5/29/2007 1
Where are we now?-----------------
Black Liquor Gasification According to Chemrec
TAPPI 2007 International Conference on Renewable Fuels Atlanta, USA
May 10-11, 2007
Ingvar LandälvChemrec AB
www.chemrec.se
5/29/2007 2
Chemrec Ownership and Business
The Opportunity: large untapped energy potential in the pulp industry, aging mills, industry restructuring and high energy pricesThe Response: Chemrec’s Black Liquor Gasification Technology converts PulpMills to Biorefineries to produce green fuel or power
• Renewable fuel generation potential at pulp mills ~3 % of current US consumption of automotive fuels. Potential in Canada is ~7%, in Sweden ~30% and in Finland ~50%.
• Renewable fuel generation at pulp mills becomes a second main product adding 30%- 50 % to the cash flow from the pulp, at fuel prices competitive with diesel and gasoline at 30 USD/bbl crude oil.
• Alternatively the technology has the potential to profitably generate ~60 TWh addedgreen power in the US and proportional amounts abroad.
Chemrec AB
VantagePointVenture Partners
NykombSynergetics
Volvo Technology Transfer(AB Volvo)
5/29/2007 3
“STAND ALONE” CONCEPTCOMPARISON
5/29/2007 4
Definition of ConceptsBIOMASSTO FUELS
BIOMASS TO FUELS AT A PULP MILL(utilizing the BLGMF concept)
BLGMF
Heat&PowerPlant
PulpMill
Gasification-basedFuel
Production
Gasification-basedFuel
Production
Bl. Liquor
PowerSteam
Fuel ProductBiomass
5/29/2007 5
Definition of a “Stand Alone” ConceptBIOMASSTO FUELS
BIOMASS TO FUELS AT A PULP MILL(utilizing the BLGMF concept)
BLGMF
Heat&PowerPlant
PulpMill
Gasification-basedFuel
Production
BLGMF
Heat&PowerPlant
PulpMill
0 MW
Gasification-basedFuel
Production
Bl. Liquor
PowerSteam
Fuel ProductBiomass
0 MW(compared to Pulp Mill
without BLGMF)
5/29/2007 6
Definition of Biomass to Fuel Efficiency for “Stand Alone” Concepts
BIOMASSTO FUELS
BIOMASS TO FUELS AT A PULP MILL(utilizing the BLGMF concept)
BLGMF
Heat&PowerPlant
PulpMill
Gasification-basedFuel
Production
PowerSteam
Fuel ProductBiomass
BLGMF
Heat&PowerPlant
PulpMill
0 MW
Gasification-basedFuel
Production
nG Bl. Liquor
Energy in FuelEnergy in Biomass=0 MW
(compared to Pulp Millwithout BLGMF)
5/29/2007 7
A EUROPEAN PERSPECTIVE
5/29/2007 8
The Renew Project“Renewable Fuels from Advanced Powertrains”
Main objectives:Development and comparative assessment of pathways
from biomass to various motor vehicle fuels with a single common intermediate product: the synthesis gas.
The fuel pathways to be compared through Life Cycle Analysis (LCA) and a technical and economic assessment.
Duration: 2004-2007Budget: 20 MM€ (EU support: 10 MM€)
5/29/2007 9
Suitability for Willow Salix in the European Union
Cartographies by ECBREC, Renew 2007
Not suitable
Suitable
Not suitable
Suitable
5/29/2007 10
Biomass to Automotive Fuels: Replacement Potential within EU-25 in 2040
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
(TWh/year)
DME / MeOH
FTD
28% substitution of 2002 consumption
17% substitution of 2002 consumption
Transport share
Energy in transports 2002
Total biomass potentials 2040
Usedtoday
Potentialtoday
Potentialadded to
2040
Source: EU project Renew within FP6 and EUCAR/Concawe/JRC (2005)
5/29/2007 11
Renew Project: Comparison of Production Cost
*DE:
die
sele
quiv
alen
t
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
2
UET FZK CUTEC TUV/BKG TUV/BKG(local)
Chemrec
fuel
pro
duct
ion
cost
s [€
/lD
E*]
overall production costsbiomass costs free plant gate
Source: Renew, IE 2007
DMEFT-DieselFT-DieselFT-DieselFT-DieselFT-Diesel
entrained flowgasifier
fluidized bed gasifier(alloth.)
