Experiences in Development of Gasification for · PDF fileProcess development ... TPS Termiska Processer AB Energy-related Product and Services with Emphasis on: Biomass and waste

1 IPT Biomass Gasification Symposium

Sao Paulo, Brazil, 2012-09-17

Lars Waldheim

Alsätravägen 130

12736 SKÄRHOLMEN

lars.waldheim @waldheim-consulting.se

Experiences in Development of

Gasification for Power



Brief technology overview

Process development

Process applications

Sugar mill applications

Some final words

Synopsis



TPS Termiska Processer AB

Energy-related Product and Services with Emphasis on:

Biomass and waste

Combustion and gasification

Heat and electricity generation

Environment

Products/ Engineering: TKC for boiler systems < 30 MW

CFB and FB bed boiler technology

CFB gasification system

Wood pellet and PF burners

Special flow measurement devices

Licensing, technical know-how transfer

Engineering consultancy and services

StockholmNyköping

Roots in the national energy laboratory Studsvik, Nyköping:

Formed in 1992 by staff buy-out

Part of TallOil in 2004

Part of ACAB Invest 2007

Ceased operation in 2010



Pressurised Gasification

Steam &

Oxy gen

Oxy gen

BoilerFeedwater

Feeder800°C

30 atm.

High Temperature

Fly ash Filter

LockHopper

Ash

Fly ash

LockHopper

Steam

950°C

Final Treatment

RawSy nthesis

Gas

FuelGas

Ammonia

Combined Cycle

Local Distribution

Iron pre-reduction

Oxo Chemicals

Methanol

with Cataly st

Secondary Reformer

Peat

Wood residues

Bark

Chipping

Dry ing

MINO process 1978-1986

• pressurised 28 bar, oxygen blown, hot gas cleaning

• 2 MWth pilot plant at Studsvik national laboratory

CFB know-how in-house

Proprietary CFB boiler design licensing



Gasification Flexibility in Products

CONVERSION TECHNOLOGY

GASIFICATION MEDIUM HEATING VALUE (MCV) GAS

HYDROGEN

ALCOHOLS DME

ENGINE

FINAL PRODUCTS PROCESSING TECHNOLOGY

PRIMARY PRODUCTS

LOW HEATING VALUE (LCV) GAS

SYNTHESIS

TURBINE HYDOROCARBONS

ELECTRICITY

PROCESS STEAM

COMBUSTION STEAM & ELECTRICITY BOILER FLUE GAS

BOILER / FURNACE

PROCESS ENERGY



Adapted from: VTT PowerBiGPower –project no. 019761 2009

Gasification Power Potential



Biomass Gasifier Technologies

Fuel

Air

Gas

Ash

10 kW 1000 kW 10 MW 100 MW FUEL THERMAL CAPACITY

DOWNDRAFT

FIXED BED

UPDRAFT

FIXED BED

INDIRECT

DOUBLE BED

CFB

Fluidyne

Xylowatt

PPC

Pyroforce

TERI

ENTRAINED FLOW

CFB or FB P>1 MPa

,

Bioneer

B&W Völund

Nexterra

Repotec

Ortner

FERCO

Taylor

(TPS)

Foster Wheeler

Metso

Carbona

Host

Foster Wheeler

Carbona

UHDE

Enerkem

UHDE

Chemrec

(CHOREN)



Gasifiers and Prime Movers

IGCC (Integrated Gasification Combined-Cycle)

5 10 2520 3015 70 90858075 100 MWe95

DUAL FUEL + STEAM

CYCLEDUAL FUEL (INJECTION IGNITED

DIESEL ENGINE)

