1 Biomass gasification technologies for advanced power systems and synfuels - Status and Present R&D activities at VTT Esa Kurkela IV Liekkipäivä- National Flame Days Tampere 23.1.2008 VTT TECHNICAL RESEARCH CENTRE OF FINLAND This presentation is based primarily on material from the following R&D projects carried out at VTT • UCG – project 1.1.2004 – 31.5.2007: Synthesis gas and ultra clean fuel gas from biomass • EU/BiGPower 1.10.2005 – 30.9.2008: Advanced biomass gasification for high-efficiency power • EU/LahtiSTREAMS: Advanced Integrated Waste Management and WtE demonstration • Previous Tekes and EU projects at VTT on biomass and waste gasification
Transcript
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Biomass gasification technologies foradvanced power systems and synfuels
- Status and Present R&D activities at VTT
Esa Kurkela
IV Liekkipäivä- National Flame DaysTampere 23.1.2008
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
This presentation is based primarily on material fromthe following R&D projects carried out at VTT
• UCG – project 1.1.2004 – 31.5.2007: Synthesis gas andultra clean fuel gas from biomass
• EU/BiGPower 1.10.2005 – 30.9.2008: Advanced biomassgasification for high-efficiency power
• EU/LahtiSTREAMS: Advanced Integrated WasteManagement and WtE demonstration
• Previous Tekes and EU projects at VTT on biomass andwaste gasification
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Coal
Oil
Biomass
Waste/SRF
O2Air
Steam
Syngas
Energy(Fuel gas)
Gasification
SOFCIGCCCo-firingGas engineCHP
FT-synthesisHydrogenSNGMetOH
CARBON
GAS
CLEANUP
VTT TECHNICAL RESEARCH CENTRE OF FINLAND4
Drivers for Biomass and Waste Gasification
High-efficiency power from biomass atsmall-to-medium scale
Efficient utilisation of wastes
Liquid biofuels, renewable methaneor H2 for transport
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND5
CFB GASIFIER
REACTOR
850 °C
900 °CBIOFUEL FEED
BOTTOM ASH COOLING SCREW
HOT LOW CALORIFICGAS (750 - 650 °C)
AIR PREHEATER
RET
UR
N L
EGGASIFICATION AIR FAN
UNIFLOW CYCLONE
Atmospheric-pressure gasificationfor kilns and boilers• Commercial lime-kiln gasifiers
were constructed in 1980’s byAhlström Oy
• New development by FosterWheeler in 1990’s for boilerapplications
• Gasifiers are now offered by• Foster Wheeler• Carbona/Andritz• Metso Power
• Feasible in size range 15-150 MW• Fuel drying is often neededto achieve required flame properties
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Efficient utilisation of wastes and biomassresidues in existing power plants
a cost-effective way to reduce CO2 emissions of power plants
CFB gasifier of 60MW
Main boiler360 MWth
Gasifier feedpreparation
- in operation since 1998- no commissioning problems- 50 000 operating hours- gasifier availability > 95 %- boiler emissions decreased- payback time ca. 8 years
CFB gasifier of 60MW
Main boiler360 MWth
Gasifier feedpreparation
- in operation since 1998- no commissioning problems- high fuel flexibility- gasifier availability > 95 %- boiler emissions decreased- payback time ca. 8 years
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Source: T.Anttikoski, Foster Wheeler Energia Oy
Plastic reject materialwith 10 % aluminium
Corenso gasifier in Varkaus, Finland- gasification of aluminium containing plastic reject material- complete recycling of liquid cartoons (milk & juice packaging)- 50 MW gas to boiler, 2100 t/year aluminium for re-use- developed by VTT & Foster Wheeler Energia Oy in 1998 - 2000
in operation since autumn 2001
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Waste utilisation by gasification
Lahti II – Alternative forconventional incineration:
Gasification + Gas cleaning + Gasfired boiler + Flue gas cleaning
• Fluidised bed gasification of SRF/RDF• Product gas cleaning• Removal of (corrosive) Cl and ash
components (metals)• Clean gas fired in a gas fired boiler• No fouling or corrosive impurities
• => High steamtemperature & pressure
• High power production efficiency
Gasification process for high-alkalibiofuels, demolition wood and RDF
Bedmaterials
Air +Steam
Bottomash
CFBgasifier
20-150MW
Waste Fuel
Cleangas
Fly ashCa(OH)2
300-500°C
FiltrationGas cooler
Ashtreatment
Gasification process for high-alkalibiofuels, demolition wood and RDF
Bedmaterials
Air +Steam
Bottomash
CFBgasifier
20-150MW
Bedmaterials
Air +Steam
Bottomash
CFBgasifier
20-150MW
Waste Fuel
Cleangas
Fly ashCa(OH)2
300-500°C
FiltrationGas cooler
Fly ashCa(OH)2
300-500°C
FiltrationGas cooler
Ca(OH)2
300-500°C
FiltrationGas cooler
300-500°C
FiltrationGas cooler
Ashtreatment
Ashtreatment
Lahti Energia Oy 160 MWthgasification based WtE plant
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Removal of chlorine & heavy metalsby barrier filtration
Filtration temperaturerange 150 – 800 °CDepends on impurity to beremoved, tar content, filtermedia, etc.
