char
Boiler
Scrubber
CondenserBoiler
Oil
Green liquor
Flue gas
Air
BL +carbon
(~1958-1980)
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Tampella Entrained-Flow Gasifier(~1988-1993)
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State of the Art: Entrained Flow Rector
Chemrec
Entrained Flow Gasifier
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State of the Art — Chemrec
• Entrained flow gasifier• High temperature (~975°C)• Two applications:
– “Booster” system for capacity increase– “BLGCC” system to replace recovery boiler
More details in following presentation
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Refractory design Cooling screen design
Chemrec Gasifier Designs
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The Future of BLG
• Continued interest in BLG is apparent– Pulp & paper industry– Utility suppliers– Oxygen suppliers
Multi-party funding with government partners needed to overcome risk of first units
• Demonstration that “roadblocks” have been addressed– New Bern (refractory issues)– Big Island (carbon conversion)
Success will accelerate development
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The Future of BLG
• Demonstration of BLGCC / Tomlinson replacement capability– Performance / availability / economics– “First to market”
Identification of favored technology
• Emergence of other BLG suppliers– BLG becomes more economically attractive– Improvements in BLG performance
Competitive with Tomlinson in 15 years?
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Conclusions
• Over 20 efforts to develop/commercialize BLG– 50/50 low/high temp– Mix of groups
• Currently 2 visibly active development efforts– MTCI– Chemrec
• Currently on brink of commercialization– MTCI involved in several commercial projects– Chemrec offering booster commercially– Chemrec progressing with BLGCC commercialization