Gasification Activities in Finland 2009

8/13/2019 Gasification Activities in Finland 2009

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Biomass gasification technologies for

advanced 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 FINLAND

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Biomass and waste gasification

for boilers and kilns


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CFB GA SIFIER

REACTOR

850 C

900 CBIOFUEL FEED

BOTTOM ASH COOLING SCREW

HOT LOW CALORIFICGAS (750 - 650 C)

AIR PREH EAT ER

RETURNL

EG

GASIFICA TION AIR FAN

UNIFLOW CYCLONE

Atmospheric -pressure CFB/BFBgasification for kilns and boilers

Commercial lime-kiln gasifierswere constructed in 1980s byAhlstrm Oy

New development by FosterWheeler in 1990s 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: FosterWheeler


Efficient utilisation of wastes and biomass

residues in existing power plantsa cost-effective way to reduce CO2 emissions of power plants

CFB gasifier of 60MW

Main boiler360 MWth

Gasifier feedpreparation

- in operation since1998

- no commissioning problems

- 50 000 operating hours

- gasifier availability> 95 %

- boiler emissions decreased

- paybacktime ca. 8 years

CFB gasifier of 60MW

Main boiler360 MWth

Gasifier feedpreparation

- in operation since1998

- no commissioning problems

- high fuel f lexibil i ty

- gasifier availability> 95 %

- boiler emissions decreased

-

From: FosterWheeler


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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: FosterWheeler


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Gas cleaning: gas cooling followed by filtration

Gascooler

Filter

Fuelfeeding

Gasburner

Coalburners

Bed material/

Ca-based

additive

Sorbent


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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 Z n Mo Cr Si Mg

%o

foutput

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 Z n Mo Cr Si Mg

%o

foutput

Bottom ash Cyclone dust Filter dust Gas

Fuel: SRF (RDF); Ceramic fabric filter (3M FB-900); Cyclonetemperature 700-750oC; filter temperature 395oC)

VTT data fromlate 1990s


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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, Kymijrvi)

- SRF fuelled gasification based WtE plant (CHP)- 2 x 80 MWth gasification & gas cleaning trains- 160 MWth gas fired boiler


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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/


From: Metso Power
http://www.lahtistreams.com/http://www.lahtistreams.com/


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Biomass gasification for

High-Efficiency Power


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 fil tration

MEL Chemicals, United Kingdom NortaUAB, Lithuania Madison Filter Ltd, United Kingdom

R&D organisations supporti ng indus trial 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, Fi nland

Repotec GmbH, Austr ia

Biomasse KraftwerkGssing, Austria (Kokemki & Skive sites)

Power production equipment GE Jenbacher, Austria MTU CFC Solution s GmbH, Germany


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Dual Fluidised-Bed Steam Gasifi cation(Repotec, TUV & Biomasse Kraftwerk Gssing)

Biomass-CHP-Plant-Gssing, 2 MWe + 4.5 MW heat

from: Repotec and TUV

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Gasification CHP Plant, DenmarkAs result of Carbonas domest ic and international R&D cooperation

3 GAS ENGINES

SKIVE PROCESS DIAGRAM

DISTRICTHEATING12MWth

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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Novel power plant: 1.8 MWe + 3.3 MW heat Supplier: Condens Oy Kokemki, Finland

Novel

gasifier

Tar reformer

Gas coolerand Filter

Scrubber

Gas engines


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Large-scale Power with Integrated Gasification

Combined-Cycle - IGCC

Fluidised-Bed Gasification at 20 bar, 800-950 oC

Gas filtration at 400 - 600 oC

Combined Gas Turbine and Steam Turbine Process

Biomass IGCCDemonstration Plant,Vrnamo, Sweden

Developed and demonstrated in 1990s

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 VTTin EU-BiGPower project in 2007-08

New demonstration projects when?


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Biomass gasification for

liquid biofuels and green chemicals


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

Gasifier

1200 C +

Biomass Raw synthesis gas

to cooling, clean-upand conditioning

Gasifier

e.g. 900 C

Biomass Raw synthesis gas

to cooling, clean-upand conditioning

Reformer

1200 C +

(thermal)

or

e.g. 900 C

(catalytic)

Main technical challenge:

prehandling, feeding of biomass

Main technical challenge:

reforming of gas

Typically: oxy gen-blown

entrained-flow gasifier

Typically: fluidi sed-bed

gasifier, either oxygen-

blown or indirectly

heated (twin bed)