GAS ENGINE

PRESSURISED FLUIDISED BED

ATM. CIRC. FLUIDISED BED

105 15 25 70 100 MWe

ATMOSPHERIC FLUIDISED BED

20 80 9060

DOWNDRAFT FIXED BED

UPDRAFT FIXED BED



Gasifier, Post-treatment & Applications GASIFICATION

CYCLONE GAS CLEANING EXTENSIVE GAS CLEANING

FIRING IN

BOILER

CO-FIRING

IN BOILER

FIRING IN

BOILER

GAS

TURBINE

CO-FIRING

IN BOILERENGINE

· Lime kilns

· Bioneer

·

· Lahti

· Ruien

· Amercentrale

· (Amercentrale) · Harboøre

· Güssing

· Skive

· Móra d’Elbe

· Värnamo

· ARBRE

· Lahti II

SYNTHESIS

· (CHOREN)

· GoBiGas

· Bio2G

· Enerkem

The technical aspects of gas cleaning, relative to the quality

requirements of boilers, engines gas turbines, and last but not

least, chemical syntheses are among the main technical hurdles



Fuel Contaminants

CHO

Nitrogen

Sulfur

Chloride

Fluoride

Heavy metalls

Alkalis

Ash

POPs

Fuel component

Tar, CxHy, CO

NH3, HCN

H2S, COS, org. S

HCl, org. Cl, KCl

HF

Hg, Cd, Zn etc.

Ash particles

Gasifier gas

emission pre-cursors

CO

VOC, PAH

NOx, SOx, HCl, HF

Org. Cl

(incl. Dioxine)

Heavy metalls

Particulates

Flue gas

Stack emissions



Tar Yield for Different Fuels

Source: VTT



CFB Gasification CFBG developed for lime kilns with ABB Fläkt in 2 MW pilot

Proprietary TPS technology dolomite tar cracker developed

Target market CHP 5- 20 MW heat demand (eq. 4-18 MWe)

Vattenfall power

Hedemora Diesel



FLA

RE

D O L O M IT E

a n d S A N D

C O O L E RG A S

F ILT E R

FLY-ASH SILOTA R C R A C K E R

G A S I F I E R

A I R

A I R

D O L O M IT E

1 2

3

4

20

21

22

7

6

8

9

5

2524

12

11

10

3233

31

30

13

14

27

26

S C R U B B E R17

18

15

16

FU

RN

AC

EF U E L

TPS 2 MW CFBG Pilot Plant

Lessons learned

+Tar cracker validation.

Economy of scale!

Engine emissions! (even with oxidation catalyst)

Tests with 500 kWe dual fuel diesel engine > 700 hrs op.



Tar in Pilot Plant Tests, Wood Fuels

780 800 820 840 860 880 900 920

0

2000

4000

6000

8000

10000

TEMPERATURE (°C)

PILOT PLANT DATA WITH SAND 1988

LABORATORY DATA WITH DOLOMITE

PILOT PLANT DATA WITH DOLOMITE, SHORT PERIODS

IINITIAL PILOT PLANT CONTINUOUS OPERATION

TAR CONTENT

(mg/Nm gas) 3

OPTIMIZED PILOT PLANT TESTS, CONTINUOUS OPERATION



Grève-in-Chianti WtE

Technical characteristics

• 2 Gasifiers, 15 MWth each

• Gas Boiler and Flue Gas Cleaning

• 6.7 MWe Condensing Turbine

• Fuel Gas to Cement Factory

• Licensee: Ansaldo Aerimpianti History

• Start-up of Gasifier # 1: Nov. 1991

• Turned over to Client: Aug. 1992

• Start-up of Gasifier # 2: Sep. 1992

• Turned over to Client: March 1993

• 4000 and 5000 ton RDF processed

in 1999 and 2000, resp.

