Black liquor gasification Black liquor gasification – the fast lane to the – the fast lane to the

biorefinerybiorefineryIngrid NohlgrenIngrid Nohlgren

Energy Technology Centre (ETC) Energy Technology Centre (ETC) Piteå, SwedenPiteå, Sweden

Within a few years …Within a few years …

30% of Sweden’s automotive fuels may come 30% of Sweden’s automotive fuels may come from Swedish pulp millsfrom Swedish pulp mills

Power production equivalent to that from a large Power production equivalent to that from a large river (1000 MW) may come from the millsriver (1000 MW) may come from the mills

Valuable chemicals synthesised from black Valuable chemicals synthesised from black liquor can give additional revenue to the millsliquor can give additional revenue to the mills

The key is black liquor gasification technologyThe key is black liquor gasification technology

The Pulp MillThe Pulp Mill

Wood chips

Pulp

Black Liquor Energy

Biomass Energy

Black liquorBlack liquor

Is a by-product from pulping Is a by-product from pulping (water, cooking chemicals, (water, cooking chemicals, lignin and other wood lignin and other wood components)components)

Liquid biomassLiquid biomass

Approx half the wood ends up Approx half the wood ends up in the black liquorin the black liquor

Has a heating value of ~14 Has a heating value of ~14 MJ/kg DS (Oil: ~42 MJ/kg)MJ/kg DS (Oil: ~42 MJ/kg)

Is smelly (sulphur compounds)Is smelly (sulphur compounds)

… is renewable energy

0

50

100

150

200

250

300

1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025

Black Liquor as Dry Solids (Mton)

0.0

0.6

1.2

1.8

2.4

3.0

3.6

Approx. Energy Content, LHV (EJ)

South America

Oceania

North America

Europe

Asia

Africa

Estimated black liquor productionEstimated black liquor production

Japan50 TWh

South America44 TWh

Sweden39 TWh

World~ 600 TWh

ASIA80 TWh

Europe120 TWh

North America350 TWh

(Chemrec)

Illustration of Recovery Boiler Capacities in Europe

= clusters of mills together having a large boiler capacity

= important single mill

Today’s technology Today’s technology (Recovery boiler)(Recovery boiler)

WoodYard

Lime Kiln

Pulping mill

Evaporators

RecoveryBoiler

White Liquor

Pulp storage

Fibre LineLiquor Cycle

BL Storage

Boiler

Chips

The Recovery boiler is replaced by BLGThe Recovery boiler is replaced by BLG

Woodchips

Pulp

Black liquor energy

Biomass

BLGMF DME/MeOH

Addition of biomass to the system to Addition of biomass to the system to balance the energy demandbalance the energy demand

Woodchips

Pulp

Black liquor energy

Biomass

BLGMF DME/MeOH

The DP1 plant in PiteåThe DP1 plant in Piteå

ETC CHEMREC

Kappa Kraftliner

DP-1 PlantDP-1 Plant

Tomorrow’s technologyTomorrow’s technology

Raw gas

GREEN LIQUOR

Condensate

BLACK LIQUOR

GAS COOLER

REACTOR

QUENCH

Whiteliquor

Feed water*

LP-steam*

MP-steam*

Weak wash

GASIFICATION

GAS ANDSMELT

SEPARATION

GAS COOLING AND CLEANING

OXYGEN

Atomisingmedia

Coolant

SULFUR REMOVAL

SHORT TIMECONTACTORS

CLEAN, COOLSYNTHESIS

GAS (to flare)

* In DP1 cooling water

Chemrec’s gasifier DP1 in Piteå, Sweden

Advantages compared to the Advantages compared to the Recovery boilerRecovery boiler

High quality synthesis gas with mainly hydrogen High quality synthesis gas with mainly hydrogen and carbon monoxide (ratio 1:1)and carbon monoxide (ratio 1:1)

Can be used directly as fuel for gas turbinesCan be used directly as fuel for gas turbines Can be used for synthesis of motor fuels after Can be used for synthesis of motor fuels after

additional cleaning and shifting of H2/COadditional cleaning and shifting of H2/CO No water vapour to the atmosphere (better No water vapour to the atmosphere (better

efficiency)efficiency) Sulphur and sodium can be obtained in two Sulphur and sodium can be obtained in two

separate streams (better process control = more separate streams (better process control = more paper)paper)

How much does it cost?How much does it cost?

Investment cost slightly higher than for the Investment cost slightly higher than for the Recovery boilerRecovery boiler

””Pay-off time” for the extra cost ≈ 2 yearsPay-off time” for the extra cost ≈ 2 years The investment can only be done when it The investment can only be done when it

is time to replace the boileris time to replace the boiler But … the time is right since many of the But … the time is right since many of the

boilers are oldboilers are old

Year of construction for Year of construction for Scandinavian boilersScandinavian boilers

0

2

4

6

8

10

12

1950-1954

1955-1959

1960-1964

1965-1969

1970-1974

1975-1979

1980-1984

1985-1989

1990-1994

1995-1999

Nu

mb

er o

f R

eco

very

Bo

ilers

Norway

Finland

Sweden

Are tax subsidies necessary?Are tax subsidies necessary?

