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E-raamat: Industrial Coal Gasification Technologies Covering Baseline and High-Ash Coal

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  • Ilmumisaeg: 07-Aug-2014
  • Kirjastus: Blackwell Verlag GmbH
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  • ISBN-13: 9783527336920
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Industrial Coal Gasification Technologies Covering Baseline and High-Ash CoalSuurem pilt
  • Formaat: PDF+DRM
  • Ilmumisaeg: 07-Aug-2014
  • Kirjastus: Blackwell Verlag GmbH
  • Keel: eng
  • ISBN-13: 9783527336920
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The ongoing discussion about reaching the "peak-oil point" (maximal delivery rate with conventional methods) emphasizes a fundamental change of the frame conditions of oil-based basic products. The alternative with the largest potential is the use of coal. Coal gasification is the production of coal gas (a mixture of mainly hydrogen and carbon monoxide) from coal adding agents like steam/water and oxygen, which can be used in a number of industrial processes (e.g. hydroformulation and Fischer-Tropsch process). Many different kinds of coal do naturally occur, and due to shrinking natural resources, there has been a substantial gain of interest in poor, ash-rich coal. Beside the quality of coal, there is a number of other parameters influencing the efficiency of coal gasification, such as temperature, pressure, and reactor type. Although several books dealing with the subject of gasification have recently been published, few are strictly focussed on coal as feedstock. This monograph provides the reader with the necessary chemical background on coal gasification. Several types of coal (baseline coal and ash-rich coal) are compared systematically, pointing out the technological efforts achieved so far to overcome this challenge. Using a new, innovative order scheme to evaluate the gasification process at a glance (the ternary diagram), the complex network of chemistry, engineering, and economic needs can be overviewed in a highly efficient way.

This book is a must-have for Chemical and Process Engineers, Engineering Students, as well as Scientists in the Chemical Industry.
Preface xv
1 Introduction 1(2)
References
2(1)
2 Coal Gasification in a Global Context 3(22)
2.1 Applications of Coal Gasification
3(1)
2.2 The Three Generations of Coal Gasifiers
4(5)
2.2.1 First Generation of Coal Gasifiers
5(1)
2.2.2 Second Generation of Coal Gasifiers
5(1)
2.2.3 Third Generation of Coal Gasifiers
6(3)
2.3 Typical Feedstock and Products
9(7)
2.3.1 Feedstock
9(1)
2.3.2 Products
9(9)
2.3.2.1 Ammonia
10(1)
2.3.2.2 Methanol and Derivatives
11(1)
2.3.2.3 Electricity (Integrated Gasification Combined Cycle)
12(1)
2.3.2.4 Substitute Natural Gas (Synthetic Natural Gas)
12(1)
2.3.2.5 Fischer-Tropsch Liquids
13(1)
2.3.2.6 Hydrogen Production
14(1)
2.3.2.7 Others
14(2)
2.4 Main Markets for Coal Gasification
16(1)
2.5 Challenges and Opportunities for Coal Gasification
