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Fuel Pellets from Torrefied Biomass – The SECTOR Project
Wolfgang Stelte, Danish Technological Institute
24.May 2013
Outline
Danish Technological Institute – DTI
Who we are and what we do
Center for Biomass and Biorefinery
Our Projects
Biomass for Energy production in Denmark and Europe
Market and Outlook
Biomass Logistics
Development of new types of Biofuels
Torrefaction of Biomass – The SECTOR project
Danish Technological Institute
Status
An independent, not-for-profit institution
Approved as a technological service institute by the Danish Ministry of Science, Technology and Innovation.
Objectives
Address the needs of the industrial sector and society as a whole through the development and dissemination of technological innovation.
Poland
Hirtshals
Aarhus
Kolding Odense
Taastrup
Gothenburg
Warsaw
Roskilde
Sweden
Denmark
Norway
Poland
USA
Center for Biomass & Biorefiney
Part of the Division for Energy and Climate
Around 30 people in 4 locations in Denmark
Grenå – Algae Center Denmark
Aarhus – Biomass Laboratory and Offices
Sdr. Stenderup – Pilot plant and production facilities
Taastrup – Offices
Center for Biomass & Biorefiney
- Biomass Resources
- Characterization
- Pre-treatment
- Conversion
- Bio-Refinery
- Storage and Logistics
Fuels: Liquid, Solid, Gas Materials Food, Feed & Fertilizer High Value Products
Center for Biomass & Biorefiney
Important Projects / Focus areas
- Large scale Utilization of Bio pellets for energy Applications
- Upgrading Fuel Properties of Solid Biomass and Waste by Torrefaction
- Biomass pelletization – Solid biofuels from various types of biomass
- Bio refinery: Food, feed, fuel, fertilizer and high value products from Biomass
- Biowaste utilization
- Quality control and characterization of biofuels
- Combustion systems for Biofuels
- Energy Production from Marine Biomass
- Value Chain Utilization of Aquatic Biomass
Outline
Danish Technological Institute – DTI
Who we are and what we do
Center for Biomass and Biorefinery
Our Projects
Biomass for Energy production in Denmark and Europe
Market and Outlook
Biomass Logistics
Development of new types of Biofuels
Torrefaction of Biomass – The SECTOR project
Biomass for Energy production in Denmark and Europe
The use of Biomass for Energy production is mainly driven by political goals
EU targets till 2020: 20 % renewables of the total primary energy consumption, 10 % biofuels in transport sector
Wind and solar power depend on climate, daylight and are unstable resources Biomass can be used according to energy demand
Existing infrastructure: Use biomass in existing coal power plants
Co-firing with coal
Switch totally to Biomass
Power plants in Denmark
Source: Dong Energy
Source: Ingeniøren
Bioenergy – DK and EU-27
Share of Bioenergy on total Energy production in Europe is expected to double until 2035 Amount of Biomass is increasing
EU-27 Denmark
Source: ENS Source: World Energy Outlook, 2012
Bioenergy – Global perspective
Share of bioenergy on global energy production today
Renewables will replace fossil fuels in the future
Strong increases of bio-energy share is expected
International Energy Agency – IEA & Bauen et al.
Many different routes to convert biomass into energy
and materials
Basu P.
If we want to replace fossil resources (oil, gas, coal) with biomass, large quantities of biomass are required
Biomass for energy
Biomass yields are highest in warm climate zones (close to equator)
Biomass growth best far away from where energy is needed
Local resources are often limited Import
Beringer, T. et al.
Biomass for energy
P. Lamers et al. / Renewable and Sustainable Energy Reviews 16 (2012) 3176-3199
Industrial pellets Residential pellets European market Oversea (US, Canada) Data from 2010
Streams in kilo tons
Global trade of Biomass: Pellets
Wood pellet import into the EU in tons 2011 Data from Eurostat
Import of pellets into the EU
Market for Solid Biofuels is increasing
Global pellet production and estimated future development
Pöyry, Management Consulting, 2011 (Prediction 2015 & 2020)
Large amounts of biomass are transported over long distance
Biomass is a porous bulk material
Most volume of dry biomass is air
Load volumes of carriers (trucks, ships) are reached before mass limit
is reached
Pre-treatment to increase density of biomass
Pelletization
Torreraction
Why biomass pre-treatment?
Major barriers for bioenergy utilization is its low density
Why biomass pre-treatment?
