Where are we now? · 2007. 5. 30. · Steam Fuel Product Biomass. 5/29/2007 5 Definition of a...

5/29/2007 1

Where are we now?-----------------

Black Liquor Gasification According to Chemrec

TAPPI 2007 International Conference on Renewable Fuels Atlanta, USA

May 10-11, 2007

Ingvar LandälvChemrec AB

www.chemrec.se

5/29/2007 2

Chemrec Ownership and Business

The Opportunity: large untapped energy potential in the pulp industry, aging mills, industry restructuring and high energy pricesThe Response: Chemrec’s Black Liquor Gasification Technology converts PulpMills to Biorefineries to produce green fuel or power

• Renewable fuel generation potential at pulp mills ~3 % of current US consumption of automotive fuels. Potential in Canada is ~7%, in Sweden ~30% and in Finland ~50%.

• Renewable fuel generation at pulp mills becomes a second main product adding 30%- 50 % to the cash flow from the pulp, at fuel prices competitive with diesel and gasoline at 30 USD/bbl crude oil.

• Alternatively the technology has the potential to profitably generate ~60 TWh addedgreen power in the US and proportional amounts abroad.

Chemrec AB

VantagePointVenture Partners

NykombSynergetics

Volvo Technology Transfer(AB Volvo)

5/29/2007 3

“STAND ALONE” CONCEPTCOMPARISON

5/29/2007 4

Definition of ConceptsBIOMASSTO FUELS

BIOMASS TO FUELS AT A PULP MILL(utilizing the BLGMF concept)

BLGMF

Heat&PowerPlant

PulpMill

Gasification-basedFuel

Production


Production

Bl. Liquor

PowerSteam

Fuel ProductBiomass

5/29/2007 5

Definition of a “Stand Alone” ConceptBIOMASSTO FUELS


BLGMF

Heat&PowerPlant

PulpMill


Production

BLGMF

Heat&PowerPlant

PulpMill

0 MW


Production

Bl. Liquor

PowerSteam

Fuel ProductBiomass

0 MW(compared to Pulp Mill

without BLGMF)

5/29/2007 6

Definition of Biomass to Fuel Efficiency for “Stand Alone” Concepts

BIOMASSTO FUELS


BLGMF

Heat&PowerPlant

PulpMill


Production

PowerSteam

Fuel ProductBiomass

BLGMF

Heat&PowerPlant

PulpMill

0 MW


Production

nG Bl. Liquor

Energy in FuelEnergy in Biomass=0 MW

(compared to Pulp Millwithout BLGMF)

5/29/2007 7

A EUROPEAN PERSPECTIVE

5/29/2007 8

The Renew Project“Renewable Fuels from Advanced Powertrains”

Main objectives:Development and comparative assessment of pathways

from biomass to various motor vehicle fuels with a single common intermediate product: the synthesis gas.

The fuel pathways to be compared through Life Cycle Analysis (LCA) and a technical and economic assessment.

Duration: 2004-2007Budget: 20 MM€ (EU support: 10 MM€)

5/29/2007 9

Suitability for Willow Salix in the European Union

Cartographies by ECBREC, Renew 2007

Not suitable

Suitable

Not suitable

Suitable

5/29/2007 10

Biomass to Automotive Fuels: Replacement Potential within EU-25 in 2040

0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000

(TWh/year)

DME / MeOH

FTD

28% substitution of 2002 consumption

17% substitution of 2002 consumption

Transport share

Energy in transports 2002

Total biomass potentials 2040

Usedtoday

Potentialtoday

Potentialadded to

2040

Source: EU project Renew within FP6 and EUCAR/Concawe/JRC (2005)

5/29/2007 11

Renew Project: Comparison of Production Cost

*DE:

die

sele

quiv

alen

t

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

1,8

2

UET FZK CUTEC TUV/BKG TUV/BKG(local)

Chemrec

fuel

pro

duct

ion

cost

s [€

/lD

E*]

overall production costsbiomass costs free plant gate

Source: Renew, IE 2007

DMEFT-DieselFT-DieselFT-DieselFT-DieselFT-Diesel

entrained flowgasifier

fluidized bed gasifier(alloth.)

fluidized bedgasifier (alloth.)

fluidized bed gasifier(autoth.)


Carbo V gasifier

black liquorresource

centralisedpretreament



decentralisedpretreament


DMEFT-DieselFT-DieselFT-DieselFT-DieselFT-Diesel


fluidized bed gasifier(alloth.)

fluidized bedgasifier (alloth.)

fluidized bed gasifier(autoth.)