EU-BigPowerBiomass Gasification for High Efficiency Power
Duration: 36 months (October 2005 – September 2008 )Overall Budget for the project: 2 943 k€
Financed in part by EU FP6
Catalytic Gas Cleaning and filtration• MEL Chemicals, United Kingdom• NortaUAB, Lithuania• Madison Filter Ltd, United Kingdom
R&D organisations supporting industrial development• VTT - Technical Research Centre of Finland• TUV - Technical University of Vienna, Austria• CERTH - Centre of Research & Technology Hellas,Greece• TKK - Helsinki University of Technology, Finland
Gasification systems• Condens Oy, Finland• Carbona Oy, Finland• Repotec GmbH, Austria• Biomasse Kraftwerk
Güssing, Austria• (Kokemäki & Skive sites)
Power production equipment• GE Jenbacher, Austria• MTU CFC Solutions GmbH, Germany
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Novel power plant: 1.8 MWe + 3.3 MW heat- supplier: Condens Oy- Kokemäki, Finland- Commissioning phase- total investment 5 M€- electric efficiency 30 %
Novelgasifier
Tar reformer
Gas coolerand Filter
Scrubber
Gas engines
Impurity Control method Content andremovalefficiency
Particulates Bag filters < 10 mg/m3n( > 99 %)
Tars Catalytic reformer < 100 mg/m3n(> 95 %)
Nitrogen compounds(NH3 ja HCN)
Catalytic reformerand gas scrubbing
< 10 mg/m3n(> 95-99 %)
Sulfur Low sulfur feedstock andgas scrubbing
< 10 mg/m3n
Chlorine Low chlorine feedstock,gas filtering and scrubbing
+ Lower operation temperature ~700 °C+ Tolerates catalyst poisons- Tar conversion not complete- Under development and testing
Nickel+ Decomposes tar and ammonia simultaneously+ Commercially available- Requires high temperature 900 °C- Deactivates easily by coke & sulphur
Precious metals+ High activity- Very expensive- Long-term stability?
0
10
20
30
40
50
60
70
80
90
100
550 600 650 700 750 800 850 900Temperature (°C)
Tar
mod
elco
mpo
und
conv
ersio
n(%
)
Precious metal A Ni ZrO2
H. Rönkkönen et al. Book of Abstracts, 1st International Congress on GreenProcess Engineering, 24-26.4.2007 Toulouse, France p. 277
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EU BigPower: WP1: Advanced Gas Cleaning(VTT, TKK, TUV, Madison Filter, MEL, Norta)
New catalyst powders, MEL- new materials and optimised production- supply of tailored raw materialsto VTT, TKK & Norta
New monoliths, VTT & TKK- new catalyst material and production method
Metal substrate catalysts, Norta- input from VTT, TKK and MEL- improved plasma coating method
Catalytic filters, Madison Filter- improved catalysts and production methods
Testing of new catalysts- laboratory-scale screening tests- extended-time slip-stream testsat Kokemäki and Güssing
- full-scale testing of selected catalystsat Kokemäki
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10
20
30
40
50
60
70
80
500 600 700 800 900 1000
Temperature (°C)
Con
vers
ion
(%)
ZrO2
A doped ZrO2
B doped ZrO2
C doped ZrO2
gamma-Al2O3
Toluene
Example of screening test results
Metal substrate catalysts by Norta
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Recycling of scrubber effluents- characterisation of waste watersfrom Kokemäki demo plant
- recycling of effluents to the gasifier
Replacement of nickel monolithsby more robust & cheaper catalysts- slip-stream testing – started in May 2006- testing in full gas stream – since fall 2007- new materials from WP1 also in 2007
In-situ catalytic tar reforming- construction of testing equipment- single element testing at Kokemäki
Novel air-blown fixed-bed gasifierBiGPower Tasks & Results from WP3
Slip-stream catalyst testing at Kokemäki
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Advanced Gas Engines and MCFCTasks and Results of GE Jenbacher and MTU Fuel Cell Solutions
Increased Engine performance andlower investment and operation costs- higher efficiency and throughput- evaluation of the effects of different designparameters on engine performance withBiGPower product gases
- materials optimisation and methods forminimising tar-related problems
- CO and NOx emission control- testing at GEJ and Güssing
MTU’s Fuel Cell HotModule- process calculation tool for gasification gases- MCFC process design for BiGPower gases- performance and costs of BiG-MCFC systems- design basis for demonstration project
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Biomass – IGCC power plantBiGPower Tasks and Results from WP4
Concept studies• Gas turbine survey by Carbona• Process modelling by CERTH• Optimised concept• Integration to existing power plants
Advanced gas cleaning• Increased filtration temperature• New ceramic filter media• Testing of catalytic filters• Selective oxidation of ammonia
• Lab-scale testing by TKK• Tests at VTT’s new500 kW pressurised gasifier
control valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elements
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
control valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elements
