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At least 73 records · Page 4

Influence of Structure and Mineral Association of Tuyere-Level Coke on Gasification Process

The gasification properties of feed coke and tuyere coke were investigated by non-isothermal thermogravimetric method under CO{sub 2} atmosphere. The physical and chemical structure features were also systematically tested, as well as the mineral composition. The pore characteristics, graphitization degree of carbon matrix, and ash content were the main factors determining the reactivity of coke. Higher L{sub c} decreases the reactivity of tuyere coke in low temperature, while larger porosity increases the reactivity in high temperature, forming an intersection with the gasification process of the feed coke. The high content of Fe{sub 2}O{sub 3} in 25 to 20 mm tuyere coke made a rapid gasification reaction. The SiC produced in the tuyere area increased the porosity of coke especially the 5 to 1 mm coke at the edge of BF, which promoted the gasification process of coke in the area.

01 COAL, LIGNITE, AND PEAT↗

Enhancing biomass flowability for entrained flow Gasification: The role of densification and torrefaction

Gasification presents a key strategy in addressing future energy demands while minimizing environmental impact. This has been recognized as a promising method to convert biomass to higher value products such as biofuels or hydrogen. Among gasification technologies, high-temperature and high-pressure reactors, particularly the R-GAS® system, emerge as an advanced option boasting superior conversion efficiency. However, akin to conventional high-temperature and high-pressure gasifiers, R-GAS® necessitates small particle sizes for optimal carbon conversion, a requirement yet to be fully explored for biomass. Hence, this study investigated the effectiveness of combined mechanical and thermal preprocessing techniques in modifying the physicochemical properties of biomass to suit gasification systems. Mechanical techniques including densification and pulverization, alongside thermal techniques such as torrefaction and steam explosion, were examined. The results demonstrate that torrefaction fosters producing of uniform granular material, enhancing flowability and reducing energy requirements for pulverization compared to steam explosion. Notably, torrefied corn stover exhibited lower internal friction angles and effective cohesion (40.09 ± 0.22° and 0.56 ± 0.01 kPa, respectively) compared to steam exploded corn stover (41.87 ± 0.65° and 0.83 ± 0.06 kPa, respectively), indicative of improved flowability. Additionally, pulverization of torrefied corn stover required approximately 16 % less energy than steam exploded corn stover and 91 % less energy than raw corn stover. Furthermore, the torrefaction-induced alterations in particle size, shape, and packing densities emphasize its potential to optimize flow and handling processes for gasification. These findings underline that densification followed by torrefaction effectively addresses biomass variability, leading to more efficient and sustainable energy conversion.

09 - BIOMASS FUELS↗

Microwave-assisted co-gasification of mixed plastics and corn stover: A synergistic approach to produce clean hydrogen

Co-gasification of waste plastic and corn stover into hydrogen is an effective way of reducing hydrogen cost and carbon footprint. However, current gasification technologies are energy intensive and cannot accommodate flexible feedstock. Microwave gasification offers several advantages including higher H 2 yield and enhanced selectivity to syngas over tars. Herein this work presents parametric optimization study of microwave co-gasification of mixed plastics and corn stover for hydrogen-rich syngas. High hydrogen yields of 30.5 mmol H2 /g feed at 700 °C were obtained using a microwave reactor, as opposed to 0.9 mmolH 2 /g feed at 700-950 °C with conventional heating. Hydrogen yields are >98% of the theoretical extractable hydrogen from feedstock. Microwaves enhanced plastic and corn stover synergy and reduced tar yields. H-poor carbon formation resulting from the dehydrogenation of tar and coke, and light olefins decomposition, triggered by the external microwave electric fields, allowed further cracking of intermediate hydrocarbons to produce additional H 2 .

