Siemens Fuel Gasifier System

1. Siemens Fuel Gasification
Technology
Fuel gasification technology for Integrated Gasification Combined Cycle
and industrial applications
Answers for energy.

2. High oil and gas prices have lead to a resurgence projects are attractive solutions as they can offer
of coal as an affordable energy source. Especially environmentally friendly plants with lower emissions
coal-rich regions have increasingly been tapping and the combination with readily available techno-
their local resources. This allows them to reduce logy for CO2 Capture and Storage (CCS).
their reliance on foreign imports of natural resourc-
The Siemens Fuel Gasification (SFG™) techno-
es and at the same time achieving stable prices to
logy continues a long-held Siemens tradition of
meet ever growing energy demands.
satisfying the needs of our customers worldwide.
Gasification offers one of the cleanest and most High availability, low life-cycle costs and multi-fuel
flexible ways of converting coal and low-grade capability are among the most important factors
fuels into high-value products – electricity, chemi- for being competitive. The Siemens Fuel Gasification
cals or synthetic fuels. Combining gasification with technology addresses all of these key competitive
advanced gas turbines in Integrated Gasification drivers. The technology is flexible with regard to
Combined Cycle (IGCC) power plants results in a feedstock and products, and can utilize all types
highly efficient technology for coal-based power of coal, ranging from anthracite to lignite, as well
generation. as refinery residues (petcoke and liquids), and bio-
Environmental requirements are becoming more mass.
and more stringent all over the world. Gasification
2

3. Siemens Fuel Gasifier
The entrained-flow Siemens Fuel Gasifier
Benefits of Siemens Fuel Gasifier:
(SFG™) is able to convert a large range
Feedstock flexibility: Fuel Oxygen, steam
of fuels and is ideally suited for lower-rank
fuels like lignite with high ash and mois- Suitable for all kind of coal types, Pressurized Pressurized
ture content. The syngas leaving the especially lignite, biomass, petcoke water inlet water
outlet
gasifier island mainly consists of CO, and liquid refinery residues
hydrogen and small amounts of CO2 and High carbon conversion: > 98 % Burner
is free of any higher hydrocarbons. Operating pressures: 40 bar and
Noxious components such as particulates, above
sulfur and nitrogen compounds which Shorter start-up times
are typical of gasification are removed Cooling
Smaller dimensions for reduced screen
by conventional gas treatment and con- equipment costs
ditioning processes downstream the
High availability and low mainte-
gasification process.
nance
Main features of Siemens Fuel Gasifi- Proven experience: Quench
cation technology: More than 20 years of successful water
Dry solids feeding for high efficiency operating experience
and low O2 consumption
Top-mounted dust burner with extend-
ed burner lifetime
Cooling screen for high availability and Gas
low maintenance outlet
Full water quench for simple and reli-
able design
Granulated slag
3

4. Design of Siemens Fuel Gasifier The reactor design with cooling screen Dry Feeding System
is ideally suited for fuels with ash con-
The gasifier is equipped with a cooling For solid fuels, a dry feeding is used,
tents of more than 1-2 % by weight.
screen, consisting of spiral-wounded based on a pneumatic dense-phase feed-
For fuels with lower ash content like
tubes filled with cooling water. Molten ing system. This makes the process more
refinery residues, an alternative design
slag builds up a protection layer against efficient and applicable to low-rank coals.
with refractory wall is also available.
the high reaction temperatures. Liquid Particle size distribution and moisture
slag from the reaction phase only comes level depend on the type of feedstock
in contact with the solidified slag layer, used; typical ranges are below 0.5 mm
Gasification Process
and hence no corrosion of the reactor and 2-12 % moisture.
wall can take place. The feedstock together with oxygen
Pulverized solid fuel is first supplied into
and steam is supplied via top-mounted
The cooling screen design ensures long lock hoppers and pressurized with a feed-
burners. Conversion takes place at tem-
gasifier availability periods before re- ing gas like nitrogen or CO2 to gasifier
peratures of around 1,300°C to 1,800°C
quiring repair or relining. This design operating pressure. From there, it passes
(2,350°F to 3,250°F). These high temper-
has been in successful operation for over into a feeder vessel and further on into
atures, in combination with the dry feed
12 years. Compared with a conventional the gasifier. Dry feeding allows use of
system, allow for the almost complete
refractory lining the cooling screen is robust dust burners with lifetimes well
conversion of the feedstock.
insensitive to high ash content or fluc- above one year.
tuating ash composition. After the reaction chamber, raw gas
and slag discharge into a quench section
The gasifier can startup or shut down
arranged beneath the reaction chamber.
within few minutes. Cold startup can be
By injection of water the gas is cooled
done in less than two hours vs. refactory
to temperatures of around 220°C (430°F)
lined gasifiers which can take days to
and the molten slag solidifies.
startup.
The vitrified slag granulates, accumulates
in the water-filled quench bottom and
discharges via a lock hopper. The slag is
non-leachable and can be sold for use as
building or road construction material.
4