16(2)
2.6 Environmental Aspects
18(3)
2.6.1 Air Emissions
18(2)
2.6.1.1 Pollutants
18(1)
2.6.1.2 Greenhouse Gases
19(1)
2.6.2 Water Effluents
20(1)
2.6.3 Solid Waste
20(1)
References
21(4)
3 Coal Characterization for Gasification 25(82)
3.1 Coal as Gasification Feedstock
25(1)
3.2 Petrographic Coal Analysis
26(9)
3.2.1 Introduction to Macerals
26(1)
3.2.2 Technological Background
26(1)
3.2.3 Groups of Macerals
27(3)
3.2.3.1 Huminite and Vitrinite
27(2)
3.2.3.2 Liptinite
29(1)
3.2.3.3 Inertinite
29(1)
3.2.4 Blend Identification
30(3)
3.2.4.1 Background
30(1)
3.2.4.2 Terms and Definitions
30(1)
3.2.4.3 Interpretation of a Reflectance Analysis
31(2)
3.2.5 Temperature Estimation Using Optical Reflectance
33(1)
3.2.6 Detection of Other Material
34(1)
3.3 Coal Classification
35(8)
3.3.1 Introduction
35(1)
3.3.2 Reporting of Coal Analyses
36(2)
3.3.3 Classification According to the American Society for Testing and Materials Standard
38(2)
3.3.4 Classification According to the International Organization for Standardization
40(1)
3.3.5 Other Nomenclatures Relevant to Gasification
40(4)
3.3.5.1 Salty Coals
40(1)
3.3.5.2 Ballast Coals
40(2)
3.3.5.3 Low-Value or Low-grade Gasification Coals
42(1)
3.3.5.4 Three-High Coals
42(1)
3.4 Coal Sampling
43(1)
3.5 Proximate Analysis
44(4)
3.5.1 Moisture Content
44(2)
3.5.1.1 Technological Background
44(1)
3.5.1.2 Analysis of Moisture
45(1)
3.5.2 Ash Content
46(1)
3.5.3 Volatile Matter Content
47(1)
3.5.4 Fixed Carbon
48(1)
3.5.5 Alternative Method
48(1)
3.6 Fischer Assay
48(1)
3.7 Ultimate Analysis
49(5)
3.7.1 Technological Background
49(1)
3.7.2 Analysis Procedure
49(1)
3.7.3 Carbon
50(1)
3.7.4 Hydrogen
51(1)
3.7.5 Nitrogen
51(1)
3.7.6 Sulfur
52(1)
3.7.7 Oxygen
53(1)
3.7.8 Chlorine
53(1)
3.8 Heating Values
54(3)
3.8.1 Technological Background
54(1)
3.8.2 Analysis Procedure
54(1)
3.8.3 Estimation by Empirical Correlations
55(1)
3.8.4 Enthalpy of Formation
55(2)
3.9 Caking Properties
57(2)
3.9.1 Gray-King Assay
57(1)
3.9.2 Free-Swelling Index
58(1)
3.9.3 Roga Index
58(1)
3.9.4 Dilatation Test
59(1)
3.10 Reactivity
59(9)
3.10.1 Technological Background
59(1)
3.10.2 Determination of Reactivity
60(7)
3.10.2.1 General Considerations
60(1)
3.10.2.2 Thermogravimetric Analysis
61(4)
3.10.2.3 Fixed-Bed Reactors
65(1)
3.10.2.4 Entrained Particle Reactors
66(1)
3.10.2.5 Wire-Mesh Reactors
67(1)
3.10.3 Spontaneous Ignition
67(1)
3.11 Mineral Matter and Ash Analysis
68(18)
3.11.1 Technological Background
68(1)
3.11.2 Minerals in Coal
69(2)
3.11.2.1 Origin of Coal Mineral Matter
69(1)
3.11.2.2 Minerals in High-Rank Coals
70(1)
3.11.2.3 Minerals in Low-Rank Coals
70(1)
3.11.2.4 Analysis of Mineral Matter in Coal
71(1)
3.11.3 Transformation of Mineral Matter to Ash
71(1)
3.11.4 Ash Component Analysis
72(1)
3.11.5 Ash Fusion Analysis
73(6)
3.11.5.1 Ash Fusion Test
73(2)
3.11.5.2 Ash Clinkering Test
75(1)
3.11.5.3 Influence of Atmosphere
76(1)
3.11.5.4 Influence of Ash Compositions
76(3)
3.11.6 Slag Viscosity Analysis
79(5)
3.11.6.1 High-Temperature Viscometer Test
