Update on STF technology Freiberg test plant for the production of high octane gasoline from synthesis gas Dr. Mario Kuschel, May 2012
1 Review STF technology 2 First Results 3 Outlook
Raw Material Synthesis gas generation Production of gasoline Natural gas Crude oil associated gas Coal Biomass Partial non catalytic oxidation Catalytic auto thermal reforming Syngas to Methanol Methanol to Fuel Gasoline
Fresh synthesis gas Steam Methanol synthesis reactor Steam condensate system Steam Boiler feed water Fuel synthesis reactor Electric energy Instrument & compressed air Circulation compressor Power supply Instrument and compressed air supply Control room Analytics Methanol Recycle gas Overhead product Flare Circulation compressor Recycle gas Cooling and separation Cooling and separation Instable fuel Fuel stabilization column Heavy fuel Absorption refrigerating machine Recooling plant Nitrogen supply Feed water buffer vessel Feed water Methanol separation column Process waste water CO + H2 gas Purifed water Stable fuel Produkt - Lager Catalytic waste water purification
Technical University Bergakademie Freiberg, Department of Energy Process Engineering and Chemical Engineering, Reiche Zeche STF plant Synthesis gas plant
Novelties of Technology: Employment of new isothermal reactors Advantage: more stabile and better product quality Employment of new developed catalysts in section of gasoline production and treatment of process water (formed in process) Advantage: higher product yields and better product quality Lower rate of circulation gases in combination with isothermal plant operation Advantage: Lower rates of circulation gases are necessary in comparison to adiabatic operation mode.
11 Die Review Chemieanlagenbau STF technologychemnitz GmbH stellt sich vor 2 First results 2.1 Test campaigns 2.2 Results of full load mode 2.3 Results of partial load mode 3 Outlook
Test campaigns: 1. June 2010 2 weeks 2.1 December 2010 2 weeks 2.2 Feb./March 2011 4 weeks 3. Aug./Sept. 2011 4 weeks total 12 weeks forecast: 5. May/June 2012 6 weeks
1 st campaign: 15.06.2010 Feed of synthesis gas and Start-up of main process units in test mode 17.06.2010 Sampling of first STF fuel produced in test facility 2 nd campaign: (Febr./March 2011) Supply Syngas Methanol, pure Gasoline, instable 3 rd campaign: (Aug./Sept. 2011) Supply Syngas Methanol, pure Gasoline, instable 95 h 9,170 kg 4,000 kg 240 h 12,850 kg 8,800 kg
Properties of STF fuel Density (15 C) Molecular mass Paraffins Olefins Naphthenes STF fuel 750 760 95 96 30 40 4 6 7 9 DIN EN 228:2004-03 gasoline, regular 720 775 max. 18 kg/m³ kg/kmol wt% wt% wt% Aromatic compounds Benzene Durene 34 36 0,2 0,4 max. 3 max. 35 max. 1 wt% % vol. % vol. Research octane number Motor octane number Steam pressure Boiling range 93 95 84 85 66,7 40 186 min. 91 min. 82,5 max. 100 - kpa C
First results of full load mode: tests with a modern fuel injection motor (Downsizing Concept) Comparative fuel: Gasoline RON 95 ( Super E10 with 5.1% Ethanol) p me [bar] 26 24 22 20 18 16 14 12 STF Benzin Charge 2 Basis Benzin ROZ95 16 Valuation of Results: With STF gasoline nearly same results under full load at constant charging pressure Ignition angle with STF gasoline minimal later (ca. 1 KW), this means knocking behavior slightly higher Specific fuel demand Beff until 4000 1/min for both fuels identical, at higher speed (number of revolutions) slightly higher Beff [g/kwh] 400 375 350 325 300 275 250 1000 2000 3000 4000 5000 6000 12 8 4 0-4 -8-12 Ignition Angle [-] Zündwinkel [-] in cooperation with: Drehzahl [1/min] Speed [1/min]
First results of partial load mode: fuel consumption for STF similar to commercial gasoline, with ethanol addition increasing value due to decreasing cross value with STF increased HC emissions at higher loads, slight decrease through E10 NO x with STF at level of commercial gasoline, STF E20 as expected at lowest level ROZ 95 ROZ98 STF1 STF3 STF3 E10 STF3 E20 in cooperation with: HC [ppm] 1500 1250 1000 750 500 250 0 4500 4000 3500 3000 2500 2000 1500 1000 500 0 2 4 6 8 10 12 14 0 16 pme [bar] 600 520 440 360 280 200 Beff [g/kwh] NOx [ppm]
1 Review STF technology 2 First Results 3 Outlook
Open points: Constant operation with all units Optimization of process parameters of gasoline synthesis especially heat transfer Development of improved reactor for gasoline synthesis Variation in methanol quality and investigation of impurities due to different sources of methanol Improvement of sampling e.g. Sampling under high pressure Target: First commercial plant in Engineering Phase latest end of 2013
Acknowledgement The project is supported with public funding by the Saxon State Ministry for Economic Affairs and Labour (SMWA) represented by the Sächsische AufbauBank (SAB) financed by the European Regional Development Fund (ERDF) as well as by private investors. European Union European Regional Development Fund
Chemieanlagenbau Chemnitz GmbH Augustusburger Str. 34 09111 Chemnitz Germany Phone: +49 371 68 99 0 Fax: +49 371 6899 342 Internet: www.cac-chem.de Email: info@cac-chem.de