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Biomass gasification technologies foradvanced power systems and synfuels
- Status and Present R&D activities in Finland
Esa Kurkela
FINNISH – SWEDISH FLAME DAYSNaantali, January 29, 2009
VTT TECHNICAL RESEARCH CENTRE OF FINLAND2
Biomass and waste gasificationfor boilers and kilns
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND3
CFB GASIFIER
REACTOR
850 °C
900 °CBIOFUEL FEED
BOTTOM ASH COOLING SCREW
HOT LOW CALORIFICGAS (750 - 650 °C)
AIR PREHEATER
RET
UR
N L
EGGASIFICATION AIR FAN
UNIFLOW CYCLONE
Atmospheric-pressure CFB/BFBgasification for kilns and boilers• Commercial lime-kiln gasifiers
were constructed in 1980’s byAhlström Oy
• New development by FosterWheeler in 1990’s for boilerapplications
• Gasifiers are now offered by• Foster Wheeler• Carbona/Andritz• Metso Power
• Feasible in size range 15-150 MW• Fuel drying is often neededto achieve required flame properties
From: Foster Wheeler
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Efficient utilisation of wastes and biomassresidues in existing power plants
a cost-effective way to reduce CO2 emissions of power plants
CFB gasifier of 60MW
Main boiler360 MWth
Gasifier feedpreparation
- in operation since 1998- no commissioning problems- 50 000 operating hours- gasifier availability > 95 %- boiler emissions decreased- payback time ca. 8 years
CFB gasifier of 60MW
Main boiler360 MWth
Gasifier feedpreparation
- in operation since 1998- no commissioning problems- high fuel flexibility- gasifier availability > 95 %- boiler emissions decreased-
From: Foster Wheeler
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND5
Source: T.Anttikoski, Foster Wheeler Energia Oy
Plastic reject materialwith 10 % aluminium
Corenso gasifier in Varkaus, Finland• gasification of aluminium containing plastic reject material• complete recycling of liquid cartoons (milk & juice packaging)• 50 MW gas to boiler, 2100 t/year aluminium for re-use• developed by VTT & Foster Wheeler Energia Oy in 1998 - 2000
in operation since autumn 2001
From: Foster Wheeler
VTT TECHNICAL RESEARCH CENTRE OF FINLAND6
Gas cleaning: gas cooling followed by filtration
Gascooler
Filter
Fuelfeeding
Gasburner
Coalburners
Bed material/Ca-basedadditive
Sorbent
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
Na K Cl Al Ca Hg Sn Sb As Cd Pb V Mn Co Ni Cu Zn Mo Cr Si Mg
% o
f out
put
Bottom ash Cyclone dust Filter dust Gas
Fuel: SRF (RDF); Ceramic fabric filter (3M FB-900); Cyclonetemperature 700-750oC; filter temperature 395oC)
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
Na K Cl Al Ca Hg Sn Sb As Cd Pb V Mn Co Ni Cu Zn Mo Cr Si Mg
% o
f out
put
Bottom ash Cyclone dust Filter dust Gas
Fuel: SRF (RDF); Ceramic fabric filter (3M FB-900); Cyclonetemperature 700-750oC; filter temperature 395oC)
VTT data from late 1990’s
VTT TECHNICAL RESEARCH CENTRE OF FINLAND8
RFD
Gasifier Gas cooling
Gascleaning
Gas boiler
Highpressuresteam
Electricity,process steam
Flue gascleaning
Baghouse,Ca(OH)2+activatedcarbon
Steamturbine
Natural gas/ oilauxiliary fuel