Carbo V gasifier

black liquorresource




decentralisedpretreament


5/29/2007 12

TWO IN DEPTH STUDIES BASED ON THE “STAND ALONE”

PHILOSOPHY

5/29/2007 13

The BLGMF Report, 2003

Process engineering consultant

Gasification technologysupplier

National gasoline andoil distributor

World’s largest methanolproducer and distributor

World-known automotiveand engine developer

Automotive fuel andengine consultant

Research centre forpulp and papermaking

Report Partners

5/29/2007 14

The Princeton Biorefinery Report, 2006

5/29/2007 15

The BLGMF Study vs. the Princeton Study DMEa case

ParameterBLGMF Study

2003

Princeton Study2006

(DMEa case)

H&P Plant Boiler Boiler

BL Flow, tDS/d 3420, (487 MW) 2458(351)

DME prod. MW 275 168

Biomass added, MW 414 (161+101/0.4) 235 (77+63/0.4)

Power balance, MW As RB case As RB case

, %DME/biomass (MW)

67 71

Incrementalinvestment 164 MMEUR 116 MMUSD

5/29/2007 16

H&P Plant changed to an IGCC plantBIOMASS TO FUELS AT A PULP MILL

(utilizing the BLGMF concept)

BLGMF

Heat&PowerPlant

PulpMill

BLGMF

PulpMill

Bl. Liquor

Heat&PowerPlant

IGCCtechnology

PowerSteam

Fuel ProductBiomass

0 MW(compared to Pulp Mill

without BLGMF)

5/29/2007 17

The BLGMF Study vs. the Princeton Study Focus on Energy efficiency

ParameterBLGMF Study

2003

Princeton Study2006

(DMEa case)

Princeton Study2006

(DMEb case)

H&P Plant Boiler Boiler IGCC

2458(351MW)

168

136 (196-24/0.4)

24 (export)

124

BL Flow, tDS/d 3420, (487 MW) 2458(351MW)

DME prod. MW 275 168

Biomass added, MW 414 (161+101/0.4) 235 (77+63/0.4)

Power balance, MW As RB case As RB case

, %DME/biomass (MW)

67 71

5/29/2007 18

BLACK LIQUOR GASIFICATION

- THE USER PERSPECTIVE

5/29/2007 19

The User’s Perspective – in Summary

1. The pulp mill New process which can increase yield and bring new profit generating activity

2. The power utility Efficient production of green power3. The oil company Efficient production of green fuels4. The chemical Efficient production of green synthesis

company gas 5. The car industry Renewable, sustainable production of

green fuels6. The forest owner Maximize the revenue from the forest

land

5/29/2007 20

USER PERSPECTIVE 3:

THE OIL INDUSTRY

5/29/2007 21

Cost Data, 3Q 2005

Biomass 89 USD/mt(dry) – 1.3 €cent/kWhPulp Wood 125 USD/mt(dry) – 1.8 €cent/kWhPulp 500 EUR / tonEl. (incl. certificate) 6.8 UScent/kWh – 5.1 €cent/kWh DME-fuel price at site (gasoline equiv.) 3,48 SEK / l – 0.37 € / l –

1.88 USD/galCO2 tax, gasoline 2,16 SEK / l. – 0.23 € / l –

1.17 USD/galCO2 (liq.) at plant gate 200 SEK / ton – 22 € / ton

5/29/2007 22

Overall Energy Balance for the KAM2 Mill

45 MWe

2000 adt/dSP:81 bar/490°C

~340 MWt

KAM2 Pulp Mill4100 t/dtort SP:81 bar/490°CPulpwood

1 2 3 4 5 6 7 8Billion

SEK

5/29/2007 23

Overall Energy Balance when the Recovery Boiler has been changed into a BLGMF process

1 2 3 4 5 6 7 8Billion

SEK

KAM2 Pulp Mill 2000 adt/d4100 t/dtort

BLGMF 550 t.g.e/dBLGMF

414MWt

El-Cond.

101MWe

161 MWt

253 MWt

911 MWt

272 MWt

~340 MWt

BL GL486 MWt

45 MWe

Biomass

*) as DME ormethanol

Pulpwood

5/29/2007 24

Overall Cost and Revenue Streams for a Pulp Mill with a BLGMF Plant (per year) – Fuel calc. as gasoline energy

2000 adt/d

BLGMF 550 t.g.e/d*BLGMF

414MWt

El-Cond.

101MWe

94 MEUR

SP:81 bar/490°C

BL GL

347 MEUR

19 MEUR

44 MEUR

137 MEUR

3,48 SEK/l gasolineat refinery gate –

1.88 USD/gal

1 2 3 4 5 6 7 8Billion

SEK

KAM2 Pulp Mill4100 t/dtort

Pulpwood

Biomass

911 MWt

45 MWe


5/29/2007 25


2000 adt/d

BLGMF 550 t.g.e/dBLGMF

414MWt

El-Cond.

