Documente Academic
Documente Profesional
Documente Cultură
8
Exergetic Process Assessment
8.1
Exergy Calculations
In the logical next step of gasication process evaluation, attention is shifted from
the chemical efciency parameters to assessing the thermochemical efciency by
means of an exergetic analysis. Hence, different raw gas cooling methods, gasify-
ing agent consumption, and auxiliary consumptions will determine the results.
An exergetic analysis combines the chemical properties of the streams with their
thermomechanical state (e.g., temperature, pressure, moisture), which will be
described in detail in Section 8.1. Because the gas cooling method applied will
alter the thermomechanical state and can sometimes even change the chemical
properties (e.g., chemical quench), there is obviously a high impact on gasier
efciency. Consequently, it is instructive to understand stream changes during
gas cooling before judging the overall system.
8.1.1
Exergy and Reference Environment
Industrial Coal Gasication Technologies Covering Baseline and High-Ash Coal, First Edition.
Martin Grbner.
2015 Wiley-VCH Verlag GmbH & Co. KGaA. Published 2015 by Wiley-VCH Verlag GmbH & Co. KGaA.
320 8 Exergetic Process Assessment
Exergy ows are identical to power in the case of the change of potential, kinetic,
or electric energies. To evaluate the ow i of a uid mixture, specic exergies ei
in kJ/kg for every mass ow m _ i in kg/s must be calculated.
E_ i ei ? m
_ i: (8.2)
The last term in Equation (8.3) is not applied for most of the evaluated streams,
as the concentration potential is not usable. However, the concentration exergy
represents the minimal necessary reversible separation energy for the concen-
trated oxygen (in gasifying agents) and nitrogen ows (e.g., for dry feeding) from
the air separation unit. Therefore, it is included in these streams.
8.1.2
Exergy of Gaseous and Liquid Streams
The specic exergy of gaseous and liquid streams is calculated on a molar basis
taking the molar ow ni in kmol/s into account:
E_ i ei;n;tm ei;n;chem ei;n;conc ? n_ i : (8.4)
Using the molar fraction of water xH2 O , the thermomechanical exergy is split
into the dry gas exergy ei;n;tm;dry and moisture exergy ei;n;tm;H2 O both in kJ/kmol,
the latter referring to the condensed state of water.
ei;n;tm 1 xH2 O ? ei;n;tm;dry xH2 O ? ei;n;tm;H2 O : (8.5)
As shown in Equation (8.6), the dry exergy is calculated with regard to the mean
T
specic molar heat capacity of the dry gas mix cpm;i jT i0 in kJ/(kmolK) for the
enthalpy calculation and temperature T i in K. In the entropy expression, the dry
partial pressure pdry;i 1 xH2 O ? pi and reference pressure p0 , both in the
8.1 Exergy Calculations 321
same unit, are used, where R represents the universal gas constant (8.314462 kJ/
(kmolK)).
T T Ti pdry;i
ei;n;tm;dry cpm;i jT i0 ? T i T 0 T 0 ? cpm;i jT i0 ? ln R ? ln :
T0 p0
|{z}
enthalpy term
|{z}
entropy term
(8.6)
T
The mean specic molar heat capacity of the dry gas mix cpm;i jT i0 can be easily
calculated or extracted as a stream property from a process simulator, for exam-
ple, Aspen Plus [2]. The moisture exergy ei;n;tm;H2 O must include the complete
condensation of any water vapor. Although the specic enthalpy h0 1890:3 kJ/
kmol and entropy s0 6:616 kJ/(kmolK) of the reference water are xed, the
enthalpy hi in kJ/kmol and entropy si in kJ/(kmolK) are computed applying the
IAPWS-IF97 formulation for the gas temperature and partial H2O pressure.
ei;n;tm;H2 O hi h0 T 0 ? si s0 : (8.7)
Equation (8.7) is also used to determine the exergy of all boiler feed water or
steam ows.
As already indicated, the thermomechanical and the concentration exergy are
computed for oxygen- and nitrogen-enriched ows, reecting the separation
effort, which is suitable to compare oxygen-blown gasiers. The combined cal-
culation of ei;n;tm and ei;n;conc is shown in Equation (8.8) [1]. In the following
equation, xj and pi;j are the molar fraction and the partial pressure of the compo-
nent j and pj;air;0 stands for the partial pressure for the same component in air
referring to the reference environment.
