SNG aus Biomasse am Beispiel Göteburg · simulation, automation and supply chain. BIOENERGY 2020+...
Transcript of SNG aus Biomasse am Beispiel Göteburg · simulation, automation and supply chain. BIOENERGY 2020+...
SNG aus Biomasse am Beispiel Göteburg Bioenergy 2020+ - Biomassetag November 2017
Slide 2
Overview
Graz (Head office)
Güssing
Wieselburg
Pinkafeld
Tulln
WHAT Austrian competence centre for
biomass utilization since 15+ years
WHERE 3 offices and 2 technical research
sites across Austria
WHO ~100 researchers from all academic
career levels (mostly engineers)
HOW National and international research
funding + industry partners (~9 Mio EUR turnover per year)
Research Areas
Slide 3
Biomass combustion
Gasification Systems Biological Conversion & Integration
Three main research areas:
1. Combustion
2. Gasification
3. Bioconversion
Plus a number of additional departments: microgrids,
simulation, automation and supply chain.
BIOENERGY 2020+ GmbH, a limited company is owned mostly by public ins-
titutions like universities, ministries and similar public bodies. The single biggest
owner is an association of enterprises with commercial interest in the field.
Bioenergy 2020+ enterprise and ownership
Slide 4
~20 individual firms
Gasification & Synthesis Value Stream
Slide 5
Gasification + Synthesis
Waste, feedstock
byproducts
• Wax
• Kerosene
• Alcohols
• Diesel
• Electrical
• Thermal
• Hydrogen
• Gas - SNG
Optional: Peak-wind energy
Sh
ifti
ng
Re
se
arc
h F
oc
us
Energy
Gases
Substances
Shifting the reseach focus towards higher-value products
Slide 6
Product range
Including recycling
of phosphorus from
sewage sludge and
agricultural sources. Biofuels
Energy & Heat
Chemicals
Feed
& Food
Health
& Cos-
metics
incre
asin
g m
ark
et va
lue
Dual Fluidized Bed (DFB)
Steam Gasification Technology
Slide 7
Slide 8
Production of Synthesis Gas: Starting point for SNG
to stack gas motor, H2, CH4, fuel, wax, …
Biomass is converted into
mostly hydrogen and carbon
monoxide – a so-called
synthesis gas.
Synthesis gas is the starting
point for a number of
downstream conversion
processes, like SNG
production.
Slide 9
DFB Reactor and System Integration
Güssing Plant Layout
Slide 10
Syngas via Steam Gasification: State of the Art
Gasification
Electricity (Gas engine)
Heat (District heating)
Synthesis gas H2 + CO
Cooling (optional) (via absorption refrigeration)
Green chemistry
Carbon source
Biomass (wood, …)
Agricultural-residues
Municipial waste (plastic, sewage sludge…)
The DFB gasification system achieved several
100,000 hours of operating experience with sev-
eral plants in the range of 0.5 to 32 MW thermal
power. The demonstration plant in Güssing
achieved more than 100,000 hours of operation.
As alternative to CHP,
the synthesis gas can
be used to produce
fuels and chemicals via
catalytic synthesis.
State of the art is synthesis gas utilization
in a gas engine for the generation of elec-
tricity, as well as waste heat utilization for
district or process heat. Via absorption
chillers, also cooling is possible.
Slide 11
Syngas: Synthetic Production Routes
Liquids & Waxes Gases
Synthetic Natural Gas (SNG)
Hydrogen
Ammonia
FT Fuels & Chem-icals (diesel, wax,
kerosene, …)
Mixed alcohols
Synthesis gas H2 + CO
Methanol
Isosynthesis - Isobutane
Oxosynthesis -
Aldehyde
Carbon source (biomass, residues, waste)
Gasification
A number of different routes for synthesis of
gaseous and liquid chemicals is possible
starting from the generated synthesis gas.
Methanation: SNG from Syngas
Slide 12
CHxOy H2 + CO + CH4 + CO2
3H2 + CO CH4 + H2O Methanation takes place
at 300-400°C with a
nickel catalyst with some
pre- and after-treatment
of the gas.
SNG to grid
Syngas from gasifier Must be separated
Methanation: SNG from Syngas - Details
Slide 13
Syngas
from
gasifier
Tar
removal
Compre
ssion
Pre-
heating
H2S
removal
2nd H2S
removal
Heat
recovery
NH3
removal
Compre
ssion
CO2
removal
H2O
removal
H2
removal Bio-SNG to grid
Status of SNG Production
Slide 14
Overview of Gasification Plants
Slide 15
Location Usage / Product Fuel / Product
MW, MW Start up
Supplier /
Engineering Status
Güssing, AT Gas engine 8.0fuel / 2.0el 2002 AE&E, Repotec End of demonstration life
time reached
Oberwart, AT Gas engine /
ORC / H2
8.5fuel / 2.8el 2008 Ortner
Anlagenbau On hold / restart?
