Wasserstoffherstellung: Das industrielle Verfahren zur Wasserstoffherstellung beruht auf dem katalytischen Reformieren (Nickel-Katalysatoren) von Erdgas mit Wasserdampf. Bei diesem Prozeß erfolgt eine Dampfspaltung (steam reforming) des Erdgases (Methan). Methan wird dabei in Reaktoren bei Temperaturen von ca. 850 §C zu Wasserstoff (H2) und Kohlenmonoxid umgesetzt. Nach der Umsetzung wird das Gas schnell abgekühlt, wobei gleichzeitig Prozeßdampf gebildet wird. In einer Folgereaktion reagiert das Kohlenmonoxid und überschüssiges Wasser mit Hilfe eines Katalysators zu weiterem Wasserstoff und Kohlendioxid. Daran schließt sich eine CO2-Entfernung und die Isolierung von Wasserstoff an [CO2-Druckwäsche (Weissermel 1994); PSA, pressure swing adsorption (Ullmann 1989a)]. Wasserstoff (H2) wird heute in erster Linie aus Kohlenwasserstoffen gewonnen. Daneben gibt es noch kohlechemische und elektrochemische Prozesse, die aber von geringerer Bedeutung sind [siehe Tabelle 1, (Weissermel 1994)]. Tabelle 1: Verfahren zur Wasserstofferzeugung Welt-H2-Erzeugung 1988 (in Gew.-%) Rohöl/Erdgas-Spaltung 80 Kohlevergasung 16 Elektrolysen/Sonstige 4 gesamt (in Mio. t) ca. 45 Der wichtigste Rohstoff zur Erzeugung von H2 ist Erdgas, aber auch Naphtha und andere Rückstände der Petrochemie werden eingesetzt (Ullmann 1989a). Die Bilanzierung der vorliegenden Kennziffern erfolgt auf der Annahme, daß Wasserstoff zu 100 % aus Erdgas synthetisiert wird. Für die Bilanzierung des Prozesses wurde eine Studie der Arbeitsgemeinschaft Kunststoff (DSD 1995), die Ökoinventare für Energiesysteme (ETH 1995) und Daten aus (Ullmann 1989a) ausgewertet. Da in (DSD 1995) die ausführlichsten Daten vorliegen, wurden diese für die Berechnung der Kennziffern verwendet. Es wird angenommen, daß die dortigen Angaben sich auf die H2-Herstellung in Westeuropa in den 90er Jahren beziehen. Die Massen- und Energiebilanz ist vom verwendeten Rohstoff abhängig, somit ist eine Übertragung der Kennziffern auf andere Einsatzstoffe oder auch Produktionsverfahren nicht möglich. Allokation: keine Genese der Kennziffern: Massenbilanz: Zur Herstellung von Wasserstoff wird als Rohstoff Erdgas (1990 kg/t H2) und Wasser (4468 kg/t H2) benötigt (DSD 1995). Als weiteres Reaktionsprodukt der chemischen Umsetzung von Erdgas entseht neben H2 auch Kohlendioxid (5458 kg CO2/t H2). Da CO2 kein verwertbares Produkt darstellt, wird es den prozeßbedingten Luftemissionen zugerechnet. Im Vergleich zu den obigen Angaben wird bei (Ullmann 1989a) für eine typische Steamreformer-Anlage ein Erdgasbedarf von 2160 m3 für die Erzeugung von 5000 m3 Wasserstoff (jeweils bei 0 §C und 101,325 kPa) - bzw. umgerechnet 3439 kg Erdgas/t H2 - aufgeführt. (ETH 1995) wiederum gibt einen Erdgasbedarf von 121 MJ/kg H2 (umgerechnet 2881 kg/t H2) an. Die Angaben aus (DSD 1995), (ETH 1995) und (Ullmann 1989a) zeigen deutliche Abweichungen voneinander. Da bei (DSD 1995) die vollständigste Bilanz vorliegt, werden diese Daten übernommen. Es wird angenommen, daß der unterschiedliche Rohstoffbedarf bei den verschiedenen Literaturquellen dadurch zustande kommt, daß die Wasserstoffherstellung je nach Prozeßführung auf eine maximale Produktion an Prozeßdampf, minimalen Einsatz von Erdgas , etc. optimiert werden kann. Energiebedarf: Für den Prozeß der Wasserstofferzeugung wird insgesamt eine Energiemenge von 49,25 MJ/kg H2 benötigt. 47,25 MJ des Gesamtenergiebedarfs werden durch die Verbrennung von Erdgas bereitgestellt. Davon entfallen wiederum 18,144 MJ auf die Dampferzeugung und 8,645 MJ auf die CO2-Druckwäsche. An elektrischer Energie werden 2,0 MJ Energie verbraucht (DSD 1995). Im Vergleich dazu wird der Prozeßenergiebedarf bei (ETH 1995) mit 3,47 MJ/kg elektrischer Energie, 26,55 MJ/kg Heizöl S (Industriefeuerung) und 17,8 Erdgas (Industriefeuerung) angegeben (Summe 47,82 MJ/kg). Der Energiebedarf bei (DSD 1995) und (ETH 1995) zeigt eine sehr gute Übereinstimmung. Es werden die Daten aus (DSD 1995) für GEMIS übernommen. Prozeßbedingte Luftemissionen: Nach (Ullmann 1989a) entstehen beim steam reforming 0,25 mol CO2 pro mol H2 (Methan und Wasser werden zu Wasserstoff und Kohlendioxid umgesetzt). Dieser Wert ist identisch mit der Angabe aus (DSD 1995) von 5,458 kg CO2 pro kg Wasserstoff. Es konnten keine weiteren prozeßspezifischen Daten zu den Emissionen ermittelt werden. Diese sind im Vergleich zu den Emissionen, die durch den Energieverbrauch entstehen, relativ gering (ETH 