5th International Freiberg Conference on IGCC
& XtL Technologies
Conference
21. May to 24. May 2012,
Leipzig - Germany
Development and Engineering of a
Synthetic Gas Cooler Concept
Integrated in a Siemens Gasifier Design
Ulrich Guenther (presenter)
Siemens Fuel Gasification Technology GmbH & Co. KG
© Siemens AG 2012.©All
Siemens
rights reserved.
AG 2011
Energy Sector
“A technical invention obtains
importance and significance, if
the technology itself is
advanced so far that the
invention has become feasible
and a general need”
Werner von Siemens 1892
© Siemens AG 2012.©All
Siemens
rights reserved.
AG 2011
Energy Sector
Agenda
Siemens Strategy and Place of Gasification
Main Project Landscape SFGT
Application Fields and Business Model
TEIMAB Project Overview
Conclusion and Future Opportunities
Page 3
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Siemens AG – Strategy
Reorganization in order to better serve our customers
The planned structure as of October 1, 2011
New
Industry
■ Industry Automation
Sector
Infrastructure & Cities
Energy
■ Fossil Power Generation
■ Drive Technologies
■ Power Distribution/
Smart Grid Applications
■ Service
■ Building Technologies
■ Renewable Energy
■ Mobility
■ Power Transmission
Healthcare
■ Imaging & Therapy
Siemens Fuel Gasification ■ Clinical Products
■ Oil & Gas
■ Diagnostics
■ Customer Solutions
■ Energy Service
Industry Solutions
■ Osram
Power Distribution
Osram
Building Technologies
Mobility
Page 4
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Siemens Energy Sector –
Newly focused on the markets of tomorrow
Energy products and solutions – in 6 Divisions
Oil & Gas
Fossil Power
Generation
Wind
Power
Solar &
Hydro
Energy
Service
Power
Transmission
Siemens
Fuel
Gasification
Page 5
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
SIEMENS SFGT Main Project Landscape
Capital Power
Schwarze Pumpe
Power
Syngas for Chemical Industry
CPI Yinan
Shenhua Ningxia
Coal Group
(NCPP)
SNG
1984 - 2007
Polypropylene
COD 2011
Ukraine Client
Secure Energy
Transportation Fuel
Syngas for
Chemical Industry
GSP China
Beijing
Tenaska Inc.
SNG/Power
Shanghai
Orlando
Vresova
Summit Power
Power + Ammonia
HQ Freiberg
Test Facility
JinCheng
Ammonia
Power
COD 2008
Syngas Ltd.
Transportation Fuel
Siemens Offices
Operating Units
Current Projects
Technology Selected
AEC
Ammonia
Japanese Client
Chemicals
9 SFG-500 gasifiers shipped / installed for 3 projects
8 SFG-500 gasifier under manufacturing and additional 22 SFG-500 (CtL) under contract
Page 6
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
China NCPP Project
Site Impression
Gasifier building
Slag formation on cooling
screen
Entire gasification unit with
gasifier building CO shift and
black water treatment plant
Page 7
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Siemens Fuel Gasification Technology:
Application Fields - Cooling screen reactor
SFG Gasifier
Fuel
O x y g e n , s te a m
B u rn e r
Highlights
Multi-fuel gasifier (standard 500 MWth)
accepts a wide variety of fuels with ash content of > 3%
compact size compared to other gasifiers
Ability to supply syngas at higher pressures
No ash to handle (only solid slag as saleable by-product)
P re s s u r. w a te r
o u tle t
C o o lin g s c re e n
Dry feeding (entrained flow)
P re s s u r. w a te r
in le t
Cooling screen
Q uench
w a te r
C o o lin g ja c k e t
G a s o u tle t
W a te r
o v e rflo w
G ra n u la te d s la g
Page 8
high efficiency
high carbon conversion rate (> 98%)
21. May 2012, Freiberg
short start-up / shut-down
low maintenance (lifetime > 10 years)
high availability
Full quench
simple and reliable
ideal for CO sour shift
High syngas quality (free of tar)
Minimal efforts in gas cleaning
© Siemens AG 2011
Energy Sector
New Application Fields and Business Model with HRSG
Fuel
Gas Island
Applications
Feed Water
Coal
Air Separation
Unit
Fuel
preparation
Steam
Steam Drum and
Steam Circuit incl.
