Black liquor gasification – the fast lane to the biorefinery
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Transcript of Black liquor gasification – the fast lane to the biorefinery
Black liquor gasification Black liquor gasification – the fast lane to the – the fast lane to the
biorefinerybiorefineryIngrid NohlgrenIngrid Nohlgren
Energy Technology Centre (ETC) Energy Technology Centre (ETC) Piteå, SwedenPiteå, Sweden
Within a few years …Within a few years …
30% of Sweden’s automotive fuels may come 30% of Sweden’s automotive fuels may come from Swedish pulp millsfrom Swedish pulp mills
Power production equivalent to that from a large Power production equivalent to that from a large river (1000 MW) may come from the millsriver (1000 MW) may come from the mills
Valuable chemicals synthesised from black Valuable chemicals synthesised from black liquor can give additional revenue to the millsliquor can give additional revenue to the mills
The key is black liquor gasification technologyThe key is black liquor gasification technology
The Pulp MillThe Pulp Mill
Wood chips
Pulp
Black Liquor Energy
Biomass Energy
Black liquorBlack liquor
Is a by-product from pulping Is a by-product from pulping (water, cooking chemicals, (water, cooking chemicals, lignin and other wood lignin and other wood components)components)
Liquid biomassLiquid biomass
Approx half the wood ends up Approx half the wood ends up in the black liquorin the black liquor
Has a heating value of ~14 Has a heating value of ~14 MJ/kg DS (Oil: ~42 MJ/kg)MJ/kg DS (Oil: ~42 MJ/kg)
Is smelly (sulphur compounds)Is smelly (sulphur compounds)
… is renewable energy
0
50
100
150
200
250
300
1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 2020 2025
Black Liquor as Dry Solids (Mton)
0.0
0.6
1.2
1.8
2.4
3.0
3.6
Approx. Energy Content, LHV (EJ)
South America
Oceania
North America
Europe
Asia
Africa
Estimated black liquor productionEstimated black liquor production
Japan50 TWh
South America44 TWh
Sweden39 TWh
World~ 600 TWh
ASIA80 TWh
Europe120 TWh
North America350 TWh
(Chemrec)
Illustration of Recovery Boiler Capacities in Europe
= clusters of mills together having a large boiler capacity
= important single mill
Today’s technology Today’s technology (Recovery boiler)(Recovery boiler)
WoodYard
Lime Kiln
Pulping mill
Evaporators
RecoveryBoiler
White Liquor
Pulp storage
Fibre LineLiquor Cycle
BL Storage
Boiler
Chips
The Recovery boiler is replaced by BLGThe Recovery boiler is replaced by BLG
Woodchips
Pulp
Black liquor energy
Biomass
BLGMF DME/MeOH
Addition of biomass to the system to Addition of biomass to the system to balance the energy demandbalance the energy demand
Woodchips
Pulp
Black liquor energy
Biomass
BLGMF DME/MeOH
The DP1 plant in PiteåThe DP1 plant in Piteå
ETC CHEMREC
Kappa Kraftliner
DP-1 PlantDP-1 Plant
Tomorrow’s technologyTomorrow’s technology
Raw gas
GREEN LIQUOR
Condensate
BLACK LIQUOR
GAS COOLER
REACTOR
QUENCH
Whiteliquor
Feed water*
LP-steam*
MP-steam*
Weak wash
GASIFICATION
GAS ANDSMELT
SEPARATION
GAS COOLING AND CLEANING
OXYGEN
Atomisingmedia
Coolant
SULFUR REMOVAL
SHORT TIMECONTACTORS
CLEAN, COOLSYNTHESIS
GAS (to flare)
* In DP1 cooling water
Chemrec’s gasifier DP1 in Piteå, Sweden
Advantages compared to the Advantages compared to the Recovery boilerRecovery boiler
High quality synthesis gas with mainly hydrogen High quality synthesis gas with mainly hydrogen and carbon monoxide (ratio 1:1)and carbon monoxide (ratio 1:1)
Can be used directly as fuel for gas turbinesCan be used directly as fuel for gas turbines Can be used for synthesis of motor fuels after Can be used for synthesis of motor fuels after
additional cleaning and shifting of H2/COadditional cleaning and shifting of H2/CO No water vapour to the atmosphere (better No water vapour to the atmosphere (better
efficiency)efficiency) Sulphur and sodium can be obtained in two Sulphur and sodium can be obtained in two
separate streams (better process control = more separate streams (better process control = more paper)paper)
How much does it cost?How much does it cost?
Investment cost slightly higher than for the Investment cost slightly higher than for the Recovery boilerRecovery boiler
””Pay-off time” for the extra cost ≈ 2 yearsPay-off time” for the extra cost ≈ 2 years The investment can only be done when it The investment can only be done when it
is time to replace the boileris time to replace the boiler But … the time is right since many of the But … the time is right since many of the
boilers are oldboilers are old
Year of construction for Year of construction for Scandinavian boilersScandinavian boilers
0
2
4
6
8
10
12
1950-1954
1955-1959
1960-1964
1965-1969
1970-1974
1975-1979
1980-1984
1985-1989
1990-1994
1995-1999
Nu
mb
er o
f R
eco
very
Bo
ilers
Norway
Finland
Sweden
Are tax subsidies necessary?Are tax subsidies necessary?
