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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