Villach, AT Gas engine 15fuel / 3.7el 2010 Ortner
Anlagenbau On hold / restart?
Senden/Ulm,DE Gas engine /
ORC 14fuel / 5el 2011 Repotec Operational
Burgeis, IT Gas engine 2fuel / 0.5el 2012 Repotec,
RevoGas On hold
Göteborg, Sweden BioSNG 32fuel/20 BioSNG 2013 Repotec/ Valmet Operational / On hold
California R&D 1 MW fuel 2013 GREG Operational
Gaya, France BioSNG R&D 0,5 MW fuel 2016 Repotec Operational
Thailand Gas engine 4MW fuel / 1MWel 2016 GREG Operational
Overview
Slide 16
Key figures:
• 32 MW fuel power
• 20 MW SNG output
Performance target:
• Efficiency: >65%
• Time efficiency: 8000 h/a
Status:
Operational but intended scale-
up (4x) on hold due to perfor-
mance issues.
Plant Complexity: SNG vs. Heat and Power
Slide 17
SNG plant
(GoBiGas) Heat & Power
(Güssing)
SNG Efficiency (Vesta process)
Slide 18
Biomass to SNG
efficiency: 65%
>60% demonstrated in GoBiGas
ISBL1 CAPEX vs. Feed Capacity for Various DFB Projects
Slide 19
0
5
10
15
20
25
30
35
40
45
50
0 5 10 15 20 25 30 35 40
Senden
To
tal
CA
PE
X [
Mio
EU
R]
Feed capacity [MWth]
Güssing
Oberwart
Nongbua
GoBiGas
1 ISBL – Inside Battery Limit
Estimated CAPEX for
various DFB projects
(only gasification parts
considered here) show
that GoBiGas CAPEX is
above expectations.
CAPEX here is
estimated for ISBL,
which does not include
auxiliary installations.
CAPEX Learning Curve
Slide 20
Corrected for the annual
plant cost index (steel
price, inflation, …) and
in the order of the
cumulated fuel power, a
certain learning effect is
evident.
* Estimated values, gasification part only
-
500.000
1.000.000
1.500.000
2.000.000
2.500.000
0 20 40 60 80 100 120
Specific
CA
PE
X*
(2016)
in E
UR
MW
-1
Cumulated fuel power in MW
Güssing
Oberwart Villach
Senden
GobiGas
Economic viability: Production costs for SNG
Slide 21
Raw materials
Operating labor
Utilities
Employee benefits
Supervision
Laboratory
Maintenance
Insurance and taxes
Operating supplies
Plant overhead
Depreciation
Approx 50%
of the prod-
uction costs
are CAPEX-
related costs
(fixed costs). Production costs
raw materials
labour
utilities maintenance
insurance &
tax
depreciation
Approx 50% of
the production
costs are
operating costs
(variable costs). operating
supplies
Time Efficiency: yearly operating hours
Slide 22
0
5.000
2016 2014 2015 2017
Ø 2.506
7.708
0
5.000
2008 2010 2007 2002 2003 2005 2004 2006 2009 2011 2012 2013 2014 2015
Ø 6.356 op
era
tin
g h
ou
rs / y
ea
r [h
/a]
GoBiGas
(SNG)
Güssing
(Heat&Power)
0
5.000
2012 2013 2014 2015
Ø 3.746
2016
Senden
(Heat&Power)
Target
On average: ~30%
of target operating
hours achieved
Economic viability: A sensitivity analysis
Slide 23
Values Units
Investment costs (incl. startup expenses)
29 700 000 EUR
Expenses 9 921 840 EUR a-1
SNG selling price for NPV = 0 130 EUR MWh-1
20 MWth plant
Natural Gas in Austria: ~50 EUR MWh-1
Economic viability: A sensitivity analysis
Slide 24
-40%
-30%
-20%
-10%
0%
10%
20%
30%
40%
-30% -20% -10% 0% 10% 20% 30%
SNG
pri
ce v
aria
tio
n
Variable variation
Capital
Wood price
Operating hours
How fuel cost,
CAPEX and operat-
ing hours influence
the cost of SNG.
Highest sensitivity:
Operating hours!
Conclusions: Main Challenges for SNG
Slide 25
1
2
3
Complexity
and Reliability R&D must not only focus on energetic efficieny, but strife
for simplicity and reliability of plant layout and operation.
CAPEX &
Investment Investors need to plan for realistic time frames and
targets. Big players + funding with good stamina needed!
Learning &
Experience
(Almost) none of the shown plants have been build by
the same consortium, there are improvements, but there
could be more.
Contact
Slide 26
Bioenergy2020+ GmbH
Biomass Gasification Systems
Wienerstraße 49
7540 Güssing
Austria
Research Area Manager
Gasification Systems
T + 43 (0) 3322 42606-151
Unit Head | Syngas Processes
T + 43 (0) 3322 42606-154
Unit Head | Gasification
T + 43 (0) 3322 42606-156