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2G Gasification R&D aiming toimproved biomass conversion efficiency and reduced costs
Hotel Kalastajatorppa, HelsinkiAugust 30, 2012
Esa KurkelaVTT
207/09/2012
Production of Transportation Fuels from Biomass2G-Biofuels 2020 Project
budget 7.3 M€ in 2012–14; second phase in 2015–17
Pilot-scale development of new innovative processes for improved efficiency and lower production costsGasification-based systems
Optimized high-pressure steam-oxygen gasificationprocess aiming to improved fuel-to-syngas conversionefficiency and to wider feedstock basis (above 200 MW scale)Indirectly heated gasification for smaller size range (50 - 200 MW)Syntheses with less stringent gas purityrequirements compared with present processes
Alternatives based on pyrolysis technologyPyrolysis oil production integrated to CHPCatalytic pyrolysis to improve oil qualityUpgrading of pyrolysis oil for transportation fuels
Co-production of fuels, heat and electricity – integration to forest industries and district heating => high overall efficiencyIndustrial partners: Andritz-Carbona, Foster Wheeler, Metso, UPM-Kymmene, NSE Biofuels, Fortum
307/09/2012
Syngas Route to Biofuels – Integrated Conceptstudied at VTT’s UCG-project in 2004-07
Forestry residues,mill residues,straw, energy crops,urban biowaste
Synthesis& upgrading
Gasification andgas treatment
Pulp andpaper mill
Biomasshandling
anddrying
powerplantProcess steam & power
Paperor pulp
Hydrocarbon fuels (FT)or methanol, DME, SNG, H2, etc.
Energyto drying
synthesis-gas
bark,forestryresidues,otherbiomass
fuel gas+ steam
steam & oxygen
150-300 MW
75-160 MW
50-150 MW
VTT PDU
Industrial Demoat Varkaus
GTI Pilot
607/09/2012
Production of Biomass-Derived Synthesis GasInitial step - two main approaches
Biomass Raw synthesis gas
to cooling, clean-up and conditioning
Typically: fluidised-bed gasifier, either oxygen-blown or indirectly heated
GASIFIER
e.g. 850 ºC
REFORMER
900 ºCcatalytic
Main technical challenge: reforming of gas
Biomass Raw synthesis gas
to cooling, clean-up and conditioning
Typically: oxygen-blown entrained-flow gasifier
DryPulverBIOMASS
PRE-TREATMENT
GASIFIER
1300 ºC +
Main technical challenge: prehandling, feeding of biomass
orPyrolysis
oil
707/09/2012
Biorefinery BTL Demonstration Plans in FinlandThree consortiums planned second-generation BTL-biorefineries in Finland The planned capacities were100 000 – 200 000 ton/a of diesel EU’s NER300 funding was applied- final decisions at the end of 2012 Overall investment costs in orderof € 400 - 800 million?Technologies ready for industrial demonstration
Several sites have beeninvestigated by companies
Very large-scale is needed to achievepositive economics?First plants will be more expensive than mature technology?
807/09/2012
Production and Conversion of Biomass-Derived Synthesis GasMain Steps in Overall Process
MainProduct
HP Steam
CO shift,H2S removalCO2 removal
MP Steam Off-gas
Heat
Typical pressures: 1 - 30 bar 30 bar 30 - 200 bar
Biomass
SteamSteam + O2
DRYINGGASIFICATIONREFORMING
INITIAL GAS CLEANING
SYNTHESIS/UPGRADING
FINAL GASCLEANING ANDCONDITIONING
FiltrationTar removalScrubbing
General aims of the 2G Gasification project:• To simplify the overall process concept: lower investment cost and possibility to
realize BTL production also in smaller size range (100-200 MW biomass input)• To increase the efficiency of biomass utilization to fuels + power + heat• To enlarge the feedstock basis from woody biomass to agrobiomass and wastes
907/09/2012
Possible ways to improve the synthesis gas route- 2G 2020 Gasification Pilot Development at VTT in 2012–14, total budget 4.1 M€
Optimised high-pressure steam-oxygen gasificationprocess aiming to improved fuel-to-syngas conversionefficiency and to wider feedstock basis(above 200 MW scale) – PDU test runs in 2012Indirectly heated or air-blown gasification processesfor smaller size range (50 - 200 MW) – piloting in 2013/14Simplified final gas cleaning studies in 2012/13 and slipstream tests when necessarySyntheses/catalysts with less stringent gas purityrequirements compared with present processes
- Higher inert concentration (N2)- Lower requirements for CO2 removal- Higher tolerance for sulphur
Co-production of fuels, heat and electricity –integration to forest industries and district heating
1007/09/2012
0
5
10
15
20
25
30
35
30 bar 5 bar 1 bar 5 bar 1 bar 30 bar 5 bar 1 bar 5 bar 1 bar
% o
f FT
Prod
uctio
n C
osts
O2 production Compressions
Oxygen-blown Air-blownIndirect +Oxygen-blown
Indirect +Air-blown
Evaluation of Alternative Gasification Heat Sources
VTT Research Notes 2434 (McKeough & Kurkela, 2008)
1107/09/2012
Design and Operation Challenges of High Pressure Oxygen-Blown Fluidized-Bed Gasifier
Fluidization by oxygen alone is not possible – steam and/or other diluting fluidization media is neededAt high-pressures the capacity per reactor area/volume is increasing as fluidization velocities cannot be very much reduced at increased pressure – gasification reactivity is limiting the capacityThe positive effects of calcium-based bed materials can only be utilized at below 5 bar pressure, where CaO is catalyzing tar reduction and gasificationAt higher pressures the sintering of biomass ash becomes more critical than at low pressures – special bed materials, such as MgO are neededMechanical design issues become more challenging also at above 10 bar pressure (e.g. feeding systems)Soot formation and deposition problems are also more difficult to avoid in hot filtration and reforming at higher pressures
1207/09/2012
HIGH PRESSURE GASIFICATION OPTIONS
Biomass
O2+H2O+recycle gases
850oC
High temp filtration
Gas to reformer
800-850 oC
Staged reformer
HT-Shift
Gas 650-750 oC
O2/air/steam
Steam/water
20bar
Pretreatment before filtration?- Pre-reformer?- Sorbent?- Ash recirculation?- Catalytic filter?