1995). Wasser: Neben dem Erdgas dient auch Wasser als Rohstoff zur H2-Erzeugung (Reduktion von H2O zu H2). Für die chemische Reaktion werden 4,468 kg H2O pro kg H2 benötigt (DSD 1995). Es kann jedoch davon ausgegangen werden, daß beim Herstellungsprozeß ein Überschuß an Wasserdampf eingesetzt wird. Da hierüber - ebenso wie zum Kühlwasserbedarf - keine Angaben vorliegen, wird der Wert von 4,468 kg Wasser als Kennziffer verwendet. Angaben zu Abwasserwerten und Reststoffen liegen nicht vor. Auslastung: 5000h/a Brenn-/Einsatzstoff: Brennstoffe-fossil-Gase gesicherte Leistung: 100% Jahr: 2010 Lebensdauer: 20a Leistung: 1MW Nutzungsgrad: 143% Produkt: Brennstoffe-Sonstige
technologyComment of cobalt production (GLO): Cobalt, as a co-product of nickel and copper production, is obtained using a wide range of technologies. The initial life cycle stage covers the mining of the ore through underground or open cast methods. The ore is further processed in beneficiation to produce a concentrate and/or raffinate solution. Metal selection and further concentration is initiated in primary extraction, which may involve calcining, smelting, high pressure leaching, and other processes. The final product is obtained through further refining, which may involve processes such as re-leaching, selective solvent / solution extraction, selective precipitation, electrowinning, and other treatments. Transport is reported separately and consists of only the internal movements of materials / intermediates, and not the movement of final product. Due to its intrinsic value, cobalt has a high recycling rate. However, much of this recycling takes place downstream through the recycling of alloy scrap into new alloy, or goes into the cobalt chemical sector as an intermediate requiring additional refinement. Secondary production, ie production from the recycling of cobalt-containing wastes, is considered in this study in so far as it occurs as part of the participating companies’ production. This was shown to be of very limited significance (less than 1% of cobalt inputs). The secondary materials used for producing cobalt are modelled as entering the system free of environmental burden. technologyComment of natural gas production (CA-AB): Canadian data completed with german data. The uncertainty has been adjusted accordingly. Data used in original data contains no information on technology. technologyComment of natural gas production (DE): Data in environmental report contains no information on technology. technologyComment of natural gas production (RoW): The data describes an average onshore technology for natural gas to 13% out of combined oil gas production. Natural gas is assumed to 20% sour. Leakage in exploitation is estimated at 0.38% and production 0.12%. It is further assumed that about 30% of the produced water is discharged in surface water. Water emissions are differentiated between combined oil and gas production and gas production. technologyComment of natural gas production (RU): The data describes an average onshore technology for natural gas with a share of 4% out of combined oil gas production and 96% from mere natural gas production. Natural gas is assumed to 20% sour. It is assumed that about 30% of the produced water is discharged in surface water. Water emissions are differentiated between combined oil and gas production and gas production. technologyComment of natural gas production (US): US data (NREL) for emissions completed with german data. Emissions from NREL include combined production (petroleumm and gas) and off-shore production. The uncertainty has been adjusted accordingly. Data used in original data contains no information on technology. technologyComment of petroleum refinery operation (CH): Average data for the used technology. technologyComment of primary zinc production from concentrate (RoW): The technological representativeness of this dataset is considered to be high as smelting methods for zinc are consistent in all regions. Refined zinc produced pyro-metallurgically represents less than 5% of global zinc production and less than 2% of this dataset. Electrometallurgical Smelting The main unit processes for electrometallurgical zinc smelting are roasting, leaching, purification, electrolysis, and melting. In both electrometallurgical and pyro-metallurgical zinc production routes, the first step is to remove the sulfur from the concentrate. Roasting or