30 DIRECT ENERGY CONVERSION↗

Noble-metal-free bimetallic alloy nanoparticle-catalytic gasification of phenol in supercritical water

The exploration of non-noble-metal catalysts for high efficiency gasification of biomass in supercritical water (SCW) is of great significance for the sustainable development. A series of Ni–M (M = Co or Zn) bimetallic nanoparticles supported on graphitized carbon black were synthesized and examined as catalysts for gasification of phenol in SCW. We found that a nearly complete gasification of phenol can be achieved even at a low temperature of 450 °C with the bimetallic nanoparticles catalysts. Kinetic study indicated the activation energy for phenol gasification were 20.4 ± 2.6 and 43.6 ± 2.6 kJ/mol for Ni20Zn15 and Ni20Co15 catalyst, respectively. Furthermore, XRD, XPS and TEM were performed to characterize the catalysts and the results showed the formation of NiCo and NiZn alloy phase. Catalyst recycling experiments were also conducted to evaluate the stability of the catalysts. The characterization of used catalysts suggest that the severe agglomeration of nanoparticles leads to the decrease in catalytic activity.

36 MATERIALS SCIENCE↗

Two stage fluid bed-plasma gasification process for solid waste valorisation: Technical review and preliminary thermodynamic modelling of sulphur emissions

Highlights: Black-Right-Pointing-Pointer We investigate sulphur during MSW gasification within a fluid bed-plasma process. Black-Right-Pointing-Pointer We review the literature on the feed, sulphur and process principles therein. Black-Right-Pointing-Pointer The need for research in this area was identified. Black-Right-Pointing-Pointer We perform thermodynamic modelling of the fluid bed stage. Black-Right-Pointing-Pointer Initial findings indicate the prominence of solid phase sulphur. - Abstract: Gasification of solid waste for energy has significant potential given an abundant feed supply and strong policy drivers. Nonetheless, significant ambiguities in the knowledge base are apparent. Consequently this study investigates sulphur mechanisms within a novel two stage fluid bed-plasma gasification process. This paper includes a detailed review of gasification and plasma fundamentals in relation to the specific process, along with insight on MSW based feedstock properties and sulphur pollutant therein. As a first step to understanding sulphur partitioning and speciation within the process, thermodynamic modelling of the fluid bed stage has been performed. Preliminary findings, supported by plant experience, indicate the prominence of solid phase sulphur species (as opposed to H{sub 2}S) - Na and K based species in particular. Work is underway to further investigate and validate this.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Process and technological aspects of municipal solid waste gasification. A review

Highlights: Black-Right-Pointing-Pointer Critical assessment of the main commercially available MSW gasifiers. Black-Right-Pointing-Pointer Detailed discussion of the basic features of gasification process. Black-Right-Pointing-Pointer Description of configurations of gasification-based waste-to-energy units. Black-Right-Pointing-Pointer Environmental performance analysis, on the basis of independent sources data. - Abstract: The paper proposes a critical assessment of municipal solid waste gasification today, starting from basic aspects of the process (process types and steps, operating and performance parameters) and arriving to a comparative analysis of the reactors (fixed bed, fluidized bed, entrained bed, vertical shaft, moving grate furnace, rotary kiln, plasma reactor) as well as of the possible plant configurations (heat gasifier and power gasifier) and the environmental performances of the main commercially available gasifiers for municipal solid wastes. The analysis indicates that gasification is a technically viable option for the solid waste conversion, including residual waste from separate collection of municipal solid waste. It is able to meet existing emission limits and can have a remarkable effect on reduction of landfill disposal option.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

Investigation of sewage sludge treatment using air plasma assisted gasification

Highlights: • Thermal air plasma assisted gasification of sewage sludge is examined. •Comparison of the process performance with and without plasma reactor was evaluated. • Plasma processing reduces gas calorific value but increases the yield. • Producer gas further can be utilized for drying of sewage sludge. - Abstract: This study presents an experimental investigation of downdraft gasification process coupled with a secondary thermal plasma reactor in order to perform experimental investigations of sewage sludge gasification, and compare process parameters running the system with and without the secondary thermal plasma reactor. The experimental investigation were performed with non-pelletized mixture of dried sewage sludge and wood pellets. To estimate the process performance, the composition of the producer gas, tars, particle matter, producer gas and char yield were measured at the exit of the gasification and plasma reactor. The research revealed the distribution of selected metals and chlorine in the process products and examined a possible formation of hexachlorobenzene. It determined that the plasma assisted processing of gaseous products changes the composition of the tars and the producer gas, mostly by destruction of hydrocarbon species, such as methane, acetylene, ethane or propane. Plasma processing of the producer gas reduces their calorific value but increases the gas yield and the total produced energy amount. The presented technology demonstrated capability both for applying to reduce the accumulation of the sewage sludge and production of substitute gas for drying of sewage sludge and electrical power.

