VTT TECHNICAL RESEARCH CENTRE OF FINLAND1

CHP plants based onadvanced biomass gasification

- EU BiGPower project 2005 - 2008

Esa KurkelaVTT – Technical Research Centre of Finland

January, 2006

Esa.Kurkela@vtt.fi 24.1.2006

VTT TECHNICAL RESEARCH CENTRE OF FINLAND2

CHP plants based on biomass gasification- most potential gasification technologies

Smallest size range: < 500 kWe + 1 MWheatdowndraft gasifiers and gas engines (naturally aspirating)new types of downdrafr gasifier?

Medium size range: 0.5 – 15 MWe + 1 – 15 MWheatDifferent gasification systems available: Modified updrafts, fluidised-bed, staged procesesTurbo-charged gas enginesGas cleaning is most critical process stepFuel cell plants or small gas turbines also possible in futureCompetition with fluidised-bed combustion with steam turbine cycle at > 3-5 MWe

Large-scale biomass power plants: 15–150 MWe + 15-150 MWheatPressurised fluidised-bed gasification with hot filtrationCombined Gas and Steam Turbine Cycle or engine-steam turbine cycle?Competition with CFB and BFB boilers with steam cycles

Co-firing in coal or natural gas power plants, gasifiers > 50 MWfuelFluidised-bed gasificationNo gas cleaning with clean biomass in PC boilersFiltration and chlorine removal with waste fuels

Esa.Kurkela@vtt.fi 24.1.2006

VTT TECHNICAL RESEARCH CENTRE OF FINLAND3

GE Jenbacher, Itävalta

VTT:n kaasutustutkimus v. 2006aihe: Korkean hyötysuhteen CHP-tekniikat

EU-BiGpower – Advanced Biomass Gasification for High-Efficiency Power

– VTT:n koordinoima EU/Tekes-projekti 1.10.2005 – 30.9.2008– 13 partneria, Suomesta VTT, TKK, Carbona ja Condens– VTT:n volyymi v. 2006 noin 330 k€– kaasutukseeen perustuvat moottorivoimalat, polttokennovoimalat ja kombivoimalat – kaasun puhdistus em. käyttökohteisiin (katalyytit ja suodatus)– koetoimintaa: Otaniemen prosessikoesali, Kokemäki, UCG-PDU– kaasutus CHP:n systeemitarkastelut

CATDEMO- Katalyyttisen kaasunpuhdituksen tuotteistaminen ja demonstrointi

– Volyymi v. 2006 noin 300-400 k€ – Kokemäen demonstraatioprojekti ja tutkimusasema– Skiven demonstraatiohanke– Katalyyttivalmistuksen tuotteistaminen ja IPR:n vahvistaminen

MTU FCS, Saksa

Esa.Kurkela@vtt.fi 24.1.2006

VTT TECHNICAL RESEARCH CENTRE OF FINLAND4

Requirements for real success stories in medium-to-large-scale gasification

• Fuel flexibility with respect to particle size, ash composition and moisture content

• Elimination of tars without waste water problems

• Effective final gas cleaning to protect gas engines, turbines or other downstream equipment

• Automatic operation, good reliability and low service costs

• High power production efficiency of 30 – 50 % in order to be competitive with boilers and steam cycles

VTT TECHNICAL RESEARCH CENTRE OF FINLAND5

UPDRAFT GASIFIER“BIONEER”- developed in 1980’s, 10 plants- for boilers and kilns, 5 MW scale- tar containing gas- high carbon conversion- robust, flexible, fully automated

5 MW district heating plant, Jalasjärvi, Finland, in operation since 1987; 145 000 operating hours

Fuel silo

Gas boiler

Hot gas -

District heating -

Electricity

Ash

VTT TECHNICAL RESEARCH CENTRE OF FINLAND6

Novel – an improved updraft gasifier

humidifier

gasification air

cooling

FORCED FUEL FEEDING

- use of low density fuelspossible

TWO-STAGE OPERATION- counter-current bottom bed- tars decomposed above the bed by additional air feeding

OXIDISING ZONE- complete carbon conversionand fully oxidised bottom ash

PRODUCT GAS-high temperature & low tars-700-850 oC, 1-4 g/m3n tars

VTT TECHNICAL RESEARCH CENTRE OF FINLAND7

Novel power plant: 1.8 MWe + 3.3 MW heat- Kokemäki, Finland- plant under comissioning- total investment 4.8 M€- electric efficiency 30 %

Optimal plant:- biomass moisture 50 %- drying to 15 % by waste heat- power efficiency up to 35 %- suitable to 0.5 - 5 MWe- power production cost < 5 c/kWh

Tarreformer

Scrubber

Novelgasifier

Gas coolerand Filter

3 Gas engines

VTT TECHNICAL RESEARCH CENTRE OF FINLAND8

Time table of the Kokemäki Novel CHP plantConstruction work: completed in April 2005Commissioning and Testing periods

Gasifier and the gas boiler: April - MayGas cleaning and heat recovery: May – AugustStart-up with one JMS 316 engine (520 kW): NovemberOperation with one gas engine and gas boiler: 2006

performance and emission measurementstests with different fuels & plant optimisation

2nd and 3rd gas engines: 1.8 MWe: end 2006 Further R&D activities

EC BiGPower: slip stream testing of 2nd generation catalytic gas clean-up and scrubbing water recycling (Oct. 2005 … Sept 2008)Testing with waste-derived fuels and agrobiofuels within other projects