101MWe

153 MEUR

SP:81 bar/490°C

BL GL

347 MEUR

19 MEUR

44 MEUR

3,48 SEK/l gasolineat ref. gate + CO2 tax

3.05 USD/gal

1 2 3 4 5 6 7 8Billion

SEK


137 MEUR

Pulpwood

Biomass

911 MWt

45 MWe


5/29/2007 26


2000 adt/d

BLGMF550 t.g.e/d

BLGMF

414MWt

El-Cond.

101MWe

153 MEUR

SP:81 bar/490°C

BL GL

347 MEUR

19 MEUR

44 MEUR

3,48 SEK/l gasolineat ref. gate + CO2 tax

+ CO2 export

1 2 3 4 5 6 7 8Billion

SEK


Pulpwood

Biomass

911 MWt

45 MWe

ca 93 t CO2/tim

16 MEUR

137 MEUR

5/29/2007 27

USER PERSPECTIVE 4:

THE CHEMICAL INDUSTRY

5/29/2007 28

Gas utilization together with HT BLG process

• Oxygen:Ca 600 ton O2 per 1000 ADt of pulp

• Nitrogen, Argon and other rare gases:N2 as inert gas in the BLG process

• Carbon dioxide:Available at > 90% purity from the BLGMF process. Possible to produce also from BLGCC.

• H2 and CO:As fuel gas for combined cycle, as feedstock for synthesis or for other use

5/29/2007 29

BLG for Ammonia/Urea production

ASU

EL

Oxygen

Rågas

Syngas = H2

Gascooling

Gas Cleaning(Rectisol) +

N2-wash

Ammonia Synthesis

Gasifi/cation

150MW /gasifier3x50%1000°C30 bar

Ånga

White Liquor

Sulphur-handling

Weak wash

Black Liq.

LS Green Liq.

Polysulphide

Ammonia Ureasynthesis

Urea

Nitrogen

CO2

2000 tds/d => ~260000 ton NH3/y

2000: 200 EUR/t4Q, 2006: 300 EUR/t

5/29/2007 30

USER PERSPECTIVE 5:

THE CAR INDUSTRY

5/29/2007 31

VOLVO:sVOLVO:s DMEDME--powered Truckpowered Truck

5/29/2007 32

Well to Wheel Analysis (heavy duty vehicles)

0%

10%

20%

30%

40%

Diesel

(crude oil)

DME (remote

NG)

Compres

sed NG

(remote

7000

km)

Syntheti

c Diesel

(remote

NG)DME (w

ood, b

lack l

iquor)

Synthe

ticDies

el (w

ood, blac

k liquo

r)DME (w

ood)

Syntheti

c Dies

el(w

ood)

RME (rapes

eed) EU

Compresse

d Biogas(w

aste)

Ethanol (w

heat) E

U

Ethanol (c

orn) US

Ethanol (s

ugar ca

ne) Braz

il

Ethanol (c

ellulose

)

0

250

500

750

1000

Energy efficiency, %CO2-equivalents, g/kWh

g/kWh

Fossil Renewable

Source: AB Volvo

5/29/2007 33

WHERE WE AREAND

NEXT STEPS

5/29/2007 34

Air-blown, atmospheric Booster in New Bern, NC

Operates as a booster unit to the recovery boiler in the Weyerhaeuser pulp mill inNew Bern, North Carolina

Corresponds to ~15% of the mill’s production

Start up: Dec 1996Capacity: 330 tDS/day

50 MWOxidant: AirPressure: Atmospheric

5/29/2007 35

Pressurized, O2-blown Black Liquor Gasification- General Scheme -

Airseparation

Power

Oxygen

Rawgas

Synthesis gas

Gascooling

Gasi-fication

and

Quench

Steam

Weak wash

Black liquor

LS Green liq.

Gas PurificationWhite liquor

Sulphur Management Poly Sulph.