Pellets
Main advantages of pelletization
Increase of density (straw: 40 kg/m3 750 kg/m3)
Decrease of transportation, storage, handling costs
Standardized size automated feeding into boiler systems
More homogeneous fuel uniform combustion in boilers
Pelletizing Process
Pelletization
Pellet production
Drying in field and forest / in case of wood additional drying is necessary Size reduction: chopper, hammer mill (< 5 mm particle size) Drying or addition of steam. Moisture content should be ca. between 5-20 % Pellet mill (80-100 °C / 2000-4000 bar pressure) Cooling and screening of pellets with air
Biomass
Pellets
Pelletization
Vattenfall – Straw pellet plant in Køge, Denmark 4 pellet mills a 4 tons/h 16 tons /h
Utilization in own heat and power plants
Pellet mill Matrix with press channels
Pelletization
Two types of mills: Ring die Flat die type
Layer by layer assembly of a pellet Every time roller passes a new amount of biomass is squeezed into the press channel High friction results in high pressure and temperature ca. 2000-4000 bar pressure 80-100 °C
Pelletization
Different types of biomass need to be handled and utilized differently It would be good to have a process that transforms all kinds of biomass into one homogeneous product Torrefaction
Torrefaction
Most existing power plants today are coal fired
High pressure on energy providers to phase out fossil fuels
Existing power plants are not compatible with biomass
Its expensive and takes time to rebuilt power plants
Demand for Biomass with coal like properties Torrefaction
Situation in power industry today
Torrefaction is thermal treatment of biomass in an oxygen free
environment
Process is a bit similar to charcoal production but much more
controlled environment
Resulting in biomass with favorable combustion properties
better mechanical properties and higher energy density
Torrefaction
Torrefaction
Torrefied biomass, especially after it has been pelletized has similar properties as coal Ideal bio based fuel to replace coal in existing power plants
Data from Kleinschmidt, CP
Torrefaction
Outline
Danish Technological Institute – DTI
Who we are and what we do
Center for Biomass and Biorefinery
Our Projects
Biomass for Energy production in Denmark and Europe
Market and Outlook
Biomass Logistics
Development of new types of Biofuels
Torrefaction of Biomass – The SECTOR project
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
SECTOR - Production of Solid Sustainable
Energy Carriers from Biomass by Means of
Torrefaction
A European R&D Project funded within the Seventh
Framework Programme by the European Commission
31
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
project brief
Collaborative project: SECTOR
Project start: 01.01.2012
Duration: 42 months
Total budget: 10 Mio. Euro
Participants: 21 from 9 EU-countries
Coordinator: DBFZ
32
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
a pan European consortium
33
Kick-off meeting at ECN
(14-15 February 2012)
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
SECTOR objectives
Support the market introduction of torrefaction-based bioenergy carriers as a commodity renewable solid fuel
Further development of torrefaction-based technologies (up to pilot-plant scale and beyond)
Development of specific production recipes, validated through extensive lab-to-industrial-scale logistics and end-use performance testing
Development and standardisation of dedicated analysis and testing methods for assessment of transport, storage, handling logistics and end-use performance
Assessment of the role of torrefaction-based solid bioenergy carriers in the bioenergy value chains and their contribution to the development of the bioenergy market in Europe
Full sustainability assessment of the major torrefaction-based biomass-to-end-use value chains
Dissemination of project results to industry and into international forums (e.g. EIBI, EERA, CEN/ISO, IEA and sustainability round tables)
34
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
SECTOR in the roadmap of torrefaction
35
Proof-of-concept
• Experimentally based process
designs
• Technology identification
• Knowledge base
• Experimental infrastructures
torrefaction
• Economic evaluations full-scale
(study about 30%)
• Set-up pilot phase of
development
Prototype development
(pilot-scale evaluation)
• Pilot plants / prototype technology
• Demo technical feasibility
• Process & product characterisation
(design)
• Economic evaluations full-scale
(preliminary ca. 20%)
• Business plan(s) (technical demo,
semi-commercial)
Technical demonstration
• Demonstration plants (semi-
commercial)
• Technical optimisation (refined
design)
• Product applications (logistics &
end-use)
• Economic evaluations full-scale
(definite ca. <10%)
• Business plan(s) (commercial
operation)
Commercial role out
• Commercial plants (full-
operation)
• Quality control and assurance
(product)
• Best practice for sustainability
• Product standardisation
• Purchase agreements (from
energy & chemical sector)
2004 2006 2008 2010 2012 2014
Woody
biomass
Time
Capacity 5-10 kg/h 30-200 kg/h 60-200 kton/a 20-50 kton/a
Proof-of-
principle
Prototype
(pilot-scale)
Commercial
role out
Technical
demonstration
Proof-of-
concept
Proof-of-
principle Proof-of-concept
Prototype
(pilot-scale)
Commercial
role out
2002
Proof-of-
principle
Technical
demonstration
2016 2018
Non-woody
biomass residues
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
Handling and logistics of torrefied material
Advantages
• Increased feedstock basis as option to
reduce transport distances
• High energy density of torrefied
products effective transport
• Reduced water retention force
(hydrophobicity)
• Slower biodegradation potential
• Better grindability due to embrittlement
• Decreased costs for handling, storage
and transport
• Biomass torrefaction can create new
markets and trade flows as a commodity
fuel ( product standards are needed).
