docBiomass-to-Liquids (B2L) Technologies
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Biomass-to-Liquids (B2L) Technologies
Experiences in Development of Gasification for Power Lars Waldheim Alsätravägen 130 12736 SKÄRHOLMEN lars.waldheim @waldheim-consulting.se IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 1 Synopsis Brief technology overview Process development Process applications Sugar mill applications Some final words IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 2 TPS Termiska Processer AB Roots in the national energy laboratory Studsvik, Nyköping: Formed in 1992 by staff buy-out Part of TallOil in 2004 Part of ACAB Invest 2007 Ceased operation in 2010 Energy-related Product and Services with Emphasis on: Stockholm Nyköping Biomass and waste Combustion and gasification Heat and electricity generation Environment Products/ Engineering: TKC for boiler systems < 30 MW CFB and FB bed boiler technology CFB gasification system Wood pellet and PF burners Special flow measurement devices Licensing, technical know-how transfer Engineering consultancy and services IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 3 Pressurised Gasification CFB know-how in-house Proprietary CFB boiler design licensing Peat Wood residues Bark High Tem perature Fly ash Filter Chipping Secondary Reform er with Cataly st Oxy gen Dry ing 950°C Boiler Feedwater 30 atm . 800°C Feeder Fly ash Lock Hopper Steam Steam & Oxy gen Ash Lock Hopper Final Treatm ent Raw Sy nthesis Gas Fuel Gas Am monia Methanol Oxo Chem icals Iron pre-reduction Local Distribution Combined Cy cle MINO process 1978-1986 • pressurised 28 bar, oxygen blown, hot gas cleaning • 2 MWth pilot plant at Studsvik national laboratory IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 4 Gasification Flexibility in Products CONVERSION TECHNOLOGY PRIMARY PRODUCTS PROCESSING TECHNOLOGY FINAL PRODUCTS ALCOHOLS DME SYNTHESIS GASIFICATION HYDROGEN HYDOROCARBONS MEDIUM HEATING VALUE (MCV) GAS TURBINE LOW HEATING VALUE (LCV) GAS ENGINE ELECTRICITY BOILER/ FURNACE PROCESS STEAM PROCESS ENERGY COMBUSTION IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 FLUE GAS BOILER STEAM & ELECTRICITY 5 Gasification Power Potential Adapted from: VTT PowerBiGPower –project no. 019761 2009 IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 6 Biomass Gasifier Technologies Repotec Ortner FERCO Taylor Bioneer B&W Völund Nexterra Fluidyne Xylowatt PPC Pyroforce TERI (TPS) Foster Wheeler UHDE Foster Wheeler Carbona Chemrec Metso UHDE (CHOREN) Carbona Enerkem Gas Host Fuel Air INDIRECT DOUBLE BED CFB DOWNDRAFT FIXED BED 10 kW UPDRAFT FIXED BED 1000 kW IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 10 MW Ash CFB or FB P>1 MPa , 100 MW ENTRAINED FLOW FUEL THERMAL CAPACITY 7 Gasifiers and Prime Movers PRESSURISED FLUIDISED BED ATM. CIRC. FLUIDISED BED ATMOSPHERIC FLUIDISED BED UPDRAFT FIXED BED DOWNDRAFT FIXED BED 5 10 15 20 60 25 70 90 80 100 MWe IGCC (Integrated Gasification Combined-Cycle) DUAL FUEL + STEAM CYCLE DUAL FUEL (INJECTION IGNITED DIESEL ENGINE) GAS ENGINE 5 10 15 20 IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 25 30 70 75 80 85 90 95 100 MWe 8 Gasifier, Post-treatment & Applications GASIFICATION CYCLONE GAS CLEANING FIRING IN BOILER · Lime kilns · Bioneer · CO-FIRING IN BOILER · Lahti · Ruien · Amercentrale EXTENSIVE GAS CLEANING FIRING IN BOILER · Lahti II CO-FIRING IN BOILER · (Amercentrale) ENGINE · · · · Harboøre Güssing Skive Móra d’Elbe GAS TURBINE · Värnamo · ARBRE SYNTHESIS · · · · (CHOREN) GoBiGas Bio2G Enerkem The technical aspects of gas cleaning, relative to the quality requirements of boilers, engines gas turbines, and last but not least, chemical syntheses are among the main technical hurdles IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 9 Fuel Contaminants Fuel component CHO Nitrogen Sulfur Chloride Fluoride Heavy metalls Alkalis Ash POPs IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 Gasifier gas emission pre-cursors Tar, CxHy, CO NH3, HCN H2S, COS, org. S HCl, org. Cl, KCl HF Hg, Cd, Zn etc. Ash particles Flue gas Stack emissions CO VOC, PAH NOx, SOx, HCl, HF Org. Cl (incl. Dioxine) Heavy metalls Particulates 10 Tar Yield for Different Fuels Source: VTT IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 11 CFB Gasification CFBG developed for lime kilns with ABB Fläkt in 2 MW pilot Proprietary TPS technology dolomite tar cracker developed Target market CHP 5- 20 MW heat demand (eq. 4-18 MWe) Vattenfall power Hedemora Diesel IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 12 TPS 2 MW CFBG Pilot Plant (even with oxidation catalyst) G A S I F IE R D O LO M IT E and S A N D FURNACE FLARE Tests with 500 kWe dual fuel diesel engine > 700 hrs op. Lessons learned +Tar cracker validation. Economy of scale! Engine emissions! 