Production of Fischer-Tropsch fuels based on syngas from the AER gasifier

Master Thesis

March 26, 2012

Production of Fischer-Tropsch fuels based on syngas from the AER gasifier

Master Thesis Stefan Hemetsberger Vienna University of Technology Supervision: Lasse Rngaard Clausen Department of Mechanical Engineering, DTU Lyngby Hermann Hofbauer Department of Chemical Engineering, Vienna

Fischer Tropsch Process in ASPEN PLUS

DTU Electrical Engineering, Technical University of Denmark

Fischer Tropsch Process

Advantages FT- Diesel: + no engine changes are required + no changes in distribution

DTU Electrical Engineering, Technical University of Denmark

Fischer Tropsch Process

Low temperature process (210-250 C) using Co- based catalyst creating of middle distillates (diesel, waxes) Slurry reactor

High temperature process (320-350 C) using Fe- based catalyst creation of shortchain products (gasoline, -olefins, compounds containing oxygen) Fluidized bed

DTU Electrical Engineering, Technical University of Denmark

Fischer Tropsch Process

Fischer Tropsch simulation data will be compared to experimental lab scale data from CHP Plant in Gssing

DTU Electrical Engineering, Technical University of Denmark

Gssing
City in Austria 4000 inhabitants Self- sufficient energy supply Wood input of 1760 kg/h Heat energy (4,5MW) for district heating system covers >85% of demand Electric Power 2 MW Research for FT- diesel Future goal: whole district energy self- sufficient

DTU Electrical Engineering, Technical University of Denmark

Feedstock Biomass
Because of Syngas production via Gasification in comparison to Fermentation -> Exact Composition less important Biomass = Wood:

DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Absorption Enhanced Reforming Dual fluidized bed reactor Product gas with H2 high content Flue gas with high CO2 content

Bubbling fluidized bed in gasification reactor

Circulating fluidized bed in combustion reactor

Biomass

Bed material - Catalyst

Steam

Air

DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Gasification Reactor Bubbling fluidized bed Conditions: Temperature 600-700C Pressure atmospheric

Biomass bbbbbbb bbbbbb b

Biomass

Steam

10

DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Gasification Reactor Bubbling fluidized bed Drying 100-150C Heat Pyrolytic Devolization 200-650C Gasification 700-1000C Steam

Biomass

Biomass dry

Char

Ash

Steam

Gaseous pyrolysis products

Product of char gasification

Volatile matter (H2, CO, CO2, CH4, etc.)

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DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Gasification Reactor Bubbling fluidized bed Conditions: Temperature 600-700C Pressure atmospheric Volatile CO2 from WGS reaction CO + H2O CO2 + H2 (exothermic)

Biomass bbbbbbb bbbbbb b

is absorbed by CaO (bed material) Bi Biomass Steam CaO + CO2 CaCO3

calcium carbonate is formed

12

DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Combustion Reactor Circulating fluidized bed Conditions: Temperature 800-900C Pressure 0,1 bar Regeneration of bed material CaO + CO2 CaCO3 (endothermic)

Bed material revitalized: CaO + heat Bi Biomass

Bed material loaded: CaCO3 + ungasified char

Air

13

DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Absorption Enhanced Reforming Product gas with H2 high content Flue gas with high CO2 content

Bubbling fluidized bed in gasification reactor

Circulating fluidized bed in combustion reactor

Biomass

Bed material

Steam

Air

14

DTU Electrical Engineering, Technical University of Denmark

AER- Gasification
Comparison to Fast Internally Circulating Fluidized Bed (FICFB) Process FICFB (Gssing) same process but bed material is just for heat transport no CO2 absorption

Biomass

15

DTU Electrical Engineering, Technical University of Denmark

AER- Productgas Cleaning

RME Product gas Product gas with H2 high content Fabric filter Flue gas with high CO2 content tars particles Scrubber RME Syngas

tars

water

Biomass

Steam
16

Air

DTU Electrical Engineering, Technical University of Denmark

FT- Synthesis
Process Gssing Lab Scale Gas/Liquid conversion Syngas Steam Reformer Scrubber RME Off-gas

Activated charcoal

Cooler OGC Scrubber OGS

Compressors

FT reactor

Condenser

ZnO reactor

CuO reactor
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DTU Electrical Engineering, Technical University of Denmark

FT- Synthesis
Scrubber Syngas Steam Reformer RME Scrubber RME Off-gas

H2Activated O Aromatic compounds charcoal

Cooler OGC Scrubber OGS

Compressors

FT reactor

Condenser

ZnO reactor

CuO reactor
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DTU Electrical Engineering, Technical University of Denmark

FT- Synthesis
Activated charcoal Syngas Steam Reformer Scrubber RME Off-gas

Activated charcoal converts H2S to elementary sulphur which is absorbed Sulphur deactivates Co- catalyst in FT reactor !

Activated charcoal

Cooler OGC Scrubber OGS

Compressors

FT reactor

Condenser

ZnO reactor

CuO reactor
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DTU Electrical Engineering, Technical University of Denmark

FT- Synthesis
Purification Syngas Steam Reformer Scrubber RME Off-gas

Activated charcoal

Cooler OGC Scrubber OGS

Compressors

FT reactor

Condenser

Purification to a sulphur content of <1ppm or even 60 ppb

20

ZnO reactor

CuO reactor

DTU Electrical Engineering, Technical University of Denmark

FT- Synthesis
FT reactor 3 phase Slurry reactor FT product Off-gas + 30% less investment costs comparing to fixed bed + homogeneous temperature Cooler OGC distribution Scrubber OGS Syngas olid catalyst particle: Co- ZnO S based iquid phase: waxes L reactor FT reactor Condenser

CuO reactor
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DTU Electrical Engineering, Technical University of Denmark

+ FT- reaction temperature is removed fast by waxes -> no deactivation of catalyst because of sintering + isothermal reactor -> higher temperature -> higher conversion rate

FT- Synthesis
Condenser Syngas Steam Reformer Scrubber RME Off-gas

Activated charcoal

Cooler OGC Scrubber OGS

Compressors

FT reactor

Condenser

ZnO reactor

CuO reactor
22
DTU Electrical Engineering, Technical University of Denmark

Condensing long hydrocarbons and water from product containing gas

FT- Synthesis
Scrubber - OGS Syngas Steam Reformer Scrubber RME Off-gas

Activated charcoal

Cooler OGC Scrubber OGS

Compressors

FT reactor

ZnO reactor

Condenser Removing FT waxes ->no packing blockage

CuO reactor
23
DTU Electrical Engineering, Technical University of Denmark

FT- Synthesis
Cooler - OGC Syngas Steam Reformer Scrubber RME Off-gas

Activated charcoal

Cooler OGC Scrubber OGS Condensation of short hydrocarbon chains Condenser

Compressors

FT reactor

ZnO reactor

CuO reactor
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DTU Electrical Engineering, Technical University of Denmark

Production of Fischer-Tropsch fuels based on syngas from the AER gasifier

Master Thesis Goal: Simulation of an industrial scale process for FT- diesel production based on FT- process in Gssing Current state: Modeling AER gasifier in Aspen Plus

Ma

Thank you for your attention.