sintering achieves this. The concentrate is heated in a furnace with operating temperature above 900 °C (exothermic, autogenous process) to convert the zinc sulfide to calcine (zinc oxide). Simultaneously, sulfur reacts with oxygen to produce sulfur dioxide, which is subsequently converted to sulfuric acid in acid plants, usually located with zinc-smelting facilities. During the leaching process, the calcine is dissolved in dilute sulfuric acid solution (re-circulated back from the electrolysis cells) to produce aqueous zinc sulfate solution. The iron impurities dissolve as well and are precipitated out as jarosite or goethite in the presence of calcine and possibly ammonia. Jarosite and goethite are usually disposed of in tailing ponds. Adding zinc dust to the zinc sulfate solution facilitates purification. The purification of leachate leads to precipitation of cadmium, copper, and cobalt as metals. In electrolysis, the purified solution is electrolyzed between lead alloy anodes and aluminum cathodes. The high-purity zinc deposited on aluminum cathodes is stripped off, dried, melted, and cast into SHG zinc ingots (99.99 % zinc). Pyro-metallurgical Smelting The pyro-metallurgical smelting process is based on the reduction of zinc and lead oxides into metal with carbon in an imperial smelting furnace. The sinter, along with pre-heated coke, is charged from the top of the furnace and injected from below with pre-heated air. This ensures that temperature in the center of the furnace remains in the range of 1000-1500 °C. The coke is converted to carbon monoxide, and zinc and lead oxides are reduced to metallic zinc and lead. The liquid lead bullion is collected at the bottom of the furnace along with other metal impurities (copper, silver, and gold). Zinc in vapor form is collected from the top of the furnace along with other gases. Zinc vapor is then condensed into liquid zinc. The lead and cadmium impurities in zinc bullion are removed through a distillation process. The imperial smelting process is an energy-intensive process and produces zinc of lower purity than the electrometallurgical process. technologyComment of rare earth oxides production, from rare earth oxide concentrate, 70% REO (CN-SC): This dataset refers to the separation (hydrochloric acid leaching) and refining (metallothermic reduction) process used in order to produce high-purity rare earth oxides (REO) from REO concentrate, 70% beneficiated. ''The concentrate is calcined at temperatures up to 600ºC to oxidize carbonaceous material. Then HCl leaching, alkaline treatment, and second HCl leaching is performed to produce a relatively pure rare earth chloride (95% REO). Hydrochloric acid leaching in Sichuan is capable of separating and recovering the majority of cerium oxide (CeO) in a short process. For this dataset, the entire quantity of Ce (50% cerium dioxide [CeO2]/REO) is assumed to be produced here as CeO2 with a grade of 98% REO. Foreground carbon dioxide CO2 emissions were calculated from chemical reactions of calcining beneficiated ores. Then metallothermic reduction produces the purest rare earth metals (99.99%) and is most common for heavy rare earths. The metals volatilize, are collected, and then condensed at temperatures of 300 to 400°C (Chinese Ministryof Environmental Protection 2009).'' Source: Lee, J. C. K., & Wen, Z. (2017). Rare Earths from Mines to Metals: Comparing Environmental Impacts from China's Main Production Pathways. Journal of Industrial Ecology, 21(5), 1277-1290. doi:10.1111/jiec.12491 technologyComment of scandium oxide production, from rare earth tailings (CN-NM): See general comment. technologyComment of sulfur production, petroleum refinery operation (Europe without Switzerland): The technology level in Europe applied here represents a weighted average of BREF types II (62%), III (29%), IV (9%) refineries; API 35; sulfur content 1.03%. technologyComment of sulfur production, petroleum refinery operation (PE): The technology represents BREF type II refinery; API 25; sulfur content 0.51% technologyComment of sulfur production, petroleum refinery operation (BR): The technology represents BREF type II refinery; API 25; sulfur content 0.57% technologyComment of sulfur production, petroleum refinery operation (ZA): The technology represents a weighted average of BREF types II and III refineries; API 35; sulfur content 0.7% technologyComment of sulfur production, petroleum