Most other ”green” fuels must be subsidised to Most other ”green” fuels must be subsidised to make them competitive (e.g. ethanol)make them competitive (e.g. ethanol)

The cost/km for methanol from black liquor The cost/km for methanol from black liquor would be about the same as for gasoline before would be about the same as for gasoline before taxtax

Rising oil prices will be in favour of the black Rising oil prices will be in favour of the black liquor alternativeliquor alternative

Conclusion: Tax subsidies are not necessary in Conclusion: Tax subsidies are not necessary in the futurethe future

However, subsidies may be necessary as an However, subsidies may be necessary as an incentive for new investmentsincentive for new investments

Automotive fuel cost (excl tax)Automotive fuel cost (excl tax)FuelFuel Energy Energy

ContentContentEurocent per Eurocent per

literliterEurocent per Eurocent per

kWh kWh Eurocent per Eurocent per

kgkg

Fuel cost Fuel cost per km per km 1)1)

(Eurocent)(Eurocent)

Ethanol, from Ethanol, from wheatwheat2)2)

5.90 5.90 kWh/literkWh/liter

5555 9.39.3 6969 7.3 7.3

Ethanol, from Ethanol, from forestry feedstockforestry feedstock2)2)

5.90 5.90 kWh/literkWh/liter

33 - 3433 - 342)2) 6.56.5 49 – 5649 – 56 5.2 – 5.95.2 – 5.9

Methanol, 150 Methanol, 150 USD/ton Spot price USD/ton Spot price average, Eur. average, Eur.

4.33 4.33 kWh/literkWh/liter

1212 2.92.9 1616 2.32.3

DME 215 USD/tonDME 215 USD/ton 5.27 5.27 kWh/literkWh/liter

1515 2.92.9 2222 1.91.9

Gasoline, 85 Gasoline, 85 USc/galUSc/gal

8.72 8.72 kWh/literkWh/liter

22222)2) 2.52.5 2727 2.32.3

City diesel, City diesel, 85USc/gal85USc/gal

9.77 9.77 kWh/literkWh/liter

2222 2.22.2 2727 1.51.5

References: 1) Basic Data for “Jämförelseprojektet” (The Comparison Project), STEM, Dec-2001Standard car, gasoline =3.4 MJ/ km Standard car, methanol, (=ethanol?)= 2.86 MJ/km 0.794

kWh/kmStandard car, diesel =2.43 MJ/km

2)Ny Teknik (a weekly Swedish technology magazine), Nr 9, 28 Febr, 2002, sid 12-13.

3) Energiläget 2001. Swedish CO2 tax at 0.53 SEK/kg CO2 for fossil fuels

corresponds for fossil methanol an extra cost of 70 USD/ton on top of the spot price 100 USD/ton.

Syngas Syngas

Power $3.8 billion

Or

Liquid Fuels/Chemicals$5.5. billion

O2

Pulp$5.5 billion

BL GasifierWood Residual GasifierCombined Cycle SystemProcess to manufacture Liquid Fuels and Chemicals

The Forest Biorefinery– Net Revenue

Manufacturing

CO2

Extract Hemicellulosesnew products chemicals & polymers

$3.3 billion

Black Liquor & Residuals

Net Revenue Assumptions:Acetic Acid - $1.73/gallon Purchased Electricity - $43.16/MWHEthanol - $1.15/gallon Exported Electricity - $40.44/MWHPulp - $100/ton net profit Renewable Fischer Tropsch Fuel - $57/bbl

Steam, Power & Chemicals

Crucial research issuesCrucial research issues

Conversion of all organic carbonConversion of all organic carbon ””High quality” green liquorHigh quality” green liquor Durable materials for containmentDurable materials for containment Gas cleaningGas cleaning Mill integrationMill integration Scale up from the DP1 scale (x15, x100)Scale up from the DP1 scale (x15, x100)

Activities in Piteå and at ETCActivities in Piteå and at ETC

ETC Coordinating National Research ETC Coordinating National Research Effort:Effort: ””Black liquor gasification Program” 2004-2006Black liquor gasification Program” 2004-2006

Development plant under commissioning in Piteå Development plant under commissioning in Piteå

(aiming for first syngas in Aug 2005)(aiming for first syngas in Aug 2005) 8 research projects8 research projects Budget 100 MSEK (11 MEUR)Budget 100 MSEK (11 MEUR)

Collaborators – BLG programCollaborators – BLG program

Raw material suppliers End users

Researchers

Process industry

Governmental support

SummarySummary Black liquor gasification is a key technology for:Black liquor gasification is a key technology for:

Green power productionGreen power production Green automotive fuel productionGreen automotive fuel production Green chemicals productionGreen chemicals production

Green fuel can be produced at the same cost as Green fuel can be produced at the same cost as fossile fuels 2005fossile fuels 2005

Pulp mills are ideally suited to become Pulp mills are ideally suited to become biorefineries (infrastructure in place and large biorefineries (infrastructure in place and large knowhow)knowhow)

Very strong research effort in SwedenVery strong research effort in Sweden First commercial gasifier (300 tds/day) expected First commercial gasifier (300 tds/day) expected

around 2007around 2007