Synthesis- andDistillation

Power & SteamCombined

Cycle or

DME/Methanol

or

DP-1plant

Rawgas

Synthesis gas

Gascooling

Gasi-fication

and

Quench

Steam

G

5/29/2007 36

DP-1: High Temp, O2 blown Plant, Piteå, Sweden GAS COOLER

Raw syngas

GreenLiquor Condensate

BlackLiquor

REACTOR

QUENCH

WhiteLiquor

BFW*

LP-steam*

MP-steam*

WeakWashLiquor

Oxygen

Atomisingmedium

H2S-ABSORPTION

Purified andcooled syngas

(to flare)

Cooling water

* Cooling waterin DP1

5/29/2007 37

DPDP--1 Plant Location in Pite1 Plant Location in Piteåå

5/29/2007 38

DPDP--1 Ground Floor1 Ground Floor

5/29/2007 39

First StartSept 30 2005

5 days, 20 bar,Excellent

C-conversion

25 bar,Good

C- conversion

Hours

Summer -06

13 daysContinuous

run

1000 hrs Operation 2006

27 bar

30 bar,76% load

Accumulated Operating Hours DP1 End April 2007

Four more operatorsat Chemrec staff

5/29/2007 40

May 12, 2006: Low Content of Char, No Soot and Excellent Settling of Dregs in Green Liquor

5/29/2007 41

Time Schedule for HT Pressurized BLG Development in Sweden: DME Pilot Project

5/29/2007 42

A DME Pilot at the DP-1 Plant in Piteå, Sweden

ZnOAbsorber

Amin Wash (Guard-Bed)

DME or MeOHP.D.U

Process DevelopmtUnit

H2/CO = 1/1

Raw MeOHor DMEHP-steam

(Dp-1/mill) LP-st(Dp-1/mill)

CO2

C.W

Train /Truck

~4 ton DME / day

DP-1

The DME Pilot

ActivatedCarbon

CO2

- Which results?- Who should tackle?

5/29/2007 43

Activities - Work packages

• WP 1 – Upgrade of syngas unit• WP 2 – Development of a DME production pilot plant• WP 3 – Production of DME• WP 4 – Fuel properties and distribution• WP 5 – Fuel injection equipment• WP 6 – Vehicle procurement • WP 7 – Vehicle field test• WP 8 – Evaluation• WP 9 – Dissemination and Project management

5/29/2007 44

Time Schedule for HT Pressurized BLG Development in Sweden : Demonstration Project

5/29/2007 45

Incremental Capacity Increase at a Pulp Mill through a small BLGMF Plant

Typical5-600 MW

Pulp

Black liq. energy

Biomass~400 tds/d

SmallBLGMF

PlantDME/MeOH

~25 000 t DME/y

5/29/2007 46

BL Storage tank

BL Feeding & Preparation

BL GasificationUnit

Raw gas cooling& washing

Gas Cleaningunit

CO-Shiftconversion

Gas Cleaningunit

Offsites andutilities

DME & MeOHsynthesis

DME & MeOHDistillation

Productstorage MeOH

GL Storage tank

Air Separation

O2 supplyand N2 system

Sulphurrecovery unit

Low sulphiditygreen liquor

Black liquor

Productstorage DME

MeOHFinal Product

Air

O2 N2

O2O2

LP steam and hot water

Alt 1&2: White liquor

CO2 to tall oil production or pulp wash

Syngas

DMEFinal Product

MeOHabsorbent Fusel oil

Purge gas

Cooking

Fibre line 1(SCMBB)

Cold alkaliimpregnation

Warm BLtreatment

Hot BLtreatment

Bleaching

Wood chips

Weak liquor

Evaporation

Drying

Pulp

Digester

Blackliquor

N2

Alt 1: PS liquorAlt 2: High S white liquor

Screening & washing

Weak white liquor

Alt 2: Relatively high S white liquor

Clausoff-gas

BLGMF Block flow diagram

BL Storage tank

BL Feeding &Preparation

BL GasificationUnit

Raw gas cooling& washing

Gas Cleaningunit

CO-S- hiftconversion

Gas Cleaningunit

Offsites andutilities

DME & MeOHsynthesis

DME & MeOHDistillation

Productstorage MeOH

GL Storage tank

Air Separation

O2 supplyand N2 system

Sulphurrecovery unit

Low sulphiditygreen liquor

Black liquor

Productstorage DME

MeOHFinal Product

Air

O2 N2

O2O2

LP steam and hot water

Alt 1&2: White liquor

CO2 to tall oil production or pur lp wash

Syngas

DMEFinal Product

MeOHabsorbent Fusel oil

Purge gas

N2

Alt 1: PS liquorAlA t 2: High S white g liquorliquor

WeWeaakk wwhhiteite liquorliquor

Alt 2: Relatively high S white liquor

Clausoff-gas

Södra pulp mill BLGMF system

Fibreline 2

Torecovery

boiler

5/29/2007 47

The SmurfitKappa Mill with Chemrec’s DP-1 Plant. Planned Site for DME Pilot and a Demonstration Plant for Fuel or Electricity Generation (DP-2)

ExiatingDP-1

PlannedDME Pilot

The MillTentative Site

for DP-2

In Piteå,North Sweden

5/29/2007 48

Dosomething !

Questions ?

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