54 ENVIRONMENTAL SCIENCES↗

Enabling Entrained-Flow Gasification of Blends of Coal, Biomass and Plastics (Final Report)

This project demonstrated the technical feasibility of gasifying blends of coal, biomass and mixed waste plastics in a high pressure entrained-flow gasifier for production of hydrogen. This was achieved by creating slurries of coal, biomass pyrolysis liquids and liquefied plastic oil. Specific objectives of the project included (1) determining compositions of coal-biomass-plastic mixtures that produce a stable slurry suitable for pumping to high pressure, (2) designing and testing a novel burner to effectively atomize the mixed feedstock slurry in a pressurized gasifier, and (3) acquiring first-of-a-kind performance data for pressurized, oxygen-blown entrained-flow gasification of slurried blends of coal, biomass and plastic. A key focus of the project was preparation of mixtures of coal, biomass and plastic. To facilitate easy pumping to high pressure, slurries were created using (i) bioliquid resulting from a well-established rapid thermal treatment pyrolysis process, (ii) oil produced from waste plastic via an available thermal conversion process, and (iii) ground coal. Lab-scale tests were conducted to evaluate viscosity and stability/propensity for the mixtures to separate over time. Larger batches of the most promising slurry compositions were prepared and subjected to pumping studies. It was found that mixtures containing less than about 40% coal and less than about 30% plastic oil were stable and of low enough viscosity to facilitate pumping to high pressure. A high-performance hot oxygen burner (HOB) was designed and fabricated for use in an existing 1 ton/day pressurized entrained-flow gasifier. Ex-situ testing demonstrated that the HOB provides excellent atomization of the slurries and creates a very uniform and robust flame. Performance of the HOB in the gasifier was exceptional and resulted in better conversion to syngas than any previous generation of burner. Fabricating the HOB for this project was challenging due to the relatively small scale of the gasifier. Performance in larger-scale systems is expected to be even better. Gasification of mixtures of coal, bioliquid and plastic oil proved to be relatively easy. The gasifier was able to be started up, pressurized and transitioned to the blended slurry feedstock with no technical difficulty. Syngas rich in CO and H 2 , with relatively low concentrations of CO 2 , was produced. During startup and at low gasification temperatures, soot formation was observed, as is typical for gasification of petroleum-based feedstocks. No slag buildup was observed under the conditions tested. The project was successful in demonstrating the technical feasibility of the concept. Future development should broaden the range of feedstocks under consideration, more deeply explore performance of the gasifier, and evaluate scale-up and implementation strategies.

08 HYDROGEN↗

Fluidized Bed Gasification For Conversion of Biomass and Waste Materials to Renewable Hydrogen