79(2)
3.11.6.2 Prediction of Slag Viscosity
81(3)
3.11.7 Devolatilization of Mineral Compounds
84(2)
3.11.7.1 Partitioning
84(1)
3.11.7.2 Behavior of Alkali Metals
85(1)
3.11.8 Utilization Properties of Ash and Slag
86(1)
3.12 Relevant Physical Properties
86(14)
3.12.1 Coal Density
87(3)
3.12.1.1 True Density
87(1)
3.12.1.2 Apparent Density
88(1)
3.12.1.3 Bulk Density
88(1)
3.12.1.4 Washability Test
89(1)
3.12.2 Thermal Properties
90(1)
3.12.2.1 Heat Capacity
90(1)
3.12.2.2 Thermal Conductivity
91(1)
3.12.3 Granulometric Properties
91(4)
3.12.3.1 Technological Background
91(1)
3.12.3.2 Representative Diameters
92(1)
3.12.3.3 Rosin-Rammler-Sperling-Bennett Particle Size Distribution
92(1)
3.12.3.4 Fragmentation
93(1)
3.12.3.5 Hardgrove Grindability Index
94(1)
3.12.3.6 Abrasion Index
95(1)
3.12.4 Fluid-Dynamic Properties
95(17)
3.12.4.1 Technological Background
95(1)
3.12.4.2 Coal Bed Pressure Drop
95(1)
3.12.4.3 Minimum Fluidization Velocity
96(1)
3.12.4.4 Fluid Bed Pressure Drop
96(1)
3.12.4.5 Terminal Entrainment Velocity
97(1)
3.12.4.6 Visualization in the Reh Diagram
98(2)
References
100(7)
4 Fundamentals 107(22)
4.1 Terms and Definitions
107(1)
4.2 Gasification Reactions
108(1)
4.3 Pyrolysis Reactions
109(1)
4.4 Gasification Parameters
110(2)
4.5 Classifying Gasification Methods
112(14)
4.5.1 Bed Type (Particle Size)
112(2)
4.5.1.1 Moving-Bed Gasifiers
112(1)
4.5.1.2 Fluid-Bed Gasifiers
113(1)
4.5.1.3 Entrained-Flow Gasifiers
114(1)
4.5.2 Temperature Range
114(2)
4.5.3 Pressure Level
116(1)
4.5.4 Feeding Method
116(4)
4.5.4.1 Dry Feed Systems
116(2)
4.5.4.2 Hydraulic Feed Systems
118(2)
4.5.5 Wall Type
120(1)
4.5.6 Syngas Cooling
121(1)
4.5.7 Oxidant
122(1)
4.5.8 Solid Residue Removal
123(1)
4.5.9 Addition of Catalysts
124(7)
4.5.9.1 General Considerations
124(1)
4.5.9.2 Groups of Catalysts
125(1)
4.5.9.3 Application of Catalytic Coal Gasification
126(1)
References
126(3)
5 Coal Gasification Modeling 129(40)
5.1 Introduction
129(1)
5.2 Balancing of Gasification Systems
130(1)
5.3 Thermodynamic Modeling
131(4)
5.3.1 Equilibrium Constant-Based Calculations
131(3)
5.3.2 Minimization of Gibbs Free Energy
134(1)
5.4 Kinetic Modeling
135(10)
5.4.1 Conversion Processes
135(1)
5.4.2 Fundamentals
135(3)
5.4.3 Heterogeneous Reaction Kinetics
138(6)
5.4.3.1 Analysis of Kinetic Data from Literature
138(1)
5.4.3.2 Selection of Kinetic Data for Modeling
139(5)
5.4.4 Homogeneous Reaction Kinetics
144(1)
5.5 Computational Fluid Dynamics Modeling of Coal Gasifiers
145(7)
5.5.1 Background
145(1)
5.5.2 Typical Case Setup
145(3)
5.5.2.1 Definition of the Calculation Domain
145(2)
5.5.2.2 Solver Settings and Numerical Submodels
147(1)
5.5.3 Convergence Strategies
148(1)
5.5.4 Results for the Internal Circulation Gasifier Case
148(2)
5.5.5 Conclusions of the Computational Fluid Dynamics Study
150(2)
5.6 Generic Models for Case Studies
152(12)
5.6.1 Temperature Approach Concept
152(1)
5.6.2 Modeling Approach
153(1)
5.6.3 Limitations of the Approach Temperature Concept
154(1)
5.6.4 Boundary Conditions