!!
Ti Ti Ti X pi;j
ei;n;tmconc cpm;i jT 0 ? T i T 0 T 0 ? cpm;i jT 0 ? ln R? xj ln :
T0 j
pj;air;0
(8.8)
The chemical exergy of the gas mixture is calculated using a simplied equation
neglecting mixing exergies occurring during the reactions. Because this portion
is very small in comparison to the reaction exergy (0.10.7%), an approxima-
tion using the mean value of the reaction exergies ej;R in kJ/mol is justied.
X
ei;n;chem xj ? ej;R : (8.9)
j
The specic molar reaction exergies are calculated for the pure components j
according to the reference environment as described earlier (see Section 8.1.1)
assuming that energy is released through stoichiometric oxidation with air at
reference conditions, see Equation (8.10). The molar higher heating value
322 8 Exergetic Process Assessment
Table 8.1 Molar standard entropies in kJ/(kmolK) at T 0 298:15 K and p0 1013:25hPa [3].
HHVn;j in kJ/kmol and the molar standard entropies of the component sj , of the
dry reference air sair;0 , and of the reaction products sk (all in kJ/(kmolK)) are
necessary for the calculation.
!
X
ej;R HHVn;j T0 ? sj l1 ? sair;0
vk ? sk : (8.10)
k
All necessary molar entropies, which are presented in Table 8.1, were taken from
the literature [3] and all gaseous components must be corrected to match the
reference pressure. The specic molar production of a reaction product pertain-
ing to the pure gas component is represented by vk (e.g., kmol(CO2)/kmol(j)).
The molar stoichiometric air demand l1 in kmol(air)/kmol(j) is multiplied with
the dry reference air sair;0 entropy, which is calculated by the following equation,
where i N2 ; O2 ; Ar:
X X
1
sair;0 xi ? si R ? xi ? ln : (8.11)
i i
x i
The results of the evaluation and reactions investigated to convert the pure com-
ponents into the reference components are shown in Table 8.2.
Table 8.2 Reactions, molar heating values, and molar reaction exergies of the pure compo-
nents j in kJ/kmol.
8.1.3
Exergy of Solid Streams
For all dry solid ows, the mean specic heat capacity cm;i in kJ/(kgK) is calcu-
lated based on coal enthalpy model HCOALGEN as implemented, for exam-
ple, in Aspen Plus [2], which features a linear dependency from temperature i
(in C):
T
cm;i jT i0 cm;0 i ? cm ;
kJ
cm;0 0:76095 ; (8.13)
kg ? K
kJ
cm 2:9308 10 4
:
kg ? K2
The exact chemical exergy can only be determined for pure carbon (graphite), as
shown in Table 8.2. For the coal-feed streams, an approximation equation was
used in line with literature [4], Equation (8.14), where HHVi is to be provided in
MJ/kg, yielding the same unit for the chemical exergy.
8.1.4
Denition of Efforts and Benets
Exergy is balanced in the three zones (gasier balance, cooling balance, overall
balance) indicated in Figure 8.1. The benet is always dened as the thermome-
chanical and chemical exergy ow of the product gas plus additional exergy
ows due to steam production (E_ steam E_ BFW ). All recycled streams were sub-
tracted from the benet. All other streams were put by denition in the denomi-
nator (effort) of Equation (8.1). Every preheated stream is treated in the hot
state. The electric energy demand for coal milling and transporting it is
assumed further drying is not necessary is given by the literature [5] as
26 kWh/t coal for an average grain size of 90 m and 13 kWh/t for an average
grain size of 1 mm. In the gas cooling section, only the recycle gas compressor
for the Shell cold gas quench consumes noticeable electricity.
