GASIFICATION
Reference:
Invensys - SimSci - Dynsim
DYNSIM is a comprehensive, dynamic process simulator that enables users to meet and beat the dynamic challenges of designing and operating a modern process plant safely and profitably. By assisting in process design, controls checkout and control system design, DYNSIM enables process yield improvement and reduction of capital investment costs. The DYNSIM operator training simulator provides safer operation while improving performance and productivity.
5. E-Gas Technology for Gasification
1. The E-Gas Technology for
Gasification features ****.
2. With more than 20 years of
proven commercial
experience, this technology is
****.
Slide 5
Slurry
Oxygen
Slurry
Slurry
Oxygen
Raw Syngas
Slag
Char
Recycle
Slag Quench
Water
7. High Fidelity Dynamic Simulation
• ConocoPhillips is interested in the development of a dynamic model
for the E-Gas gasification process using Invensys’ Dynsim program.
• The objectives of the project are to:
– ****
– ****
– ****
– ****
Slide 7
8. Why Choose Dynsim?
• Dynsim is Invensys’ comprehensive, rigorous, field proven dynamic
process simulation software. Some of its key features are critical for
the success of this project:
Slide 8
Play the ConocoPhillips E-GAS & Dynamic Simulation Movie (used in GTC)
Ref. Left Diagram from DOE Topical Report Number 20
E-Gas Gasification
ConocoPhillips' newest addition to its downstream technology portfolio is the E-Gas Technology for Gasification.
E-gas has the potential to make use of our most abundant energy resource – coal – in such a way as to dramatically reduce its environmental impact.
Acquired in July of 2003, this proven technology is the cleanest, most efficient commercial process for converting coal or petroleum coke into a hydrogen rich synthesis gas, ideally suited for refining, power and chemicals application. The process can cost-effectively remove 90-95 percent of the mercury in coal. Up to 99 percent of the sulfur can be recovered and marketed for use in the fertilizer industry. The gasification process produces no ash and recycles byproducts into useful products including road construction materials.
With more than 20 years of proven commercial experience in Integrated Gasification Combined Cycle (IGCC) application, this technology provides a highly efficient, environmentally superior, and competitive based-load power alternative. In a refinery setting, the technology can process high sulfur petroleum coke into power, steam and hydrogen for the refinery and surrounding markets.
Advantages of E-Gas Technology
The E-Gas Technology for Gasification features a proprietary two-stage, slurry-fed, oxygen-blown, entrained-flow design, which converts feedstock energy into high-quality synthesis gas at a high conversion efficiency. The two-stage gasifier design, coupled with our unique continuous slag removal system results in a very compact plant design, reducing both capital and operating cost. The use of a fire-tube boiler for synthesis gas cooling was pioneered during the early development of the E-Gas process, and now this proven design provides an additional cost and operations advantage to the E-Gas technology. Other unique features of the E-Gas process can be found in particulate removal, sulfur hydrolysis, and sulfur removal from the synthesis gas. The many advantages of the process are brought together by the experienced ConocoPhillips team to meet the licensee's needs for today's stringent project requirements. Our breadth of experience, from research, development, process design, engineering, operation and maintenance, allows us to offer licenses as well as the support services needed by the client.
Ref. Left Diagram from Gasification Technologies Council Brochure
A Feedstock
Gasification enables the capture — in an environmentally beneficial manner — of the remaining “value” present in a variety of low-grade hydrocarbon materials (“feedstocks”) that would otherwise have minimal or even negative economic value. Gasifiers can be designed to run on a single material or a blend of feedstocks: all types of coal and petroleum coke (a low value byproduct of refining) and biomass, such as wood waste, agricultural waste, and household waste.
B Gasifier
The ConocoPhillips oxygen-blown coal gasification technology features a slurry-fed, two-stage gasifier, a slagging first stage and an entrained flow second stage. The gasifer is a refractory-lined vessel, which produces raw synthesis gas and an inert, vitreous slag containing the mineral content of the feedstock. The slag may be used for various construction applications. Syngas produced is about 1900 °F, contains entrained solids from the second stage and is cooled in a fire-tube boiler to produce saturated high-pressure steam.
C Oxygen Plant
The gasification system uses almost pure oxygen (as opposed to air) to help facilitate the reaction in the gasifier. This oxygen (95–99% purity) is generated in a plant using proven cryogenic technology. The oxygen is then fed into the gasifier through separate co-feed ports in the feed injector.
D Gas Clean-up
The raw syngas exiting the syngas cooler is filtered to remove the unreacted entrained solids, which are recycled to the gasifier. The filtered "sour" gas consists mainly of Hydrogen (H2), carbon monoxide (CO), carbon dioxide (CO2), water (H2O), and smaller quantities of Nitrogen (N2), methane (CH4), hydrogen sulfide (H2S), and carbonyl sulfide (COS). The sour gas is cooled further to about 100 °F. The cooling is accomplished within several heat exchangers. Water condenses from the gas as it is cooled, generating a condensate containing ammonia (NH3), some of the H2S and CO2, which is sent to water treatment.
The Dynamic Simulation Suite (DSS) is Invensys’s full life cycle dynamic simulation solution for supporting design, operability analysis, safety studies, controls checkout and full-functioning operator training.
INTRODUCTION
Dynsim includes the following systems for accurate dynamic process modeling:
• Base equipment models to model typical plant equipment in power generation or process industries.
• Process equipment models to model equipment in the process industries.
• Control models to simulate process control systems
• Electrical models to simulate electrical systems including motor drivers
• Accurate and detailed thermodynamics to match design or operating conditions
Combining these models with rigorous thermodynamics, control, and electrical models enables Dynsim to simulate various process plants including the process control system, safety control system including trip interlocks, and the electrical distribution system.
BASE EQUIPMENT LIBRARY
The Base equipment library comes standard with Dynsim, FSIM Plus, and TRISIM Plus. Dynsim's Base Equipment models are designed with two objectives in mind:
• Fast and robust simulation for OTS applications
• Rigorous and accurate simulation for engineering studies.
To meet these two goals, the Dynsim Base Equipment Library includes the following features in its design:
• Robust pressure flow solution
• Reverse flow in all models
• Vessel port heights for vapor breakthrough in liquid lines and liquid overfilling of vapor lines.
• Shaft rotational inertia with any number of rotating equipment components
• Metal thermal inventory and heat loss to ambient in vessels, towers, columns, pipes, headers, and heat exchangers
• Accurate depressuring thermodynamics with isentropic expansion efficiency specification
• Three phase equilibrium in any model
• Tracking of solids components.