Most other ”green” fuels must be subsidised to Most other ”green” fuels must be subsidised to make them competitive (e.g. ethanol)make them competitive (e.g. ethanol)
The cost/km for methanol from black liquor The cost/km for methanol from black liquor would be about the same as for gasoline before would be about the same as for gasoline before taxtax
Rising oil prices will be in favour of the black Rising oil prices will be in favour of the black liquor alternativeliquor alternative
Conclusion: Tax subsidies are not necessary in Conclusion: Tax subsidies are not necessary in the futurethe future
However, subsidies may be necessary as an However, subsidies may be necessary as an incentive for new investmentsincentive for new investments
Automotive fuel cost (excl tax)Automotive fuel cost (excl tax)FuelFuel Energy Energy
ContentContentEurocent per Eurocent per
literliterEurocent per Eurocent per
kWh kWh Eurocent per Eurocent per
kgkg
Fuel cost Fuel cost per km per km 1)1)
(Eurocent)(Eurocent)
Ethanol, from Ethanol, from wheatwheat2)2)
5.90 5.90 kWh/literkWh/liter
5555 9.39.3 6969 7.3 7.3
Ethanol, from Ethanol, from forestry feedstockforestry feedstock2)2)
5.90 5.90 kWh/literkWh/liter
33 - 3433 - 342)2) 6.56.5 49 – 5649 – 56 5.2 – 5.95.2 – 5.9
Methanol, 150 Methanol, 150 USD/ton Spot price USD/ton Spot price average, Eur. average, Eur.
4.33 4.33 kWh/literkWh/liter
1212 2.92.9 1616 2.32.3
DME 215 USD/tonDME 215 USD/ton 5.27 5.27 kWh/literkWh/liter
1515 2.92.9 2222 1.91.9
Gasoline, 85 Gasoline, 85 USc/galUSc/gal
8.72 8.72 kWh/literkWh/liter
22222)2) 2.52.5 2727 2.32.3
City diesel, City diesel, 85USc/gal85USc/gal
9.77 9.77 kWh/literkWh/liter
2222 2.22.2 2727 1.51.5
References: 1) Basic Data for “Jämförelseprojektet” (The Comparison Project), STEM, Dec-2001Standard car, gasoline =3.4 MJ/ km Standard car, methanol, (=ethanol?)= 2.86 MJ/km 0.794
kWh/kmStandard car, diesel =2.43 MJ/km
2)Ny Teknik (a weekly Swedish technology magazine), Nr 9, 28 Febr, 2002, sid 12-13.
3) Energiläget 2001. Swedish CO2 tax at 0.53 SEK/kg CO2 for fossil fuels
corresponds for fossil methanol an extra cost of 70 USD/ton on top of the spot price 100 USD/ton.
Syngas Syngas
Power $3.8 billion
Or
Liquid Fuels/Chemicals$5.5. billion
O2
Pulp$5.5 billion
BL GasifierWood Residual GasifierCombined Cycle SystemProcess to manufacture Liquid Fuels and Chemicals
The Forest Biorefinery– Net Revenue
Manufacturing
CO2
Extract Hemicellulosesnew products chemicals & polymers
$3.3 billion
Black Liquor & Residuals
Net Revenue Assumptions:Acetic Acid - $1.73/gallon Purchased Electricity - $43.16/MWHEthanol - $1.15/gallon Exported Electricity - $40.44/MWHPulp - $100/ton net profit Renewable Fischer Tropsch Fuel - $57/bbl
Steam, Power & Chemicals
Crucial research issuesCrucial research issues
Conversion of all organic carbonConversion of all organic carbon ””High quality” green liquorHigh quality” green liquor Durable materials for containmentDurable materials for containment Gas cleaningGas cleaning Mill integrationMill integration Scale up from the DP1 scale (x15, x100)Scale up from the DP1 scale (x15, x100)
Activities in Piteå and at ETCActivities in Piteå and at ETC
ETC Coordinating National Research ETC Coordinating National Research Effort:Effort: ””Black liquor gasification Program” 2004-2006Black liquor gasification Program” 2004-2006
Development plant under commissioning in Piteå Development plant under commissioning in Piteå
(aiming for first syngas in Aug 2005)(aiming for first syngas in Aug 2005) 8 research projects8 research projects Budget 100 MSEK (11 MEUR)Budget 100 MSEK (11 MEUR)
Collaborators – BLG programCollaborators – BLG program
Raw material suppliers End users
Researchers
Process industry
Governmental support
SummarySummary Black liquor gasification is a key technology for:Black liquor gasification is a key technology for:
Green power productionGreen power production Green automotive fuel productionGreen automotive fuel production Green chemicals productionGreen chemicals production
Green fuel can be produced at the same cost as Green fuel can be produced at the same cost as fossile fuels 2005fossile fuels 2005
Pulp mills are ideally suited to become Pulp mills are ideally suited to become biorefineries (infrastructure in place and large biorefineries (infrastructure in place and large knowhow)knowhow)
Very strong research effort in SwedenVery strong research effort in Sweden First commercial gasifier (300 tds/day) expected First commercial gasifier (300 tds/day) expected
around 2007around 2007