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Doubling of synthetic biofuelproduction via H2 from RES
Seminar presentation, Chalmers Dec 5th 2014Ilkka HannulaVTT Technical Research Centre of Finland
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There are nearly 100 professionals working atVTT around the fluidised bed technologyplatform
Combustion, gasification and pyrolysisprocesses share the common ”process heart” -fluidised bed
The main differences between processes aremostly related to the temperature levels andgas atmosphere
Process integrations, close co-operation withindustry & excellent experimental capabilities
Catalytic processes, CFD modeling andTechno-economic calculation competences tosupport thermal conversion processdevelopment
COMBUSTION
CATALYTICPROCESSES GASIFICATION
PYROLYSIS
VTT competencies & capabilities
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Industry FocusBiomass to 2nd generation biofuels
Pretreatmentand hydrolysis
Fermentation Productrecovery
Ethanol and otheralcoholsLipids Diesel, jet fuel
BIOTECHNOLOGY
Thermal orcatalytic fastPyrolysis
Product upgradingGasolineDiesel, jet fuel
FAST PYROLYSIS
Gasification Gas cleaningto syngas
Liquid fuelsynthesis
Methanol, DMEGasolineDiesel, Jet Fuel
Hydrogen
SNGMethanation
PSA
GASIFICATION
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Oil
Coal
Biomass
Waste/SRF
GASIFICATION800 – 1400° C
O2AIR
STEAM
WideFeedstock
BasisHigh-Quality
Final Products
SYNGAS(CO + H2)
FUEL GAS
Methanol,DME, Gasoline,jet-fuel, methane,hydrogen,Chemicals
Industrial kilnsCo-firing in boilersGas turbinesEnginesFuel cells
Biomass gasification to high-value products
GAS
CLEANING
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1995 2000 2005 2010 2015 20201985 2025 2030
LAHTI II, 160 MW WASTE-TO-ENERGY
WASTE-TO-ENERGY PLANTSWITH MATERIAL RECOVERYo HIGH ELECTRIC EFFICIENCYo RECOVERY OF VALUABLE METALS
WASTE-TO-ENERGY PLANTSWITH MATERIAL RECOVERYo HIGH ELECTRIC EFFICIENCYo RECOVERY OF VALUABLE METALS
LIME-KILNGASIFIERS
REPLACEMENT OFFOSSIL FUELSIN BOILERS AND KILNSo WOOD, AGROBIOMASSo 10-200 MW FUEL
BIOMASS/WASTEGASIFIERS FOR POWER
CBF/BFBGASIFICATION R&DAND PILOTING
R&D ono HOT GAS FILTRATIONo WASTE AND STRAW
GASIFICATION
R&D NEEDS 2013 - 17o FILTER ASH UTILISATIONo RECOVERY OF METALSo IMPROVED GAS CLEANING
JOUTSENO LIME KILN 2012
Biomass and waste gasification for boilers and kilns
LAHTI 60 MW
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RECENT PROJECTS:Biomass and wastegasification forboilers and kilns
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Biomass gasification for fuels and chemicals
PEAT AMMONIA PLANTOULU, FINLAND
SYNGAS R&D FOR BIOFUELSo GASIFICATION PROCESS DEVELOPMENTo CATALYTIC REFROMINGo FINAL GAS CLEANINGo TESTING OF SYNTHESIS CATALYSTS
GASIFICATIONR&D AND PILOTINGUSA, GERMANY,SWEDEN, FINLAND
2010 2015 20201985 2005 203020001995 2025
BIO-DME PLANTPITEÅ, SWEDEN
GTI PILOT, USA
NSE BIOFUELS, FINLAND
BIO-FUELS ANDCHEMICALSo DIESEL, MeOH, DME,
SNG, H2, GASOLINEo OLEFINS, OTHER CHEMICALSo FOREST & AGRO-INDUSTRY
INTEGRATIONo INTEGRATION TO HEAT
AND POWERo INTEGRATION TO SOLAR &
WIND ENERGYo NEW WASTE-TO-FUEL
CONCEPTS
SKIVE CHP, DENMARK
CEGABTL 2015 - 2017o IMPROVED LARGE-SCALE
GASIFICATION PROCESSo NEW PROCESSES FOR SMALLER SCALEo SIMPLER, CHEAPER GAS CLEANINGo NEW CONCEPTS FOR INTEGRATED
PRODUCTION OF FUELS, POWER AND HEAT
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Production of Synthesis Gas from Solid FuelsInitial step - two main approaches
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2G-Biofuels 2020 Projectbudget 7.3 M€ in 2012–14; second piloting phase in 2015–17
Gasification task
PressurisedO2-gasification
>150 MW bioIndustrial integ.
Low-pressuresteam gasification
<150 MW bioMunicipal integ.