Pumps
Lignite
Combined Cycle
Gas turbine
Steam turbine
Generator
FT Synthesis
Power Island
Power
Transportation
fuels
Gasifier
Petcoke
Syngas
(CO + H2)
CO Shift
(optional)
Ammonia
Production
Ammonia /
Fertilizer
SNG Production
Sulfur
Removal
CO2 Removal
(optional)
Siemens Basic Engineering & Design
Third Party Scope for FEED and EPC
Page 9
Methanol
Gasifier Island
Refinery
residues
Biomass
Methanol
Synthesis
21. May 2012, Freiberg
SNG
Hydrogen
Chemicals and Synfuel Production
Siemens Supply of Key Equipment
Siemens EPC
HRSG - Heat Recovery Steam Generator
© Siemens AG 2011
Energy Sector
Project Organization Chart
Germany Government ( BMWI / PTJ )
funded R&D Project COORETEC
Page 10
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
TEIMAB Project Time Schedule
Page 11
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Step 1: Variation of Main Tech. Sys. Gasification Island
Comparison of Process
Modells:
Variant A:
2
1
3
0001
WBL UT
290-????
A
4
5
6
7
8
9
10
11
12
13
14
15
16
2310-001
A
0002
WBM UT
290-????
FC
0003
SI UT
290-????
B
13-26
0004
FG UT
290-????
C
0013
SL Heater
280-????
0014
SL Header
280-????
Cooling Water
2039
FC
13-02
0005
NH UT
280-????
BCC Cooler
E-23101
BURNER
B-23101
C
Cooling Water
2039
13-25
13-04
0006
GX UT
280-????
PC
FC
13-03
0007
CD Feeding
221-????
D
B
BCC Drum
D-23101
CSC Drum
D-23102
13-18
BCC Fine Filter
F-23101
13-05
BCC Pump
P-23101 A/B
D
LC
13-19
Emergency Quench Water Vessel
D-23105
CSC Steam Drum
E-23102
13-10
CSC Pump
P-23102 A,B/C
0015
SH ????
?????
E
E
0016
WBH ????
?????
2310-030
0017
GR Gas Scrubber
251-0001
2310-032
0018
BW Flash1
261-0001
2310-033
0019
WS Slag Discharge
241-???
Gasifier
R-23101
CJ Drum
D-23104
F
LC
0008
WCR
290-????
F
2310-001
CJ Cooler
E-23104
0009
WC UT
290-???
G
E
G
CJ Pump
P-23104 A,B
H
H
0010
WQ Venturi
251-0001
2310-013
0011
CG K/O Drum
251-0001
2310-014
Quench Water Ves sel
D-23103
I
0012
WK ????
290-????
LC
2310-015
CONFIDENTIAL
Battery Limit Gasifier Island
2
J
I
Notes:
- not all minor equipment is shown on the PFDs
D
1
1 OSBL
2 ISBL (SIEMENS)
PRELIMINARY
J
2310-016
SIEMENS
Fuel Gasification
Technology GmbH
Customer
SIEMENS AG
Quench Water Pump
P-23103 A/B/C
Project
Projec t Number
F&E TEIMAB
2310-017
K
K
Description
Quench Water Filter
F-23103 A/B
L
Drawing Number
Gasifier Line 1
PROCESS FLOW DIAGRAM
Variante A
PFD - 231 - 0001
Drawn
Date:
2009-02-11
Name:
T. Fleisc her
Prepared
Date:
2009-02-11
Name:
T. Fleischer
Rev.