refinery operation (CO): The technology represents a weighted average of BREF types II and IV refineries; API 35; sulfur content 0.56% technologyComment of sulfur production, petroleum refinery operation (IN): The technology represents a weighted average of BREF types II and IV refineries; API 35; sulfur content 1.39% technologyComment of sulfur production, petroleum refinery operation (RoW): This dataset represents the prevailing technology level in Europe, this is a weighted average of BREF complexity types II (62%), III (29%), IV (9%) refineries (see BREF document, European Commission, 2015); API 35; sulfur content 1.03%. Reference(s): European Commission (2015) Best Available Techniques (BAT) Reference Document (BREF) for the Refining of Mineral Oil and Gas, Industrial Emissions Directive 2010/75/EU Integrated Pollution Prevention and control, accessible online at http://eippcb.jrc.ec.europa.eu/reference/BREF/REF_BREF_2015.pdf, February 2019 technologyComment of synthetic fuel production, from coal, high temperature Fisher-Tropsch operations (ZA): SECUNDA SYNFUEL OPERATIONS: Secunda Synfuels Operations operates the world’s only commercial coal-based synthetic fuels manufacturing facility of its kind, producing synthesis gas (syngas) through coal gasification and natural gas reforming. They make use of their proprietary technology to convert syngas into synthetic fuel components, pipeline gas and chemical feedstock for the downstream production of solvents, polymers, comonomers and other chemicals. Primary internal customers are Sasol Chemicals Operations, Sasol Exploration and Production International and other chemical companies. Carbon is produced for the recarburiser, aluminium, electrode and cathodic production markets. Secunda Synfuels Operations receives coal from five mines in Mpumalanga (see figure attached). After being crushed, the coal is blended to obtain an even quality distribution. Electricity is generated by both steam and gas and used to gasify the coal at a temperature of 1300°C. This produces syngas from which two types of reactor - circulating fluidised bed and Sasol Advanced SynthoTM reactors – produce components for making synthetic fuels as well as a number of downstream chemicals. Gas water and tar oil streams emanating from the gasification process are refined to produce ammonia and various grades of coke respectively. imageUrlTagReplacea79dc0c2-0dda-47ec-94e0-6f076bc8cdb6 SECUNDA CHEMICAL OPERATIONS: The Secunda Chemicals Operations hub forms part of the Southern African Operations and is the consolidation of all the chemical operating facilities in Secunda, along with Site Services activities. The Secunda Chemicals hub produces a diverse range of products that include industrial explosives, fertilisers; polypropylene, ethylene and propylene; solvents (acetone, methyl ethyl ketone (MEK), ethanol, n-Propanol, iso-propanol, SABUTOL-TM, PROPYLOL-TM, mixed C3 and C4 alcohols, mixed C5 and C6 alcohols, High Purity Ethanol, and Ethyl Acetate) as well as the co-monomers, 1-hexene, 1-pentene and 1-octene and detergent alcohol (SafolTM).
technologyComment of hydroformylation of propylene (RER, RoW): In the oxo reaction (hydroformylation), carbon monoxide and hydrogen are added to a carbon – carbon double bond in the liquid phase in the presence of catalyst (hydrocarbonyls or substituted hydrocarbonyls of Co, Rh, or Ru). In the first reaction step aldehydes are formed with one more C-atom than the original olefins. For olefins with more than two C-atoms, isomeric aldehyde mixtures are normally obtained. In the case of propylene these consist of 1-butanal and 2-methylpropanal. imageUrlTagReplace600920a3-5103-4466-9c05-fd1d8ed0d89c There are several variations of the hydroformylation process, the differences being in the reaction conditions (pressure, temperature) as well as the catalyst system used. The classic high-pressure process exclusively used until the beginning of the 1970s operates at pressures of 20 – 30 MPa (200 – 300 bar) CO/H2 and temperatures of 100 – 180 °C. The catalyst is Co. It leads to about 75 % 1-butanol and about 25 % 2-methyl-1-propanol. The new process developments of the past few years have led to a clear shift in the range of products. The processes operating at relatively low pressures (1 – 5 MPa , 10 – 50 bar) use modified Rh-catalysts. The isomeric ratios achieved are about 92 : 8 or 95 : 5 1-butanol to 2-methyl-1-propanol. However, by the use of unmodified Rh the percentage of 2-methyl-1-propanol can be increased to about 50 %. Catalytic hydrogenation of the aldehydes leads to the formation of the corresponding alcohols. As only primary alcohols can be obtained via the oxo synthesis, it is not possible to produce 2-butanol and 2-methyl-2-propanol by this process. Reference: Hahn, H., Dämkes, G., Ruppric, N.: Butanols. In: Ullmann's Encyclopedia of In-dustrial Chemistry, Seventh Edition, 2004 Electronic Release (ed. Fiedler E., Grossmann G., Kersebohm D., Weiss G. and Witte C.). 