Presentation of Envirotherms

BGL Gasification Process

Gasification

ENVIROTHERM

Gasification
is the conversion by partial oxidation of solid or liquid feedstock
containing carbon into valuable and easy-to-process fuel gas or
synthesis gases
consists of numerous interdependent chemical reactions
requires energy which is provided by full oxidation (combustion) of
part of the feedstock
Feedstock may consist of

coal: (sub-) bituminous coal, lignite, petcoke

residual material
waste materials
biomass

Envirotherms Gasification Technologies

ENVIROTHERM

Coal
Crude Gas
350 - 600 C
Gas Solids
Steam +
Oxygen

Tar/Oil

Slag

Pressurized
BGL Gasification

Atmospheric
CFB Gasification

BGL: History (1)

ENVIROTHERM

Lurgi patent granted in 1927 for coal pressure gasification

(dry ash process)

total of 170 units installed worldwide

present Lurgi/SASOL process:

dry ash process with certain limitations

BGL: History (2)

ENVIROTHERM

Joint development between British Gas and Lurgi

of a slagging version of the Lurgi gasifier
in order to overcome these limitations
from 1974 onwards in Westfield/Scotland

Process goals:
generate non-leachable vitreous slag rather than dry ash
improve specific reactor throughput
increase fines content acceptable in feed
reduce steam consumption
consequently reduce gas condensate production
recycle tars/oils to extinction
increase CO and H2 yields
5

BGL: History (3)

The BGL achieved these goals,

proved successfully its reliability and
demonstrated its flexibility by
testing a wide range of coals
and other solid fuels

Installation of the first commercial plant

for coal and waste for East German SVZ
in 2000

Take-over of the technology by Advantica

and Envirotherm

Further development together with SVZ

ENVIROTHERM

Modern slagging fixed bed

gasification system
6

BGL: Dry Bottom and Slagger

ENVIROTHERM
/ WASTE

Feed

Feed Lock

Gas Offtake

Wash Cooler
Crude Gas

Ash Grate
(rotating)
Ash Lock

Steam/Oxygen

Ash

Lurgi/SASOL Dry Bottom Gasifier

BGL Slagging Gasifier

7

BGL: Technical Development and Proof

ENVIROTHERM

Adoption from the proven Lurgi gasifier

lock hoppers
fuel Distributor
quench cooler

Modifications / Improvement of Lurgi design

steam and oxygen injection
refractory liner
slag removal
ability to recycle tars to extinction

Modifications have been proven at Westfield and SVZ

BGL: Proven Design and Robust Machinery
8

Comparison of Dry Bottom and Slagger (1)

ENVIROTHERM

BGL

Lurgi / SASOL

Slagger

Dry Bottom

fixed bed

fixed bed

slag

dry ash

lignite, (sub-) bituminous

coal, petcoke, waste

lignite, reactive
bituminous coal

< 25% preferred

no limitation

< 1,300
addition of flux is
possible

> 1,200

non caking to highly

caking

non caking to highly

caking

Preferred fuel reactivity

any

high

Other feedstock
limitations like S, Cl, etc.

none

none

Bed type
Ash removed as
Suitable fuel
Ash content in fuel
Preferred ash melting
temperature
Caking / swelling

Comparison of Dry Bottom and Slagger (2)

ENVIROTHERM

BGL

Lurgi / SASOL

Slagger

Dry Bottom

lump coal
6 50mm
fines above a certain
amount to be briquetted

lump coal
6 50mm
lower fines tolerance

oxygen +
steam

oxygen +
steam (up to 7x)

Oxygen consumption

low

low

Steam consumption

zero to low

high

Fuel size requirements

Gasification agents

Gasification pressure

bar

20 35

20 35

Gas temperature ex
gasifier

350 700

300 600

Carbon conversion

99.9

98 99

Oil and tar

% of
fuel

23
can be partly recycled to
gasifier

7
can be partly recycled to
gasifier
10

Comparison of Dry Bottom and Slagger (3)

Products
Cold gas efficiency
Typical gas composition
from bituminous coal,
oxygen blown

H2 %
CH4 %
CO %
CO2 %
N2 %
C2+ %

Methane

ENVIROTHERM

BGL

Lurgi / SASOL

Slagger

Dry Bottom

towngas, syngas,
fuelgas

towngas, syngas,
fuelgas

up to 5% higher

high

29.1
7.3
57.9
2.0
2.9
0.8

39.0
7.9
23.3
27.0
1.5
1.3

7 10
increases at higher
pressure

7 10
increases at higher
pressure

11

Comparison of Dry Bottom and Slagger (4)

ENVIROTHERM

BGL

Lurgi / SASOL

Slagger

Dry Bottom

Heat / HP steam
generation

no

no

Upstream gasifier

briquetting plant
required for fines;
requires steam boiler

briquetting plant
required for fines;
requires steam boiler

liquid handling required

liquid handling required

lower

higher due to high

steam usage

Application for
Power/IGCC

yes

no reference

Application for chemicals

production

yes

yes, but CO2 is high;

good H2/CO for FT

yes, best suited

yes

Downstream gasifier
Waste water discharge

Application for SNG or

fuel gas

12

Fixed Bed Slagger: BGL Benefits (1)