HotFiltration
&Catalytic
Reforming
Synthetic fuels andchemicals + heat
- MeOH, DME- FTL, MTG- MTO
SNG, H2 + heat
Industrial partners: Andritz-Carbona, Foster Wheeler, Metso, UPM-Kymmene, NSE Biofuels,Fortum. Main financier: Tekes
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Gasification Hot gasfiltration
Reforming of thefiltered product gas
T = 850 °C
T = 550 °C
T = 950 °C
Gasification Hot gasfiltration
Reforming of thefiltered product gas
T = 850 °C T = 850 °C T = 850 °C
HOT GAS FILTRATION• Hot gas filtration R&D focused on filter
blinding phenomenon.• Experimental work with a bench-scale
pressurised hot gas filtration unit ALMA.• The main variables to be studied:
• Filtration temperature and pressure• Particulate and tar concentrations• Use of different sorbents and additives
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-20
0
20
40
60
80
100
0102030405060708090
100
760 810 860 910
CH4
conv
ersi
on,%
Conv
ersi
on,%
T, ºC
Catalyst A- Tar
Catalyst A – CH4
Catalyst B and C - Tar
Catalyst C – CH4
Catalyst B – CH4
Reforming of tars and light hydrocarbon gasesVTT’s reformer is based on staged reforming without soot formationDifferent catalysts from alternative suppliers can be usedComplete tar and C2-hydrocarbon conversionCH4 conversion depends on temperature, catalyst type and reactor volume
N.Kaisalo & P.Simell, Vetaani-project:laboratory results 2012
1301/03/2015 13Source: Spath & Dayton, 2003, NREL/TP-510-34929
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Updated Techno-Economic Assessment
Detailed evaluation of 20individual plant configurationsMeOH, DME, FTL & MTGPlant configurations technicallyproven at pre-commercial scaleImpact of further R&D to theoverall economics estimatedLarge scale: 300 MWth of biomass(~1500 mtpd, dry)Nth plant economicsAvailable for download:http://bit.ly/192Vl3G
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16*Liquid transportation fuels via large-scale fluidised-bed gasification of lignocellulosic biomass, Hannula, Ilkka; & Kurkela, Esa 2013. VTT, Espoo. 114 p. + app. 3 p. VTT Technology: 91
• Mature technology• No investment support• No CO2 credits• No tax assumptions
Gasoline@150$/bbl
Gasoline@100$/bbl
Before taxRef.margin: 13.4$/bbl
1€ = 1.33$ (2010)
Levelised production cost estimates*300 MW biomass @ 17 €/MWh, 0.12 ann. factorElectricity 50 €/MWh, DH 30 €/MWh@5500 h/a
Electrolyser enhancedbiofuels production
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Base case layout forsynthetic biofuelsproduction allows:• 50 – 60 % fuel
efficiency and• up to 80 % overall
efficiency.
These numbers areamong the best in theindustry.
GASIFICATION SYNTHESISGAS CLEAN-UP UPGRADINGBiomassresidues
Syntheticfuel
PurgegasRecycle
CO2
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Despite the high energy efficiency, about half of the feedstock carbon needs tobe rejected from the process, as there is not enough hydrogen to convert it intofuels.
The traditional conversion route is therefore hydrogen constrained.
GASIFICATION SYNTHESISGAS CLEAN-UP UPGRADINGBiomassresidues
Syntheticfuel
PurgegasRecycle
CO2
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Feed carbon
Surplus carbonFeed hydrogen
FuelBiomassfeedstock
However, by adding hydrogen from external source, the surplus carboncould be hydrogenated to fuel as well.
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Feed carbon
Surplus carbon
External hydrogen
Feed hydrogenFuelBiomass
feedstock
However, by adding hydrogen from external source, the surplus carboncould be hydrogenated to fuel as well.
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Feed carbon
Fuel
Surplus carbon
External hydrogen
Feed hydrogenFuelBiomass
feedstock
However, by adding hydrogen from external source, the surplus carboncould be hydrogenated to fuel as well.
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But the surplus carbon is in the form of CO2, instead of CO!
Implications:- Only methane and methanol have reaction route via CO2- More H2 is required to produce one mole of fuel from CO2 than from CO.- CO2 has higher activation energy than CO => more catalyst needed- Byproduct water from CO2 hydrogenation inhibits methanol catalysts
CO
Fuel
CO2
H2
H2FuelBiomass
feedstock
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Despite challenges related to CO2 hydrogenation, the potential increase infuel output is enormous:
Fuel output can be easily doubled from the base case… and in some casesalmost tripled!
CO
Fuel
CO2
H2
H2FuelBiomass
feedstock
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• Fuel output when CO fully hydrogenated with internal hydrogen viawater-gas shift
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• Fuel output when CO fully hydrogenated with internal hydrogen viawater-gas shift
• Fuel output when CO fully hydrogenated using internal and then externalhydrogen source
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• Fuel output when CO fully hydrogenated with internal hydrogen viawater-gas shift
• Fuel output when CO fully hydrogenated using internal and then externalhydrogen source
• Fuel output when CO and CO2 fully hydrogenated using internal and thenexternal hydrogen source
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