This project was undertaken in order to study the potential for hydrogen production, at low cost, from mixtures of biomass and municipal solid waste (MSW). This approach allows for the production of hydrogen with a very low fossil carbon burden, while taking advantage of tipping fees (associated with MSW) to improved process economics. The team sourced three primary feedstocks (wood, MSW, and waste plastics) and characterized them comprehensively using established techniques with a long track record in the field of gasification. All three primary feedstocks were highly reactive and lost most of their mass during initial devolatilization. The production of tars, including heavy tars, was quite high, and was most problematic in the case of the MSW and Waste Plastics feedstocks. Little practical difference was identified between the MSW and Waste Plastics materials, and the addition of bed-forming materials (dolomite and brown alumina) to the feedstocks was found to reduce production of tars during devolatilization under thermogravimetric analysis and/or Fischer Assay conditions. A series of four tests in a lab-scale bubbling-fluidized-bed gasifier, at 50 psig of pressure and about 825 C, confirmed these findings. Pellet feedstocks, broken into fragments, were used for these tests, and pellets comprised of 50% MSW and 50% biomass were found to be the best option in terms of fossil carbon burden, economic potential, and gasification characteristics. Tests were then undertaken in a pilot-scale gasifier facility based on the GTI U-Gas fluidized-bed gasification technology. The feedstock handling train of the 20 TPD U-Gas pilot-scale gasifier located in Des Plaines, IL, was operated under simulated gasification conditions, and the 50/50 pellets were found to be very robust and unproblematic. An improved design for the forward end of the feedstock injection screw of the gasifier was developed and installed. The design approach was based on improved passive cooling of the front-most shroud at the end of the screw, since this approach was found in comprehensive modeling studies to be more than sufficient to accomplish the project objectives associated with this phase of the work, while also avoiding thermal gradients that could have caused heat-stress-induced damage to the refractory around the feedstock inlet if an active cooling approach had been applied. Careful technoeconomic analysis (TEA) of two possible 1000 TPD facilities was carried out. The TEA of conversion of MSW with corn stover in one case, and MSW with woody feedstock in the other case, showed that both had the potential to provide hydrogen at about $1/kg (minimum selling price, 2018 dollar basis). Of the two TEA cases, the one that was based on the conversion of wood in the southeastern USA was found to have slightly better economic potential. The other TEA case was based on a real location in Nebraska and called for corn stover feedstock conversion along with MSW. An underserved communities outreach program plan was developed in cooperation with personnel from the Nebraska Public Power District.

08 HYDROGEN↗

Method for Hot Real-Time Sampling of Gasification Products

The Thermochemical Process Development Unit (TCPDU) at the National Renewable Energy Laboratory (NREL) is a highly instrumented half-ton/day pilot scale plant capable of demonstrating industrially relevant thermochemical technologies from lignocellulosic biomass conversion, including gasification. Gasification creates primarily Syngas (a mixture of Hydrogen and Carbon Monoxide) that can be utilized with synthesis catalysts to form transportation fuels and other valuable chemicals. Biomass derived gasification products are a very complex mixture of chemical components that typically contain Sulfur and Nitrogen species that can act as catalysis poisons for tar reforming and synthesis catalysts. Real-time hot online sampling techniques, such as Molecular Beam Mass Spectrometry (MBMS), and Gas Chromatographs with Sulfur and Nitrogen specific detectors can provide real-time analysis providing operational indicators for performance. Sampling typically requires coated sampling lines to minimize trace sulfur interactions with steel surfaces. Other materials used inline have also shown conversion of sulfur species into new components and must be minimized. Sample line Residence time within the sampling lines must also be kept to a minimum to reduce further reaction chemistries. Solids from ash and char contribute to plugging and must be filtered at temperature. Experience at NREL has shown several key factors to consider when designing and installing an analytical sampling system for biomass gasification products. They include minimizing sampling distance, effective filtering as close to source as possible, proper line sizing, proper line materials or coatings, even heating of all components, minimizing pressure drops, and additional filtering or traps after pressure drops.

09 BIOMASS FUELS↗

Microwave-assisted catalytic gasification of mixed plastics and corn stover for low tar, hydrogen-rich syngas production

The challenge for efficient management of post-consumer plastic and biomass waste has grown over the past few decades due to their dramatic increases. In comparison to conventional gasification, microwave-assisted co-gasification of plastics and corn stover offers many benefits, including increased H 2 yield and gas components compared to unfavorable char/tar. Nonetheless, for future commercialization of the process and ease of product separation, further reduction of the undesirable tar is necessary, which can be achieved over the catalytic route. Here, in this work, we studied the catalytic effect of magnetite for microwave-assisted co-gasification of corn stover and plastic to make syngas with higher H 2 and lower tar selectivity over non-catalytic conditions. A 1:1:1 ratio of plastic-corn stover-magnetite was used to evaluate the reaction parameters such as temperature, space velocity, heating media, and catalytic cycles under gasification conditions. In comparison with the microwave non-catalytic route, a 100% increase in the total H 2 yield with 76% higher H 2 production efficiency (mmol/kWh) was achieved in the presence of the magnetite catalyst, while reducing the overall tar formation from 9% to 2%. When magnetite was reduced in situ during the reaction, it coupled with microwave and delivered oxygen radicals that cracked down plastic and corn stover intermediates generated from the synergistic effect under microwave heating. Soon after the oxygen transfer process initiated, magnetite reached its final oxidation state consisting of microwave-active Fe and Fe 3 C phases that continued coupling with microwaves along with the generated graphitic carbon to maintain the heat necessary to further reduce the generated tar and make additional gaseous products, as confirmed by XRD, Raman, and TGA analyses.

