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2G Gasification R&D aiming to improved biomass conversion efficiency and reduced costs Hotel Kalastajatorppa, Helsinki August 30, 2012 Esa Kurkela VTT

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2G Gasification R&D aiming toimproved biomass conversion efficiency and reduced costs

Hotel Kalastajatorppa, HelsinkiAugust 30, 2012

Esa KurkelaVTT

207/09/2012

Production of Transportation Fuels from Biomass2G-Biofuels 2020 Project

budget 7.3 M€ in 2012–14; second phase in 2015–17

Pilot-scale development of new innovative processes for improved efficiency and lower production costsGasification-based systems

Optimized high-pressure steam-oxygen gasificationprocess aiming to improved fuel-to-syngas conversionefficiency and to wider feedstock basis (above 200 MW scale)Indirectly heated gasification for smaller size range (50 - 200 MW)Syntheses with less stringent gas purityrequirements compared with present processes

Alternatives based on pyrolysis technologyPyrolysis oil production integrated to CHPCatalytic pyrolysis to improve oil qualityUpgrading of pyrolysis oil for transportation fuels

Co-production of fuels, heat and electricity – integration to forest industries and district heating => high overall efficiencyIndustrial partners: Andritz-Carbona, Foster Wheeler, Metso, UPM-Kymmene, NSE Biofuels, Fortum

307/09/2012

Syngas Route to Biofuels – Integrated Conceptstudied at VTT’s UCG-project in 2004-07

Forestry residues,mill residues,straw, energy crops,urban biowaste

Synthesis& upgrading

Gasification andgas treatment

Pulp andpaper mill

Biomasshandling

anddrying

powerplantProcess steam & power

Paperor pulp

Hydrocarbon fuels (FT)or methanol, DME, SNG, H2, etc.

Energyto drying

synthesis-gas

bark,forestryresidues,otherbiomass

fuel gas+ steam

steam & oxygen

150-300 MW

75-160 MW

50-150 MW

VTT PDU

Industrial Demoat Varkaus

GTI Pilot

407/09/2012

From: K.Salo, Andritz Carbona presentation at IEA gasification seminar, Piteå, 2011

507/09/2012

From: Sami Kokki, Foster Wheeler

607/09/2012

Production of Biomass-Derived Synthesis GasInitial step - two main approaches

Biomass Raw synthesis gas

to cooling, clean-up and conditioning

Typically: fluidised-bed gasifier, either oxygen-blown or indirectly heated

GASIFIER

e.g. 850 ºC

REFORMER

900 ºCcatalytic

Main technical challenge: reforming of gas

Biomass Raw synthesis gas

to cooling, clean-up and conditioning

Typically: oxygen-blown entrained-flow gasifier

DryPulverBIOMASS

PRE-TREATMENT

GASIFIER

1300 ºC +

Main technical challenge: prehandling, feeding of biomass

orPyrolysis

oil

707/09/2012

Biorefinery BTL Demonstration Plans in FinlandThree consortiums planned second-generation BTL-biorefineries in Finland The planned capacities were100 000 – 200 000 ton/a of diesel EU’s NER300 funding was applied- final decisions at the end of 2012 Overall investment costs in orderof € 400 - 800 million?Technologies ready for industrial demonstration

Several sites have beeninvestigated by companies

Very large-scale is needed to achievepositive economics?First plants will be more expensive than mature technology?

807/09/2012

Production and Conversion of Biomass-Derived Synthesis GasMain Steps in Overall Process

MainProduct

HP Steam

CO shift,H2S removalCO2 removal

MP Steam Off-gas

Heat

Typical pressures: 1 - 30 bar 30 bar 30 - 200 bar

Biomass

SteamSteam + O2

DRYINGGASIFICATIONREFORMING

INITIAL GAS CLEANING

SYNTHESIS/UPGRADING

FINAL GASCLEANING ANDCONDITIONING

FiltrationTar removalScrubbing

General aims of the 2G Gasification project:• To simplify the overall process concept: lower investment cost and possibility to

realize BTL production also in smaller size range (100-200 MW biomass input)• To increase the efficiency of biomass utilization to fuels + power + heat• To enlarge the feedstock basis from woody biomass to agrobiomass and wastes

907/09/2012

Possible ways to improve the synthesis gas route- 2G 2020 Gasification Pilot Development at VTT in 2012–14, total budget 4.1 M€

Optimised high-pressure steam-oxygen gasificationprocess aiming to improved fuel-to-syngas conversionefficiency and to wider feedstock basis(above 200 MW scale) – PDU test runs in 2012Indirectly heated or air-blown gasification processesfor smaller size range (50 - 200 MW) – piloting in 2013/14Simplified final gas cleaning studies in 2012/13 and slipstream tests when necessarySyntheses/catalysts with less stringent gas purityrequirements compared with present processes

- Higher inert concentration (N2)- Lower requirements for CO2 removal- Higher tolerance for sulphur

Co-production of fuels, heat and electricity –integration to forest industries and district heating