324 8 Exergetic Process Assessment
8.2
Exergetic Analysis
8.2.1
Impact of Gas Cooling Methods
Because the gas cooling method applied alters the exergy of the product gas sig-
nicantly, there is obviously a high impact on gasier efciency. Consequently, it
is instructive to understand changes during gas cooling before looking at the
overall system balance. Figure 8.2ae presents ve different gas cooling methods
as applied in the gasication systems analyzed. The following explanation refers
to the parts of Figure 8.2:
a) Gas cooling by water evaporating into the gas, the so-called full water
quench, is applied in the Siemens system and causes the highest exergy
losses ( 5.1 % total, 37.7% thermomechanical) but saturates the raw gas
with steam, which might be useful for downstream processes. The change
in chemical exergy ow ( 0.16 %) due to the quench conversion is
negligible.
b) If the hot gas comes into contact with carbon given the presence of H2O
and/or CO2 endothermic reactions such as the Boudouard reaction (4.6)
or the heterogeneous water-gas shift (4.7) allow thermomechanical exergy
to be converted into chemical exergy. A chemical quench of this type, fol-
lowed by a convective syngas cooler, is applied in the standard E-Gas gasi-
er. Coal serves as a source of carbon and additional chemical exergy, and
is fed into the hot raw gas ow according to the slurry split (approximately
25%). The residual thermomechanical exergy is recovered by generating
steam in a convective syngas cooler limited by the gas dew point.
8.2 Exergetic Analysis 325
500 500
Sticky ash zone +79 MW chemical exergy
23 MW quench loss 27 MW
400 recovered 400
200 200
1500 1250 1000 750 500 250 1500 1250 1000 750 500 250
(a) (b)
500 500
34 MW
29 MW +23 MW Recyle
400 recovered 400
recovered gas & com-
pressor exergy
300 300
1)
RSC PWQ CGQ CSC
200 200
1500 1250 1000 750 500 250 1500 1250 1000 750 500 250
(c) (d) Temperature (C)
500
Thermomechanical exergy
34 + 12 MW Chemical exergy
Exergy flow (MW)
300 2)
RSC CSC
200
1500 1250 1000 750 500 250
Temperature (C)
(e)
Figure 8.2 Exergetic analysis of different gas cooler (GE-RC) (CGQ Cold gas quench,
cooling methods for 500 MW Pittsburgh No. 8 ChQ Chemical quench, PWQ Partial water
(Pitt#8) coal entrained-ow gasiers: (a) full quench, CSC Convective syngas cooler,
water quench (Siemens), (b) chemical quench RSC Radiant syngas cooler, 1) cooling to
(E-Gas), (c) radiant cooler followed by partial 810 C, 2) cooling to 700 C) (with permission
water quench (GE-R), (d) cold gas quench from Ref. [9]. Copyright 2014, Elsevier).
(Shell), (e) radiant and convective syngas
Except in the case of chemical quenching (E-Gas), the gas cooling inuences
the chemical exergy only marginally, for example, by quench conversion. The
residual thermomechanical exergy ow is mainly a result of the latent heat due
to gas moisture and, secondarily due to elevated pressure and temperature,
which is determined by the gas dew point. However, in practice, all convective
syngas coolers display fouling problems that reduce plant availability [8].
Whether or not the efciency gain and steam production (e.g., as moderator)
can offset the reliability problems is an economic decision.
8.2.2
Comparison of Gasication Systems
The coal exergy ow, calculated on an higher heating value (HHV) basis, is
constant (525.7 MW) and clearly dominates the input stream. Most of the
exergy is conserved in the gas phase, as can be seen from the respective val-
ues of gas chemical exergy ow, which reect the cold gas efciency to a
certain extent.
The oxygen consumption is the highest for slurry-feed GE gasication and
the lowest for the uid-bed systems. Dry-feed entrained-ow systems and
the E-Gas gasier achieve values between these extremes. The oxygen con-
sumption level for South African (SAf) coal is elevated compared to Pitts-
burgh No. 8 (Pitt#8) coal.
8.2 Exergetic Analysis 327
GE-RC GE-RC
GE-Q GE-Q
HTW HTW
E-Gas E-Gas
Shell Shell
Siemens Siemens
GE-RC GE-RC
Pitt#8 new concepts
GE-R GE-R
INCI INCI
E-Gas E-Gas
Shell Shell
Siemens Siemens
250 300 350 400 450 520 530 540 550 560 250 300 350 400 450 520 530 540 550 560
Exergy flow (MW) Exergy flow (MW)
Exergy benefits: Gas chemical & thermomechanical Steam
Exergy efforts: Coal Oxygen Steam Auxiliaries
Figure 8.3 Exergetic overview of all cases investigated (HTW high-temperature Winkler, INCI
internal circulation gasier, Pitt#8 Pittsburgh No. 8 coal, SAf South African coal) (with permis-
sion from Ref. [9]. Copyright 2014, Elsevier).