7 th Electronic Release Edition. Wiley InterScience, New York, Online-Version under: http://www.mrw.interscience.wiley.com/ueic/articles/ technologyComment of synthetic fuel production, from coal, high temperature Fisher-Tropsch operations (ZA): SECUNDA SYNFUEL OPERATIONS: Secunda Synfuels Operations operates the world’s only commercial coal-based synthetic fuels manufacturing facility of its kind, producing synthesis gas (syngas) through coal gasification and natural gas reforming. They make use of their proprietary technology to convert syngas into synthetic fuel components, pipeline gas and chemical feedstock for the downstream production of solvents, polymers, comonomers and other chemicals. Primary internal customers are Sasol Chemicals Operations, Sasol Exploration and Production International and other chemical companies. Carbon is produced for the recarburiser, aluminium, electrode and cathodic production markets. Secunda Synfuels Operations receives coal from five mines in Mpumalanga (see figure attached). After being crushed, the coal is blended to obtain an even quality distribution. Electricity is generated by both steam and gas and used to gasify the coal at a temperature of 1300°C. This produces syngas from which two types of reactor - circulating fluidised bed and Sasol Advanced SynthoTM reactors – produce components for making synthetic fuels as well as a number of downstream chemicals. Gas water and tar oil streams emanating from the gasification process are refined to produce ammonia and various grades of coke respectively. imageUrlTagReplacea79dc0c2-0dda-47ec-94e0-6f076bc8cdb6 SECUNDA CHEMICAL OPERATIONS: The Secunda Chemicals Operations hub forms part of the Southern African Operations and is the consolidation of all the chemical operating facilities in Secunda, along with Site Services activities. The Secunda Chemicals hub produces a diverse range of products that include industrial explosives, fertilisers; polypropylene, ethylene and propylene; solvents (acetone, methyl ethyl ketone (MEK), ethanol, n-Propanol, iso-propanol, SABUTOL-TM, PROPYLOL-TM, mixed C3 and C4 alcohols, mixed C5 and C6 alcohols, High Purity Ethanol, and Ethyl Acetate) as well as the co-monomers, 1-hexene, 1-pentene and 1-octene and detergent alcohol (SafolTM).
technologyComment of methanol production (GLO): For normal methanol synthesis, reforming is performed in one step in a tubular reactor at 850 – 900 °C in order to leave as little methane as possible in the synthesis gas. For large methanol synthesis plants, Lurgi has introduced a two-step combination (combined reforming process) that gives better results. In the primary tubular reformer, lower temperature (ca. 800 °C) but higher pressure (2.5-4.0 MPa instead of 1.5-2.5 MPa) are applied. More recently, Lurgi developed another two-step gas production scheme. It is based on catalytic autothermal reforming with an adiabatic performer and has economical advantages for very large methanol plants. At locations where no carbon dioxide is available most of the methanol plants are based on the following gas production technologies, depending on their capacities: steam reforming for capacities up to 2000 t d-1 or combined reforming from 1800 to 2500 t d-1 (Ullmann 2001). For the energy and resource flows in this inventory a modern steam reforming process was taken as average technology. To estimate best and worst case values, also values from combined reforming and autothermal reforming were investigated. Methanol produced using a low pressure steam reforming process (ICI LPM) accounts for approximately 60% of the world capacity (Synetix 2000a). Besides steam reforming, combined reforming has gained importance due to the production of methanol in large plants at remote locations. The reaction of the steam-reforming route can be formulated for methane, the