5. Siemens Fuel Gasifier Island
The Siemens Fuel Gasifier is the heart of Raw Gas Treatment Black Water Treatment
the Gasifier Island. Process steps like the
Downstream of the quench section, the The liquid effluents of the quench zone,
dry feed system, slag handling system,
syngas passes to a raw gas treatment water from the slag discharge units and
the raw gas treatment and the black wa-
section with venturi scrubbers and a par- scrubbing water from the raw gas treat-
ter treatment complement the gasifier is-
tial condenser. The system removes fine ment contain fine particulate matter,
land. Siemens offers design
particles, halogens and alkalines from soot, salts and volatile heavy metal
and basic engineering of the complete
the raw gas flow. The raw syngas leaving sulfides. Water from the black water
gasifier island process. The process
the gasifier island is essentially free of treatment system is recycled back to the
layout ensures efficient design, optimized
particulates. quench section.
handling of by-streams and water usage
and minimum interfaces to downstream
processes and utilities.
Dry coal Steam Oxygen
CO2 (N2)
Reactor
Raw gas Raw gas
treatment
CO2 (N2)
Quench
Black water
treatment
Slag
handling
Waste Filter Off
Granulated water cake gases
slag
5

6. Solution for many applications
Siemens gasifiers are equally well suited IGCC
for power generation in Integrated Gasifi-
Integrated Gasification Combined Cycle
cation Combined Cycle (IGCC) as well as
(IGCC) combines modern gasification
production of chemicals, and synthetic
with advanced gas turbine and steam
fuels. Resulting products may be used in
turbine power generation technology.
refineries, for iron or fertilizer production,
The concept of an IGCC power plant
transportation and in many other appli-
incorporates a gasifier producing raw
cations.
gas which is cleaned of pollutants and
Most of the downstream processes require burned in the combustion chamber of
a fixed H2/CO ratio which is adjusted in the gas turbine-generator for power
a CO shift reactor downstream of the gas- generation. Matching mass and heat
ifier. In the reactor, the equilibrium of the flow in an IGCC system offers further
CO shift reaction CO + H2O CO2 + H2 is potential to optimize overall plant effi-
influenced by adding water to increase ciency and economics.
the hydrogen content of the syngas. The
IGCC emission levels can be in compli-
raw gas from the quench is already satu-
ance with the most stringent emission
rated with water and little or no addition-
regulations. It offers performance which
al steam injection is needed for the shift
is comparable to state-of-the-art super-
reaction.
critical steam plants. Application of CO2
Gas conditioning complexity depends removal in IGCC’s is straightforward with
on the requirements of the downstream commercially available technology and
process. For desulfurization and CO2 offers flexible CO2 emission reduction to
removal, standard chemical or physical very low levels.
absorption processes can be applied.
Elemental sulfur can be removed and
sold as a marketable by-product. For
sequestration, CO2 is compressed and
transported to underground storage
sites or used for Enhanced Oil Recovery.
6

7. SOKOLOVSKÁ UHELNÁ, A.S.,
Autothermal Oil Conversion Plant
Location: Vresová, Czech Republic
Commissioning: 2008
Technical data
Capacity: 175 MWth (28 bar)
Type of reactor: Entrained-flow, refractory-lined
Type of quench system: Full quench
Feedstock: Tar and liquid by-products
of 26 fixed-bed gasifiers
Products / by-products: Syngas for power production /
slag, soot cake
Shenhua Ningxia Coal Industry Group
Location: Ningxia, China
Commissioning: 2009
Technical data
Capacity: 5x 500 MWth (40 bar)
Type of reactor: Entrained-flow, cooling screen
Type of quench system: Full quench
Feedstock: Hard coal
Product: Syngas for chemical production
Besides gasification, Siemens can pro-
vide entire power islands, air compressor Shanxi Lanhua Coal Chemical Corporation
technology, water treatment solutions
Location: Jincheng, China
and plant instrumentation and controls.
Siemens is able to offer customized Commissioning: 2010
IGCC solutions – everything from an Technical data
equipment-only solution to providing
Capacity: 2x 500 MWth (40 bar)
the complete IGCC Power Island on a
turnkey basis. Type of reactor: Entrained-flow, cooling screen
Type of quench system: Full quench
References Feedstock: Anthracite
SVZ, Waste Recycle Center “Schwarze Pumpe“ Product: Syngas for ammonia and urea
Location: Schwarze Pumpe, Germany production
Commercial operation: 1984 Secure Energy
Technical data Location: Decature, Illinois, USA
Capacity: 200 MWth (25 bar) Commissioning: 2010
Type of reactor: Entrained-flow, cooling screen Technical data
Type of quench system: Full quench Capacity: 2x 500 MWth (40 bar)
Feedstock: Lignite (1984-89) Type of reactor: Entrained-flow, cooling screen
Natural gas (1989, 1990) Type of quench system: Full quench
Liquid waste, tars & oils
(1990 – present) Feedstock: Bituminous coal
Products / by-products: Syngas for methanol and Product: Syngas for synthetic natural gas
power production / sulfur, slag production
7

