Coal Gasification as Alternative Fuel for

Glass Industry
Gasification Primer
Presented By
Donald L. Bonk
Senior Technical Advisor
National Energy Technology Laboratory
U. S. Department of Energy

Owens Corning Corporate

Headquarters

1, Owens Corning Parkway,

Toledo, OH
July 27, 2005
10:00 4:00

Meeting Objective: Develop plans to

obtain glass industry support for
an investigation to determine the
viability of using coal gasification
"synfuel" as an economical
alternative to natural gas for
melting glass.

Descriptor - include initials, /org#/date

Gasification Chemistry
Gasification with Oxygen
C + 1/2 O2
CO

Coal

Combustion with Oxygen

C + O2
CO2
Gasification with Carbon Dioxide
C + CO2
2CO

Oxygen

Gasification with Steam

C + H2O
CO + H2
Gasification with Hydrogen
C + 2H2
CH4

Steam

Water-Gas Shift
CO + H2O
H2 + CO2

Gasifier Gas
Composition
(Vol %)
H2
CO
CO2
H2O
CH4

25 - 30
30 - 60
5 - 15
2 - 30
0-5

H2S
0.2 - 1
COS
0 - 0.1
N2
0.5 - 4
Ar
0.2 - 1
NH3 + HCN 0 -0.3
Ash/Slag/PM

Methanation
CO + 3H2
CH4 + H2O
Descriptor - include initials, /org#/date

History of Gasification
Town Gas
Town gas, a gaseous product manufactured from coal,
supplies lighting and heating for America and Europe.
Town gas is approximately 50% hydrogen, with the rest
comprised of mostly methane and carbon dioxide, with 3%
to 6% carbon monoxide.
First practical use of town gas in modern times was for

street lighting
The first public street lighting with gas took place in Pall
Mall, London on January 28, 1807
Baltimore, Maryland began

the first commercial gas

lighting of residences,
streets, and businesses in
1816
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History of Gasification
Used during World War II to convert coal into

transportation fuels (Fischer Tropsch)

Used extensively in the last 50+ years to convert coal
and heavy oil into hydrogen for the production of
ammonia/urea fertilizer
Chemical industry (1960s)
Refinery industry (1980s)
Global power industry (Today)

Descriptor - include initials, /org#/date

Major Gasification Milestone

1842
1887
1910
1940
1950
1960
1970s
1970
1983
1984
1990s
1993
1994
1995
1996
1997
1998
2002

Baltimore Electric Town Gas

Lurgi Gasification Patent
Coal Gasification Common in U.S. / Europe for Town Gas
Gasification of Nature Gas for Hydrogen in the Chemical Industry
(Ammonia)
Gasification of Coal for Fischer-Tropsch (F-T) Liquids (Sasol-Sasolburg)
Coal Tested as Fuel for Gas Turbines (Direct Firing)
IGCC Studies by U.S. DOE
Gasification of Oil for Hydrogen in the Refining Industry
Gasification of Coal to Chemicals Plant (Eastman Chemical)
First Coal IGCC Demonstration (Coolwater Plant)
First Non-Recourse Project Financed Oil IGCC Projects (Italy)
First Natural Gas Gasification F-T Project (Shell Bintulu)
NUON/Demkolecs 253 MWe Buggenum Plant Begins Operation
PSI Walbash, Indiana Coal IGCC Begins Operation (DOE CCT IV)
Tampa Electric Polk Coal IGCC Begins Operation (DOE CCT III)
First Oil Hydrogen/IGCC Plant Begin Operations (Shell Pernis)
ELCOGAS 298 MWe Puertollano Plant
IGCC is now an Accepted Refinery and Coal Plant Option
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Characteristics of a Gasification Process

FEEDS
Alternatives:
Asphalt
Coal
Heavy Oil
Petroleum Coke
Orimulsion
Natural Gas
Wastes
Clean Fuels

GASIFICATION

GAS CLEANUP

END PRODUCTS

Combined Cycle
Power Block

Oxygen

Electricity
Steam

Gas & Steam

Sulfur Turbines
Removal

Gasifier
Syngas
Marketable
Byproducts:

Byproducts:

Alternatives:
Hydrogen
Ammonia
Chemicals
Methanol

Sulfur

Solids (ash)
Source: ChevronTexaco
Descriptor - include initials, /org#/date

Gasifier Configurations
Moving Bed

Fluidized Bed

Entrained Flow

Transport
Gasifier
Top

Product
Gas,
Ash

Transport
Gasifier

Coal, Char

Recycle, Gas

Coal,
Sorbent or
Inert

Recycle Drive
Gas

Steam,
Oxygen
or Air

Gasifier
Bottom
0

500

1000

1500

2000

2500

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Gasifier Types
Flow Regime

Moving (or "Fixed") Bed

Fluidized Bed

Entrained Flow

Combustion
Analogy

grate fired combustors

fluidized bed combustors

pulverized coal combustors

Fuel Type

solids only

solids only

solids or liquids

Fuel Size

5 - 50 mm

0.5 - 5 mm

< 500 microns

Residence Time

15 - 30 minutes

5 - 50 seconds

1 - 10 seconds

Oxidant

air- or oxygen-blown

air- or oxygen-blown

almost always oxygen-blown

Gas Outlet Temp.

400 - 500 C

700 900 C

900 1400 C

Ash Handling

slagging and non-slagging

non-slagging

always slagging

Commercial
Examples

Lurgi dry-ash (non-slagging),

BGL (slagging)

GTI U-Gas, HT Winkler,

KRW

GE Energy, Shell, Prenflo,

ConocoPhillips, Noell

"moving" beds are

mechanically stirred, fixed
beds are not

bed temperature below ash

fusion point to prevent
agglomeration

not preferred for high-ash

fuels due to energy penalty
of ash-melting

gas and solid flows are

always countercurrent in
moving bed gasifiers

preferred for high-ash

feedstocks and waste fuels

unsuitable for fuels that are

hard to atomize or pulverize

Comments

Note: The "transport" gasifier flow regime is between fluidized and entrained and can be air- or oxygen-blown.

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Gasifier Characteristic Comparison

Moving Bed

Fluidized Bed

Entrained
Flow

Transport Flow

Ash Cond.

Dry

Slagging

Dry

Agglomer
ate

Slagging

Dry

Coal Feed

~2in

~2in

~1/4 in

~1/4 in

~ 100
Mesh

~1/16in

Fines

Limited

Better
than dry
ash

Good

Better

Unlimited

Better

Rank

Low

High

Low

Any

Any

Any

Gas Temp.
(F)

800-1,200

800-1,200

1,7001,900

1,7001,900

>2,300

1,500-1,900

Oxidant Req.

Low

Low

Moderate

Moderate

Low

Moderate

Steam Req.

High

Low

Moderate

Moderate

Low

Moderate

Issues

Fines and
Hydrocarbon liquids

Raw gas
cooling

Control carbon
inventory and
carryover

Carbon Conversion

Descriptor - include initials, /org#/date

Gasifiers
Oxygen Blown
Entrained Flow

Texaco
E-GAS
Shell
Prenflo
Noell

Fluidized Bed

HT Winkler
Foster Wheeler

Moving Bed

British Gas Lurgi

Sasol
Lurgi

Transport Reactor

Kellogg

Air Blown
Fluidized Bed

HT Winkler
IGT Ugas
KRW
Foster Wheeler

Spouting Bed

British Coal
Foster Wheeler

Entrained Flow

Mitsubishi

Transport Reactor

Kellogg

Hybrid

Foster Wheeler
British Coal
ENERCON
FERCO/Silva

Descriptor - include initials, /org#/date

Gasification-Based Energy Production

System Concepts

Sulfur
By-Product
Fly Ash
By-Product

Slag
By-Product

Descriptor - include initials, /org#/date

Gasification-Based Industrial Concept

Descriptor - include initials, /org#/date

Moving Bed Gasifier Lurgi, BGC

Counter current flow of

reactants, products: gases and
solids

Separate zones for coal

processing

Products: top gases, hcs, tars;