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Synthesis Gas from Biomass

VTTs 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

Heatingelements

Furnace

Air

Nitrogen

Steam

Oxygen

To slip streamtesting facilities

Pressurecontrol valve

Fuel feedingequipment

Bedmaterial

Additive

PFB GASIFIER

FILTER

Gascooler

CATR

Bedremoval

Ashremoval

Heatingelements

Heatingelements

Furnace

Air

Nitrogen

Steam

Oxygen

To slip streamtesting facilities

Kemiras peat ammoniaplant in 1990

VTTs 500 kW PDUfor syngas andultraclean fuel gas


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Wood, strawenergy crops,peat, RDF

FT-synthesis& upgrading

Gasification andgas treatment

Pulp andpaper mill

Biomasshandling

anddrying

powerplant

Process steam & power

Paper

& pulp

WoodDiesel

Energy

to dryingsynthesis-gas

bark,forestresidues,otherbiomass

fuel gas+ steam

steam &oxygen

Integration of FT-synthesis plant to pulp and paper mill


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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 S NG H2

OverallEfficiency,

%Primary

energy out

Main product

(Electricity in)

/ 0.4

Feedstock drying: from 50 % moisture to 30 % with secondary heat; from 30 % to 15 % wi th by-product steam

From: McKeough & Kurkela, NWBC, Stockholm 2008


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VTT-UCG

Optimised

syngas R&D

& PDU-scale

development

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,Vrnamo, Kokemki)

Peatammonia

plantOulu/Finland

Synthesis gasR&D in Europeand USA in 1980s

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 paper

mills and at large CHP plants- diesel production: 70 -150 000 tons/plant- by-product heat for process steam ordistrict heating

- high overall efficiency

SYNTHESIS GAS FROM

BIOMASSFROM R&D TO INDUSTRIAL SUCCESS

(road map made in VTTs UCG project in 2006)


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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, Mets-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 Joint

Venture for F-T BTL Diesel Fuel

50/50 Joint Venture NSE Biofuels Oy to first developtechnology and later produce next generationrenewable diesel crude from wood / forest residues

Currently building a 12MW demonstration plant inStora Ensos 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:

FromNeste Oil and Stora Enso


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1. Commissioning as air blown lime

kiln 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

i

Dryer 12 MWGasifier

NSE Biofuels Demo 1

plant in Varkaus, Finland

FromNeste Oil and Stora Enso

8.12.200826

from: Neste Oil and Stora Enso


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BTLtec 2008

PRESSURISED GASIFICATION OF BIOMASS

Vrnamo IGCC Demonstration

Plant at 1990s

FW scope: Gasification plant

BTLtec 2008

COMMERCIAL SCALE BTL PRODUCTION PLANT

For BtL applications the size has been set roughly in the range of100,000 t/a FT-waxes200 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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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, Mets-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

CARBONA

with

The Gas Technology Insti tute

Chicago, 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 -- BTLBTL

BackboneBackbone ofofUPM'sUPM's BiofuelBiofuel initiativeinitiative

Current status

Biomass to

liquids

development

Exclusive alliance with Andritz/Carbona

Piloting in Gas Technology Institute facility in

Des Plaines, IL

Commercial scale plant engineering ongo ing &EIA initiated

Site selection pro cess ongoing

Wood supply chain & logisti cs survey ongoing

Route:

FB-gasification

Fischer Tropsch synthesis

Product upgrade

UPM strengths:

Acc ess to raw material

Mill integration Close to core business

from: UPM

Wood

sourcing

WoodWood

sourcingsourcing

Our 2G BTL ConceptOur 2G BTL Concept

Gasification

& purification

GasificationGasification

& purification& purificationFT-synthesis

& up-grading

FTFT--synthesissynthesis

& up& up--gradinggrading

Water

treatment

WaterWater

treatmenttreatmentCHP

plant

CHPCHP

plantplant

Pulp & paper millPulp & paper millPulp & paper mill

SyntheticSynthetic

biodieselbiodieselHH22+CO+CO

CCnnHH2n+22n+2Biomass

drying

BiomassBiomass

dryingdrying

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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UCGFUNDA 2008 - 2010Biomass gasification for synthesis applications

- fundamental studies supporting industrial development projects

VTT, TKK and bo 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 gascontaminants

IEA groups: Biomass thermal gasification and Biomass Hydrogen


Coal

Oil

Biomass

Waste/SRF

O2A

i

r

S

t

e

a

m

Syngas

Energy

(Fuel gas)

Gasification

SOFCIGCCCo-firingGas engineCHP

FT-synthesisHydrogenSNGMetOH

C

A

R

BO

N

G

A

S

C

L

EA

NU

P

Gasification Activities in Finland 2009

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