1007/09/2012

0

5

10

15

20

25

30

35

30 bar 5 bar 1 bar 5 bar 1 bar 30 bar 5 bar 1 bar 5 bar 1 bar

% o

f FT

Prod

uctio

n C

osts

O2 production Compressions

Oxygen-blown Air-blownIndirect +Oxygen-blown

Indirect +Air-blown

Evaluation of Alternative Gasification Heat Sources

VTT Research Notes 2434 (McKeough & Kurkela, 2008)

1107/09/2012

Design and Operation Challenges of High Pressure Oxygen-Blown Fluidized-Bed Gasifier

Fluidization by oxygen alone is not possible – steam and/or other diluting fluidization media is neededAt high-pressures the capacity per reactor area/volume is increasing as fluidization velocities cannot be very much reduced at increased pressure – gasification reactivity is limiting the capacityThe positive effects of calcium-based bed materials can only be utilized at below 5 bar pressure, where CaO is catalyzing tar reduction and gasificationAt higher pressures the sintering of biomass ash becomes more critical than at low pressures – special bed materials, such as MgO are neededMechanical design issues become more challenging also at above 10 bar pressure (e.g. feeding systems)Soot formation and deposition problems are also more difficult to avoid in hot filtration and reforming at higher pressures

1207/09/2012

HIGH PRESSURE GASIFICATION OPTIONS

Biomass

O2+H2O+recycle gases

850oC

High temp filtration

Gas to reformer

800-850 oC

Staged reformer

HT-Shift

Gas 650-750 oC

O2/air/steam

Steam/water

20bar

Pretreatment before filtration?- Pre-reformer?- Sorbent?- Ash recirculation?- Catalytic filter?

Sec oxygen

Targetted Advantages:1) High pressure =>

lower power consumption will increase efficiency

2) No gas intercoolingOxygen consumption and CO2-content of gas are lower

3) Other ideas:- recycle-gas fluidisation- high steam fluidisation- staged oxygen feed- bed additives andagrobiomass

- optimised reformer fordifferent applications

SIMPLIFIED FINAL

GAS CLEANUP

Transportationfuels

Fuel gasfor energyproduction

Potential Advantages- lower investment costs- simplified process- Possibility to oxygen enriched air gasification?

- Full energy integration

SYNTHESISFOR 200 MW

SCALE

1307/09/2012

Filtration of raw gas from CFB/BFB gasification• Filtration between the gasifier and reformer is

needed to achieve efficient reforming• Previous experiences from biomass-IGCC and

waste gasification development• Target: increased filtration temperature – in optimal

case filtration without raw gas cooler

Basic process: filtration at 550 oC• Efficient removal of Na, K etc.• Not sensitive to high tar

concentrations • Protects the reformer

Increased filtration temperature• First tests in spring 2012• Filtration at 650-680 oC• More sensitive to tar & soot

– stable pressure drop only with low tar conditions and with high dust load

• Tests continue in Oct. 2012• Effects on overall process?

• reformer operation?• gas cooler after reformer?• overall efficiency?

14

PDU-Reformer results from 2012 Test Runs- improved design of the pre-reformer

- the effect of operation temperature on tar and methane conversion- gas filtration before reforming at ca. 550 oC, 6 bar pressure

15

Next test runs are scheduled to Oct - Nov 2012

Final O2/steam gasification tests at the present test rigModified distributor for fluidization gases –simulating the recycle of FT-off gasAdditional tests with increased filter temperature – alkali measurementsNew reformer design for increased inlet temperature

Design of the new 25 bar Steam-O2 and air gasification test rig will be started in autumn 2012 – commissioning in late 2014

16

R & D on Hot GasFiltration and Catalytic Gas

Cleaning

IGCC development

SYNGAS R&D AT VTT• Concept development for biofuels• Gasification process development

• Support to industrial demonstrations• Improved process concepts in 2G Biofuels project 2012->

INDUSTRIAL PILOT

• VARKAUS • CHICAGO

NEW APPLICATIONS• Fuel cells, 2nd gen. IGCC• Hydrogen, synthetic methane,

Chemicals • Hybrid Renewable Systems• Material Recovery from Waste

BIOMASS/WASTE GASIFICATION FOR POWERPIONONEERING DEMO’S: LAHTI,

CORENSO,VÄRNAMO

Gasification testsIn USA and Germany +

Supporting R&Dat VTT for Oulu

1995 2000 2005 2010 2015 20201985 2025 2030

BIOREFINERIES AT PULP AND PAPER MILLS AND AT LARGE CHP PLANTS• Bio-Diesel production100-200 ktons/plant• NER300 financial support to first plants?• Gasoline, SNG, H2 in next phase

BIOMASS AND WASTE GASIFICATIONFROM R&D TO INDUSTRIAL SUCCESS

PEATAMMONIA

PLANTOULU/FINLAND

19805 p-years

199015 p-years

200020 p-years

201025 p-years

WASTE-TO-ENERGY PLANTS ANDCO-FIRING IN COAL BOILERS• Corenso 2001, Lahti II 2012, Vaasa 2013• High electric efficiency, material recovery• Replacement of coal by biomass-derived gas

as part of fuel conversionactivities of 60 p-years

(gasification, synthesis, pyrolysis, fuel cells)

BIOMASS-TO-POWER PLANTS• Small-scale CHP by gas engines 0.1-5 MW• IGCC plants 30-150 MW

Bioneer Gasifierfor Small-scale