Sec oxygen
Targetted Advantages:1) High pressure =>
lower power consumption will increase efficiency
2) No gas intercoolingOxygen consumption and CO2-content of gas are lower
3) Other ideas:- recycle-gas fluidisation- high steam fluidisation- staged oxygen feed- bed additives andagrobiomass
- optimised reformer fordifferent applications
SIMPLIFIED FINAL
GAS CLEANUP
Transportationfuels
Fuel gasfor energyproduction
Potential Advantages- lower investment costs- simplified process- Possibility to oxygen enriched air gasification?
- Full energy integration
SYNTHESISFOR 200 MW
SCALE
1307/09/2012
Filtration of raw gas from CFB/BFB gasification• Filtration between the gasifier and reformer is
needed to achieve efficient reforming• Previous experiences from biomass-IGCC and
waste gasification development• Target: increased filtration temperature – in optimal
case filtration without raw gas cooler
Basic process: filtration at 550 oC• Efficient removal of Na, K etc.• Not sensitive to high tar
concentrations • Protects the reformer
Increased filtration temperature• First tests in spring 2012• Filtration at 650-680 oC• More sensitive to tar & soot
– stable pressure drop only with low tar conditions and with high dust load
• Tests continue in Oct. 2012• Effects on overall process?
• reformer operation?• gas cooler after reformer?• overall efficiency?
14
PDU-Reformer results from 2012 Test Runs- improved design of the pre-reformer
- the effect of operation temperature on tar and methane conversion- gas filtration before reforming at ca. 550 oC, 6 bar pressure
15
Next test runs are scheduled to Oct - Nov 2012
Final O2/steam gasification tests at the present test rigModified distributor for fluidization gases –simulating the recycle of FT-off gasAdditional tests with increased filter temperature – alkali measurementsNew reformer design for increased inlet temperature
Design of the new 25 bar Steam-O2 and air gasification test rig will be started in autumn 2012 – commissioning in late 2014
16
R & D on Hot GasFiltration and Catalytic Gas
Cleaning
IGCC development
SYNGAS R&D AT VTT• Concept development for biofuels• Gasification process development
• Support to industrial demonstrations• Improved process concepts in 2G Biofuels project 2012->
INDUSTRIAL PILOT
• VARKAUS • CHICAGO
NEW APPLICATIONS• Fuel cells, 2nd gen. IGCC• Hydrogen, synthetic methane,
Chemicals • Hybrid Renewable Systems• Material Recovery from Waste
BIOMASS/WASTE GASIFICATION FOR POWERPIONONEERING DEMO’S: LAHTI,
CORENSO,VÄRNAMO
Gasification testsIn USA and Germany +
Supporting R&Dat VTT for Oulu
1995 2000 2005 2010 2015 20201985 2025 2030
BIOREFINERIES AT PULP AND PAPER MILLS AND AT LARGE CHP PLANTS• Bio-Diesel production100-200 ktons/plant• NER300 financial support to first plants?• Gasoline, SNG, H2 in next phase
BIOMASS AND WASTE GASIFICATIONFROM R&D TO INDUSTRIAL SUCCESS
PEATAMMONIA
PLANTOULU/FINLAND
19805 p-years
199015 p-years
200020 p-years
201025 p-years
WASTE-TO-ENERGY PLANTS ANDCO-FIRING IN COAL BOILERS• Corenso 2001, Lahti II 2012, Vaasa 2013• High electric efficiency, material recovery• Replacement of coal by biomass-derived gas
as part of fuel conversionactivities of 60 p-years
(gasification, synthesis, pyrolysis, fuel cells)
BIOMASS-TO-POWER PLANTS• Small-scale CHP by gas engines 0.1-5 MW• IGCC plants 30-150 MW
Bioneer Gasifierfor Small-scale
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