fluidized bedgasifier (alloth.)
fluidized bed gasifier(autoth.)
entrained flowgasifier
Carbo V gasifier
black liquorresource
centralisedpretreament
centralisedpretreament
centralisedpretreament
decentralisedpretreament
centralisedpretreament
DMEFT-DieselFT-DieselFT-DieselFT-DieselFT-Diesel
entrained flowgasifier
fluidized bed gasifier(alloth.)
fluidized bedgasifier (alloth.)
fluidized bed gasifier(autoth.)
entrained flowgasifier
Carbo V gasifier
black liquorresource
centralisedpretreament
centralisedpretreament
centralisedpretreament
decentralisedpretreament
centralisedpretreament
5/29/2007 12
TWO IN DEPTH STUDIES BASED ON THE “STAND ALONE”
PHILOSOPHY
5/29/2007 13
The BLGMF Report, 2003
Process engineering consultant
Gasification technologysupplier
National gasoline andoil distributor
World’s largest methanolproducer and distributor
World-known automotiveand engine developer
Automotive fuel andengine consultant
Research centre forpulp and papermaking
Report Partners
5/29/2007 14
The Princeton Biorefinery Report, 2006
5/29/2007 15
The BLGMF Study vs. the Princeton Study DMEa case
ParameterBLGMF Study
2003
Princeton Study2006
(DMEa case)
H&P Plant Boiler Boiler
BL Flow, tDS/d 3420, (487 MW) 2458(351)
DME prod. MW 275 168
Biomass added, MW 414 (161+101/0.4) 235 (77+63/0.4)
Power balance, MW As RB case As RB case
, %DME/biomass (MW)
67 71
Incrementalinvestment 164 MMEUR 116 MMUSD
5/29/2007 16
H&P Plant changed to an IGCC plantBIOMASS TO FUELS AT A PULP MILL
(utilizing the BLGMF concept)
BLGMF
Heat&PowerPlant
PulpMill
BLGMF
PulpMill
Bl. Liquor
Heat&PowerPlant
IGCCtechnology
PowerSteam
Fuel ProductBiomass
0 MW(compared to Pulp Mill
without BLGMF)
5/29/2007 17
The BLGMF Study vs. the Princeton Study Focus on Energy efficiency
ParameterBLGMF Study
2003
Princeton Study2006
(DMEa case)
Princeton Study2006
(DMEb case)
H&P Plant Boiler Boiler IGCC
2458(351MW)
168
136 (196-24/0.4)
24 (export)
124
BL Flow, tDS/d 3420, (487 MW) 2458(351MW)
DME prod. MW 275 168
Biomass added, MW 414 (161+101/0.4) 235 (77+63/0.4)
Power balance, MW As RB case As RB case
, %DME/biomass (MW)
67 71
5/29/2007 18
BLACK LIQUOR GASIFICATION
- THE USER PERSPECTIVE
5/29/2007 19
The User’s Perspective – in Summary
1. The pulp mill New process which can increase yield and bring new profit generating activity
2. The power utility Efficient production of green power3. The oil company Efficient production of green fuels4. The chemical Efficient production of green synthesis
company gas 5. The car industry Renewable, sustainable production of
green fuels6. The forest owner Maximize the revenue from the forest
land
5/29/2007 20
USER PERSPECTIVE 3:
THE OIL INDUSTRY
5/29/2007 21
Cost Data, 3Q 2005
Biomass 89 USD/mt(dry) – 1.3 €cent/kWhPulp Wood 125 USD/mt(dry) – 1.8 €cent/kWhPulp 500 EUR / tonEl. (incl. certificate) 6.8 UScent/kWh – 5.1 €cent/kWh DME-fuel price at site (gasoline equiv.) 3,48 SEK / l – 0.37 € / l –
1.88 USD/galCO2 tax, gasoline 2,16 SEK / l. – 0.23 € / l –
1.17 USD/galCO2 (liq.) at plant gate 200 SEK / ton – 22 € / ton
5/29/2007 22
Overall Energy Balance for the KAM2 Mill
45 MWe
2000 adt/dSP:81 bar/490°C
~340 MWt
KAM2 Pulp Mill4100 t/dtort SP:81 bar/490°CPulpwood
1 2 3 4 5 6 7 8Billion
SEK
5/29/2007 23
Overall Energy Balance when the Recovery Boiler has been changed into a BLGMF process
1 2 3 4 5 6 7 8Billion
SEK
KAM2 Pulp Mill 2000 adt/d4100 t/dtort
BLGMF 550 t.g.e/dBLGMF
414MWt
El-Cond.