bottom dry ash or slag

Issues: uniform flow of solids

and gases

Design: bottom temperature

determines H2O/O2

Effects of dry or slagging

bottom

High cold gas efficiency, low O2

Descriptor - include initials, /org#/date

Mixed Bed Gasifier Winkler, KRW, IGT

Fluidized bed, mixed flow of

reactants, products
Mixed zones of heating, drying,
devolatilization, gasification,
combustion; dependent on feed
location
Process conditions: temperature
limited by ash fusion; high
temperatures promote gasification,
limit desulfurization; flow velocity
determined by fluidization
requirements
Products: top gases, no hcs tars,
potentially desulfurized, particulates
(C, ash); bottom, ash perhaps
agglomerated
Issues: reactant feed means,
locations; ash removal means
Design: bed volume, by gasification
requirements; cross section, velocity
Moderate cold gas efficiency; O2 H2O
requirements; broad range of coals
Descriptor - include initials, /org#/date

Co Current Gasifier Krupp Koppers,

Texaco, Shell

Entrained flow of coal in O2 + H2O,

reactants

Widely dispersed particles heated by

radiation, gas mixing

Process conditions: high temperature

for ash fusion, rapid gasification

Products: CO, H2 (no CH4, hcs, oils

tars); ash slag

Issues: uniform feed of pulverized coal,

slurry, dry; separation of gases and ash;
heat recovery from high temperature
product fuel gases

Design: required volume is the time

weighted average of reactant and
product gas volumes/wt coal * the coal
flow rate * the coal conversion time

Low cold gas efficiency, high O2 demand

Descriptor - include initials, /org#/date

Entrained Staged Gasifier Kellogg Rust

Product
Gas,
Ash

Coal,
Sorbent or
Inert

Recycle Drive
Gas

Steam,
Oxygen
or Air

Coal flow into recirculating particulates,

devolatilization; char, particulates introduced
to fluid bed, combustion, gasification

Process conditions: nearly uniform

temperature limited by ash agglomeration

Products: CO, H2, devol products, ash fines

Issues: coal particle size, flow conditions for

rapid devol; recycle for char combustion,
gasification; recirculation particulates

Design: riser entrains particulates, coal;

devolatilizes, cracks oils, tars; delivers char
for gasification, combustion. Stand pipe,
particulates from cyclones, delivers to fluid
bed. Fluid bed combustion, gasification of
char; product gases, particles enter riser

Moderate efficiency, O2 demand, control of

devolatilization

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Independence does not

come cheap for
the
small utility

Based on NETL Studies

Repowered Total Plant Cost vs. Original Size of Steam Plant

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Cedar Lane Farms FGR-FBC

A Study
of
Small Project
Success & Cost

Cedar Lane Coal-Fired Flue Gas

Recirculating Fluidized Bed Boiler
Cedar Lane
Farms

Unit achieved ~7 months of

Wooster, Ohio
9,000,000 Btu FGC- FBB Demonstration

continuous computer
control operation
96.9% availability over the
193 day heating season
$200,000+ Saved over
Natural Gas this season (2
of 5 Acres)
20% reduction in coal usage
compared to old undergrate stokers
2 types of computer
controlled operation
demonstrated; demand and
slumping
Only 2 man-hours of labor
required daily
Unit up to 40,000,000 Btu
Input Available

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Economic Advantage Estimated Annual Fuel Cost

Savings with Coal-Fired AFBC at Cedar Lane Farms
Based upon a 10 million Btu high sulfur coal fired AFBC for hot water application.
Heating season set AT 250 days per year at 100% capacity.

Type Unit
AFBC
Natural Gas
Natural Gas
Natural Gas

Capital Cost
$698,600
$101,400
$101,400
$101,400

Fuel Cost
$30/ton
$6/106 Btu
$7/106 Btu
$12/106 Btu

Annual Capital
Charge and
Operating
Costs
$276,400
$470,800
$530,800
$830,800

Annual Savings
with AFBC
$246,100
$306,100
$606,100

06-FBC015-21
Descriptor - include
Cedarinitials,
Lane Farms
/org#/date
FBC

FGR-FBC Features

Energy Type Possible:

Hot Water
Steam Generation
Power Generation/ Co-Gen
Low Stack Emissions
Low Limestone Consumption
High Efficiency
No In-Bed Heat Transfer Tubes
Flue Gas Recirculation
Automatic PLC Control

Descriptor - include initials, /org#/date

2005 Ex Works Budget Costs* for Hopper-to-Stack

Equipment Similar to Cedar Lane Farms ABFB
Equipment

10 MM BTU/hr [Coal Input]

$750,000.

