Update on Technology and ProjectsPresented by Dirk Volkmann

Gasification Technologies Conference, Washington D.C., Oct. 2004

• Historical background• Feedstocks and

Applications• New Projects• New Development / R&D• New Alliances

outlet

Pressur. water

Quench

inlet

Cooling screen

Burner

Pressur. water

Fuel

Granulated slag

overflowWater

Gas outlet

Cooling jacket

Gas to pilot burnerOxygen

water

Gasification Technology Experience

Dem onstration p lants Com m ercial-scale p lants

Fixed-bed gasification 1956 1977 24 gasifiers constructed in the G as Com bine „Schw arze Pum pe“

Entrained-flow gasification

1978 1979 1980 1981 1982 1983 1984 1985 1986 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999

Lignite

Saliferous lignite

42 lignite varieties 15 hard coal varieties

(international)Pulverized hard coal and lignite

Petro l coke, fly ash

15 m unicipal and industrial sew age sludges, M SW , w aste o il, w ood, straw Slurry, , fly ashInd ustrial w aste and residues

Chlorinated organic feedsNitrogen w aste organicsBlack liquor

Lignite

Saliferous lignite

Natural gasW aste o il, tar o il

S lurry Tar o il / so lids sludges

Nitrogen w aste organics13 t/h

Year DBI

DBI

Noell

Babcock

FU TURE ENER G Y

2000 2001 2002

2003 2004

Tar o il

Gasification Facilities of FUTURE ENERGY GmbH in Freiberg

Sewage sludge drier500 kg/h

Pyrolysis unit500 kg/h

Inert gas plant1000 Nm³/h

80 bar

Oxygen plantmax. 300 Nm³/h

80 bar

Pulverized fueldosing and feeding system

up to 10 t/h

Gasifier VV100Reactor with cooling wall

2-3 MWmax. 30 bar

GasifierReactor with cooling screen

3-5 MW, max. 30 barCOS hydrolysisHCN hydrolysis

SulFerox desulfurization unitWaste water treatment

Slurry feeding300 kg/h

Proprietary Gasification Technologies

R3

Cooling screen

Raw syngas

Pyrolysis gasification

Clean gas

Iron and non-ironmetals to utilization

Mill

OxygenPyrolysis gasSlurryPyrolysis coke

MSW

high-salt low-ash ash-free ash-containing

Reactor with cooling screen and quench

OxygenFuelOxygenBlack Liquor

Burner flange

Cooling screen

Smelt outlet

Quench system

Gas outlet

Green liquor

ash-containing ash-containing

Reactor with cooling screen

Entrained-flow

Recoverable fuel

Chemical wastes Conventional fuels Residual and waste materials

FE Entrained-Flow Gasification

FE Entrained-Flow Gasification

FE Entrained-Flow Gasification

Noell Conversion Process

SyngasMethanolHydrogenFertilizers

Oxoalcohols

Gas to energetic use

Power Heat

Fuel gas

Recovered resources Hydrochlorid acid

Clean salts Granulated slag

Green liquor

Black LiquorResidual oils + tail gasesSynthesis residues Chlor. org. materials Nitrogen organic waste

OilNatural gasBiogas

TarHeavy oilOil sludgeSewage sludge

Hard coalBrown coalPetroleumcoke

MSWHazardous wasteBio-mech. treat- ment fractionsWaste classif. res.

Pyrolysis plus gasificationReactor with cooling wall

Gas outlet

Cooled wall

Refractoryliner

Coat

Partial quench system

Cooling water

Gas outlet

Granulated slag

Wateroverflow

Pressur. waterinlet

Pressur. wateroutlet

Quench-water

OxygenFuel

Coolingjacket

• Historical background• Feedstocks and

Applications• New Projects• New Development / R&D• New Alliances

outlet

Pressur. water

Quench

inlet

Cooling screen

Burner

Pressur. water

Fuel

Granulated slag

overflowWater

Gas outlet

Cooling jacket

Gas to pilot burnerOxygen

water

Potential productsReduction gas(iron ore, steel)Potential feeds

Gasifier islandwith ASU andgas cleaning

(Natural gas)

Refinery gas

Residual oil

Petroleum coke

Sewage sludge

Waste oil

Biomass (wood)

Black liquor

Municipal waste

Chemical residues

Coal

Combinedcycle

Oxygen

Nitrogen

Argon

Carbon dioxide

Sulfur/sulfuric acid

Steam

Electrical energy

Chemicalproduction

Hydrogen

Carbon monoxide

Fertilizers

Chemicals

Methanol

Fischer-Tropschsynthesis

Slag tobuilding industriesor metals recovery Acetic acid

Motor fuels

Chemicals

Market Strategy

• Europe– Gasification of chemical residues– Biomass to Liquids (BTL)

• The Americas– Coal to power and chemicals– Gasification of chemical residues and waste

• Asia– Coal to power and chemicals– Biomass to Liquids (BTL)

• Australia / NZ– Coal to power and chemicals

• Historical background• Feedstocks and

Applications• New Projects• New Development / R&D• New Alliances

outlet

Pressur. water

Quench

inlet

Cooling screen

Burner

Pressur. water

Fuel

Granulated slag

overflowWater

Gas outlet

Cooling jacket

Gas to pilot burnerOxygen

water

Autothermal Oil Conversion PlantSokolovská Uhelná, a.s., Vřesová (1)