Demonstration by Lahti Energia Oy (Lahti, Kymijärvi)- SRF fuelled gasification based WtE plant (CHP)- 2 x 80 MWth gasification & gas cleaning trains- 160 MWth gas fired boiler
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND9
LahtiStreams IP (Advanced Integrated Waste Management and WtE Demonstration)
( Lahti Energia/FI, VTT/FI, L&T/FI, Dong Energy/DK, FZK/D; total budget 23.5 M€) )- Demonstration of complete advanced waste management chain including:
> waste processing> material recovery> SRD/RDF production> advanced high efficiency WtE plant> further treatment of ashes
-R&D of - waste processing and material recovery- improved hot gas cleaning- advanced ash treatment- new gasification based high efficiency WtE technologies
http://www.lahtistreams.com/
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
From: Metso Power
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND11
Biomass gasification forHigh-Efficiency Power
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
EU-BigPowerBiomass Gasification for High Efficiency Power
October 2005 – December 2008Overall Budget for the project: 2 943 k€ - Financed in part by EU FP6
Catalytic Gas Cleaning and filtration• MEL Chemicals, United Kingdom• NortaUAB, Lithuania• Madison Filter Ltd, United Kingdom
R&D organisations supporting industrial development• VTT - Technical Research Centre of Finland• TUV - Technical University of Vienna, Austria• CERTH - Centre of Research & Technology Hellas,Greece• TKK - Helsinki University of Technology, Finland
Gasification systems• Condens Oy, Finland• Carbona Oy, Finland• Repotec GmbH, Austria• Biomasse Kraftwerk
Güssing, Austria• (Kokemäki & Skive sites)
Power production equipment• GE Jenbacher, Austria• MTU CFC Solutions GmbH, Germany
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Dual Fluidised-Bed Steam Gasification(Repotec, TUV & Biomasse Kraftwerk Güssing)
Biomass-CHP-Plant-Güssing, 2 MWe + 4.5 MW heat
from: Repotec and TUV
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Gasification CHP Plant, DenmarkAs result of Carbona’s domestic and international R&D cooperation
3 GAS ENGINES
SKIVE PROCESS DIAGRAM
DISTRICTHEATING12 MWth
POWER3x2 MWe
GAS FILTER
3 GAS ENGINES
BIOMASS
FLY ASH
2 BOILERS
TO STACK
WATER
GASSCRUBBER
GAS BUFFERTANK
2x10 MWth
BOTTOM ASH
AIR/STEAM
TAR REFORMERGASIFIER
GAS COOLERS
WOODPELLETS
6 MW POWER12 MW DISTRICT HEAT
BFB GASIFIER
2 GAS BOILERS
3 GAS ENGINES
FLARE
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND15
Novel power plant: 1.8 MWe + 3.3 MW heat• Supplier: Condens Oy• Kokemäki, Finland
Novelgasifier
Tar reformer
Gas coolerand Filter
Scrubber
Gas engines
VTT TECHNICAL RESEARCH CENTRE OF FINLAND16
Large-scale Power with Integrated GasificationCombined-Cycle - IGCC
Fluidised-Bed Gasification at 20 bar, 800-950 oCGas filtration at 400 - 600 oCCombined Gas Turbine and Steam Turbine Process
Biomass IGCCDemonstration Plant,Värnamo, Sweden
• Developed and demonstrated in 1990’s• Electric efficiency up to 42 - 48 %• Requires large-scale > 50 MWe
• Best global potential for CO2 reduction• New R&D on hot gas filtration by VTT
in EU-BiGPower project in 2007-08• New demonstration projects – when?