155(14)
5.6.4.1 Coal Selection
155(1)
5.6.4.2 Reference Case Definition
156(1)
5.6.4.3 Sensitivity Analysis
157(7)
References
164(5)
6 Coal Gasification Technology Survey 169(120)
6.1 Entrained-Flow Gasifiers
169(56)
6.1.1 Introduction
169(1)
6.1.2 Shell and Uhde Coal Gasification Technology
170(11)
6.1.2.1 Historical Background
170(1)
6.1.2.2 Process Description
170(6)
6.1.2.3 Enhancements
176(1)
6.1.2.4 Verification Case for Model Setup
177(3)
6.1.2.5 Modeling Results
180(1)
6.1.3 Siemens Fuel Gasification Technology
181(12)
6.1.3.1 Historical Background
181(1)
6.1.3.2 Process Description
182(5)
6.1.3.3 Enhancements
187(1)
6.1.3.4 Verification Case for Model Setup
188(3)
6.1.3.5 Modeling Results
191(1)
6.1.3.6 Other Similar Technologies
192(1)
6.1.4 GE Energy Technology
193(17)
6.1.4.1 Historical Background
193(1)
6.1.4.2 Process Description
194(8)
6.1.4.3 Enhancements
202(1)
6.1.4.4 Verification Case for Model Setup
203(3)
6.1.4.5 Modeling Results
206(2)
6.1.4.6 Other Similar Technologies
208(2)
6.1.5 E-Gas Technology
210(10)
6.1.5.1 Historical Background
210(1)
6.1.5.2 Process Description
211(4)
6.1.5.3 Enhancements
215(2)
6.1.5.4 Verification Case for Model Setup
217(2)
6.1.5.5 Modeling Results
219(1)
6.1.6 Other Entrained-Flow Technologies
220(5)
6.1.6.1 East China University of Science and Technology Gasifiers
220(1)
6.1.6.2 Mitsubishi Heavy Industries Gasifier
221(1)
6.1.6.3 Thermal Power Research Institute Gasifier
222(2)
6.1.6.4 Pratt & Whitney Rocketdyne Gasifier
224(1)
6.2 Fluid-Bed Gasifiers
225(19)
6.2.1 Introduction
225(1)
6.2.2 High-Temperature Winkler Technology
226(11)
6.2.2.1 Historical Background
226(1)
6.2.2.2 Process Description
227(6)
6.2.2.3 Enhancements
233(1)
6.2.2.4 Verification Case for Model Setup
234(3)
6.2.2.5 Modeling Results
237(1)
6.2.3 Other Fluid-Bed Technologies
237(7)
6.2.3.1 Utility-Gas Gasifier
237(2)
6.2.3.2 Agglomerating Fluidized-Bed Gasifier
239(1)
6.2.3.3 Kellogg Brown & Root Transport Reactor
239(3)
6.2.3.4 Kellogg Rust Westinghouse Gasifier
242(1)
6.2.3.5 Bharat Heavy Electrical Limited Technology
243(1)
6.2.3.6 HRL Integrated Drying Gasification Combined Cycle Process
243(1)
6.2.3.7 Circulating Fluidized-Bed Technology
244(1)
6.3 Moving-Bed Gasifiers
244(33)
6.3.1 Introduction
244(1)
6.3.2 Lurgi Fixed-Bed Dry Bottom Technology
245(18)
6.3.2.1 Historical Background
245(2)
6.3.2.2 Process Description
247(14)
6.3.2.3 Enhancements
261(2)
6.3.3 Other Similar Technologies
263(1)
6.3.3.1 SEDIN Dry Bottom Gasification
263(1)
6.3.3.2 Sasol Dry Bottom Gasification
263(1)
6.3.4 British Gas/Lurgi Technology
263(26)
6.3.4.1 Historical Background
263(1)
6.3.4.2 Process Description
264(11)
6.3.4.3 Operational Data
275(1)
6.3.4.4 Enhancements
275(2)
References
277(12)
7 Thermodynamic Process Assessment 289(30)
7.1 Introduction of a Ternary Gasification Diagram
289(9)
7.1.1 Basic Idea
289(1)
7.1.2 Domain Overview and Pressure Sensitivity
290(2)
7.1.3 Diagram Types
292(1)
7.1.4 Domain Boundaries for Gasification Systems
293(2)
7.1.5 Treatment of H2O Stream