20 MM Btu/hr [Coal Input]

$1,300,000.

30 MM BTU/hr [Coal Input]

$1,800,000.

NOT Included in Above:

Financing & Permitting
Foundations & Building(s)
Freight to Site
Installation; Mechanical & Electrical
Compliance Stack Testing
*Generic cost not project estimate

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Fuel and Ash Storage Considerations based upon

Cedar Lane Farms Experience

Where To Start - Good Engineering and Creditable

Vendors

Fuel, Limestone, and Ash Economics

Economic Loads = 26 tons Coal or Limestone
Therefore Storage Needs =
Coal at 55 tons
Limestone at 36 tons
Alternate Fuel at 55 tons (Tire Chips or Waste)
Ash at 55 tons

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Storage Types
Storage Horizontal or Vertical with

Preparation Equipment
List below arranged from highest labor cost
to lowest
Agriculture Horizontal (BFG) = $100,000
Agriculture Vertical (ML)
= $287,000
Industrial Vertical (F&P)
= $689,000
Utility Vertical (R&S)
= $910,000

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Cedar Lane Farms Actual Computer Graphic

Of FBC Operation

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FGR-FBC Easily Met OEPA Requirements

Testing March 25, 2004
Ohio require sulfur release below 1.3 lbs/MMBtu and
under 20% opacity on this size unit if equipped with
baghouse
Local coal was an Ohio #6 having 12,877 Btu/lbs, 6.57%

moisture and 3.46% sulfur on an as received basis

Local sorbent was a Bucyrus #18 dolomite having 80%
calcium
Control was completely automatic for three tests at an
average 8.96 MM Btu/hr
Average sorbent feed was 0.12 lbs/lbs of coal, approximately
a Ca/S ratio = 1
Average sulfur capture approximately 88% or a release of 0.65
lbs/MMBtu
Opacity = Zero
Average oxygen % dry = 3.122

Descriptor - include initials, /org#/date

NETLs Compact Industrial Hybrid

Gasifier Concept

Based Upon Cedar Lane

Experience and the Hybrid
Gasification/Combustion
Studies

Combustion/Gasification Fluidized Bed

Combustion Combined Cycle (CGFBCC)
char

pressurized
circulating
fluidized-bed
partial gasifier

Syngas
cooler

atmospheric
circulating
fluid bed
combustor

limestone
coal

fluid bed heat exchanger

SNCR

coal

syngas
urea

steam

air

generator
syngas airfeed compressor

steam turbine

Metallic
filters

topping
combustor

baghouse

ID fan

air
generator

air
compressor

exhaust
stack

gas
turbine

gas turbine

gas turbine exhaust

used CFB combustion air
Descriptor - include initials, /org#/date

NETLs Compact Industrial Hybrid Gasifier

Concept

Addresses Issues of Carbon Utilization Typical of Fluidized Bed Gasifiers

Descriptor - include initials, /org#/date

Typical Gasifier Syngas Compositions

Wabash
River

Texaco

KoppersTotzek

Shell
(Lurgi)

Winkler

Possible NETL
Compact Gasifier
Composition

Nitrogen

5.0%

5.8%

1.4%

5.1%

3.0%

Hydrogen

26.0%

27.0%

32.8%

29.7%

49.5%

32.5%

Carbon monoxide

45.0%

35.6%

58.7%

60.0%

25.0%

16.7%

Carbon dioxide

14.0%

12.6%

7.1%

2.3%

18.0%

11.1%

Water

6.7%

18.6%

Methane

2.0%

0.1%

3.0%

**37.4%

H2S

1.3%

0.8%

1.5%

2.0%

100.0%

100.0%

99.7%

Ammonia
Total

2.1%

0.1%
100.0%

99.8%

100.0%

** Methane, Ethane, Ethylene

Descriptor - include initials, /org#/date