SKIVE PROJECT, DENMARK

GASIFIER

PRODUCT GAS FILTERGAS COOLER

PRODUCT GAS COOLING(Heat Recovery)

GAS ENGINES

TAR CRACKER

BIOMASS

AIR

ASH

FLY ASH

BOILER

TO STACK

WATER TREATMENT

PRODUCT GAS SCRUBBING(Heat Recovery)

PRODUCT GASBUFFER TANK

STEAM

DISTRICT HEATING11.5 MWth

FLUE GASHEAT RECOVERY

POWER5.4 MWe

(by Carbona Oy, Salo, Patel & Horvath)

BiomassBiomass--CHPCHP--PlantPlant--GüssingGüssing

CHPCHP--PPlantlant GGüssingüssingStart upStart up in November 2001in November 2001

• Fuel Wood chips• Fuel Power 8 MW• Electrical Power 2 MW• Thermal Power 4,5 MW• Electrical Efficiency 25 %• Total Efficiency 80 %

• Investment 9 Mill. EURO• Optimisation 1 Mill. EURO

VTT TECHNICAL RESEARCH CENTRE OF FINLAND12

Large-scale Power with Integrated Gasification Combined-Cycle - IGCC

Fluidised-Bed Gasification at 20 bar, 800-950 oCGas filtration at 400 - 600 oCCombined Gas Turbine and Steam Turbine Process

Biomass IGCCDemonstration Plant,Värnamo, Sweden

• Developed and demonstrated in 1990’s• Electric efficiency 40 - 50 %• Requires large-scale > 15 MWe

• Best global potential for CO2 reduction• New R&D activities 2005 ->• New demonstration projects will come

– when and by which companies?Esa.Kurkela@vtt.fi 17.1.2006

Biomass – IGCC power plant design(by Carbona Oy; K.Salo & A.Horvath)

Small CHP plant• Power production: 7.4 MWe• District heat: 8.5 MJ/s• Electric efficiency: 40 %

Large IGCC power plant• Power production: 116 MWe• Electric efficiency: 50 %

VTT TECHNICAL RESEARCH CENTRE OF FINLAND14

500 kW PRESSURIZED FLUIDIZED BED GASIFIER (UCG-PDU)

Pressure control valve

Fuel feedingequipment

Bedmaterial

Additive

PFB GASIFIER

FILTER

Gascooler

CATR

Bed removal

Ash removal

Heating elements Heating

elementsFurnace

Air

Nitrogen

Steam

Oxygen

To slip stream testing facilities

VTT TECHNICAL RESEARCH CENTRE OF FINLAND15

New R&Dactivities

New R&DactivitiesBioneer

gasifierR&D

BioneergasifierR&D

Dual FluidBed Gasifier

R&D in Austria

Dual FluidBed Gasifier

R&D in Austria

Gas cleaning R&DNovel gasifier

Press. FB gasifierR&D in Finland

Gas cleaning R&DNovel gasifier

Press. FB gasifierR&D in Finland

- Advanced catalyticgas cleaning- New Filters

- 2nd generationgasifiers

- Improved gasengines

- MCFC concepts

BIG-MCFC Plants- efficiency 40-50 %

- size range 0.5-5 MWe

2nd generation engine plants- power efficiency 35-40 %

- size range 1 - 15 MWe

2nd generation BIGCC Plants- efficiency 45-50 %

- size range 15-100 MWe

Bioneergasifier

(heating appl.)

Bioneergasifier

(heating appl.)

Gas enginedemonstrationsKokemäki, Skive

Gussing

Gas enginedemonstrationsKokemäki, Skive

Gussing

Pressurisedgasificationpilot/demoVärnamo

& Tampere

Pressurisedgasificationpilot/demoVärnamo

& Tampere

2nd generation engine plant demos

2nd generation engine plant demos

Agrofuels & waste demonstration

Agrofuels & waste demonstration

MCFCpilot/demonstration

MCFCpilot/demonstration

gas turbine developmentactivities

gas turbine developmentactivities

MCFC HotModule development fornatural gas applications

MCFC HotModule development fornatural gas applications

- Advanced catalyticgas cleaning- New Filters

- 2nd generationgasifiers

- Improved gasengines

- MCFC concepts

1995 2005 EU-BiGPower 2010 20151985 2020 2025

Esa.Kurkela@vtt.fi 17.1.2006

VTT TECHNICAL RESEARCH CENTRE OF FINLAND16

Technology Present status Elect.Eff. Specif.Invest. % €/kWe

Target 2010 - 2015 Elect.Eff. Specif.Invest. % €/kWe

Target 2015 - 2020 Elect.Eff. Specif.Invest. % €/kWe

Gasifier-engine (1-15 MWe)

20-30 3500-6000 30-35 2500-4000 35-40 2000-3000

Gasifier-MCFC (0.5-5 MWe)

na (> 10 000) 35-40 < 10 000 45-50 2500-3000

Biomass IGCC (15-100 MWe)

35-40 3000-4500 40-45 2000-3500 45-50 1500-2000

Combustion and steam turbine

1-5 MWe

10-50 MWe

Elect.Eff. Specif.Invest. % €/kWe

17 - 25 3000-4000 only very limited development potential

25 - 37 2000-3500 (mature technology, thermodynamic limitations) na = not available yet

Advanced Biomass Gasification for high-Efficiency PowerBiGPower – project no. 019761

Targets for the gasification power plants

Esa.Kurkela@vtt.fi 17.1.2006