Further Development and Commercial Progress

of CFB Gasification and BGL Gasification Technologies

Werner-Fr. Staab, Head of Sales (Thermal Processes)

ENVIROTHERM GmbH, Essen / Germany
werner_staab@envirotherm.de

Envirotherms Gasification Technologies

ENVIROTHERM

Why Coal Gasification in India?

Demand for clean gas in various industries for

o production of ammonia, methanol and other base chemicals
o power generation
o heating purposes

Lack of sufficient natural gas resources

Abundant coal reserves

Envirotherms solution:

Two proprietary gasification technologies

o CFB Gasification: Circulating Fluidized Bed
o BGL Gasification: Slagging Fixed Bed

state of the art technologies with

distinct advantages for multiple applications
2

Envirotherms Gasification Technologies

ENVIROTHERM

BGL Gasifier

CFB Gasifier
Crude Gas

Recycling
Cyclone

CFB
Gasifier

Seal Pot
Fuel

Nozzle Grate

Ash

BGL Gasification: Main Features

ENVIROTHERM

high pressure, oxygen blown fixed bed slagging

gasifier, for application in chemical/power industry

high cold gas efficiency

high carbon conversion

low oxygen and steam consumption

low gas condensate production

non-leachable vitrified slag; for reuse

medium calorific syngas

fuel flexibility: nearly all types of (high ash) coal

and other carbonaceous fuels, e.g. waste

increased specific reactor throughput

higher fines content acceptable in feed

optional recycle of tars/oils to extinction

gasifier vessel is made from mild steel

modular design (spare/reliability)

4

ENVIROTHERM

CFB Gasification: Main Features

fuel flexibility: nearly all types of (high ash) coal

and other carbonaceous fuels, e.g. waste

gasifier vessel is made from mild steel

modular design (spare/reliability)

near atmospheric circulating fluidized bed

gasifier, well suited for fuel gas production

air blown gasifier, no ASU required

low calorific syngas

excellent heat and mass transfer due to high

turbulence of inert bed inventory

high thermal stability

high carbon conversion

HP steam production

bottom ash can be reutilized

low requirement for fuel preparation

Crude Gas

Recycling
Cyclone

CFB
Gasifier

Seal Pot
Fuel

Nozzle Grate

Ash

ENVIROTHERM

BGL Gasifier: Development

Increase in reactor diameter to 4.2m higher throughput

Increase in operation pressure (up to 40bar) higher CH4 content, less tars and oils
Stirrer implementation for caking coals, if required
Development Phase

Commercial Phase

5
Gasifier inner diameter in m

BGL 4
BGL 3
Yituo

BGL 3
SVZ

BGL 3
Hulunbeier

3
BGL 2
BGL 1

2
1
0
200

400

600

800

1000

BGL 3
Shriram

Plant

Start up

Feedstock

BGL 1

1975

Coal

BGL 2

1981

Coal

BGL 3 SVZ

2000

Coal & up to 80% Waste

BGL 3 Hulunbeier

2011

Lignite

BGL 3 Yituo

2012

Hard coal

BGL 3 Shriram

2013

High ash hard coal

BGL 4

project

Lignite

1200

1400

1600

1800

2000

Fuel throughput in t/d

6

CFB Gasifier: Development

ENVIROTHERM

Fluid bed technology was developed in the early 1920s

Circulating Fluidized Bed (CFB) process was developed applying high slip velocity,
was introduced to power plants and the process was applied to gasification of various
feedstock

Proven technology with numberless references

Envirotherms reference plants include

o first CFB gasification in the cement industry Ruedersdorf, Germany
o CFB gasification of high ash Indian coal Barbil, India

Next steps will be taken for achieving

increased unit capacities to reduce specific gas costs;
improved gas quality by application of oxygen rather than air as gasification agent.

Envirotherms Gasification Technologies

ENVIROTHERM

Current Contracts

ENVIROTHERM

Current Contracts

China

BGL Gasifier
Current Contracts Hulunbeier

ENVIROTHERM

Client

Yuntianhua United Commerce Co., Ltd. Kunming, Yunnan, PRC

Hulunbeier New Gold Chemical Co., Ltd., Hailaer, Hulunbeier, Inner
Mongolia, PRC

Location of facility

Hulunbeier, Inner Mongolia, PRC

Application

Syngas for the production of 500,000 t/y Ammonia & 800,000 t/y Urea

Feedstock

Domestic dried and briquetted lignite

Features

Two (2) + one (1) BGL gasifiers (40 bar (g) operating pressure)
Synthesis gas production 119.000 Nm/h (H2+CO)

Scope of Supply

Process Design Package for gasification and gas liquor separation

Plant erection and commissioning assistance
Process performance guarantees

Start-up (expected) Summer 2011

Project challenges Construction only during summer months possible
(winter temperatures approaching -45 C)

10

BGL Gasifier
Current Contracts Hulunbeier
Site clearance and civil work commenced: May 2008
Process Design Package delivered: 4th Quarter 2008
Detailed Design completed: 3rd Quarter 2009
Gasifier installations on site: 2009-2010
Classroom training for operational staff: August 2010

Courtesy of Hulunbeier New Gold Chemical Co. Ltd.