Index
Checked
Date:
2009-02-11
Name:
R. Schumann
Approved
Date:
2009-02-11
Name:
C. Reuther
Scale
P01
-
Drawing
dimension
-
L
UNID
P01
Index
1
2
3
4
5
Preliminary
T. Fleischer
R. Schumann
Revisions
Drawn
Checked
C. Reuther
2009-02-11
Approved
Date
Distribution and reproduction of this document, use and disclosure of the contents are prohibited, unless specifically authorized. Contraventions will be indemnified. All
patent rights on registered des igns are reserv ed.
6
7
8
9
10
11
12
13
14
15
16
6
7
8
9
10
11
12
13
14
15
16
Variant B:
1
2
3
4
5
A
A
B
B
2610-013
2610-012
Cooling Water
????
2610-015
Cooling Water
????
2610-011
Vent Gas to
BWT Plant
270-0003
C
C
2610-014
2610-007
2610-010
Flash Cooler Drum
D-2610202
D
D
Vacuum Pump
C-2610303A/B
2610-006
PC
2610-009
Flash Cooler 1
E-2610201
Separator Drum
Vacuum Pump
D-2610304A/B
Flash Cooler 2
E-2610301
E
Wash Water from
Gas Cleaning
251-0001
E
2610-002
Black Water from
Gasifier
231-0001
Flash 1
D-2610101
2610-001
PU Flash Valves
PU-2610001
F
E
Cooler Vacuum Pump
E-2610305A/B
2610-005
Cooling Water
????
2610-008
LC
2610-003
G
F
Cooling Water
????
Flash Condensate to
BWT Plant
270-0003
2610-016
2610-017
Flash 2
D-2610102
PU Flash Valves
PU-2610001
G
LC
Flash Bypass Cooler
E-2610401A/BFlash Bypass Cooler
E-2610401A/B
H
2610-004
Black Water to
Black Water Treatment
270-0003
2600-009
Vent Gas to
Black Water Treatment
270-0003
2600-008
Black Water to
Black Water Treatment
270-0003
2600-007
H
Flash Pump
P-2610103A/B
Cooling Water
2039
2600-010
Cooling Water
2039
2600-015
E
PU Flash Valves
PU-2610001
I
I
Notes:
- not all minor equipment is shown on the PFDs
Flash Bypass Drum
D-2610402
CONFIDENTIAL
Battery Limit Gasifier Island
2
1
1 OSBL
2 ISBL (SIEMENS)
PRELIMINARY
J
J
SIEMENS
Fuel Gasification
Technology GmbH
Customer
SIEMENS AG
Project
Project Number
F&E TEIMAB
K
K
Description
Drawn
Checked
L
UNID
P01
Index
1
Page 12
21. May 2012, Freiberg
2
3
4
5
6
7
8
Preliminary
T.Fleischer
R.Schumann
Revisions
Drawn
Checked
9
10
C.Reuther
2009-02-11
Approved
Date
11
Flash System Line 1
PROCESS FLOW DIAGRAM
Drawing Number
Variante B
PFD - 261 - 0001
Date:
2009-02-11
Name:
T. Fleischer
Prepared
Date:
2009-02-11
Name:
T. Fleischer
Rev.
Index
Date:
2009-02-11
Name:
R. Schumann
Approved
Date:
2009-02-11
Name:
C. Reuther
Scale
P01
-
Drawing
dimension
-
L
425 861 477
Distribution and reproduction of this document , use and disclosure of the contents are prohibited , unless specifically authorized . Contraventions will be indemnified. All
patent rights on registered designs are reserved .
12
13
14
15
16
© Siemens AG 2011
Energy Sector
Step 2 Thermodynamic Investigation
Results:
• generation of HP steam it’s
a large efficiency advantage
in relation to IP steam
generation
• efficiency improvement
between 1.4 and max. 1.9 %
points for the variants
• comparing the two cooler
types, the radiant cooler
shows a slight efficiency
advantage
IGCC Performance Data for Heat Recovery Systems (Variants Example)
Therefore, the thermodynamic results did not lead to a clear decision
criterion for concept selection.