101MWe
161 MWt
253 MWt
911 MWt
272 MWt
~340 MWt
BL GL486 MWt
45 MWe
Biomass
*) as DME ormethanol
Pulpwood
5/29/2007 24
Overall Cost and Revenue Streams for a Pulp Mill with a BLGMF Plant (per year) – Fuel calc. as gasoline energy
2000 adt/d
BLGMF 550 t.g.e/d*BLGMF
414MWt
El-Cond.
101MWe
94 MEUR
SP:81 bar/490°C
BL GL
347 MEUR
19 MEUR
44 MEUR
137 MEUR
3,48 SEK/l gasolineat refinery gate –
1.88 USD/gal
1 2 3 4 5 6 7 8Billion
SEK
KAM2 Pulp Mill4100 t/dtort
Pulpwood
Biomass
911 MWt
45 MWe
*) as DME ormethanol
5/29/2007 25
Overall Cost and Revenue Streams for a Pulp Mill with a BLGMF Plant (per year) – Fuel calc. as gasoline energy
2000 adt/d
BLGMF 550 t.g.e/dBLGMF
414MWt
El-Cond.
101MWe
153 MEUR
SP:81 bar/490°C
BL GL
347 MEUR
19 MEUR
44 MEUR
3,48 SEK/l gasolineat ref. gate + CO2 tax
3.05 USD/gal
1 2 3 4 5 6 7 8Billion
SEK
KAM2 Pulp Mill4100 t/dtort
137 MEUR
Pulpwood
Biomass
911 MWt
45 MWe
*) as DME ormethanol
5/29/2007 26
Overall Cost and Revenue Streams for a Pulp Mill with a BLGMF Plant (per year) – Fuel calc. as gasoline energy
2000 adt/d
BLGMF550 t.g.e/d
BLGMF
414MWt
El-Cond.
101MWe
153 MEUR
SP:81 bar/490°C
BL GL
347 MEUR
19 MEUR
44 MEUR
3,48 SEK/l gasolineat ref. gate + CO2 tax
+ CO2 export
1 2 3 4 5 6 7 8Billion
SEK
KAM2 Pulp Mill4100 t/dtort
Pulpwood
Biomass
911 MWt
45 MWe
ca 93 t CO2/tim
16 MEUR
137 MEUR
5/29/2007 27
USER PERSPECTIVE 4:
THE CHEMICAL INDUSTRY
5/29/2007 28
Gas utilization together with HT BLG process
• Oxygen:Ca 600 ton O2 per 1000 ADt of pulp
• Nitrogen, Argon and other rare gases:N2 as inert gas in the BLG process
• Carbon dioxide:Available at > 90% purity from the BLGMF process. Possible to produce also from BLGCC.