All non-slurry systems require moderator steam to process Pitt#8 coal; this
applies to all new concepts. For SAf coal, mineral matter moderates the tem-
perature to some extent. Consequently, only the uid-bed systems require
steam as a gasifying agent. Only for the standard Siemens, new Shell, and
new GE-Q congurations is there any question as to whether the moderator
steam demand can be covered by the internal steam production during
gasication.
The auxiliary consumptions include compressor loads, coal milling and con-
veying consumption, quench water preheat and pressurization, pilot fuels,
and injected purge gases. In all standard GE systems, the auxiliary exergy
ow increases in proportion to the quench water demand. For SAf coal, the
general level is higher due to the elevated raw gas mass ow. The high-tem-
perature Winkler (HTW) system and internal circulation uidized bed
(INCI) concept show the lowest auxiliary consumption due to the moderate
gas cooling effort and, in the case of HTW, the lower coal grinding required.
For all E-Gas systems, the gas cooling efforts are similar, but a recycle gas
328 8 Exergetic Process Assessment
compressor is needed, which increases the auxiliary load. The recycle gas
compressor featured in the standard Shell system consumes less exergy than
necessary for the quench water preheat and pressurization used in the new
concept. The Siemens systems display the highest auxiliary demand due to a
high quench water demand and additional pilot burner fuel, which increases
for the lower-grade feedstock.
Regarding steam generation, the standard GE-RC design features the highest
steam production, while the GE-Q design provides no steam at all. The stan-
dard Siemens systems and the new concepts from Shell also raise little
steam either directly or indirectly from the membrane wall. In general, the
steam production is higher in the case of the SAf coal due to the higher
mass ows (inert material, oxygen) needed for constant thermal capacity
and a higher gasication temperature.
The residual thermomechanical exergy ow of the product gas is dominated
by its H2O content, which is strongly dependent on the gas cooling method
(compare to Figure 8.2). The different GE cases reveal that the amount of
thermomechanical exergy ow remains nearly constant if the gas is added
to the steam raised. Hence, the utilization of the gas determines whether it
is benecial or not for the raw gas to have a high moisture exergy; in this
study it is treated as benecial (e.g., for CO shift conversion).
85 85
Pitt#8 SAf
75 75
Standard Advanced Standard Advanced
Siemens Siemens
Shell Shell
E-Gas E-Gas
70 HTW/ICFB HTW/ICFB 70
GE-R GE-R
70 75 80 85 70 75 80 85
ex,S (Gasifier + Raw Gas Cooling) (%) ex,S (Gasifier + Raw Gas Cooling) (%)
Figure 8.4 Change in the exergetic process 8 (Pitt#8) and South African (SAf) coal (HTW
efciency of the gasier and of the gasier high-temperature Winkler, INCI internal cir-
including raw gas cooling, comparing stan- culation gasier) (with permission from
dard and advanced design for Pittsburgh No. Ref. [9]. Copyright 2014, Elsevier).
for Pitt#8 coal. However, in the case of SAf coal, only the INCI uid-bed
approach might hold the potential to exceed 80% considerably.
8.3
Conclusions of Process Assessment
1) The Siemens gasier shows the highest syngas yield of all the standard
technologies for various coals and ash contents. It has also the highest
cold gas efciency among the standard systems, only slightly exceeded by
the HTW at 45 wt%(wf) ash. The exergetic process efciency can be
improved by +1.3 to +1.5%-pts. replacing the full water quench with par-
tial heat recovery as intended in the advanced concept. The main barrier to
higher exergetic process efciencies is the application of a pilot fuel.
2) The standard Shell gasier shows the highest exergetic process efciency
of all standard single-stage systems for Pitt#8 coal. Because of a higher
heat loss from the reaction zone, the cold gas efciency and syngas yield
are slightly lower than in the standard Siemens systems. The new simpli-
ed reaction chamber with full water quench shows the potential to exceed
all Siemens designs as long as no pilot fuel is required, especially for ash-
rich coals.
330 8 Exergetic Process Assessment
References