Disadvantages / Challenges
• Dust and dirtiness at handling and
transport
• Safety issues must be assessed
• Self ignition and spontaneous combustion
occurs at 150-170°C
• Explosion hazards increase compared to
conventional biomass but probably not
in comparison with coal
• Compacting (pellets / briquettes) is
more difficult
• Additional fuel properties (e.g. degree
of torrefaction, grindability, hydrophobic
nature, resistance against
biodegradation) and sustainability
criteria must be defined ISO work
36
sources: ECN, ofi, Kleinschmidt, Wild & Partner, Vattenfall
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
project structure
37
place, date
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP1 Project Management (DBFZ)
place, date
38
WP Leaders
Participating Partners
Ad
vis
ory
Bo
ard
Coordinator
Task Leaders
EC
Strategic Management
Board
Gen
eral Assem
bly
Coordination and administration of the project
Communication with European Commission
Reporting
Organisation of Project Meetings
Set-up and maintenance of project website www.sector-project.eu
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP2 Selection of relevant biomass feedstock (VTT)
Assessment of available biomass potential for production of
torrefied pellets from both forest and agricultural feedstock and of
the market demand
Selection of raw materials for the experimental work
place, date
39
Poplar chips Eucalyptus chips
Prunings from olive trees
Cereal straw
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP3 Torrefaction (ECN)
place, date
40
Production with available demo plant Continuous operation
Production of 100-200 tons Specific feedstock
Production with available pilot scale facilities Typical test runs 50-100 hours
Typical production per test few tons 3-6 different feedstocks
Moving bed (ECN) pilot
Rotary drum (Umeå University)
pilot
Rotary drum (CENER)
pilot
Torbed (Topell) demo
Different technologies
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP4 Densification (DTI)
Characterisation and optimisation of the densification properties of
different torrefied biomass materials according to end users
requirement based on tests in lab, bench and industrial scale
densification units (pellets and briquettes)
place, date
41
Lab-scale charact. & screen. of pelletisation parameters
(DTI)
Industrial scale pelletisation
(ECN, CENER, UMEÅ, Topell)
Bench scale briquetting
(DTI, C.F. Nielsen )
Torrefied biomass (WP3)
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP5 Demonstration Tests (Topell)
Production of torrefied materials and pellets at demo scale in
Topells 60 kt/a plant in Duiven
Products to be used for large scale test in WP6+7
place, date
42
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP6 Logistics (ECN)
Small-scale tests to characterise logistics performance
Outdoor storage and handling tests
Results will be used to adjust production processes
place, date
43
Large scale testing of storage and handling properties at existing industrial
coal based power plants
Small scale testing of specific properties of both raw torrefied biomass as well as
pelletized or briquetted torrefied biomass
Transport, storage and handling
Stefan Dusan – 4th annual biomass and bioenergy forum (Vienna, Sep. 2011)
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP7 End-use (University of Stuttgart)
Evaluation of the end-use applications of
torrefied biomass in different application
areas:
• Medium-to-large scale firing and co-firing
in pulverized-fuel boilers
• Medium-to-large scale gasification and co-
gasification in entrained-flow gasifiers,
and
• Small scale combustion in commercial
pellet boilers.
• Production of bio-chemicals or bio-
materials
place, date
44
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP8 Fuel specification & lab analysis (OFI)
Verification, development and
application of analysis methods to
access fuel properties
Development of a Material Safety
Data Sheet (MSDS)
Preparation of CEN and ISO product
and quality assurance standards
place, date
45
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP 9 Value chains and sustainability (DBFZ)
Within SECTOR three different assessment areas are
covered:
• Socio-economic assessment
• Environmental assessment
place, date
46 46
Inventory indicators
Inventory data
Characterisation
- unclear cause-effect
- aggregation
- scoring/weighting
- use of PRPs
Characterisation
- cause-effect link
- (aggregation)
- modeling impact
pathway
Midpoint category indicatorSubcategory indicator
Impact category Endpoint category
Type 1 Type 2
Cost-efficiency
ENVIRONMENT
SOCIETYECONOMY
Technical-efficiency /-compatibility
Security of supply
Environmental & climate protection
Creation of value
Impact pathways of the UNEP methodology
The research leading to these results has received funding from the European Union Seventh Framework Programme FP7/2007-2013 under grant
agreement n° 282826
WP10 Cooperation and Dissemination of project results
(DBFZ)
Dissemination of project results through
• Workshops
• Website
• International Networks and Platforms to standardisation
committees
place, date
47
Market integration
Generally initiate developments in the
market outside of SECTOR
Show advantages of torrefied fuels and
wake interest
Set it on the political agenda for the
needed framework Get feedback from the market about aspects yet to be covered or changed within the
project
Prepare market launch by staying in
touch with stakeholders
Thank you for your attention!
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