major constituent of natural gas, as follows: Synthesis gas preparation: CH4 + H2O → CO + 3 H2; ΔH = 206 kJ mol-1 CO + H2O → CO2 + H2; ΔH = - 41 kJ mol-1 Methanol synthesis: CO + 2 H2 → CH3OH; ΔH = -98 kJ mol-1 CO2 + 3 H2 → CH3OH + H2O; ΔH = -58 kJ mol-1 For an average plant the total carbon efficiency is around 75%, 81% for the synthesis gas preparation and 93% for the methanol synthesis (Le Blanc et al. 1994, p. 114). For steam reformers usually a steam to carbon ratio of 3:1 to 3.5:1 is used. As methanol production is a highly integrated process with a complicated steam system, heat recovery and often also internal electricity production (out of excess steam), there were only data of the efficiency and energy consumption of the total process available. Therefore the process was not divided into a reforming process, a synthesis process and a purification process for estimating the energy and resource flows. Also the energy and resource flows in the methanol production plants are site specific (dependent on the local availability of resources such as CO2, O2, or electricity). In this inventory typical values for a methanol plant using steam-reforming technology were used. The main resource for methanol production is natural gas, which acts as feedstock and fuel. A natural gas based methanol plant consumes typically 29-37 MJ (LHV) of natural gas per kg of methanol. This gas is needed as feedstock for the produced methanol (20 MJ kg-1 LHV) and also used as fuel for the utilities of the plant. From the converted feed, 1 kg methanol and 0.06 kg hydrogen is yielded. It was assumed that the purged hydrogen was also burned in the furnace. The only emission to air considered from burning hydrogen is NOX. The energy amount generated is not considered, because the process of the furnace is specified for natural gas as fuel. The NOX emissions of the hydrogen burning were therefore calculated separately. References: Althaus H.-J., Chudacoff M., Hischier R., Jungbluth N., Osses M. and Primas A. (2007) Life Cycle Inventories of Chemicals. ecoinvent report No. 8, v2.0. EMPA Dübendorf, Swiss Centre for Life Cycle Inventories, Dübendorf, CH. technologyComment of synthetic fuel production, from coal, high temperature Fisher-Tropsch operations (ZA): SECUNDA SYNFUEL OPERATIONS: Secunda Synfuels Operations operates the world’s only commercial coal-based synthetic fuels manufacturing facility of its kind, producing synthesis gas (syngas) through coal gasification and natural gas reforming. They make use of their proprietary technology to convert syngas into synthetic fuel components, pipeline gas and chemical feedstock for the downstream production of solvents, polymers, comonomers and other chemicals. Primary internal customers are Sasol Chemicals Operations, Sasol Exploration and Production International and other chemical companies. Carbon is produced for the recarburiser, aluminium, electrode and cathodic production markets. Secunda Synfuels Operations receives coal from five mines in Mpumalanga (see figure attached). After being crushed, the coal is blended to obtain an even quality distribution. Electricity is generated by both steam and gas and used to gasify the coal at a temperature of 1300°C. This produces syngas from which two types of reactor - circulating fluidised bed and Sasol Advanced SynthoTM reactors – produce components for making synthetic fuels as well as a number of downstream chemicals. Gas water and tar oil streams emanating from the gasification process are refined to produce ammonia and various grades of coke respectively. imageUrlTagReplacea79dc0c2-0dda-47ec-94e0-6f076bc8cdb6 SECUNDA CHEMICAL OPERATIONS: The Secunda Chemicals Operations hub forms part of the Southern African Operations and is the consolidation of all the chemical operating facilities in Secunda, along with Site Services activities. The Secunda Chemicals hub produces a diverse range of products that include industrial explosives, fertilisers; polypropylene, ethylene and propylene; solvents (acetone, methyl ethyl ketone (MEK), ethanol, n-Propanol, iso-propanol, SABUTOL-TM, PROPYLOL-TM, mixed C3 and C4 alcohols, mixed C5 and C6 alcohols, High Purity Ethanol, and Ethyl Acetate) as well as the co-monomers, 1-hexene, 1-pentene and 1-octene and detergent alcohol (SafolTM).
Das Projekt "Kohle-Muell-Vergasung" wird vom Umweltbundesamt gefördert und von Hahn-Meitner-Institut Berlin GmbH durchgeführt.