ENVIROTHERM

experience from a broad variety of world coals tested including lignite

simple and proven coal feed (lock) system

does not require

fine coal
low moisture content of feed

represents clean technology as

slag as by-product is non-leachable
slag can be utilized (road works)
harmful gaseous substances (heavy metals, mercury) are
washed out
organic material is reduced to low contents
13

Fixed Bed Slagger: BGL Benefits (2)

ENVIROTHERM

gasifier vessel is manufactured from cheap carbon steel plate

high temperatures are restricted to the hearth

far lower syngas exit temperatures than other technologies

simple, proven gas quench no sophisticated heat exchangers,

no exotic materials, as tar/oil in the crude gas protects equipment

high coal to gas efficiency, i.e. high specific throughput

14

Fixed Bed Slagger: BGL Benefits (3)

ENVIROTHERM

low oxygen and steam consumption

(0.30.6 kg O2/kg coal and 0.30.5 kg steam/kg coal)

excellent load following capabilities

co-gasification of waste with minor coal addition possible and

demonstrated

proven reliability in commercial operation

low CO2 content in syngas, depending on fuel quality

15

BGL: Feedstock Data (1)

ENVIROTHERM

Typical feedstock characteristics:

coal types: noncaking, weakly caking, strongly caking
ash: 0.5-21% wt.; silica ratio 45-85% wt
moisture: 3-28% wt.
sulfur: 0.5-5.6% wt.
chlorine: up to 0.6% wt.
particle size: x 2 (fines have impact on possible load)

16

BGL: Feedstock Data (2)

ENVIROTHERM

Tested fuels:
US Coals:
Pittsburgh No. 8, Ohio No. 9, Illinois No. 5, Belle Ayr
British Coals:
Frances, Rossington, Gedling Manton, Hucknall, Comrie,
Killoch, Manvers, Markham Main, Lynemouth, Rawdon
Opportunity Fuels:
petroleum coke, metallurgical coke, pelletized and briquetted
coal, pulverized coal, lignite, coal/water slurry, tar pellets, RDF,
sewage sludge pellets, wood, automotive shredder residues

17

BGL: Feedstock Data (3)

ENVIROTHERM

Acceptance of a wide variety of low quality coals and petcokes

Limitations in composition of fuels:

ash:

low to high
ash melting:
no limitation, addition of flux if needed
fines:
no limitation, briquetting if needed
reactivity:
no limitation
caking:
no limitation
volatiles, moisture, sulphur, chlorides:
no limitation
Due to the gasification principle
BGL is best suited for non-reactive fuels

18

BGL: Concepts for the Generation of

Reduction and Combustion Gas
Coal
Flux
HP Steam

HP Steam

HP Steam
H2/CO=1.4

H2/CO=1.0

45 BGL
Gasifiers

ENVIROTHERM

CO Shift
Conversion

Gas Cleaning
e.g. Rectisol

O2
N2

H2S

ASU

Slag
Handling

Gas Liquor
Treatment

O2
N2
45 BGL
Gasifiers

235,000 Nm/h
6 bar / 15 C

18 bar

Expanding
Gas Turbine

CO2 Gas

Claus Plant

Power

Sulphur
Power

H2S
Gas Cooling

Gas Cleaning
e.g. Rectisol

Expanding
Gas Turbine
21 bar

Coal
Flux
HP Steam

DRI Plant

Gas Boilers

750 Gcal/h
2 bar / 15 C

HP Steam

Engineering / Supply by Envirotherm

19

BGL: Concepts for the Generation of

Reduction and Combustion Gas

ENVIROTHERM

Reduction Gas

Combustion Gas

Subbituminous coal
8% moisture
36% ash
LHV 15,1 MJ/kg
HHV 15,9 MJ/kg

62,0

62,0

t/h

HP Steam 35bar; 370C

32,5

26,6

t/h

Oxygen purity 99,5%; 32bar

19,0

19,0

t/h

Limestone (flux)

13,6

13,6

t/h

El. Power

8,2

8,1

MWe

Slag

31,9

31,9

t/h

Gasliquor

16,7

6,6

t/h

Sulfur

0,3

0,3

t/h

CO2

36,6

--

t/h

Expansion turbine

1,6

5,2

Consumption figures:

Production figures (1):

MWe
20

BGL: Concepts for the Generation of

Reduction and Combustion Gas
Production figures (2):

ENVIROTHERM

Reduction Gas

Combustion Gas

54.225

65.934

Clean gas pressure after

expansion turbine

6,0

2,0

bar

Clean gas temperature after

expansion turbine

15

15

CO2

5,0

22,2

Vol-%

CO

33,8

34,1

Vol-%

H2

48,9

33,3

Vol-%

CH4

9,3

7,8

Vol-%

CnHm

0,2

0,3

Vol-%

H2S & COS

0,0

0,0

Vol-%

N2 & Ar

2,8

2,3

Vol-%

Total

100,0

100,0

Vol-%

LHV Gas kJ/Nm3

12.998

10.878

kJ/Nm3

H2/CO

1,4

1,0

MWth LHV

196

199

Clean gas

Nm3/h

21