17 SCRUBBER GAS CO O LER D O LO M IT E 6 10 16 15 31 14 30 1 2 FUEL 9 22 3 4 32 8 5 21 24 F ILT E R 11 33 13 25 A IR 7 18 27 12 26 TA R C R A C K E R FLY-ASH SILO 20 A IR IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 13 Tar in Pilot Plant Tests, Wood Fuels TAR CONTENT 3 (mg/Nm gas) 10000 8000 6000 PILOT PLANT DATA WITH SAND 1988 LABORATORY DATA WITH DOLOMITE 4000 PILOT PLANT DATA WITH DOLOMITE, SHORT PERIODS IINITIAL PILOT PLANT CONTINUOUS OPERATION OPTIMIZED PILOT PLANT TESTS, CONTINUOUS OPERATION 2000 0 780 800 820 840 860 880 900 920 TEMPERATURE (°C) IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 14 Grève-in-Chianti WtE Technical characteristics • 2 Gasifiers, 15 MWth each • Gas Boiler and Flue Gas Cleaning • 6.7 MWe Condensing Turbine • Fuel Gas to Cement Factory • Licensee: Ansaldo Aerimpianti History • Start-up of Gasifier # 1: Nov. 1991 • Turned over to Client: Aug. 1992 • Start-up of Gasifier # 2: Sep. 1992 • Turned over to Client: March 1993 • 4000 and 5000 ton RDF processed in 1999 and 2000, resp. Plant stopped in 2004 from fuel supply restrictions and the building of a large scale WtE plant in the Florence region IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 15 Grève-in-Chianti FLUE GAS TREATMENT SECTION FUEL POWER PROCESS GAS PRODUCTION SECTION GASIFICATION SECTION ELECTRIC POWER (public use) ASHES HEAT RECOVERY (MULTI-USE) CEMENT INDUSTRY IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 16 Scale-up experiencerom Pilot Plant • A pilot unit is essential to have real life experience • A number of design issues must be addressed scaling up • Preferred equipment for industrial size identified/selected • Models and other procedures developed part of know-how Gas heating value vs. scale Scale Pilot Industrial Vol (%) H2 N2 CO CH4 CO2 C2H4 11 55 14 3 16 1 17 43 25 4 10 1 LCV (MJ/Nm3) 4.6 6.9 IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 17 Atmospheric BIG-GT Flowsheet Target output range 20-60 MWe Filter and scrubber ensures gas quality Multi-stage compressor Feeding simplified, ”difficult ”fuels IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 18 SIGAME Project, Brazil Objective: A 30 MWe BIG-GT plant based on eucalyptus at Mucuri, Bahia Grant support from WB/UNDP (GEF), EU 1st. phase 1992 -1996 Development involved GE, TPS and Bioflow competing. 2nd. Phase 1996-1999 EU-BR-IDGE 2000-2003 TPS selected as gasifier supplier. Engineering and commericial development IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 19 General Electric LM 2500 Gas Turbine Aeroderivative gas turbine with nominal 24 MWe output TPS development activities included: • Several tests in the modernized pilot plant on eucalytus wood • Develop Gasifier-GT interface and performance data with GE • Plant definition and integration, performance estimation • Plant basic engineering and costing together with JPE IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 20 ARBRE – ARable Biomass Renewable Energy Eggborough Selby North Yorkshire • Owner: Kelda (FRL) 89%, from 2002 EPRL 89%, TPS 11% •Supplier: Schelde Engineering Contractrs BV, NL (TPS) • TIC: 30 M£~ 45 M$ 1997, EC grant: 35 % • PPA: 105 £/MWh ~ 150 $/MWh (2001 IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 21 Arbre Plant Technology Gas turbine (SGT 100) Steam turbine Gross output 4.7 6.0 10.7 MW Gas compressor Misc. usage on site Net output - 1.5 - 1.2 8 MW Wood feed: 7 to 8 tonne/hr wet > 30% el. efficiency LHV IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 Suppl. firing in HRSG Steam 60 bar, 485°C Atmospheric gasification Suppl. firing from Thermie Band, 8 to 12 MW, size of GT and plant, as well as conservative design reduce efficiency 22 Project ARBRE History 1994 financial support from EC THERMIE program 1994 15 year UK NFFO power purchase contract signed 1995 Arbre Energy Ltd (AEL) formed, Kelda main owner 1997 planning permission granted 1998 turnkey contract awarded to SEC (NL) 1999 turnkey contractor mother company insolvent 2001 AEL completes construction, hot