• H2 and CO:As fuel gas for combined cycle, as feedstock for synthesis or for other use
5/29/2007 29
BLG for Ammonia/Urea production
ASU
EL
Oxygen
Rågas
Syngas = H2
Gascooling
Gas Cleaning(Rectisol) +
N2-wash
Ammonia Synthesis
Gasifi/cation
150MW /gasifier3x50%1000°C30 bar
Ånga
White Liquor
Sulphur-handling
Weak wash
Black Liq.
LS Green Liq.
Polysulphide
Ammonia Ureasynthesis
Urea
Nitrogen
CO2
2000 tds/d => ~260000 ton NH3/y
2000: 200 EUR/t4Q, 2006: 300 EUR/t
5/29/2007 30
USER PERSPECTIVE 5:
THE CAR INDUSTRY
5/29/2007 31
VOLVO:sVOLVO:s DMEDME--powered Truckpowered Truck
5/29/2007 32
Well to Wheel Analysis (heavy duty vehicles)
0%
10%
20%
30%
40%
Diesel
(crude oil)
DME (remote
NG)
Compres
sed NG
(remote
7000
km)
Syntheti
c Diesel
(remote
NG)DME (w
ood, b
lack l
iquor)
Synthe
ticDies
el (w
ood, blac
k liquo
r)DME (w
ood)
Syntheti
c Dies
el(w
ood)
RME (rapes
eed) EU
Compresse
d Biogas(w
aste)
Ethanol (w
heat) E
U
Ethanol (c
orn) US
Ethanol (s
ugar ca
ne) Braz
il
Ethanol (c
ellulose
)
0
250
500
750
1000
Energy efficiency, %CO2-equivalents, g/kWh
g/kWh
Fossil Renewable
Source: AB Volvo
5/29/2007 33
WHERE WE AREAND
NEXT STEPS
5/29/2007 34
Air-blown, atmospheric Booster in New Bern, NC
Operates as a booster unit to the recovery boiler in the Weyerhaeuser pulp mill inNew Bern, North Carolina
Corresponds to ~15% of the mill’s production
Start up: Dec 1996Capacity: 330 tDS/day
50 MWOxidant: AirPressure: Atmospheric
5/29/2007 35
Pressurized, O2-blown Black Liquor Gasification- General Scheme -
Airseparation
Power
Oxygen
Rawgas
Synthesis gas
Gascooling
Gasi-fication
and
Quench
Steam
Weak wash
Black liquor
LS Green liq.
Gas PurificationWhite liquor
Sulphur Management Poly Sulph.
Synthesis- andDistillation
Power & SteamCombined
Cycle or
DME/Methanol
or
DP-1plant
Rawgas
Synthesis gas
Gascooling
Gasi-fication
and
Quench
Steam
G
5/29/2007 36
DP-1: High Temp, O2 blown Plant, Piteå, Sweden GAS COOLER
Raw syngas
GreenLiquor Condensate
BlackLiquor
REACTOR
QUENCH
WhiteLiquor
BFW*
LP-steam*
MP-steam*
WeakWashLiquor
Oxygen
Atomisingmedium
H2S-ABSORPTION
Purified andcooled syngas
(to flare)
Cooling water
* Cooling waterin DP1
5/29/2007 37
DPDP--1 Plant Location in Pite1 Plant Location in Piteåå
5/29/2007 38
DPDP--1 Ground Floor1 Ground Floor
5/29/2007 39
First StartSept 30 2005
5 days, 20 bar,Excellent
C-conversion
25 bar,Good
C- conversion
Hours
Summer -06
13 daysContinuous
run
1000 hrs Operation 2006
27 bar
30 bar,76% load
Accumulated Operating Hours DP1 End April 2007
Four more operatorsat Chemrec staff
5/29/2007 40
May 12, 2006: Low Content of Char, No Soot and Excellent Settling of Dregs in Green Liquor
5/29/2007 41
Time Schedule for HT Pressurized BLG Development in Sweden: DME Pilot Project
5/29/2007 42
A DME Pilot at the DP-1 Plant in Piteå, Sweden
ZnOAbsorber
Amin Wash (Guard-Bed)
DME or MeOHP.D.U
Process DevelopmtUnit
H2/CO = 1/1
Raw MeOHor DMEHP-steam
(Dp-1/mill) LP-st(Dp-1/mill)
CO2
C.W
Train /Truck
~4 ton DME / day
DP-1
The DME Pilot
ActivatedCarbon
CO2
- Which results?- Who should tackle?
