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Report of Dipl.-Ing. Frank Kamka, Dipl.-Ing. Andreas Jochmann SVZ Schwarze Pumpe, Germany
Speaker: Dipl.-oec. Lutz Picard
International Freiberg Conference on IGCC & XtL Technologies June 16-18, 2005
Is one of the largest german plants for the utilization of several solid and fluid kinds of waste. Installed capacities: 400,000 tpy solids among them: 50,000 tpy fluids waste plastics among them: municipal waste sewage sludge shredder residues synthesis gas methanol gypsum power oils tars solvents
processed to:
steam
Is the technology leader of the material use of waste by gasification and methanol synthesis Is a large scale operator of three types of gasifiers : entrained flow slagging rotating grate GSP BGL FDV (Lurgi)
1955 1959
Opening of the site Commissioning of the first briquetting factory and the first power station
1964 1969
In total
four power stations three briquetting factories one cokery one town gas plant additional plants, workshops etc.
(1.500 MW) 10 Mio. t/year 1.5 Mio. t/year 5.3 bill. m3 /year
from 1990
Sewage sludge
11
Methanol
2 12
Used plastics
Contaminated wood
Electricity
Steam
13
Ash, slag
Calcium sulfate
Gas
9 14 10
Cleaned effluent
1 2 3 4 5
Sewage sludge briquetting Compaction of plastics Wood chopping Waste preparation Pelletising plant
6 7 8 9 10
Entrained flow gasification BGL gasification Pressurized bed gasification Gas purification Separation of oil/water
11 Methanol production 12 13 14
Extrusion plant for waste plastics Briquetting plant for sewage sludges Municipal waste pelletizing plant Sewage sludge and tar sludge (from tar lakes) pelletizing plant Chopping plant for wood (stand-by)
Input Material n n n
Pelletizer
Pellets
Size requirement: approx. 20 x 80 mm, fine particles < 6 mm: to be minimized Suitable for transportation and handling Thermal stability up to gasification temperatures
Waste Pelletizing
Waste
Reception/Feeding Coarse crushing FE FE < 60 mm Magnetic separator Drum cobber Trommel screen > 200 mm FE, NE
FE
NE
NE Separator
Regrinder Granulator
Flow divider
Dryer 2
Screen 1 Heavy
Screen 2 Heavy
Pellets
Arsenik Lead Cadmium Chromium Copper Nickel Mercury Zink Tin Cyanide Polychlorated biphenyls Chlorine/ Halogene Dioxins/ Furans
mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mg/kg mass% g TU/kg
2 000 10 000 1 000 20 000 100 000 5 000 200 100 000 10 000 500 500 10 50
Waste materials processed at SVZ (From June 1992 until May 2005)
Solids Used plastics Sewage sludge Contaminated wood Treated domestic waste (RDF) Pellets from tar and sewage sludge Shredder residue Others Fluids Contaminated oils, Oil-/water mixtures Mixtures from solvents 1,300,000 t 900,000 t 120,000 t 225,000 t 295,000 t 160,000 t 20,000 t 95,000 t
Gasification Plant
2C
+ O2 +C
2CO
H2O 2H2O C
+C
+ 2H2
+ CO2
Oil Tank
Oil HEL
Kondensate
Deionat
Steam Turbine 30 MW
Power
Gas Mixing
Additional Heating
Gas Turbine 45 MW
Power
Deoxo Reactor
Compressor
Methanol reactor
Protector
Remover
Methanol Loading
Purified Methanol
Ammonia Synthesis
Methanol
Acetic Acid
Synthesis Gas
Formic Acid
Synthetic Petrol
Synthetic Diesel
Application of Methanol
Antifreeze
E
Acetic acid
A E C
Vitamin products
Formaldehyde - Phenolic resins - Urea resins - Melamine resins - Wood preservatives - Disinfectants etc., etc.
Chemical synthesis - for insecticides - for explosives - for scents - for plexiglass etc., etc.
MTBE
Denaturants
Fuel cells
SVZ-Methanol Quality
The quality of the methanol produced by SVZ meets international standards (ASTM, IMPCA). Grade AA- Methanol, Highest purity > 99,9 %
Heating value
Water
Ash
Methanol output
Energy efficiency
Power surplus
MJ/kg
Mass %
Mass %
MWhr
Used plastics Contaminated wood Domestic Waste (RDF) Shredded material Sewage sludge
33,7 16,8 18 11 11
32 34 31,5 24 21
BGL-Gasifier at SVZ
Gas Composition
BGL-Gasifier
Operation with high waste addings Operation with coal (Start up)
FDV-Gasifier
Operation with high waste addings
Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-% Vol.-%
18,0 33,5 16,0 18 10 0,3 2,2 0,6 0,3 0,4 < 0,05 < 0,05 0,2 0,5
28,0 56,0 2,8 6,0 6,0 0,1 0,4 0,1 <0,05 <0,05 <0,01 <0,01 0,3 0,3
26,0 11,0 39,6 14 2 0,2 4,0 1,5 0,4 0,5 < 0,05 < 0,05 0,2 0,6
BTEX-Flavours Vol.-%
Density
kg/Nm
1,1 15,8
0,9 13,0
1,2 14,4
Operational Datas II
Typical admixing rates of several kinds of waste:
Plastics
5 ... 50 %
admixing rate (part of waste in the total input) ash-content in the total input total troughput (depending from performance and input material) crude gas quantities range of capacity
until 36 t/hr between 25,000 ... 35,000 Nm3dry/hr between 4,000 and 6,000 m3 O2/hr
Gasification in the slagging gasifier (BGL) 3 days period, max. 33 t/hr 50 wt.-% ASR/MSW-Pellets , 30 wt.- % mixed plastics, 20 wt.-% coal that means: Shredder Residue 25 wt.-% (8,25 t/hr) crude gas output: 32,000 Nm3/hr
- stable run of the plant - troughput BGL-Gasifier: 26 t/hr among them 13 t/hr WEEE/MSW - Pellets - crude gas output: about 25,000 m /hr
Solution
New design and manufacturing of larger slag water coolers Decreasing of heat losses by installation of SiC-cone at the slag outlet nozzle and optimization of coolings Installation to pick out metals from the loading belts
Edge life of the nozzles for the gasification agent Stability of the fill-in shaft
Double coating of the nozzle heads with suitable wear resistant material New design of the fill-in shaft and installation of thermostable material to improve the mechanical and thermal stability Changes in the outlet-geometry of the feed hopper and control optimization of the waste/coal input Improvement of the control and adaption to the oxygen input to the requirements of the compound operation Cooling of the upper part by specific water jets
Additions of coke-like material in the upper part of the gasifier (specially on the crude gas outlet)
Rising oil and gas prices and worlwide interest in stability and reliability of energy supply will lead to a revival of coal chemical industry.
Schwarze Pumpe has best conditions for technological leadership in this field because of the long standing experience and the large scale operation. The Sustec Group as the probable new owner of SVZ has announced financial restructuring and extensive investments on the Schwarze Pumpe site: - installation of a new coal gasification (based on GSP-process) - extension of the methanol production The aim is to demonstrate the competiteveness and the technology leadership in coal and waste gasification.
For more and detailled information about SVZ and BGL operation we recommend the Technical Tour to Schwarze Pumpe.
(Saturday, 18th of June 2005)