Das Projekt "Konzeptentwicklung für das schlanke 55 Prozent plus-IGCC-Kraftwerk bis maximal 1000 MWel (55 Prozent plus-IGCC-Kraftwerk)" wird vom Umweltbundesamt gefördert und von Technische Universität Bergakademie Freiberg, Institut für Energieverfahrenstechnik und Chemieingenieurwesen durchgeführt. Die IGCC-Technik verfügt unter den Kraftwerkskonzepten über das größte technische und wirtschaftliche Potential zur CO2-Minderung und -abtrennung sowie die höchste Flexibilität für zukünftige Anforderungen bezüglich Synthesechemie und Wasserstoff-Wirtschaft. Ziel des Vorhabens ist die Konzeptentwicklung von IGCC-Kraftwerken auf Basis der Kohlevergasung (sowohl für Braunkohle als auch für Steinkohle) mit einer Leistung bis 1000 MWel und Wirkungsgraden größer 55 Prozent. Der Zeithorizont für realisierungsreife Technik für ein Demo-Kraftwerk ist 2015. Die spezifischen Kosten sollten ca. 1100 '/kWel (Stand 2000) möglichst nicht überschreiten. Als eine Option des Projektvorhabens wird auch die Möglichkeit der Synthesegaserzeugung und Wasserstofferzeugung aus Synthesegas für die Wasserstoffwirtschaft bearbeitet. Die Bearbeitung soll in vier Projektphasen vorgenommen werden: (I: Vorbereitung; II: Modellierung 55 Prozent-IGCC-Kraftwerk; III: Modellierung Synthese/H2-IGCC-Kraftwerk; IV: Vergleich und Analyse der IGCC-Konzepte). Neben der wissenschaftlichen Verwertung können die Forschungsergebnisse im Bereich der Energietechnik und der chemischen Industrie genutzt werden.
Das Projekt "Production of hydrogen for the hydrogenation of heavy oil and coal (plant assembly phase)" wird vom Umweltbundesamt gefördert und von Veba Öl AG durchgeführt. Objective: To erect a demonstration gasifier including the metering and monitoring devices. General Information: The project started in 1981 with the design of the plant, the obtaining of the approval, the basic - and detail - engineering and the acquisition of the necessary material and equipment. The current phase includes the erection of the gasifier. The gasifier of the demonstration plant is designed to produce 40000 m3/h synthesis gas. This corresponds to a feed rate of 16 t /h. The gasification pressure is 60 bars. The dust free raw gas from the demonstration plant is directed to the raw gas shift conversion, H2S/CO2 - removal and pressure swing adsorption units. The safe feeding operation of liquid hydrogenation residues is insured by special suspension pumps. The dosage of the LTC coke and the hard coal will be carried out employing the extruder feeding system for solid fuels developed by VEBA OEL on pilot plant scale. The main component of the feeding system is a twin screw extruder. In the feeder the finely ground coal or coke are mixed intensively with about 15 per cent water or oil and pressurized to form a gas-tight plug. At the extruder outlet the pressurized feed-stock is pulverised in a specifically designed discharge head and transferred by steam via a specially designed burner into the gasification reactor. Achievements: A preplanning phase served to investigate different concepts with respect to process flow, the technical design of the main parts and the integration of the demonstration plant into the RUHR OEL refinery in Gelsenkirchen-Scholven. For two process variants the basic engineering was carried out for the main process steps; a pre-basic was worked out for the conventional units of the plant, i. e. grinding, crude gas shift conversion and H2S/CO2 scrubbing. Detailed documents including construction drawings were produced for the main parts e. g. the extruder feeding-system, the burner and the gasification reactor. In order to determine whether the gasification plant would qualify for approval by the authorities a preliminary application in accordance with P9 of the Federal Environmental Protection (Immission) Act was prepared and submitted. After a thorough examination of the application and a discussion on the objections the preliminary approval was guaranted. To conclude the investigations, the investment cost were determined and the economic viability was examined for both process alternatives. The investigations have shown that a large-scale plant for the gasification of hydrogenation residues and coal is technically feasible and does quality for approval. The low energy price level does for the time being, however, not permit a cost-covering operation of coal gasification or coal hydrogenation plants. Measures are, therefore, examined to improve the economic viability of gasification and hydrogenation units. The use of solid or liquid wastes (as e. g. sewage sludge, used plastic materials, used ...