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
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Synthesis Gas from BiomassVTT’s UltraClean Gas project (1.1.2004-31.5.2007)
– pressurised gasification followed by catalytic reforming– 500 kW Process development Unit– studies for 150 – 400 MW plants integrated to pulp and paper industry
Industrial follow-up projects– preliminary planning and design was made in VTT’s UCG project in 2006-2007– 15-50 MW demonstration in 2008-10 (lime kilns or power plant)– first commercial-scale FT-plant in 2012-14
Pressurecontrol valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elementsFurnace
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
Pressurecontrol valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elementsFurnace
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
Kemira’s peat ammoniaplant in 1990
VTT’s 500 kW PDUfor syngas andultraclean fuel gas
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND21
Wood, strawenergy crops,peat, RDF
FT-synthesis& upgrading
Gasification andgas treatment
Pulp andpaper mill
Biomasshandling
anddrying
powerplantProcess steam & power
Paper& pulp
WoodDiesel
Energyto drying
synthesis-gas
bark,forestresidues,otherbiomass
fuel gas+ steam
steam &oxygen
Integration of FT-synthesis plant to pulp and paper mill
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0
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20
30
40
50
60
70
5 10 15 20Biomass Fuel Price, EUR/MWh
FT-L
iqui
ds P
rodu
ctio
n C
osts
,EU
R/M
Wh
Fully integrated, of f-gas replaces boilerbiofuel, drying w ithsec. heatFully integrated, of f-gas replaces boilerbiofuel, LP-steamdryerStand-alone; dryingw ith sec. heat
Stand-alone; LP-steam dryer
Cost of final upgrading to automotive fuels: about 4 EUR/MWh
Estimated Costs of Co-Produced FT Primary Liquids260 MWfeed, Interest on capital: 10 %, 20 a
Level ofexcise tax ondiesel andgasoline
Current Finnishprice level ofdiesel andgasoline(excluding taxesand distribution)
Typical currentprice of forestryresidues inFinland
All cost data at early 2006 level
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Notes: (1) Feedstock drying: from 50 % moisture to 30 % with secondary heat; from 30 % to15 % with by-product steam. (2) FT: Fischer-Tropsch primary liquids; reforming loop included.
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10
20
30
40
50
FT CH3OH SNG H2
Prod
uctio
n C
osts
, EU
R/M
Wh
When utilised as automotive fuel, end-usecosts increase significantly in this direction:
Estimated Production Costs for Alternative Syngas Products260 MWfeed; Feedstock at 10 EUR/MWh; Interest on capital 10 %, 20 a
All cost data at early 2006 level
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0
20
40
60
80
100
FT SNG
Cos
ts, E
UR
/MW
h
Vehicle-related extracosts
Distribution costs, incl.pressurisation for SNG
Upgrading costs (FT)
Production costs
Estimated Forest-to-Wheel Costs260 MW feed; Feedstock at 10 EUR/MWh; Interest on capital 10 %, 20 a
Forest-to-Wheel Costs: Biomass-FT < Biomass-SNG < Biomass-H2-FCAll cost data at early 2006 level
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VTT-UCGOptimised
syngas R&D& PDU-scaledevelopment
Industrial demon-stration: 15 MW
- replacement of oil/gas- start-up in 2009
Further R&D- process optimisation- waste gasification- hydrogen technologies
New applications- fuel cells, 2nd gen. IGCC- hydrogen or methane- renewable chemicals
R & D on hot filtrationand
catalytic gas cleaning
Biomass/wastegasification for power
(Lahti, Corenso,Värnamo, Kokemäki)
Peatammonia
plantOulu/Finland
Synthesis gasR&D in Europeand USA in 1980’s
First synfuel production plant- 200-250 MW feed capacity- 105 000 tons/a diesel fuel- 3 % Finnish transport fuel- start-up in 2012-14
1995 2000 2005 2010 2015 20201985 2025 2030
Biorefineries at pulp and papermills and at large CHP plants
- diesel production: 70 -150 000 tons/plant- by-product heat for process steam or
district heating- high overall efficiency
SYNTHESIS GAS FROMBIOMASS
FROM R&D TO INDUSTRIAL SUCCESS(road map made in VTT,s UCG project in 2006)
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
UCGFUNDA 2008 - 2010Biomass gasification for synthesis applications
- fundamental studies supporting industrial development projects
VTT, TKK and Åbo Akademi, total budget 1.5 M€Financing by Tekes Biorefine, VTT and 7 private companies(Carbona, Foster Wheeler, Metso Power, Neste Oil, Stora Enso, UPM & Vapo)
Biomass characterisation for pressurised steam/oxygen-blowngasificationFilter blinding and catalyst deactivation studiesTar reactions in non-catalytic and catalytic processes (reforming-cracking-oxidation)New system studies on FT-applicationsDevelopment of measuring methods for tars and other gascontaminantsFollow-up of foreign R&D projectsIEA groups: ”Biomass thermal gasification” and ”Biomass Hydrogen”