Progress

ENVIROTHERM

11

BGL Gasifier
Current Contracts Hulunbeier

ENVIROTHERM

Courtesy of TZ Engineering Co. Ltd.

Gasifier Reactor Transport over more than 1,000 km Distance

12

BGL Gasifier
Current Contracts Hulunbeier

ENVIROTHERM

Gasifier Building (2010)

13

BGL Gasifier
Current Contracts Hulunbeier

ENVIROTHERM

View to Gasifier Building (2010)

14

BGL Gasifier
Current Contracts Yituo
Client

ENVIROTHERM

China Yituo Group Co. Ltd., Luoyang, Henan Province, PRC

Location of Facility Luoyang, Henan Province, PRC

Application

Fuel gas for industrial complex

Feedstock

Local hard coal

Features

One (1) + one (1) BGL gasifiers

Gas production 43.000 Nm/h

Scope of Supply

PDP for gasification, gas cooling and gas liquor separation

Plant erection and commissioning assistance
Process performance guarantees

Start-up (expected) 2012

Progress

Process Design Package delivered in April 2010

Detailed Design commenced in August 2010
15

ENVIROTHERM

Current Contracts

India

16

BGL Gasifier
Current Contracts Shriram EPC
Client

ENVIROTHERM

Shriram EPC Ltd., Chennai, India

Location of Facility Dhamra, Orissa, India

Application

Syngas for the production of synthetic ammonia

Feedstock

High ash domestic hard coal (132 t/h, 3,200 t/d)

Features

Two (2) BGL gasifiers, one relocated from Germany, second gasifier
built identically to relocated one
Raw gas production 150.000 Nm/h

Scope of Supply

Relocation and reengineering for existing BGL,

Basic engineering for new BGL
Plant erection and commissioning assistance on request
Process performance guarantees
Project management for downstream ammonia plant

Start-up (expected) 4th Quarter of 2013

Progress

Basic Engineering completed 4th Quarter 2010

Existing BGL Gasifier transported to India in September 2010
Existing ammonia currently on the way to India
17

BGL Gasifier
Current Contracts Shriram EPC

ENVIROTHERM

Dismantling of the former SVZ BGL Gasification for Relocation

18

CFB Gasifier
Current Contracts Jindal Steel & Power
Client

ENVIROTHERM

Jindal Steel & Power, Ltd., Delhi, India

Location of Facility Barbil, Orissa, India

Application

Producer gas for pellet plant

Feedstock

High ash domestic hard coal (46 t/h, 1,100 t/d)

Features

Two (2) CFB gasifiers

Raw gas production 98.000 Nm/h

Scope of Supply

Basic Engineering for gasifier island

Commissioning assistance
Process performance guarantees

Start-up

2010

Progress

Gas successfully produced in 4th Quarter 2010

Optimization in 2011
19

CFB Gasifier
Current Contracts Jindal Steel & Power

ENVIROTHERM

Features and Principle Flow Sheet:

location: Barbil, Orissa / India
number of gasifiers: 2

feedstock: Indian hard coal, 27% ash, 8% moisture, 23t/h per gasifier
producer gas: 49,000 Nm/h per gasifier

Turbine / Generator

C.W.
Steam Drum
Deaerator

Bed
Material

Cyclone

Radiation
Pass

Air
Air

Seal Pot

Wet ESP

Sec. Air
Air

Clean Fuel Gas

Quench

Evaporator

CFB
Gasifier

Superheater

Solid
Fuel

Prim. Air

C.W.
Recirculation Pump
Ash

Air

C.W.

Bed Ash

Water

Tar
Dust
Water
20

BGL and CFB Gasifier: Summary

ENVIROTHERM

BGL Gasifier:

unique gasifier design offers major advantages including high fuel flexibility
and low consumption of steam and oxygen

applicable for all gasification routes

currently seven gasifiers under construction or in detailed design phase for

production of fertilizers, fuel gas and chemical base products

start up of first multiple train BGL gasifier plant in mid 2011

CFB Gasifier:

high fuel flexibility, esp. for high ash coal

smooth operation, no temperature peaks

simple and robust design, running reference plants

economic solution for low calorific fuel gas production

optimization on high ash Indian coal in 2011

21

ENVIROTHERM

58 m
(190 ft)

Thank you
for
your attention!
Envirotherm GmbH
Ruhrallee 185
D 45136 Essen
info@envirotherm.de
www.envirotherm.de
Phone +49 201 6346 400

0m
20 m
(66 ft)
22