08 HYDROGEN↗

Product Characterization for Entrained Flow Coal/Biomass Co-Gasification

The U.S. Department of Energy‘s National Energy Technology Laboratory (DOE NETL) is exploring affordable technologies and processes to convert domestic coal and biomass resources to high-quality liquid hydrocarbon fuels. This interest is primarily motivated by the need to increase energy security and reduce greenhouse gas emissions in the United States. Gasification technologies represent clean, flexible and efficient conversion pathways to utilize coal and biomass resources. Substantial experience and knowledge had been developed worldwide on gasification of either coal or biomass. However, reliable data on effects of blending various biomass fuels with coal during gasification process and resulting syngas composition are lacking. In this project, GE Global Research performed a complete characterization of the gas, liquid and solid products that result from the co-gasification of coal/biomass mixtures. This work was performed using a bench-scale gasifier (BSG) and a pilot-scale entrained flow gasifier (EFG).

01 COAL, LIGNITE, AND PEAT↗

Fluid-Bed Testing of GreatPoint Energy's Direct Oxygen Injection Catalytic Gasification Process for Synthetic Natural Gas and Hydrogen Coproduction: Year 6 - Activity 1.14 - Development of a National Center for Hydrogen Technology

The GreatPoint Energy (GPE) concept for producing synthetic natural gas and hydrogen from coal involves the catalytic gasification of coal and carbon. GPE’s technology “refines” coal by employing a novel catalyst to “crack” the carbon bonds and transform the coal into cleanburning methane (natural gas) and hydrogen. The GPE mild “catalytic” gasifier design and operating conditions result in reactor components that are less expensive and produce pipeline-grade methane and relatively high purity hydrogen. The system operates extremely efficiently on very low cost carbon sources such as lignites, subbituminous coals, tar sands, petcoke, and petroleum residual oil. In addition, GPE’s catalytic coal gasification process eliminates troublesome ash removal and slagging problems, reduces maintenance requirements, and increases thermal efficiency, significantly reducing the size of the air separation plant (a system that alone accounts for 20% of the capital cost of most gasification systems) in the catalytic gasification process.

01 COAL, LIGNITE, AND PEAT↗

Imperium/Lanzatech Syngas Fermentation Project - Biomass Gasification and Syngas Conditioning for Fermentation Evaluation: Cooperative Research and Development Final Report, CRADA Number CRD-12-474

LanzaTech and NREL will investigate the integration between biomass gasification and LanzaTech's proprietary gas fermentation process to produce ethanol and 2,3-butanediol. Using three feed materials (woody biomass, agricultural residue and herbaceous grass) NREL will produce syngas via steam indirect gasification and syngas conditioning over a range of process relevant operating conditions. The gasification temperature, steam-to-biomass ratio of the biomass feed into the gasifier, and several levels of syngas conditioning (based on temperature) will be varied to produce multiple syngas streams that will be fed directly to 10 liter seed fermenters operating with the Lanzatech organism. The NREL gasification system will then be integrated with LanzaTech's laboratory pilot unit to produce large-scale samples of ethanol and 2,3-butanediol for conversion to fuels and chemicals.

09 BIOMASS FUELS↗

Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO 2 Capture

This document is the final report for the project titled “Chemical Looping Gasification for Hydrogen Enhanced Syngas Production with In-Situ CO 2 Capture” under award number FE0012136 for the performance period 10/01/2013 to 12/31/2014.This project investigates the novel Ohio State chemical looping gasification technology for high efficiency, cost efficiency coal gasification for IGCC and methanol production application. The project developed an optimized oxygen carrier composition, demonstrated the feasibility of the concept and completed cold-flow model studies. WorleyParsons completed a techno-economic analysis which showed that for a coal only feed with carbon capture, the OSU CLG technology reduced the methanol required selling price by 21%, lowered the capital costs by 28%, increased coal consumption efficiency by 14%. Further, using the Ohio State Chemical Looping Gasification technology resulted in a methanol required selling price which was lower than the reference non-capture case.