commissioning started gas turbine operates on wood fuel gas 2002 April 2002 Kelda management turn-over, sells plant to EPRL July 2002 plant operation suspended, AEL in liquidation 2003 DAS Green Energy UK Ltd. buys assets, no activity on site. IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 23 Project ARBRE Flare, September 2001 IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 24 Geração de energia por biomassa Bagaço e palha de cana Integração: BIG/GT - Usina IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 Francisco A. B. Linero [email protected] Helcio M. Lamonica [email protected] 25 Bagasse and Trash as Gasifier Fuels Objectives: Characterisation of bagasse and trash gasification properties in laboratory and bench scale Pilot plant tests to demonstrate technical feasibility Initial test pelletised bagasse Tests with trash (loose & pelletised) Tests go-feeding pelletised bagasse and loose trash Gas cleaning data and contaminant data Empirical test data for modelling and scale-up studies Model data as input to sugar mill integration studies IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 26 Bagasse and Cane Trash as Gasifier Fuels Sharp edges Trash + sand IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 27 Bagasse and Cane Trash as Gasifier Fuels Incipient droplet shape bagasse+sand IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 28 Bagasse and Cane Trash as Gasifier Fuels Small agglomerate Trash + sand IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 29 Conclusion of Pilot Plant Tests Pelletised bagasse tests (3 x 1 weeks) 1998-1999 Loose trash tests (4 x 1 weeks) 2000-2001 feeding properties availability in tests gas heating value, rel. wood carbon conversion tar content in gas, rel wood agglomeration carbon content in bed ash fouling of gas cooler ammonia content, rel. wood mixed trash bagasse fuel op. other contaminants Bagasse Trash excellent excellent similar >95 % low > limit temp low not observed similar yes no good fair-good slightly less > 95 % low to medium none low not observed higher yes some S, Cl Both fuels, alone and as mixtures, acceptable for TPS process IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 30 30 Integration of a BIG-GT in a Sugar Mill Objective: determine the energy generation and the fuel and energy consumption patterns of the mill evaluate the plant integration in economic terms Assumptions: Average mill data representing state-of-the-art in 1998 General Electric LM 2500 gas turbine (data Braz. BIG-GT project) Trash available as to supplement bagasse as fuel Work split: CTC lead partner- Fuel availability and cost, mill aspects TPS input was BIG-GT cycle calculations and costs IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 31 PFD and Mill Data- Sugar and Ethanol Fibre 13.8%= Bagasse 350 000 ton/y Trash pot. 120 000 ton/y Cane: 300 000 ton/season Pol 14.8% Milling cap.300 ton/hr Juice treatment Juice extraction Cane Steam/cane 0.5 ton/ton Evaporators Crystallisation Centrifugation Product drying 8 800 bags/d Sugar Fermentation Distillation Dehydration Ethanol Ethanol: 177 m3/d hydrated 177 m3/d hydrated IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 32 Starting point-Typical Mill 1998 Excess bagasse 7% Mill is self-sufficient in electrical power 22 bar – 300 ºC Turbogenerator Multi-stage Cane prep. Single-stage Milling Single-stage Auxiliaries Single-stage 2,5 bar Process ~ 0.5 steam/cane (330 kWh/t) Export power ~ 0-10 kWh/tc 0-3 MW only in season IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 33 How to Achieve Energy Export Export of energy = less energy available for mill Reduce energy consumption – Improve steam economy • Improve evaporator train to save primary steam • Improve heat recovery from evaporated steam – Integration of drives to increase efficiency and reduce steam consumption • Change from direct turbine drives to mechanical drives • Change from single to multi stage turbines where possible • Install extraction-condensing turbine to allow off-season operation • Result: Steam/cane 0.5 → Stage I 0.34 → Stage II 0.28 t/t • Increase bagasse recovery, trash as supplementary fuel Restrictions – The least impact possible on the mill for demonstration project – Use no more than the trash realistically recoverable IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 34 Integration Flowchart 22 bar- 300 ºC or 82 bar- 400 ºC Bagasse Extract.