November 2003
ECN-RX--03-063
STATUS UPDATE OF OLGA TECHNOLOGY DEVELOPMENT
Pilot demonstration of tar removal, complete test facility
& new OLGA research topic
H. Boerrigter S.V.B. van Paasen P.C.A. Bergman
Presented at the ThermoNET Meeting, Helsingør, Denmark, 17-20 October 2003
Revisions A B Made by: H. Boerrigter
Checked by: R. van Ree
Approved/Issued by: Issued: H.J. Veringa
ECN Biomass
2 ECN-RX--03-063
Status update of OLGAtechnology development
Pilot demonstration of tar removal, complete test facility & new OLGA research topic
ThermoNET meeting, Helsingør, 17-20 October 2003
Harold Boerrigter, Sander van Paasen & Patrick BergmanEnergy research Centre of the Netherlands (ECN)ECN Biomass
(1) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Content
• Principles of OLGA technology & Development
• Current status- Lab-scale results
- Pilot-scale demonstration
• Integrated ECN test facility
• New OLGA research topic = dust
• Conclusions & Outlook
(2) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
ECN-RX--03-063 3
Reasoning of OLGANeed for new solution
Tar is the “Achilles heel” of biomass gasification
• Water quench/washer is state-of-the-art- Troublesome mixture of dust, tar, and water
- Process water contaminated with tars
• Fouling, loss of availability
• Removal efficiencies insufficient for advanced applications (e.g. Fischer-Tropsch synthesis)
(3) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Available gas cleaning processes
NH3 HCl light tar heterocyclictardust heavy tar
thermal cracker 100% 100% 100%
50%
p r o c e s s t e m p e r a t u r e
bag house
filter
adsorption char 100% 50% 80%
aqueous scrubber 100% 100%
70% 40% 90%
ceramic filter
cyclone
monolit reactor / reversed flow cracker
95% ESP 95%
water dewpoint
tar dewpoint
Avoid mixing of impurities !!
Reasoning of OLGA
(4) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
4 ECN-RX--03-063
OLGA TechnologyPrevention of waste water
NH3 HCl light tar heterocyclictardust heavy tar
thermal cracker 100% 100% 100%
50%
p r o c e s s t e m p e r a t u r e
bag house
filter
adsorption char 100% 50% 80%
aqueous scrubber 100% 100%
70% 40% 90%
ceramic filter
cyclone
OLGA (advanced tar scrubber)
100% 100% 100%
monolit reactor / reversed flow cracker
95% ESP 95%
water dewpoint
tar dewpoint
(5) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Tars removed above
water dewpoint
Principles of OLGASimplified process sheet
(6) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
product gas tar-loaded
product gas tar-free
tar-loaded stripper gas to gasifier
stripper gas (gasification air)
heavy tars to gasifier
• Application of an organic scrubbing liquid
• Tars recycled to gasifier & destroyed
ECN-RX--03-063 5
OLGA tar removal performance
40%
60%
80%
100%
tar r
emov
al
heavy tars 49% 99% 100%
light tars 62% 74% 100%
heterocyclic 79% 79% 99%
Dew-point [°C] 180 60 -17
Wet scrubbing Idem+ESP OLGA
-17
compared to wet-scrubbing gas cleaning
(7) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
The “Tar Problem” solved
Gas quality sufficient for advanced
applications!!
Performance of OLGAExperimental lab-scale tar removal results
(8) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
• Typically, tar dewpoints achieved below –10°C- only little amounts of BTX remain
• Long duration test of 100 hours
• Tested with variable tar loads: 6 – 20 g/mn3
• Cleaned product gas successfully applied forFischer-Tropsch synthesis
• Scaleable technology=> pre-design for 200 mn
3/h pi lot
6 ECN-RX--03-063
(9) ECN Biomass – ThermoNET meeting , Helsingør, 17-20 October 2003
Installationat ECN site
OLGA pilot-unit
(10) ECN Biomass – ThermoNET meeting , Helsingør, 17-20 October 2003
Installationat ECN site
OLGA pilot-unit
ECN-RX--03-063 7
(11) ECN Biomass – ThermoNET meeting , Helsingør, 17-20 October 2003
OLGA piloterected at ECN site
• Installed July 2003
• Commissioning ongoing
• Test programme:Dec’03 – Jan’04
Outlook of OLGADemonstration and Projected costs
(12) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Projected direct investment costs: 200-300 euro/kWe
(for 10 MWth; extrapolated from pilot )
2001 2002 2003 2004 Conceptual Design Proof-of-Principle (lab-scale) Proof-of-Concept (bench-scale)Full-scale Demonstration
8 ECN-RX--03-063
Complete integrated facility for research
(13) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
• ECN has extended the test infrastructure
• Based on 10 years ongoing research
• Development of three commercial relevant processes:
1. Direct combustion or co-firing in boilers
2. CHP application with gas engines
3. Application for turbines, fuel cells, and biosyngas for synthesis of chemicals & fuels
ECN R&D Developments
Test facilities at ECNDirect combustion or co-firing on boiler