01 COAL, LIGNITE, AND PEAT↗

Wabash Valley Integrated Gasification Combined Cycle, Coal to Fischer Tropsch Jet Fuel Conversion Study

This reports examines the feasibility of converting the existing Wabash Integrated Gasification Combined Cycle (IGCC) plant into a liquid fuel facility, with the goal of maximizing jet fuel production. The fuels produced are required to be in compliance with Section 526 of the Energy Independence and Security Act of 2007 (EISA 2007 §526) lifecycle greenhouse gas (GHG) emissions requirements, so lifecycle GHG emissions from the fuel must be equal to or better than conventional fuels. Retrofitting an existing gasification facility reduces the technical risk and capital costs associated with a coal to liquids project, leading to a higher probability of implementation and more competitive liquid fuel prices. The existing combustion turbine will continue to operate on low cost natural gas and low carbon fuel gas from the gasification facility. The gasification technology utilized at Wabash is the E-Gas™ Technology and has been in commercial operation since 1995. In order to minimize capital costs, the study maximizes reuse of existing equipment with minimal modifications. Plant data and process models were used to develop process data for downstream units. Process modeling was utilized for the syngas conditioning, acid gas removal, CO 2 compression and utility units. Syngas conversion to Fischer Tropsch (FT) liquids and upgrading of the liquids was modeled and designed by Johnson Matthey Davy Technologies (JM Davy). In order to maintain the GHG emission profile below that of conventional fuels, the CO 2 from the process must be captured and exported for sequestration or enhanced oil recovery. In addition the power utilized for the plant’s auxiliary loads had to be supplied by a low carbon fuel source. Since the process produces a fuel gas with sufficient energy content to power the plant’s loads, this fuel gas was converted to hydrogen and exported to the existing gas turbine for low carbon power production. Utilizing low carbon fuel gas and process steam in the existing combined cycle power plant provides sufficient power for all plant loads. The lifecycle GHG profile of the produced jet fuel is 95% of conventional jet fuel. Without converting the fuel gas to a low carbon fuel gas, the emissions would be 108% of conventional jet fuel and without any GHG mitigation, the profile would be 206%. Oil prices greater than $120 per barrel are required to reach a targeted internal rate of return on equity (IRROE) of 12%. Although capital expenditure is much less than if a greenfield facility was built, the relatively small size of the plant, assumed coal price, and the CTL risk profile used in the economic assumptions lead to a high cost of production. Assuming more favorable factors, the economic oil price could be reduced to $78 per barrel with GHG mitigation and $55 per barrel with no GHG mitigation.

01 COAL, LIGNITE, AND PEAT↗

Second stage gasifier in staged gasification and integrated process

A second stage gasification unit in a staged gasification integrated process flow scheme and operating methods are disclosed to gasify a wide range of low reactivity fuels. The inclusion of second stage gasification unit operating at high temperatures closer to ash fusion temperatures in the bed provides sufficient flexibility in unit configurations, operating conditions and methods to achieve an overall carbon conversion of over 95% for low reactivity materials such as bituminous and anthracite coals, petroleum residues and coke. The second stage gasification unit includes a stationary fluidized bed gasifier operating with a sufficiently turbulent bed of predefined inert bed material with lean char carbon content. The second stage gasifier fluidized bed is operated at relatively high temperatures up to 1400.degree. C. Steam and oxidant mixture can be injected to further increase the freeboard region operating temperature in the range of approximately from 50 to 100.degree. C. above the bed temperature.

42 ENGINEERING↗

Gasification of Waste Plastic to Enable a Circular Economy: Literature Review Focusing on H2/Syngas Production

This report briefly reviews 1) the physicochemical properties of feedstocks; 2) hydrogen/syngas production from plastic gasification and co-gasification of plastic with coal and/or biomass, including the discussions on effects of operating conditions on H2 production; and 3) the mechanism of plastic gasification, including the formation and decomposition of char/tar during gasification process.

Shi, Fan↗