Das Projekt "Coal gasification - waste heat utilization - phase 2 stage 2 -" wird vom Umweltbundesamt gefördert und von Krupp Koppers durchgeführt. Objective: The aim of the project is the energetic optimisation of the PRENLO-process for the gasification of solid fuels under pressure by development and testing of a new waste heat boiler system. The engineering and construction of a PRENFLO-plant (Pressurized Entrained flow Coal Gasification) with a capacity of 48 t/d Coal throughput at design pressure (Contract LG/018/83/DE) and the execution of the subsequent test programme (Phase 2 of the project; LG/270/85/DE and the present contract, LG/354/87/DE) served to justify the technical and economic risks of commercializing the process on a large industrial scale and demonstrate the long-term availability of the system and of newly developed components. General Information: The PRENFLO process is based on the atmospheric Koppers-Totzek process. This new technology is characterized by high gasifier unit capacity, high thermal efficiency, independence of coal quality, high gas quality and low environmental impact. To demonstrate the PRENFLO process and to test as well as optimize the components of the system a 48 t/d PRENFLO plant was erected on the site of the technology centre of the Saarbergwerke AG in Forstenhausen (Saarland, Germany), project LG/018/83/DE. PRENFLO gasification operates according to the entrained flow principle. Coal dust with a grain size of smaller than100 m is conveyed under pressure, using nitrogen, to a reactor with a water-cooled refractory lining. The gasification agents oxygen and steam are added at the gasifier burners. The gasification of the coal dust, i.e. reactor with a water-cooled refractory lining. The gasification agents oxygen and steam are added at the gasifier burners. The gasification of the coal dust, i.e. the partial oxidation of the carbon to carbon monoxide, takes place in a flame reaction at temperatures of more than 2000 deg. C and a pressure of 24 to 30 bar, the coal substance being converted into CO, H2 and small amounts of CO2. The sulphur content in the coal is converted into H2S and to a limited extent COS, the chlorine into HCl. Coal ash flows as liquid slag out of the gasifier into a water bath and is discharged from there as granulated inert high-temperature slag. Some of the coal ash is removed from the reactor as fly ash together with the raw gas. The raw gas leaves the reactor from the top and is normally quenched with cole and cleaned recycle gas in order to solidify discharged liquid ash particles. The raw gas is further cooled in the waste heat boiler. High pressure steam generation is coupled with the cooling system of the reactor. The steam produced in both systems is passed to super heaters. The downstream raw gas cleaning system comprises a dry dedusting unit, Venturi scrubber, a high-pressure separator and a scrubbing water circulation system with a pressure filter for separation of filter cake and a stripper for waste water purification. In the present programme (LG/255/89/DE) the raw gas leaving the PRENFLO reactor is not
Das Projekt "Verwertung von Hausmuell durch Co-Vergasung mit Braunkohle in der Wirbelschicht" wird vom Umweltbundesamt gefördert und von RWE Rheinbraun durchgeführt. Ziel des Projektes war die grosstechnische Demonstration des Einsatzes von aufbereitetem Hausmuell in der Hoch-Temperatur-Winkler-Vergasung (HTW). Gemeinsam mit den Firmen Krupp Uhde GmbH, Dortmund, Intecsa-Uhde Industrial S.A., Madrid und Rheinbraun AG sollte die Co-Vergasung von Braunkohle und aufbereitetem Hausmuell im grosstechnischen Massstab demonstriert werden. Neben der Demonstration der grosstechnischen Einsetzbarkeit des HTW-Verfahrens zur effizienten und umweltgerechten Verwertung von Hausmuell durch Co-Vergasung mit Braunkohle, sollte durch Absicherung der Datenbasis an einer grosstechnischen Anlage, insbesondere hinsichtlich Feststoffhandling, Vergasungsverhalten, Brenngasqualitaet und Emissionen, eine Markteinfuehrung des Verfahrens unterstuetzt werden. Die Versuche sind erfolgreich abgeschlossen. Ueber die Firmen Krupp Uhde wurde eine Lizenz zur Anwendung dieses Verfahrens nach Japan erteilt.
Das Projekt "Ausfuehrungsplanung fuer das Kombi-Kraftwerk mit GSP-Vergasung Frankfurt/Oder - Phase I" wird vom Umweltbundesamt gefördert und von Deutsche Babcock Werke durchgeführt. Gesamtziel des Vorhabens ist, ein Kombikraftwerk mit integrierter GSP-Vergasung am Standort Frankfurt/Oder von ca 47 MW TH Prozess- und Heizwaerme und ca 50 MW elektrischer Energie zu errichten und in die vorhandene Infrastruktur einzubinden. Das Kombikraftwerk soll ein am Standort vorhandenes sehr altes und stark abgenutztes Heizkraftwerk ersetzen. Das GSP-Kohlevergasungsverfahren in Verbindung mit modernster Abhitzenutzung fuehrt nicht nur zu ca 100 Prozent Wirkungsgradverbesserung der bestehenden Anlage, sondern auch zur erheblichen Reduzierung der Emissionen von NOX und SOX unter die zulaessigen Grenzen in der BRD. Das vom Energieversorgungsunternehmen in Frankfurt/Oder zu errichtende HKW entspricht dem neuesten energiewirtschaftlichen und umwelttechnischen Stand. Unmittelbares foerderpolitisches Ziel ist neben der Planung und dem Basic-Engineering, Phase 1, das Detail-Engineering und der Bau dieses Heiz-Kombi-Kraftwerkes, Phase 2.