kinetic entrained-flow gasifier modelling in aspen plus ... plus – a simulation ... heterogeneous...
TRANSCRIPT
Die Ressourcenuniversität. Seit 1765.
TU Bergakademie Freiberg I Department of Energy Process Engineering and Chemical EngineeringReiche Zeche I 09596 Freiberg I Germany I Phone +49(0)3731/39-4511 I Fax +49(0)3731/39-4555
Email [email protected] I Web www.iec.tu-freiberg.de
Department of Energy Process Engineeringand Chemical Engineering
Kinetic Entrained-flow Gasifier Modelling in Aspen Plus – A Simulation Study on Fuel Blends
Lars-Erik Gärtner*, Martin Gräbner, Danny Messig, Wolfgang Heschel, Bernd Meyer
*Email: [email protected], Phone: +49 3731 39 4774
2
Content
1 Project and task description
2 Gasifier model development
3 Gasifier model verification
4 Results and discussion
5 Next steps
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0.0 0.2 0.4 0.6 0.8 1.0
0.0
0.2
0.4
0.6
0.8
1.0 0.0
0.2
0.4
0.6
0.8
1.0Carbon Conversion in %
CRC252
CRC2
99 (C
har)
CRC274 (Char)
30 32 34 36 38 40 42 44 4646< 46
Maximum Gasifier Temperature
Maximum Carbon Conversion (45.4%)
Carbon Conversion Contour Lines
No ignition zone
▲
1 4
4 3
,1 1
R Rsm s
m
m R Mx
1
3
1 ibi - Project description
Concept of a staged process chain for integral non-energetic utilization of lignite with high wax content (Central Germany)
Gasifier must be able to process fuel blendswith varying composition depending on plant operation
▲1
4
1 ibi – Description of modeling task
Influence of fuel blend composition on carbon conversion, cold gas efficiency and temperature profile inside the gasifier
Entrained-flow gasifier
Dried ligniteVM (waf) = 64%FC (waf) = 36%
Extraction residueVM (waf) = 58%FC (waf) = 42%
Char (cat.-crack.)VM (waf) = <15%FC (waf) = >85%
Ternary fuel blend
Syngas
Mathematical gasifier model with ability to process ternary fuel blends
Detailed flow sheet model of entire process chain
Blend composition varies during plant
operation
▲1
5
1 Gasifier Design Approach – Two Stages▲
1
6
2 Gasifier model development▲
Modeling environment of choice: Aspen Plus
• Integratability of detailed gasifier model in complex flow sheet
model of the ibi process chain (plant optimization)
• Availability of physical and thermodynamic properties database
Reactor model properties
• Part 1: drying and devolatilization (product yield)
• Part 2: kinetic 1D plug flow gasification reactor (rate and product
yield)
• Processing of ternary fuel blends
• Isothermal or adiabatic process mode
• Radial temperature und gas composition gradients are neglected
• Particle inherits temperature of gas phase
• Robust convergence behavior
2
7
2 Gasifier model development▲
Considered heterogeneous gasification reactions
Considered homogeneous gas phase reactions
12 2
1 1 22 1 1RC O CO CO
22 2 RC CO CO
32 2 RC H O CO H
42 42 RC H CH
52 2
12
RCO O CO
62 2 2
12
RH O H O
74 2 2 22 2RCH O CO H O
82 2 2 RCO H O H CO
92 2 2 RH CO CO H O
2
8
2 Gasifier model development▲
5 91 4
4 3 9
,1 1 5
( ) ( ) R RR Rii i m i i i m i
m m
m R M R Mx
1 9
9 3
, ,1 1
R Rm m
m
H R hx
Conservation of mass
Conservation of energy
1 4
4 3
,1 1
R Rsm s
m
m R Mx
Capital lettersm Mass flow ( kg / s )x Length ( m )R Reaction rate ( kmol / m / s )M Molar weight ( kg / kmol )
Stoichiometric coefficientH Enthalpy flow ( kJ / s )h Heat of reaction ( kJ / kmol )
Subscriptss Solidm Reaction index
Fuel indexi Gas species indexSuperscripts
Reactant gasProduct gas
´
´´
2
9
2 Gasifier model development▲
Calculation of reaction rates
Heterogeneous Homogeneous
1 4 1 4, , , , , ,
mnR R R Rm m p t S m mR a p k ,5 9 5 9
1
m iN
nR R R Rm m i
i
R k c
1 4 1 4 ,, , exp
mR R R Rm m
p
Ek A
T5 9 5 9 exp
R R R R mm m
p
Ek AT
,int, ,int, ,0 0( ) (1 ) 1 ln(1 )p C p C Ca X a X X
, , ,int, , , p t p p exa a a
,, , ,
3 1 1tanh
m
m m m
,1 4 1, , , , ,int, ,,
,, , ,
13 2
mnR Rm m p m p g S mp
ms i eff p
n k a T prM D
[2]
[1]
[1]
[1]
[1] Laurendeau, N.M.; Heterogeneous Kinetics of Coal Char Gasification and Combustion; Progress in Energy and Combustion Science 1978(4):221-270. [2] Bhatia, S.K., Perlmutter, D.D.; A Random Pore Model for Fluid-Solid Reactions: I. Isothermal, Kinetic Control; AIChE Journal 1980;26(3):379-386.
