Objective
- Demonstration of the suitability of the High-Temperature-Winkler gasification process (HTW) for efficient utilisation of brown coal and municipal solid waste (MSW) by co-gasification in a fluidised bed system at commercial scale.
- Support of market penetration by confirming the engineering data base in a commercial-scale plant, in particular with respect to gasification behaviour, appropriate gasifier layout, fuel gas quality, solids handling and emissions.
- Reliable separation of all relevant pollutants and harmful species in a simple and tested gas-cleaning system.
- Saving of fossil energy by substitution of brown coal with municipal solid waste (1 ton pre-treated MSW substitutres about 0.6 to brown coal). Estimated payback/about 3 years.
Phase 1 : preparing /planning
As a result of the detailed planning during phase 1, it was decided to procure the amount of about 1000 t of pre-traeted (dried and pelletised) municipal solid waste from several suppliers. The project partners regarded this as the best way to meet two major points : firstly, a high availability of pre-treated waste during the test series at the dates specified in the time schedule of the programme and secondly to have the opportunity to gain more technical experience with waste from different sources and origin to enlarge the database for later evaluation. Even the last issue is very important due to the fact that different waste-collecting systems in different regions influence the composition of the waste material.
During an initial test about 42 tons of pre-treated waste were conveyed successfully through the feeding system of the gasifier.
Phase 2 : demonstration
The demonstration phase was divided into three test series; During the first test 329 tons of pre-treated waste were co-gasified with the regularly used brown coal. Here, the co-feeding rate of waste was about 5 t/h. During the second test, 316 tons of pre-treated waste were gasified. After starting this test with a co-feeding rate of 25% as mentioned, the rate was increased up of waste was increased to 10 t/h while decreasing the mass-flow of brown coal to below 10 t/h. so, finally, experience was gained with an overall feeding rate of waste of more than 50%.
During the test series 1051 tons of pre-treated waste were gasified most successfully to the entire satisfaction of the projects partners.
On-line analyses were inconspicious and the gas composition did not show significant changes in comparison to mono-gasification with brown coal. Only the content of H2S increased from 600 ppm to 1000 ppm as expected.
The test series performed with the use of a pilot hot gas filter for part stream desulphurisation revealed that desulphurisation rates of up to 95% are feasible and it was thus substantiated that this simple method is well suited for thermal treatment of MSW.
Phase 3: verification
The evaluation of the trace constituent analyses programme confirmed that the ash is fully suitable for dumping except for its carbon content and that the hot gas filter method permits a removal of all ecologically off-specification substances from the raw gas stream, except for the nitrogenous compounds. An expert opinion document issued by the FZ Karlsruhe confirms that the German emmission regulations (17th BImSchV) are fully met.
The experience gained in the project enables us to make the following statement:
- the suitability of the High-Temperature-Winkler gasification process (HTW process) for efficient and non-polluting utilisation of brown coal and municipal solid waste by co-gasification in a fluidised bed system at commercial scale has been demonstrated.
- the demonstration project yielded useful operating experience and process engineering data and provides engineering reliability for the design of future plants and a reference for marketing.
1.INNOVATIVE TECHNOLOGY :
- co-utilisation by co-gasification of brown coal and pre-treated municipal waste (MSW) according to the HTW process.
- production of fuel gas or synthesis gas suitable for high efficient utilisation in gas engines and gas turbines or as a feedstock for chemical synthesis.
-transition from atmospheric gasification or incineration of MSW to gasification under elevated pressure by co-gasification with brown coal in a fluidized bed system.
- demonstration of a reliable separation of all relevant pollutants and harmful species in a simple and tested gas-cleaning system.
2. CONTEXT :
20 years ago, Rheinbraun AG as the plant operator and Krupp Udhe as the engineering partner started the development of the HTW fluidised bed gasification process at elevated pressure. So far, several different feedstocks have been successfully tested to produce syngas for different purposes. The high flexibility of the HTW process has been demonstrated even for low-grade feedstocks with a high content of ash. At Berrenrath, Germany, Rheinbraun operates a HTW plant gasifying brown coal to produce syngas for a downstream methanol plant.
The aim of the project is to substitute up to about 5t/h of the brown coal (normally 27 t/h, mf) with pre-treated MSW.
3. ECONOMIC ASPECTS :
- cost effective energy production due to the substitution of brown coal with MSW
- cost-effective waste disposal and protection of the environment
- the pay-back for the additional equipment required is about 3,2 years.
4. Monitoring :
All necessary process data will be monitored to confirm engineering data in respect of energy and mass balances, gas, ash and dust composition and emissions.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
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- engineering and technology environmental engineering energy and fuels fossil energy coal
- natural sciences chemical sciences organic chemistry alcohols
- engineering and technology environmental engineering waste management waste treatment processes
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Coordinator
44141 Dortmund
Germany
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