Biomass gasification technologies for advanced … gasification technologies for advanced power...

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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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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-


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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



Gas cleaning: gas cooling followed by filtration

Gascooler

Filter

Fuelfeeding

Gasburner

Coalburners

Bed material/Ca-basedadditive

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 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


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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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/

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Biomass gasification forHigh-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 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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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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Novel power plant: 1.8 MWe + 3.3 MW heat• Supplier: Condens Oy• Kokemäki, Finland

Novelgasifier

Tar reformer

Gas coolerand Filter

Scrubber

Gas engines


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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Biomass gasification forliquid biofuels and green chemicals


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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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


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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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-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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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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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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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”


Coal

Oil

Biomass

Waste/SRF

O2Air

Steam

Syngas

Energy(Fuel gas)

Gasification

SOFCIGCCCo-firingGas engineCHP

FT-synthesisHydrogenSNGMetOH

CARBON

GAS

CLEANUP

Biomass gasification technologies for advanced … gasification technologies for advanced power...

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