5/29/2007 43
Activities - Work packages
• WP 1 – Upgrade of syngas unit• WP 2 – Development of a DME production pilot plant• WP 3 – Production of DME• WP 4 – Fuel properties and distribution• WP 5 – Fuel injection equipment• WP 6 – Vehicle procurement • WP 7 – Vehicle field test• WP 8 – Evaluation• WP 9 – Dissemination and Project management
5/29/2007 44
Time Schedule for HT Pressurized BLG Development in Sweden : Demonstration Project
5/29/2007 45
Incremental Capacity Increase at a Pulp Mill through a small BLGMF Plant
Typical5-600 MW
Pulp
Black liq. energy
Biomass~400 tds/d
SmallBLGMF
PlantDME/MeOH
~25 000 t DME/y
5/29/2007 46
BL Storage tank
BL Feeding & Preparation
BL GasificationUnit
Raw gas cooling& washing
Gas Cleaningunit
CO-Shiftconversion
Gas Cleaningunit
Offsites andutilities
DME & MeOHsynthesis
DME & MeOHDistillation
Productstorage MeOH
GL Storage tank
Air Separation
O2 supplyand N2 system
Sulphurrecovery unit
Low sulphiditygreen liquor
Black liquor
Productstorage DME
MeOHFinal Product
Air
O2 N2
O2O2
LP steam and hot water
Alt 1&2: White liquor
CO2 to tall oil production or pulp wash
Syngas
DMEFinal Product
MeOHabsorbent Fusel oil
Purge gas
Cooking
Fibre line 1(SCMBB)
Cold alkaliimpregnation
Warm BLtreatment
Hot BLtreatment
Bleaching
Wood chips
Weak liquor
Evaporation
Drying
Pulp
Digester
Blackliquor
N2
Alt 1: PS liquorAlt 2: High S white liquor
Screening & washing
Weak white liquor
Alt 2: Relatively high S white liquor
Clausoff-gas
BLGMF Block flow diagram
BL Storage tank
BL Feeding &Preparation
BL GasificationUnit
Raw gas cooling& washing
Gas Cleaningunit
CO-S- hiftconversion
Gas Cleaningunit
Offsites andutilities
DME & MeOHsynthesis
DME & MeOHDistillation
Productstorage MeOH
GL Storage tank
Air Separation
O2 supplyand N2 system
Sulphurrecovery unit
Low sulphiditygreen liquor
Black liquor
Productstorage DME
MeOHFinal Product
Air
O2 N2
O2O2
LP steam and hot water
Alt 1&2: White liquor
CO2 to tall oil production or pur lp wash
Syngas
DMEFinal Product
MeOHabsorbent Fusel oil
Purge gas
N2
Alt 1: PS liquorAlA t 2: High S white g liquorliquor
WeWeaakk wwhhiteite liquorliquor
Alt 2: Relatively high S white liquor
Clausoff-gas
Södra pulp mill BLGMF system
Fibreline 2
Torecovery
boiler
5/29/2007 47
The SmurfitKappa Mill with Chemrec’s DP-1 Plant. Planned Site for DME Pilot and a Demonstration Plant for Fuel or Electricity Generation (DP-2)
ExiatingDP-1
PlannedDME Pilot
The MillTentative Site
for DP-2
In Piteå,North Sweden
5/29/2007 48
Dosomething !
Questions ?