Objetivo The aim of the overall project were the planning, construction and industrial testing of a commercial-size entrained-flow gasification plant for the generation of hydrogen, which can be operated on solid fuels, e. g. pyrolysis coke and coal just as well as on liquid hydrogenation residues.The objectives of this project were the determination of data enabling an evaluation of the technical feasibility, the possibilities for official approval and the economic viability of the demonstration plant before the final decision on its construction was taken.Parallel to te planning of the demonstration plant, gasification tests were to be made in an existing pilot plant. These tests were in the first place to determine the design data for the demonstration plant as well as to test and to improve the solid feeding-system and the gasification burner. See project LG/20/84/DE.A preplanning phase served to investigate different concepts with respect to process flow, the technical design of the main parts and the integration of the demonstration plant into the RUHR OEL refinery in Gelsenkirchen-Scholven.For two process variants the basic engineering was carried out for the main process steps; a pre-basic was worked out for the conventional units of the plant, i. e. grinding, crude gas shift conversion and H2S/CO2 scrubbing.Detailed documents including construction drawings were produced for the main parts e. g. the extruder feeding-system, the burner and the gasification reactor.In order to determine whether the gasification plant would qualify for approval by the authorities a preliminary application in accordance with P9 of the Federal Environmental Protection ( Immission) Act was prepared and submitted. After a thorough examination of the application and a discussion on the objections the preliminary approval was garanted.To conclude the investigations, the investment cost were determined and the economic viability was examined for both process alternatives.The investigations have shown that a large-scale plant for the gasification of hydrogenation residues and coal is technically feasible and does quality for approval. The low energy price level does for the time being, however, not permit a cost-covering operation of coal gasification or coal hydrogenation plants. Measures are, therefore, examined to improve the economic viability of gasification and hydrogenation units. The use of solid or liquid wastes (as e. g. sewage sludge, used plastic materials, used oils) is considered to form a large economic potential. Under the aspect of a CO2-neutral replacement of fossil sources of energy, renewable raw-materials and the use of biomass may in the medium and long term also constitute an alternative.The pilot plant tests have shown that the extruder is available as universal system for the feeding of solid fuels into pressure vessels. In addition to the entrained-flow gasification of coke and coal examined here, the extruder has further potential fields of application, viz. :- Gasification and combustion of solid fuels in a pressurized fluidized bed- Pressure hydrogenation of used plastic materials and- Supercritical extraction of biomass.For the hydrogenation of coal or heavy oil, a major consideration is the economical and environment-friendly utilization of the hydrogenation residues containing heavy metals which become available as unavoidable byproducts. As against possible combustion, the gasification of the hydrogenation residues provides the advantage that, in addition to environmentally safe disposal of the residues, it is also possible to produce the hydrogen required after the hydrogenation units. For energetic reasons the direct feeding of the hot hydrogenation residues to the gasification seems to be the most appropriate solution. Because of the interconnection of the gasification and the hydrogenation plants is, therefore, largely dependent on the availability of the residue gasification. In order to avoid this it is necessary to provide for the disconnection of the two processes. This disconnection requires the solidification of the liquid residues and the intermediate storage of the solidified residues. Solidification can be effected by pryrolysis of the hydrogenation residues in indirectly heated rotary drums. The coke from the pyrolysis can be used for hydrogen generation. Because of the production of pyrolysis oil, the residue pyrolysis enables an increase of the total oil yield of hydrogenation plants.The dosage of the solid fuels to the pressurized gasification reactor would be carried out with an extruder feeding-system developed on pilot plant scale by VEBA OEL AG and Maschinenfabrik Werner & Pfleiderer. This feeding system consists essentially of a twin-screw extruder. The finely ground fuel and a small portion of a liquid binding-agent are metered pressure-free into the extruder. Hydrocarbons (heavy oils, used oils) as well as water can be used as binding agents. In the extruder, the solid fuel and the binding agent are first mixed, whereupon the mixture is compressed to a pressure above the reactor pressure.The optimum liquid content for the operation of the extruder depends greatly on the type and granulation of the solid fuel. The compacted fuel leaves the extruder via a nozzle atomized by means of a gas and conveyed to the burner in the top of the gasification reactor.This feeding system was developed as an alternative to the pmeumatic and water/slurry feeding of solids and offers the following advantages :- as against slurry feeding : reduction of the liquid (water) content by approx. 50 %, which results in a higher specific gas yield and a lower consumption of oxygen- as against pneumatic feeding : forgoing of a lockhopper system used to pressurize the solid fuels up to the gasification pressure; this leads to lower costs for investment and energy.It was decided to build the demonstratin plant on an unbuilt area in front of the RUHR OEL refinery in Gelsenkirchen-Scholven. Programa(s) ENG-ENALT 1C - Programme (EEC) of financial support for projects to exploit alternative energy sources, 1979-1984 Tema(s) 5.1 - GASIFICATION Convocatoria de propuestas Data not available Régimen de financiación DEM - Demonstration contracts Coordinador Veba Oel AG Aportación de la UE Sin datos Dirección Alexander-von-Humboldt-Straße 45896 Gelsenkirchen Alemania Ver en el mapa Coste total Sin datos