295(1)
7.1.6 Displaying Gasifiers with Multiple Inlets
296(1)
7.1.7 Optimum User Diagrams
296(2)
7.2 Diagrams for Pittsburgh No. 8 Coal
298(6)
7.2.1 Temperature and Carbon Conversion Diagram
298(2)
7.2.2 Cold Gas Efficiency and Methane Yield Diagram
300(1)
7.2.3 Syngas Yield and H2/CO Diagram
300(1)
7.2.4 Optimum User Diagram
301(1)
7.2.5 Optimum Correlations
301(3)
7.3 Diagrams for South African Coal
304(6)
7.3.1 Temperature and Carbon Conversion Diagram
304(2)
7.3.2 Cold Gas Efficiency and Methane Yield Diagram
306(1)
7.3.3 Syngas Yield and H2/CO Diagram
306(1)
7.3.4 Optimum User Diagram
307(1)
7.3.5 Optimum Correlations
307(3)
7.4 Technology Potential Analysis
310(2)
7.5 Influence of the Ash Content
312(2)
7.6 Other Gasification Systems
314(1)
7.7 Conclusions
315(1)
References
316(3)
8 Exergetic Process Assessment 319(12)
8.1 Exergy Calculations
319(5)
8.1.1 Exergy and Reference Environment
319(1)
8.1.2 Exergy of Gaseous and Liquid Streams
320(3)
8.1.3 Exergy of Solid Streams
323(1)
8.1.4 Definition of Efforts and Benefits
323(1)
8.2 Exergetic Analysis
324(5)
8.2.1 Impact of Gas Cooling Methods
324(2)
8.2.2 Comparison of Gasification Systems
326(8)
8.2.2.1 Exergy Flow Analysis
326(2)
8.2.2.2 Exergetic Process Efficiency
328(1)
8.3 Conclusions of Process Assessment
329(1)
References
330(1)
9 Concept Study: The Internal Circulation Gasifier 331(20)
9.1 Introduction
331(2)
9.2 Basic Principle
333(1)
9.3 Detailed Process Description
334(7)
9.3.1 Fuel Preparation and Feeding
334(1)
9.3.2 Reaction Chamber
334(4)
9.3.2.1 Fluid-Bed Zone
334(2)
9.3.2.2 Moving-Bed Zone
336(1)
9.3.2.3 Particle Behavior
337(1)
9.3.3 Gasifying Agent Injection
338(1)
9.3.4 Process Control
339(1)
9.3.5 Gas Cooling
340(1)
9.3.6 Ash Removal and Cooling
340(1)
9.4 Thermodynamic Modeling of the Internal Circulation Gasifier
341(7)
9.4.1 Model Description
341(3)
9.4.1.1 Flow Sheet Setup
341(1)
9.4.1.2 Property Method and Block Settings
342(1)
9.4.1.3 Design Specifications
342(2)
9.4.2 Expected Performance
344(1)
9.4.3 Derived Reactor Design
345(1)
9.4.4 Process Scale-up
345(3)
9.5 Next Development Steps
348(1)
References
348(3)
10 Trends of Gasification Development 351(4)
Reference
353(2)
Index 355
Dr.-Ing. Martin Gräbner is senior research engineer for coal gasification at the Research and Technology Center of Air Liquide in Frankfurt/Main, Germany. Receiving scholarships from the Konrad-Adenauer-Stiftung and from the German National Academic Foundation, he has studied energy process engineering at the Technische Universität Bergakademie Freiberg, Germany, and the University of Cincinnati, Ohio. For his excellent course of studies, he received the Georgius Agricola Medal and the Helmut Erich Rammler Award. While obtaining his doctoral degree from the Technische Universität Bergakademie Freiberg, Germany, he spent several years working as team leader of the gasifier development group at the Institute of Energy Process Engineering and Chemical Engineering in Freiberg.
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