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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Biomassasta ja jätteestä
synteesikaasua
- suomalainen ratkaisu liikenteen biopolttoaineille
sekä kotimaahan että vientimarkkinoille
Esa Kurkela, Pat McKeough & Pekka Simell
VTT
II LIEKKI-päivä
24.1.2006, Turku
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Tankkausta
2010-luvulla
EU: 5,75 %
biopolttoaineita
2010 jälkeen
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Kaikki biomassat
Kaasutuksen avulla
konversio hyvällä
hyötysuhteella
Kaikki lopputuotteet
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Suomalaisen synteesikaasutusprosessin kehitys


VTT kehittää toisen sukupolven kaasutusprosessia synteesikaasun
valmistukseen biomassasta:
– leijukerroskaasutus, soveltuu lajalle polttoainepohjalle
– puupolttoaineet ja turve
– olki , ruokohelpi ja muut peltobiomassat
– kierrätyspolttoaineet
– innovatiivinen katalyyttinen kaasunpuhditus
– reformoidun tuotekaasun hienopuhdistus
Yrityskumppanit: Foster-Wheeler, Neste Oil, Andritz ja Vapo,
kokeellinen T&K yhdessä TKK:n kanssa

T&K-hanke 2004-07: 4M€, 500 kW prosessinkehityslaitteisto Otaniemessä

Uuden kaasutusprosessin teollinen demonstrointi 2008 – 2010; 30-50 MW

Tavoitteena kaupallinen kokoluokka 200 - 300 MWfeed; mieluiten
integroituna energiaa kuluttavaan teollisuuteen, kuten paperitehtaaseen
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Peat from MoDo
steam dryer
Peat crush
moisture 15 %
Steam
HTW gasifier
10bar
750950°C
Steam
Oxygen
SYNGAS FROM PEAT AND WOOD
HTW-PLANT AT OULU KEMIRA
AMMONIA PLANT, 120 MWfuel
Benzene from
naphthalene
extraction
Waste
heat
boiler
Gas to amisol scrubber
1500 k mol/h 29 bar
Benzene
scrubber
Water
scrubber
Recycle gas
To naphthalene
extraction
Improvements to the process:
Sludge separation
Dust
Ash
Pressurised steam/O2-blown gasifier
• 1st generation technology was successfully
demonstrated in late 1980’s (Oulu, Berrenrath)
• Single gasifier train 100-300 MW feasible
• Optimised gasifier design
- fuel flexibility, high availability
• Reforming of hydrocarbons
- high syngas yield
- no tar-related problems
- optimal H2/CO ratio
- conventional final gas cleaning
unit operations can be applied
• Advanced gas filtration, gas cooler
design and ash oxidation
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
UCG-process development unit at VTT, 0.5 MW
new innovative technology
Fuel-Flexible
Fluidised-Bed
Gasification
- steam/oxygen
(indirect heating)
Gas Cleaning
Ultra Cleanup
- tar & hydrocarbon
reforming
- chlorine & metal
removal & filtration
- dirty shift
-sulphur, NH3, HCN,
halides, etc.
- conventional
processes available,
optimisation needed
FT-diesel
CH3OH
Hydrogen
SNG
clean fuel
gas to fuel
cells
Gasifier targets:
-
no ash-related problems
simple design and high reliability
high C-conversion to gas + tars
no need for tar decomposition
low oxygen consumption
Gas cleaning targets:
-
complete tar and benzene decomposition
over 95 % methane reforming
H2/CO ratio suitable to FT-synthesis
reliable operation
minimum overall gas cleanup train costs
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Fuel-Flexible Fluidised-Bed gasification
Required feedstock basis
-
different wood residues
straw, other agricultural residues
energy crops and short rotation wood
MSW and other solid waste streams
Industrial-scale experiences
- pressurised gasification and filtration for IGCC;
two processes were developed in 1990’s
- wood & waste gasification in Lahti since 1998
- gasification of aluminium
containing plastics
in Varkaus since 2001
- in operation since 1998
- no commissioning problems
- pilot-scale R&D with
35 000 operating hours
different waste-derived -- gasifier
availability > 95 %
boiler
emissions
feedstocks (gasification - payback time ca. decreased
8 years
& gas cleaning)
Gasifier feed
preparation
Main boiler
360 MWth
CFB gasifier of 60MW
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Catalytic gas treatment: recent developments at VTT
• Tar decomposition with nickel monolith
- R&D at VTT since mid 1990’s
- MW-scale demonstration at Kokemäki and
Skive gas engine plants 2005-06
• Tar decomposition by zirconia-based
catalysts – R&D since 2000
Ta
rs
Ncompounds
• Selective oxidation of ammonia since 1990’s
• Catalytic reforming of natural gas and
light fuel oil for SOFC, 2004