2, , ,4 p ex pa r
( ²)( )
( / ² / / ) (1 / )
( / ² / / ) ( / ³ / )( / )
n
n
Effectivness Factora Surface area mp Partial pressure atmk Reaction rate constant
kg m s atm or sA Frequency factor
kg m s atm or kmol m sE Activation energy kJ kmoln Order of reaction
Particle roughnes
( )
( ² / )
C
eff
s factorX Carbon conversion
Particle structural parameter RPMThiele modulusStoichiometry coefficient
D Effective diffusivity m s
2
10
2 Gasifier model development▲
Schematic structure of gasifier model in Aspen Plus
2
11
CR C299
CR C252
CR C274
Set v a lue of s ubs tr eam NC in s trea m CO AL 1, C OAL2 o r C OAL3 to 1E- 08( not z er o ) if s pec ific c oal is n ot pr es e nt in s o lid fu el mix tur e!
2 Gasifier model development
Aspen Plus Flowsheet Model
▲2
12
3 Gasifier model verification▲
Verification data from single coal gasification experiments (1)
• Case setup data taken from PEFR experiments of CSIRO [3]
• Devolatilization product distribution data derived from wire mesh
reactor experiments [4]
• 3 Australian coals where investigated (CRC252, CRC274, CRC299)
[3] Hla, S., Harris, D.J., Roberts, D.G.; Gasification Conversion Model – PEFR: Research Report 80, Pullenvale, Australia; 2007.[4] Mill, C.; Pyrolysis of Fine Particles at High Heating Rate and Pressure, PhD-Thesis, Sydney; 2000.
Fig. 1: Model carbon conversion profiles and exp. data points
3
13
3 Gasifier model verification▲
Verification data from single coal gasification experiments (2)
Fig. 4: Model CO2 mole fraction profiles and exp. data points Fig. 5:Sensitivity analysis oxygen to carbon molar ratio
model and experiment (CRC274)
Fig. 2: Model CO mole fraction profiles and exp. data points Fig. 3: Model H2 mole fraction profiles and exp. data points
3
14
4 Results and discussion▲
Fuel system
Unit Fuel 1 Fuel 2 Fuel 3
Fuel typeCRC252
(as received)
CRC274
(char)
CRC299
(char)
HHV (Dulong) MJ/kg (wf) 28.62 29.22 20.82
Proximate analysis
Fixed carbon wt.% 39.1 86.2 61.4
Volatile matter wt.% 38.8 0.0 0.0
Ash wt.% 11.3 13.8 38.6
Moisture wt.% 10.7 0.0 0.0
Ultimate analysis
C wt.% (waf) 78.1 100.0 100.0
H wt.% (waf) 5.9 0.0 0.0
O wt.% (waf) 14.4 0.0 0.0
N wt.% (waf) 1.1 0.0 0.0
S wt.% (waf) 0.5 0.0 0.0
4
Tab. 1: Fuel system designed for binary and ternary fuel blend gasification simulations
15
4 Results and discussion▲
Simulation results - binary fuel blend gasification
• Adiabatic reactor (PEFR geometry)
•
4
Fig. 6: Binary fuel blend gasification results - system CRC274-CRC252 Fig. 7: Binary fuel blend gasification results – system CRC299-CRC252
• Char LHV controls maximum gasifier temperature, thus carbon and char conversion
• Ignition of char blend CRC299-CRC252 takes place with lower CRC274 blend content then blend CRC274-CRC299
, ,. ; . ; . . / ;N O in N inm LHV const kW m const kg h T T C 2 2 285 0 3 36 2 200
0
200
400
600
800
1000
1200
1400
0
10
20
30
40
50
0 0,2 0,4 0,6 0,8 1M
axim
um G
asifi
er T
empe
ratu
re in
°C
Con
vers
ion
in %
M ass Fraction CRC252
Carbon ConversionChar ConversionTmax Gasifier
0
200
400
600
800
1000
1200
1400
0
10
20
30
40
50
0 0,2 0,4 0,6 0,8 1M ass Fraction CRC252
Max
imum
Gas
ifier
Tem
pera
ture
in °
C
Con
vers
ion
in %
Carbon ConversionChar ConversionTmax Gasifier
16
4 Results and discussion▲
Simulation results - ternary fuel blend gasification
4
# of single simulations: 1000Calculation time: 12h 54min
Fig. 8: Ternary fuel blend gasification results - system CRC274-CRC252-CRC299
17
4 First results and discussion▲
The kinetic fuel blend synergy effect in gasification
4
Fuel 1High VM content
Fuel 2Low to no VM contentHigh LHV
Fuel blend gasification
Fuel 2 benefits from Fuel 1 volatile combustion(Fuel2 activation energy barrier is exceeded → ignition)
Fuel1 and Fuel2 char conversion is accelerated by increased max. gasification reactor temperature
from high LHV of Fuel2
Higher total carbon conversion
18
5 Next steps▲
Fuel blend validation experiments in new GMEQ reactor
• Fuel system: (1) Central German lignite, (2) extraction residue and
(3) char from catalytic cracking process
• Data analysis to obtain Langmuir-Hinshelwood (LHW) type kinetic
parameters
5
Model enhancement towards LHW kinetic expression
• Modification of existing gasifier model
• Implementation of measured LHW constants in gasifier model
Development of plant flow sheet model
• Integration of gasifier model in plant flow sheet
• Sensitivity study of plant process parameters
Fuel blend gasification with 2D CFD simulations
• Verification of the fuel blend synergy effect in gasification
19
Acknowledgments
We like to thank the German Federal Ministry of Education and
Research for the financial support of the present work within
the framework of the research initiative ibi – Innovative
Process Technology (R&D code 03WKBZ06C). Special thanks is
regarded to A. Laugwitz for constructive discussions during
the model development and verification phase.
▲5