Plant stopped in 2004 from fuel supply restrictions and the

building of a large scale WtE plant in the Florence region



CEMENT INDUSTRY

(MULTI-USE)

PROCESS GAS

POWER

PRODUCTION

SECTION

GASIFICATION

SECTION

FLUE GAS

TREATMENT SECTION

ELECTRIC POWER

(public use)

ASHES

HEAT RECOVERY

FUEL

Grève-in-Chianti



Scale Pilot Industrial

Vol (%)

H2 11 17

N2 55 43

CO 14 25

CH4 3 4

CO2 16 10

C2H4 1 1

LCV (MJ/Nm3) 4.6 6.9

• A pilot unit is essential to have real life experience

• A number of design issues must be addressed scaling up

• Preferred equipment for industrial size identified/selected

• Models and other procedures developed part of know-how

Scale-up experiencerom Pilot Plant

Gas heating value vs. scale



Atmospheric BIG-GT Flowsheet

Feeding simplified, ”difficult ”fuels

Filter and scrubber ensures gas quality

Multi-stage

compressor

Target output range 20-60 MWe



Objective:

A 30 MWe BIG-GT plant

based on eucalyptus at

Mucuri, Bahia

Grant support from

WB/UNDP (GEF), EU

1st. phase 1992 -1996

Development involved GE,

TPS and Bioflow competing.

2nd. Phase 1996-1999

EU-BR-IDGE 2000-2003

TPS selected as gasifier

supplier. Engineering and

commericial development

SIGAME Project, Brazil



General Electric LM 2500 Gas Turbine Aeroderivative gas turbine with nominal 24 MWe output

TPS development activities included:

• Several tests in the modernized pilot plant on eucalytus wood

• Develop Gasifier-GT interface and performance data with GE

• Plant definition and integration, performance estimation

• Plant basic engineering and costing together with JPE



• Owner: Kelda (FRL) 89%, from 2002 EPRL 89%, TPS 11%

•Supplier: Schelde Engineering Contractrs BV, NL (TPS)

• TIC: 30 M£~ 45 M$ 1997, EC grant: 35 %

• PPA: 105 £/MWh ~ 150 $/MWh (2001

ARBRE –

ARable Biomass Renewable Energy

Eggborough

Selby

North Yorkshire



Arbre Plant Technology

Suppl. firing in HRSG

Steam 60 bar, 485°C

Atmospheric gasification

Suppl. firing from Thermie

Band, 8 to 12 MW, size of

GT and plant, as well as

conservative design

reduce efficiency

Gas turbine (SGT 100) 4.7

Steam turbine 6.0

Gross output 10.7 MW

Gas compressor - 1.5

Misc. usage on site - 1.2

Net output 8 MW

Wood feed: 7 to 8 tonne/hr wet

> 30% el. efficiency LHV



July 2002 plant operation suspended, AEL in liquidation

Project ARBRE History

1994 financial support from EC THERMIE program

1994 15 year UK NFFO power purchase contract signed

1995 Arbre Energy Ltd (AEL) formed, Kelda main owner

1997 planning permission granted

1998 turnkey contract awarded to SEC (NL)

1999 turnkey contractor mother company insolvent

2001 AEL completes construction, hot commissioning

started 2002 gas turbine operates on wood fuel gas

April 2002 Kelda management turn-over, sells plant to EPRL

2003 DAS Green Energy UK Ltd. buys assets,

no activity on site.



Project ARBRE

Flare, September 2001



Integração: BIG/GT - Usina

Francisco A. B. Linero [email protected]

Helcio M. Lamonica [email protected]

Geração de energia por biomassa

Bagaço e palha de cana



Bagasse and Trash as Gasifier Fuels

Objectives:

Characterisation of bagasse and trash gasification

properties in laboratory and bench scale

Pilot plant tests to demonstrate technical feasibility

Initial test pelletised bagasse

Tests with trash (loose & pelletised)