Page 13
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
HRSG
Step 3 Comparison of Design Concepts
3D Detail studies
Investigation:
• Process integration
• Additional CAPEX
and OPEX
Page 14
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Step 4 Technical Assessment and Decision
Development criterias technical evaluation:
• New Equipment necessary ?
• Availibility of new equipment ?
• Range of load control ?
• Risk of fouling and scaling ?
• Cleaning possibilities of new equipment ?
SFGT Gasifier extended by a Radiant Cooler promises
• lowest complexity
• use proven design with full quench and wet gas cleaning
• offers a high efficiency for future IGCC plants ( > 1.5 % )
Page 15
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
SFGT Gasifier with Heat Recovery
Fuel, oxygen, steam
Design features
Radiant Cooler followed by full quench of raw gas
Cooling screen
Efficient use of the high temperature heat in the
steam generator for HP steam generation
High raw gas water content benefits CO-shift
Proven reactor and quench design extended by
Radiant Cooler
Heating surface
Pressure vessel
Efficiency improvement potential:
IGCC w/o CO2 capture
Plant net efficiency
Quench water
Raw Gas
outlet
(depends upon coal type, water/steam condition, gas turbine)
IGCC with CO2 capture
Plant net efficiency
Granulated slag
Page 16
ca. + > 3,5 %
ca. + > 1.5 %
(depends upon process conditions of CO-shift, coal type,
water/steam condition)
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
University Partner Scope LUAT CFD Modelling
Verification and Validation of Submodels
• Ensure the process parameter
•Selection of suitable material for the walls depending
• Sensitive
study
onsuitable
water nozzle
angles
•Selection
material
for the walls depending
on
heat
loadof
on heat load
•Find an appropriate cleaning system for the walls
•Find an appropriate
cleaning system for the walls
depending
on particle load
depending on particle load
1.00
100 %
105 %
70 %
inner
walls
[-] < 0.01
related heat
flux
0.40
outer wall
[-] <
0.01
related heat
flux
Page 17
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Conclusion And Siemens SFGT Future Opportunities
→ Risk
and cost reduction of mega coal to chemical plants
→ Where: support of China pioneers mega CTL and CTO technologies
→ Have a possibility to integrate a HRSG in Siemens SFGT Gasifier if
profitable
→ Maximum product flexibility: chemicals/liquid fuels ↔ electricity
→ Long terme issues: attractive for peak load and energy storage
→ Energy storage by importing renewable power to balance auxiliary
power consumption
Current and future application for coal gasification with
polygeneration concepts worldwide with the option to implement
a radiant cooler
Page 18
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Thank you for your attention!
“A Winner Is A Dreamer Who
Never Gives Up “
Nelson Mandela
NCPP | Large Coal to Chemical Plant in China
Page 19
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
Disclaimer
This document contains forward-looking statements and information – that is, statements related to future, not past,
events. These statements may be identified either orally or in writing by words as “expects”, “anticipates”, “intends”,
“plans”, “believes”, “seeks”, “estimates”, “will” or words of similar meaning. Such statements are based on our current
expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of
factors, many of which are beyond Siemens’ control, affect its operations, performance, business strategy and results
and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from
any future results, performance or achievements that may be expressed or implied by such forward-looking
statements. For us, particular uncertainties arise, among others, from changes in general economic and business
conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies
by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide,
changes in business strategy and various other factors. More detailed information about certain of these factors is
contained in Siemens’ filings with the SEC, which are available on the Siemens website, www.siemens.com and on
the SEC’s website, www.sec.gov. Should one or more of these risks or uncertainties materialize, or should underlying
assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking
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assume any obligation to update or revise these forward-looking statements in light of developments which differ from
those anticipated.
Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners.
Page 20
21. May 2012, Freiberg
© Siemens AG 2011
Energy Sector