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND17
Biomass gasification forliquid biofuels and green chemicals
VTT TECHNICAL RESEARCH CENTRE OF FINLAND18
Production of Biomass-Derived Synthesis GasInitial step - two main approaches
Gasifier
1200 ºC +
Biomass Raw synthesis gas
to cooling, clean-upand conditioning
Gasifier
e.g. 900 ºC
Biomass Raw synthesis gas
to cooling, clean-upand conditioning
Reformer1200 ºC +(thermal)
ore.g. 900 ºC(catalytic)
Main technical challenge:prehandling, feeding of biomass
Main technical challenge:reforming of gas
Typically: oxygen-blownentrained-flow gasifier
Typically: fluidised-bedgasifier, either oxygen-blown or indirectlyheated (twin bed)
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND19
Synthesis Gas from BiomassVTT’s UltraClean Gas project (1.1.2004-31.5.2007)
• VTT,TKK, Foster Wheeler, Neste Oil, Andritz, Vapo, PVO,UPM, StoraEnso, M-real, Botnia
• pressurised gasification followed by catalytic reforming• 500 kW Process development Unit• studies for 150 – 400 MW plants integrated to pulp and paper industry
Pressurecontrol valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elementsFurnace
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
Pressurecontrol valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elementsFurnace
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
Kemira’s peat ammoniaplant in 1990
VTT’s 500 kW PDUfor syngas andultraclean fuel gas
VTT TECHNICAL RESEARCH CENTRE OF FINLAND20
Wood, strawenergy crops,peat, RDF
FT-synthesis& upgrading
Gasification andgas treatment
Pulp andpaper mill
Biomasshandling
anddrying
powerplantProcess steam & power
Paper& pulp
WoodDiesel
Energyto drying
synthesis-gas
bark,forestresidues,otherbiomass
fuel gas+ steam
steam &oxygen
Integration of FT-synthesis plant to pulp and paper mill
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Efficiencies with Industrial-Heat ProductionEfficiency = 100 x [LHV-energy of main product + high-grade byproduct energy - {electricity /
0.4}] / [LHV-energy of as-received feedstock]
-40
-20
0
20
40
60
80
100
FT CH3OH SNG H2
Ove
rall
Effic
ienc
y, % Primary
energy outMain product
(Electricity in)/ 0.4
Feedstock drying: from 50 % moisture to 30 % with secondary heat; from 30 % to 15 % with by-product steam
From: McKeough & Kurkela, NWBC, Stockholm 2008
VTT TECHNICAL RESEARCH CENTRE OF FINLAND22
VTT-UCGOptimised
syngas R&D& PDU-scaledevelopment
Industrial demon-stration: 15 MW
- replacement of oil/gas- start-up in 2009
Further R&D- process optimisation- waste gasification- hydrogen technologies
New applications- fuel cells, 2nd gen. IGCC- hydrogen or methane- renewable chemicals
R & D on hot filtrationand
catalytic gas cleaning
Biomass/wastegasification for power
(Lahti, Corenso,Värnamo, Kokemäki)
Peatammonia
plantOulu/Finland
Synthesis gasR&D in Europeand USA in 1980’s
First synfuel production plant- 200-250 MW feed capacity- 105 000 tons/a diesel fuel- 3 % Finnish transport fuel- start-up in 2012-14
1995 2000 2005 2010 2015 20201985 2025 2030
Biorefineries at pulp and papermills and at large CHP plants
- diesel production: 70 -150 000 tons/plant- by-product heat for process steam or
district heating- high overall efficiency
SYNTHESIS GAS FROMBIOMASS
FROM R&D TO INDUSTRIAL SUCCESS(road map made in VTT’s UCG project in 2006)
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND23
The Finnish Development Path – NSE Biofuels
• National UCG project: budget 4 MEUR, duration 2004 – 2007
– Biomass gasification and gas reforming experiments employing the0.5 MW process development unit (PDU) at VTT
– Wide industrial consortium: Foster-Wheeler, Neste Oil, Andritz-Carbona, Vapo, PVO, UPM, M-real, Metsä-Botnia, Stora-Enso
• Demonstration phase now under way:
– Demonstration plant under construction at Varkaus, Finland;consortium: Neste Oil and Stora-Enso
Stora Enso / Neste Oil JointVenture for F-T BTL Diesel Fuel• 50/50 Joint Venture “NSE Biofuels Oy” to first develop
technology and later produce next generationrenewable diesel crude from wood / forest residues
• Currently building a 12MW demonstration plant inStora Enso’s Varkaus mill, to be in use spring 2009
• Investment decision for a commercial scale plant whenthe parties have enough experience from thedemonstration plant