Tests go-feeding pelletised bagasse and loose trash

Gas cleaning data and contaminant data

Empirical test data for modelling and scale-up studies

Model data as input to sugar mill integration studies



Bagasse and Cane Trash

as Gasifier Fuels

Trash + sand

Sharp edges



Bagasse and Cane Trash

as Gasifier Fuels

bagasse+sand

Incipient

droplet

shape



Bagasse and Cane

Trash as Gasifier Fuels

Trash + sand

Small

agglomerate


Sao Paulo, Brazil, 2012-09-17 30

Conclusion of Pilot Plant Tests

Pelletised bagasse tests (3 x 1 weeks) 1998-1999 Loose trash tests (4 x 1 weeks) 2000-2001

Bagasse Trash feeding properties excellent good availability in tests excellent fair-good gas heating value, rel. wood similar slightly less carbon conversion >95 % > 95 % tar content in gas, rel wood low low to medium agglomeration > limit temp none carbon content in bed ash low low fouling of gas cooler not observed not observed ammonia content, rel. wood similar higher mixed trash bagasse fuel op. yes yes other contaminants no some S, Cl

Both fuels, alone and as mixtures, acceptable for TPS process



Integration of a BIG-GT in a Sugar Mill

Assumptions: Average mill data representing state-of-the-art in 1998

General Electric LM 2500 gas turbine (data Braz. BIG-GT project)

Trash available as to supplement bagasse as fuel

Work split: CTC lead partner- Fuel availability and cost, mill aspects

TPS input was BIG-GT cycle calculations and costs

Objective:

determine the energy generation and the fuel and energy

consumption patterns of the mill

evaluate the plant integration in economic terms



PFD and Mill Data- Sugar and Ethanol

Cane Juice extraction

Juice treatment

Evaporators Crystallisation Centrifugation

Product drying

Sugar

Fermentation Distillation Dehydration

Ethanol

Cane: 300 000 ton/season Pol 14.8%

Milling cap.300 ton/hr

Ethanol:

177 m3/d hydrated

177 m3/d hydrated

8 800 bags/d

Fibre 13.8%=

Bagasse 350 000 ton/y

Trash pot. 120 000 ton/y

Steam/cane

0.5 ton/ton



Starting point-Typical Mill 1998

Multi-stage

22 bar – 300 ºC

2,5 bar

Process ~ 0.5 steam/cane (330 kWh/t)

Turbogenerator Auxiliaries Milling

Single-stage

Excess bagasse 7%

Mill is self-sufficient

in electrical power

Single-stage

Cane prep.

Single-stage

Export power ~ 0-10 kWh/tc 0-3 MW only in season



How to Achieve Energy Export Export of energy = less energy available for mill

Reduce energy consumption

– Improve steam economy

• Improve evaporator train to save primary steam

• Improve heat recovery from evaporated steam

– Integration of drives to increase efficiency and reduce steam

consumption

• Change from direct turbine drives to mechanical drives

• Change from single to multi stage turbines where possible

• Install extraction-condensing turbine to allow off-season operation

• Result: Steam/cane 0.5 → Stage I 0.34 → Stage II 0.28 t/t

• Increase bagasse recovery, trash as supplementary fuel

Restrictions

– The least impact possible on the mill for demonstration project

– Use no more than the trash realistically recoverable



Integration Flowchart

Gas Turbine Cooling tower

Boiler

Back-pressure

Steam Turbine

Extract.-cond.

Steam Turbine

Bagasse

Dryer

Gasification and

Gas Cleaning

Clean LCV

gas

Exhaust flue

gas

Bagasse

and trash

Process

2.5 bar

One or two units

22 bar- 300 ºC

or 82 bar- 400 ºC



New HP Boiler– Optimisation Ia

Export power ~ 90 kWh/tc

10 MW season and 20 MW off-season

22 bar – 300 ºC

Process~ 0.34 steam/cane (220 kWh/t)

2,5 bar

Multi-stage

Turbogenerator Milling

Single stage

Preparation

Single stage

Turbogenerator

Para caldeiras

Condenser

Auxiliaries – E-motor

New mill boiler 82 bar 480

ºC



Partial Integration – Optimisation



22 bar – 300 ºC

Process~ 0.34 steam/cane (220 kWh/t)