-cond. Steam Turbine and trash Exhaust flue Back-pressure Steam Turbine gas Gasification and Gas Cleaning Bagasse Dryer Boiler Clean LCV gas 2.5 bar Process Gas Turbine One or two units IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 Cooling tower 35 New HP Boiler– Optimisation Ia New mill boiler 82 bar 480 ºC 22 bar – 300 ºC Turbogenerator Turbogenerator Multi-stage Auxiliaries – E-motor Preparation Single stage Milling Single stage Condenser Para caldeiras 2,5 bar Process~ 0.34 steam/cane (220 kWh/t) Export power ~ 90 kWh/tc 10 MW season and 20 MW off-season IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 36 Partial Integration – Optimisation 1 module BIG-GT 22 bar 300 ºC Mill boiler Consumption 100% of bagasse ~ 40% of trash potential 22 bar – 300 ºC Turbogenerator Auxiliaries – E-motor Preparation Single stage Milling Single stage Condenser 2,5 bar Para caldeiras Process~ 0.34 steam/cane (220 kWh/t) Export power ~ 170 kWh/tc 28 MW season and 29 MW off-season IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 37 New HP Boiler Optimisation II 82 bar – 400 ºC 21 bar – 300 ºC Auxiliaries – E-motor Cane prep. – E-Motor Turbogenerator Milling Multi-stage Single-stage Condenser 2,5 bar Return to boilers Process ~ 0.28 steam/cane (185 kWh/t) Export power ~ 180 kWh/tc 20 MW in season, 40 MW in off-season IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 38 Total Integration-Optimisation II 1 module BIG-GT 1 module BIG-GT 80 bar – 480 ºC Consumption: 100% of bagasse available ~ 70 % of trash potential 21 bar – 300 ºC Auxiliaries – E-motor Cane prep. – E-Motor Turbogenerator Milling Multi-stage Single-stage Condenser 2,5 bar Return to boilers Process ~ 0.28 steam/cane (185 kWh/t) Export power ~ 290 kWh/tc 43 MW season and 60 MW off-season IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 39 Integration of a BIG-GT in a Sugar Mill - Without steam savings 500 kg/tc, low export potential - Old boiler system 0-10 kWh/tc - new boiler, 10-20 kWh/tc - With moderate optimization and steam saving 340 kg/tc - With new HP boiler 90 kWh/tc - With BIG-GT partial integration 170 kWh/tc - With moderate optimization and steam saving 280 kg/tc - With new HP boiler 170 kWh/tc - With BIG-GT full integration 290 kWh/tc Conclusion for first BIG-GT demonstration plant: - partial integration preferred due to increased reliability - Cost 73 M$, op cost 5 M$, - Required PPA 73 $/MWhe w/o any grant - Formation of a PPP to realize project failed IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 40 The ”Mountain of Death” BIG-GT Developments stranded on the west slope However, the potential for high efficiency remains Source EPRI, USA IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 41 SYDKRAFT BIG-GT Plant at Värnamo Mothballed in 2000 as revenues • Supplier: Bioflow (Foster Were too low to cover op. costs Wheeler, Sydkraft (EON)) VVBGC IGCC Plant • Tests 1995-2000, 2007 • Fuel 18 MW • Power 4,2+1,8= 6 MW • Heat 9 MW • Typhoon GT (Siemens SGT 100) •18 bar pressure. • >8000 hours of gasifier and 3 600 hours of GT operation • Good emission data IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 42 LCV Gas Turbines Gas turbine supplier Model Development status on LCV gas Power MW GE 10 Developed for one project 10 GE LM2500 Developed for one project 24 GE Frame 6B Developed for projects 43 Siemens SGT 100 3 installations 5 Typhoon Siemens SGT 400 Initial developments 13 Tornado Siemens SGT 600 Initial developments 25 GT 10B Siemens SGT 1000F 5 non-biomass LCV installations 68 V64.3 Mitsibushi MW261 Initial developments 32 Rolls Royce RB211 Initial developments 25 Volvo Aero VT 4400 Developed for one project 4.4 GT older name Nuovo Pignone GT10 Dresser Rand 4400 Most larger gas turbine are available for heavy residue, coal gasification LCV gas IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 43 It Takes a Bit of Time Vintage 1904 Coal Gasifier Integrated with a 200 hp (very nominal) Gas Turbine IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 44 Acknowledgement For further gasification information IEA Biomas Agreeement Task 33 Thermal Gasification www.ieatask33.org Work presented was sponsored by Global Environmental Facility (GEF), through UNDP European Commission (EU) FP5 ENERGIE program (EU-BR-IDGE Project NNE5-0489) Swedish National Energy Agency IPT Biomass Gasification Symposium Sao Paulo, Brazil, 2012-09-17 45