(14) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Fuels: chicken manure, straw, sunflower husk
ash
air
biomass
solids
flue gas
1
2
3
10
(1) CFB gasifier (500 kWth)(2) staged gas cooler(3) cyclone (300°C) (10) low-NOxburner
ECN-RX--03-063 9
CFB Gasifier “BIVKIN”
• Circulating Fluidised Bed (CFB) gasifier “BIVKIN”
• D = 20 cm / H = 6 m
• Constructed 1996
• Feed rate: 100 kg/hCapacity: 500 kWth
• More than 20 fuels tested,e.g. wood, straw, RDF, chicken manure
(15) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Test facilities at ECNSmall CHP with gas engine
(16) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Application: small size distributed installations
ash
air
biomass
solids
water, tars, dust
1
2
3
8
7
9
11
NH3
flue gas
6
(1) CFB gasifier (500 kWth)(2) staged gas cooler(3) cyclone (300°C)(6) quench(7) ElectroStatic Pr ecipitator (ESP)(8) NH3 scrubber(9) booster (11) gas engine (optional)
10 ECN-RX--03-063
ElectroStatic Precipitator (ESP)
• wet ESP- condensation water
• T = 25°C
• Removal efficiencies- dust fines: 100%- condensable tars: 100%- dewpoint: ~40°C
• Operates very well
(17) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Test facilities at ECNGasification for turbine, fuel cell, or synthesis
(18) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Available: compressor, two Fischer-Tropsch reactors, SOFC
ash
air
biomass solids
water
1
2
4
58
9
NH3
tar 6
Advanced gas applications
(5) OLGA(6) condenser(8) NH3 scrubber(9) boos ter
(1) CFB gasifier (500 kWth)(2) staged gas cooler(4) hot gas filter (350°C)
ECN-RX--03-063 11
ash
air
biomass
solids
solids
water, tars, dust
flue gas
1
2
3
4
58
7
9
11
10
NH3
tar
flue gas
6
Test facility at ECNComplete integrated facility for research
(19) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Based on 10 years development
Motivation & Objective
(20) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
Dust removal with OLGA
• Current OLGA research-units designed for dust-free gas• Hot-Gas Filter required (expensive, reliability?)
• Combined tar & dust removal with OLGA
air
biomass
T > H2O dewpoint
BFB
coarse & fine dust
OLGA
T > tar dew point [dust] = ~3 g/mn
3
T = 850°C [dust] = ~3 g/mn
3
• Test line-up:
12 ECN-RX--03-063
(21) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
OLGA IN OLGA OUT16 mg/mn
3
Dust removal with OLGAFirst removal results
WOB, 1 kg/h beech, air, ER = 0.25, 1.6 mn3/h product gas, 3.2 g/mn
3 dust
Process lay-out design
air
biomass
T > H2O dewpoint
BFB
fine dust
OLGA
T > tar dew point
T = 850°C [dust] = 3-20 g/mn
3
coarse dust
[dust] = 2-6 g/mn3
Dust removal with OLGA
• Cyclone to remove fouling-critical coarse dust• Suitable for high dust loads
(22) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
ECN-RX--03-063 13
Conclusions
• OLGA is a very efficient tar removal technology that generates no new waste streams
• Technology ready for first demonstration early 2004
• Complete integrated test facility available at ECN,including an OLGA with upstream Hot-Gas Filter
• OLGA is suitable for combined tar & dust removal
(23) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
OLGA technology
More information
Please contact:
Dr. ir. Harold Boerrigter Publications can be found on:phone +31 224 56 4591 www.ecn.nl/biomassfax +31 224 56 8487email [email protected]
(24) ECN Biomass
Visit also: “Phyllis” - internet database for b iomass, coal, and residues: www.phyllis.nl
“Thersites” – internet database for tar dewpoint calculations: www.thersites.nl
14 ECN-RX--03-063
Justification & AcknowledgementIn the OLGA development, ECN Biomass collaborates with Dahlman Industrial Group (Maassluis, the Netherlands)
The Netherlands Agency for Energy and the Environment (Novem) is acknowledged for financial support for the OLGA development.
(25) ECN Biomass – ThermoNET meeting, Helsingør, 17-20 October 2003
ECN Biomass
Contributing to the implementation of biomass (and waste)
in the Dutch and global (energy) infrastructure
by means of short-term, mid-term, and long-term
research, technology development, and knowledge
dissemination.
Contributing to the implementation of biomass (and waste)
in the Dutch and global (energy) infrastructure
by means of short-term, mid-term, and long-term
research, technology development, and knowledge
dissemination.
Mission
ECN Biomass is a business unit of theEnergy research Centre of the Netherlands (ECN)
(26) ECN Biomass
ECN-RX--03-063 15
ECN BiomassResearch Clusters
Power Generation! Slagging, fouling, co-combustion, co-firing, ash-quality
Combined Heat and Power! gasification, combustion, gas clean-up, prime-movers
Fuels and Products! liquid fuels, gaseous energy carriers, syngas, bio-refinery,
co-generation
Impl
emen
tatio
n tim
e
(27) ECN Biomass
16 ECN-RX--03-063