• Feed stock: 15 to/h generator tars and3 to/h secondary fuel

• Reactor conditions: 28 bar at 1.400 °C

• Reaction-Volume: 15 m3

• Gas utilization: 440 MW Combined Cycle Power Plant

• Syngas production: 50.000 Nm3/hdry = 140 MWth

• Reactor: Ø 3.4 m, h with quench 11.8 m, refractory lined

• Effluents: waste water 4-8 m3, soot 100 – 240 kg/h, vents ~ 500 Nm3 /h

Autothermal Oil Conversion PlantSokolovská Uhelná, a.s., Vřesová (2)

• Input: O2 17,500 Nm3/hdry, steam 7.2 t/h, N2 400 Nm3/hdry

• FE BE scope: product feeding / media supply systems / gas cleaning / gasifier system incl. cooling, monitoring purging / special burner design / soot water treatment plant / slag discharge

• Supplies: Gasifier/Quench, refractories, burners

• Project status: under construction(start-up 2005)

Vresóva Plant

24 fixed-bedgasifiers28 bar

24 fixed-bedgasifiers28 bar

CondensationCondensation Rectisolplant

Rectisolplant

GuDcombined-cycle

plant

GuDcombined-cycle

plant

Hard brown coal

Oxygen

Entrained-flowgasification

28 bar

Entrained-flowgasification

28 bar

TarSteam

Oxygen

Steam

Waste water

Electricity

440 MW

Raw gas

Fischer-Tropsch Demonstration PlantFUTURE ENERGY site Freiberg, Germany (1)

• Location: FE test facility in Freiberg

• Input: Tar/coke slurry 500 kg/hOxygen 450 Nm3/h

• Output: Synthesis gas (H2/CO = 2:1) 1010 Nm3/hDiesel 125 kg/h

• Reaction conditions: pressure 25 bar

temperature 1,400 °Cvolume 276 l

Fischer-Tropsch Demonstration PlantFUTURE ENERGY site Freiberg, Germany (2)

• Equipment addedto existing plant: slurry feeding & preparation, CO-shift-

conversion, WWT, gas synthesis (F-T) product upgrading, hydro-cracking, fractioning

• Project Status: selection of F-T technologystart of BE in 2004(start-up 2006)

• Historical background• Feedstocks and

Applications• New Projects• New Development / R&D• New Alliances

outlet

Pressur. water

Quench

inlet

Cooling screen

Burner

Pressur. water

Fuel

Granulated slag

overflowWater

Gas outlet

Cooling jacket

Gas to pilot burnerOxygen

water

Generation of Hydrogen from Biomass(Straw*, hay*, wood, paper/cardboard, waste plastics)

delivery, storage

Educt preparationchopping, pre-drying

Fast pyrolysis1 bar, ~500 °C, t few s

Chaff

Heat transfermedium loop

Oil/char slurry

Rail transport of slurryfrom 20 to 40 pyrolysis plants

to a large-size centralizedsyngas generation + utilization plant

Tarfree raw syngas

Gas cleaningGas conditioning

Residual gas Technical hydrogen

Electrical energy

Reg

iona

l 50

MW

(th)

fast

pyr

olys

is p

lant

s

Entrained-flow gasification~1300 °C, >60 bar, t 2-3 s-

* critical biofuels having high ash, K and Cl contents

PROPERTIES OF SLURRIESFROM BIOMASS PYROLYSIS OIL AND CHAR

porosityε 0.5 - 0.8

charparticle

• critical particle volume fraction φcritdepends on shape (aspect ratio) and size spectrum:~ 0.6 spherical, ~ 0.45 regular crystals

• viscosity η (slurry) = η (liquid) (1+ 5/2φ + 6.2 φ2);/ one order reduction from 20 to 80 °C

• density: oil ~ 1200 kg/m3, char (true) ~ 1500 kg/m3

slurry ~ 1300 kg/m3, char (bulk) ~ 200 - 400 kg/m3

30 % char/raw tar slurry

spec

. CO

2-em

issi

ons

[g C

O2/k

m]

year2000 2010 2020 2030

NG bio-mass Solar-H2

gasoline,diesel SynFuelDieselgasolinespecial CCSfueltransition toSun Fuel hydrogenfuel

Synthesis gas (H2, CO, CO2)

crude

motor withCCS-process

Mild HybridFSI,TDI

FSI,TDIopt. Otto& Diesel

H2-Fuel cell

Source: Volkswagen

New Development / R&D

• New reactor size (upscaling)• New reactor design at 85 bar (dry and slurry

feed)• New recovery boiler development• New concepts for the gasification of

MSW/RDF• New approach for black liquor gasification

Comparison of size of FE-Entrained Flow Gasifiers (25 bara)

130 MW 400 MW 800 MW50.000 m /h3

N 160.000 m /h 320.000 m /h

Ø2000

3500

525 0

Ø2900

Ø3650

6700

N3

N3

• Historical background• Feedstocks and

Applications• New Projects• New Development / R&D• New Alliances

outlet

Pressur. water

Quench

inlet

Cooling screen

Burner

Pressur. water

Fuel

Granulated slag

overflowWater

Gas outlet

Cooling jacket

Gas to pilot burnerOxygen

water

New Alliances

• Forschungszentrum Karlsruhe– Development of a reliable, large scale process chain for the

production of BTL(flash pyrolysis, gasification, F-T)

• Close cooperation (exclusively ?) with a technology based Engineering Company

Get in touch with us !

FUTURE ENERGY GmbHHalsbruecker Strasse 3409599 Freiberg – GermanyT +49-3731-785-300 info@future-energy.deF +49-3731-785-352 www.future-energy.de