Consumption 100% of bagasse

~ 40% of trash potential

1 module

BIG-GT

2,5 bar

Milling

Single stage

Preparation

Single stage

Turbogenerator

Para caldeiras

Condenser

Auxiliaries – E-motor

Mill boiler 22 bar

300 ºC



New HP Boiler Optimisation II


20 MW in season, 40 MW in off-season

2,5 bar

Multi-stage

Milling

Single-stage


Turbogenerator

Return to

boilers

Condenser

21 bar – 300 ºC

Auxiliaries – E-motor Cane prep. – E-Motor

82 bar – 400 ºC



Total Integration-Optimisation II



2,5 bar

Multi-stage

Milling

Single-stage

Consumption: 100% of bagasse available

~ 70 % of trash potential


80 bar – 480 ºC

1 module

BIG-GT 1 module

BIG-GT

Turbogenerator

Return to

boilers

Condenser

21 bar – 300 ºC

Auxiliaries – E-motor Cane prep. – E-Motor



Integration of a BIG-GT in a Sugar Mill - Without steam savings 500 kg/tc, low export potential

- Old boiler system 0-10 kWh/tc

- new boiler, 10-20 kWh/tc

- With moderate optimization and steam saving 340 kg/tc

- With new HP boiler 90 kWh/tc

- With BIG-GT partial integration 170 kWh/tc

- With moderate optimization and steam saving 280 kg/tc

- With new HP boiler 170 kWh/tc

- With BIG-GT full integration 290 kWh/tc

Conclusion for first BIG-GT demonstration plant:

- partial integration preferred due to increased reliability

- Cost 73 M$, op cost 5 M$,

- Required PPA 73 $/MWhe w/o any grant

- Formation of a PPP to realize project failed



The ”Mountain of Death”

Source EPRI, USA

BIG-GT Developments stranded on the west slope

However, the potential for high efficiency remains



SYDKRAFT BIG-GT Plant at Värnamo

• Supplier: Bioflow (Foster

Wheeler, Sydkraft (EON))

• Tests 1995-2000, 2007

• Fuel 18 MW

• Power 4,2+1,8= 6 MW

• Heat 9 MW

• Typhoon GT (Siemens SGT 100)

•18 bar pressure.

• >8000 hours of gasifier and

3 600 hours of GT operation

• Good emission data

Mothballed in 2000 as revenues Were too low to cover op. costs

VVBGC IGCC Plant



LCV Gas Turbines

Gas turbine supplier

Model

Development status on LCV

gas

Power

MW

GT older name

GE 10 Developed for one project 10 Nuovo Pignone GT10

GE LM2500 Developed for one project 24

GE Frame 6B Developed for projects 43

Siemens SGT 100 3 installations 5 Typhoon

Siemens SGT 400 Initial developments 13 Tornado

Siemens SGT 600 Initial developments 25 GT 10B

Siemens SGT 1000F 5 non-biomass LCV installations 68 V64.3

Mitsibushi MW261 Initial developments 32

Rolls Royce RB211 Initial developments 25

Volvo Aero VT 4400 Developed for one project 4.4 Dresser Rand 4400

Most larger gas turbine are available for heavy residue, coal gasification LCV gas



It Takes a Bit of Time

Vintage 1904 Coal Gasifier Integrated with a

200 hp (very nominal) Gas Turbine



Acknowledgement

Work presented was sponsored by

Global Environmental Facility (GEF), through UNDP

European Commission (EU) FP5 ENERGIE program (EU-BR-IDGE Project NNE5-0489)

Swedish National Energy Agency

For further gasification information IEA Biomas Agreeement

Task 33 Thermal Gasification www.ieatask33.org

Documents

Experiences in Development of Gasification for · PDF fileProcess development ... TPS Termiska Processer AB Energy-related Product and Services with Emphasis on: Biomass and waste