• Strong development consortium– Joint Venture partners:– Testing & research partner:– Gasification supplier:
From Neste Oil and Stora Enso
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1. Commissioning as air blown limekiln gasifier
2. Testing period as O2/H2O gasifier,gas cleaning, FT tests
3. Return to lime kiln gasifier
Limekiln
5 MWGas cleaning
and FT
BiomassSiloKuivur
iDryer 12 MW
Gasifier
NSE Biofuels Demo 1plant in Varkaus, Finland
From Neste Oil and Stora Enso
8.12.200826
from: Neste Oil and Stora Enso
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BTLtec 2008
PRESSURISED GASIFICATION OF BIOMASS
Värnamo IGCC DemonstrationPlant at 1990’s
FW scope: Gasification plant
BTLtec 2008COMMERCIAL SCALE BTL PRODUCTION PLANT
• For BtL applications the size has been set roughly in the range of–100,000 t/a FT-waxes–200 – 300 MW fuel
• FW already has draft layout of full-scale gasification plant forsynthetic gas production
• The same biomass gasification concept could be appliedfor the production of:
– SNG– Hydrogen– Methanol– Ethanol– Electricity by biomass IGCC
from: Foster Wheeler
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND29
The Finnish Development Path - UPM
• National UCG project: budget 4 MEUR, duration 2004 – 2007
– Biomass gasification and gas reforming experiments employing the0.5 MW process development unit (PDU) at VTT
– Wide industrial consortium: Foster-Wheeler, Neste Oil,Andritz-Carbona, Vapo, PVO, UPM, M-real, Metsä-Botnia,Stora-Enso
• Demonstration phase now under way:
– Demonstration plant under construction at Varkaus, Finland;consortium: Neste Oil and Stora-Enso
– Pilot-plant testing at Gas Technology Institute, Chicago, USA;consortium: UPM and Carbona
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International Gasification R&D Cooperation
CARBONAwith
The Gas Technology InstituteChicago, USA
• long term exclusive cooperation• pressurized BFB gasification• biomass fuels• air and oxygen gasification• gas cleanup systems• for IGCC and BTL
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CurrentCurrent BiofuelBiofuel activitiesactivities -- BTLBTLBackboneBackbone ofof UPM'sUPM's BiofuelBiofuel initiativeinitiative
Current status
Biomass toliquidsdevelopment
Exclusive alliance with Andritz/Carbona
Piloting in Gas Technology Institute facility in
Des Plaines, IL
Commercial scale plant engineering ongoing &EIA initiated
Site selection process ongoing
Wood supply chain & logistics survey ongoing
Route:FB-gasificationFischer Tropsch synthesisProduct upgrade
UPM strengths:Access to raw materialMill integrationClose to core business
from: UPM
Woodsourcing
WoodWoodsourcingsourcing
Our 2G BTL ConceptOur 2G BTL Concept
Gasification& purification
GasificationGasification& purification& purification
FT-synthesis& up-grading
FTFT--synthesissynthesis& up& up--gradinggrading
Watertreatment
WaterWatertreatmenttreatment
CHPplant
CHPCHPplantplant
Pulp & paper millPulp & paper millPulp & paper mill
SyntheticSyntheticbiodieselbiodieselHH22+CO+CO
CCnnHH2n+22n+2
Biomassdrying
BiomassBiomassdryingdrying
PulpPulp
woodwood
BarkBark
StumpsStumps
ResiduesResidues
Paper mill unitsPaper mill units
Additional unitsAdditional units
Material flowMaterial flow
Energy flowEnergy flow
Gas Technology Institute, Des Plaines, Illinois, USGas Technology Institute, Des Plaines, Illinois, US
from: UPM
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
UCGFUNDA 2008 - 2010Biomass gasification for synthesis applications
- fundamental studies supporting industrial development projects
• VTT, TKK and Åbo Akademi, total budget 1.5 M€• Financing by Tekes Biorefine, VTT and private companies
(Carbona, Foster Wheeler, Metso Power, Neste Oil, Stora Enso, UPM & Vapo)
• Biomass characterisation for pressurised steam/oxygen-blowngasification: ash behaviour and reactivity
• Filter blinding and catalyst deactivation studies• Tar reactions in non-catalytic and catalytic processes• System studies on BTL-applications and hydrogen production• Development of measuring methods for tars and other gas
contaminants• IEA groups: ”Biomass thermal gasification” and ”Biomass Hydrogen”
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Coal
Oil
Biomass
Waste/SRF
O2Air
Steam
Syngas
Energy(Fuel gas)
Gasification
SOFCIGCCCo-firingGas engineCHP
FT-synthesisHydrogenSNGMetOH
CARBON
GAS
CLEANUP