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Enefit technology and development DEVELOPING AN IMPROVED SOLID HEAT - - PowerPoint PPT Presentation
Enefit technology and development DEVELOPING AN IMPROVED SOLID HEAT - - PowerPoint PPT Presentation
Enefit technology and development DEVELOPING AN IMPROVED SOLID HEAT CARRIER PROCESS ENEFIT 280 Indrek Aarna, Andreas Orth Enefit Outotec Technology Agnes von Garnier, Peter Weber Outotec October 18-20, 2010 30th Oil Shale Symposium
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Contents
§ From Enefit 140 to Enefit 280 § Project schedule and status § Test work performed § Direct drying tests § Combustion of spent shale § Computational analysis § SolidSim – a new tool for particle class balance § CFD analysis of Waste Heat Recovery Unit § Dynamic modeling § Enefit test and pilot plant § Conclusions
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Improvements to Enefit 140 Process
- Lower air emissions
- Lower organic carbon content in ash (processed shale)
- Lower water consumption
- Increased thermal efficiency of the process
- Increased availability of the plant
- Lower dust content of shale oil (< 0.15 %)
- Lower specific gravity of oil (< 1.0 kg/l)
- Double existing unit capacity of 140 t/h oil shale throughput
Capacity Product Quality Efficiency Environment
Enefit 280
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Project schedule
July, 10, 2009
u Contract to built 1.5 Mbbl/a shale oil plant in Narva signed u Joint Venture Enefit Outotec Technology founded
May, 3rd, 2010
u “breaking ground” event
June 2010
u Piling completed u Commencement of civil works
October 2010
u Commencement of mechanical
erection with oversize retort lift 1st Quarter 2012
u Start of hot commissioning
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Narva plant site, October 2010
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Oil shale test work: Analytical data
Ash analysis
- CaO:
- SiO2:
- MgO:
- Al2O3:
- Fe:
- K:
Properties
- Heating value: 8.4 MJ/kg w
- Density: 1000 kg/m3
- Oil yield in ENEFIT 280:15.1% d.b.
Proximate Analysis
- Mineral content:
- Moisture:
- Organic content:
Analysis (dry basis)
- Ash:
- Ctot:
- H:
- S:
- N:
- Cmineral:
- TOC:
52.2% 25.4% 2.31% 0.39% 0.12% 6.7% 18.7% 42 - 50% 9 - 12% 25 - 30% 51.8% 22.8% 6.5% 5.6% 2.9% 2.0% Fischer assay
- Oil:
- Gas:
- Water:
- Semi coke:
16.1 % 5.8 % 2.5 % 75.6 %
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Aspen+ model: using the analytical data
RETORT CONDENSATION CFB Oil shale Proximate + ultimate analysis, mineral composition Ash Mineral composition Semicoke composition Oil composition Gas yield Flue gas Fischer Assay Analytical data Enefit 140 Water Vapor-gas mixture Gas composition Oil yield Semicoke yield
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Aspen+ model: Heat and mass balance (Estonian example)
ENEFIT 280 Energy balance (specific) 6.64 t OS (wet) 1 t Shale Oil 17.5 MWh 11.4 MWh 0.34 t Retort Gas 3.2 MWh 0.3 MWh El. Energy 0.9 MWh el. Energy Losses 2.4 MWh Efficiencies Specific oil yield 0.151 t Oil / t Oilshale dry Total energy efficiency 0.87 Total efficiency related to oil 0.64
Oil winning
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700mm CFB pilot plant (at Outotec R&D Center, Frankfurt)
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700mm CFB pilot plant (at Outotec R&D Center, Frankfurt)
Modifications for drying tests
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5 10 15 20 25 30 35 40 45 50 55 0 - 100 100 - 200 200 - 315 315 - 500 500 - 1000 1000 - 2000 2000 - 4000 > 4000 grain size [µm] fraction [%]
OS 45/09<6,3mm Cyc 2 Discharge Test 6 Cyc 2 Discharge Test 7 Cyc 2 Discharge Test 8
Direct drying of oil shale (700mm CFB pilot plant)
PHASE III: oil shale feed < 6,3mm, 2. Day / With widening [DN100->DN125] Combined PSD (Cyclone II Discharge + Dust Loss)
5 10 15 20 25 30 35 40 45 50 55 0 - 100 100 - 200 200 - 315 315 - 500 500 - 1000 1000 - 2000 2000 - 4000 > 4000
grain size [µm] fraction [%]
OS 45/09<6,3mm Cyc 2 Discharge Test 6 Cyc 2 Discharge Test 7 Cyc 2 Discharge Test 8
Phase III: oil shale feed < 6.3 mm PSD cyclone II discharge
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SolidSim – a new tool for particle class balance First design
Retort CFB WHB
Oil Shale Gas to Condensation Ash
Venturi Ash Scrubber
Primary Air Steam Secondary Air
Ash Cooler ESP
Ash
Dust Chamber Air Slide WHB Cyclone
36 t/h 1.7 t/h
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SolidSim – a new tool for particle class balance Improved design
Retort CFB WHB
Oil Shale Gas to Condensation Ash
Venturi Ash Scrubber
Primary Air Steam Secondary Air
Ash Cooler ESP
Ash
Dust Chamber Air Slide WHB Cyclone
11 t/h 0.6 t/h
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Combustion of spent shale (700mm CFB pilot plant)
100 200 300 400 500 600 700 800
29.09. 22:00 30.09. 00:00 30.09. 02:00 30.09. 04:00 30.09. 06:00 30.09. 08:00 30.09. 10:00 30.09. 12:00 30.09. 14:00 30.09. 16:00 30.09. 18:00 30.09. 20:00 30.09. 22:00 01.10. 00:00
date / time
feed and discharge rate [kg/h] / Temperature [°C] 0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 CO2-offgas [%, d.b.]
Semi Coke Feed [kg/h] bottom ash discharge [kg/h] T225 CFB bottom [°C] CO2 [%]
Test 1 Test 2 Test 3 Test 4 Test 5
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Environmental: Emissions optimized and proven
- SO2 < 50 mg/m3 (stp)
– Excess of limestone absorbs sulphuric oxides
- PM < 25 mg/m3 (stp)
– ESP with 5 fields guarantees low dust emissions
- NOx < 200 mg/m3 (stp)
– Air staging in CFB prevents high temperature zones for thermal NOx generation
- TOC (ash) ~ 0
– CFB has excellent heat and mass transfer conditions and provides enough retention time
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CFD analysis - waste heat recovery unit
Original design
baffles inlet
- utlet
superheater
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bypass current
m/s
CFD analysis - waste heat recovery unit
Weak points
- 1. inhomogeneous flow in vertical channel
- 2. vortex zone
- 3. dead zone between inlet channels
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CFD analysis - waste heat recovery unit
Improved design
displayed cross sections m/s
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