8. Siemens Gasification
Test Center Ultimate / proximate analysis
determination of ash fusion temperature
With the Gasification Test Center in
Freiberg, Germany, Siemens owns one
of the most comprehensive gasification
test facilities in the world. More than
60 different fuels have been tested so Slag viscosity and deeper
Ash properties no
far, which gives Siemens a rich body of known fuel analysis (e.g. Petrological)
experience.
The centerpiece of the Siemens Gasifica-
tion Test Center is a 5 MWth gasification
reactor with operating pressures up to
Determination of moisture level
26 bar. The test gasifier is complement-
and particle size distribution
ed by a range of feedstock preparation
systems and related gas cleaning process
units. Further equipment for coal and
slag analysis (e.g. fluidization behavior
and viscosity) is available. Fluidization Gasification tests for high ash containing
With this equipment, a broad range of tests fuels or critical fusion temperature
test conditions can be simulated. For
gasification-based projects, for instance,
Figure: Testing procedure
it can be used to test how to:
Determine detailed analytical data of
feedstock and gasification products
Optimize feedstock preparation to
maximize efficiency and carbon con- Siemens Fuel Gasification Technology GmbH
version rate Location: Freiberg, Germany
Determine the optimum gasification Commercial operation: 1996
process conditions Technical data
Gain valuable information about the Capacity: 3-5 MWth
expected products and environmental Type of reactor: Entrained-flow, cooling screen,
performance. retrofittable with refractories,
dry or liquid feeding possible
Feedstock: More than 60 different fuels tested
Dry feeding test rig
so far
The Siemens Gasification Test Center
furthermore provides a test rig for high-
pressure coal feeding. This test rig With our test center and extensive knowl-
consists of a fully equipped dry feeding edge and experience in gasification tech-
system and can be used to find optimized nology, Siemens offers an unparalleled
feeding solutions. In particular, it allows level of solutions that help the customers
the following aspects to be explored: achieve compatibility and profitability
faster and easier.
Investigation of fluidization behavior
under elevated pressure conditions
Comparison of different coal density
and velocity measurement systems
Investigation of different feeding
gases for solid feeding
Test of alternative dry feeding systems
8

9. Scope of supply and services
Siemens is entirely committed to deliv- Siemens scope of supply includes: Gasification tests
ering tailored technology that is more Engineering services and Technical
Licensing of the Siemens Fuel Gasifica-
reliable, more efficient, more competi- Field Assistance
tion technology
tive, and easier to maintain. The solu-
tions we offer push the highest limits Process Design Package (PDP) and As part of our commitment to being cus-
of efficiency and reliability. According Basic Engineering Design Package tomer focused, we provide an established
to the customer’s needs, Siemens pro- (BEDP) for the Gasifier Island powerful and responsive service network.
vides all services from engineering the We are available for you worldwide when
Supply of key equipment like reactor, and where you need us – for technical
Gasifier Island to key equipment and
cooling screen, burner, and more field assistance, parts, or operations and
project execution.
Feasibility and FEED studies for the maintenance services.
Gasifier Island
Fuel Gas Island Applications
IGCC
Fuel Air Separation Combined
Coal Power
Preparation Unit Cycle
Lignite FT Transportation
Synthesis fuels
Gasifier
Syngas Methanol
Petcoke Methanol
(CO + H2) Synthesis
Gasifier Island
Ammonia Ammonia /
Refinery Production Fertilizer
residues CO Shift
Hydrogen
Biomass Sulfur CO2 Removal Chemicals and Synfuel
Removal
Production
Siemens Basic Engineering & Design Siemens Supply of Key Equipment Siemens EPC
9

10. Published by and copyright © 2008:
Siemens AG
Energy Sector
Freyeslebenstrasse 1
91058 Erlangen, Germany
Siemens Fuel Gasification Technology GmbH
Halsbrücker Strasse 34
09599 Freiberg, Germany
Siemens Power Generation, Inc.
4400 Alafaya Trail
Orlando, FL 32826-2399, USA
For more information, contact our
Customer Support Center.
Phone: +49 180/524 70 00
Fax: +49 180/524 24 71
(Charges depending on provider)
e-mail: support.energy@siemens.com
Fossil Power Generation Division
Order No. A96001-S90-A545-V3-4A00
Printed in Germany
Dispo 05400, c4bs No. 4493, 4503
107960M WS 05082.
Printed on elementary chlorine-free bleached paper.
All rights reserved.
Trademarks mentioned in this document are
the property of Siemens AG, its affiliates, or their
respective owners.
Subject to change without prior notice.
The information in this document contains general
descriptions of the technical options available, which
may not apply in all cases. The required technical
options should therefore be specified in the contract.
www.siemens.com/energy