and Catalytic after burner for SOFC, 2005
• New catalytic system for methane
reforming and dirty shift conversion
CATALYST
500-900 °C
CO, CO2,
H2, H2O
Design basis for multifunctional catalytic
cleanup process for the UCG-PDU plant
N2, H2,
H2O
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
500 kW PRESSURIZED FLUIDIZED BED GASIFIER (UCG-PDU)
PFB GASIFIER
To slip stream
testing facilities
Bed
material
Additive
CATR
Gas
cooler
Pressure
control valve
Fuel feeding
equipment
Heating
elements
FILTER
Oxygen
Ash
removal
Steam
Air
Nitrogen
Bed
removal
Heating
elements
Furnace
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
UCG-prosessin teknistaloudelliset tarkastelut
 Eri
prosessivaihtoehtojen ja lopputuoteiden hyötysuhteiden ja
kustannusten alustava arviointi (2004)
 Kaasutusprosessin valinta (2004-05)
– toimintapaine
– happikaasutus vs. epäsuora höyrykaastus
– reformerin ja shift-reaktorn suorituskyvyn vaikutukset
 Kaasun loppupuhdistuksen merkitys (2004-05)
 Yksityiskohtainen prosessisuunnittelu ja kustannusten arviointi (2006)
 Ensimmäisen (30-50 MW) ja toisen (100-300 MW) demolaitoksen
suunnittelu ja kustannusarvio (2006)
Pulp & Paper
Mill
Biofuel production
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VTT
VTT TECHNICAL
PROCESSESRESEARCH CENTRE OF FINLAND
Basic Layout of Processes for Bio-Syngas Production and Conversion
CO shift,
CO2 removal
HP Steam
Biomass
Gasification
& Reforming
Gas
Cleaning
Gas
Conditioning
Possible
synthesis loop
MP/LP Steam
Off-gas
Synthesis/
Separation
Upgrading
Main
Product
CC, FCCC Applications
1 – 30 bar
1 – 30 bar
30 bar
850 °C
40 - 280 °C (final)
(IGCC: 500 °C)
40 - 350 °C
(initial)
Abbreviations:
CC
FCCC
FT
SNG
DME
H2/trad
H2/PSA
FT, SNG, H2: 20 – 30 bar
CH3OH, DME: 100 bar
FT, CH3OH, DME, SNG, H2/trad: 200 – 300 °C
H2/PSA: 40 °C
Combined-Cycle energy production
Fuel-Cell Combined-Cycle energy production
Fischer-Tropsch liquid fuels
Synthetic Natural Gas (CH4)
Di-Methyl Ether
Traditional process for H2 production from syngas
H2 production based on separation by Pressure Swing Absorption
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Modelling of Bio-Syngas Conversion
Applications Examined and their Abbreviations
FT:
Fischer-Tropsch primary liquids (C5+); once-through
FT/R:
Fischer-Tropsch primary liquids (C5+); with reforming loop
CH3OH:
Methanol; high-conversion gas-phase synthesis
SNG:
Synthetic natural gas; mainly CH4; H2 (e.g. 2 vol. %)
and inerts (e.g. 1 vol. %) also present; delivered at 30 bar
H2/trad:
Hydrogen via traditional method; CH4 (e.g. 2 vol. %) and
inerts (e.g. 1 vol. %) also present; delivered at 30 bar
H2/PSA:
Hydrogen via separation by Pressure Swing Adsorption;
high-purity; delivered at 30 bar
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Modelling of Biosyngas Conversion
LHV-Efficiency for Main Product, %
Comparisons of Efficiencies of Base Cases
100
90
80
70
60
50
40
30
20
10
0
FT
FT/R
CH3OH
SNG
H2/trad
H2/PSA
FT: Fischer-Tropsch primary liquids, once-through process with
reasonably high once-through performance
FT/R: process with reforming loop; same once-through FT performance
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Benefits of Integration with Energy Consumer
Overall Efficiencies for Different Applications (Base Cases)
LHV-Efficiency, %
100
90
80
70
60
50
40
30
20
10
0
to main product
A
H
2/
PS
ad
H
2/
tr
SN
G
C
H
3O
H
/R
FT
FT
to main product, offgas and steam
Note: steam = HP and LP steam produced in gas cooling and MP/LP steam produced in synthesis/shift.
Conclusion: overall efficiency of FT is exceptionally high (heat of condensation of product liquids and
heat of condensation of part of product H2O recovered as LP steam) while overall efficiency of methanol
is lower. Benefits of integration will vary accordingly.
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Typical Investment Breakdown
Capacity: about 300 MW input
67 %
Pretreatment
Gasification
Reforming
Gas cleaning
O2 plant
33 %
Gas
conditioning
Synthesis
Upgrading
+10 % to
In addition:
+30 %
Energy production
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Modelling of Bio-Syngas Conversion
Important Bases of the Cost Estimates





Capacity of plant: 300 MW of feedstock (LHV basis)
Annual operating time: 8000 h/a
Interest on capital: 10 % for 20a
O&M costs: 4 % of investment
Base values for purchased/sold energy (other values applied in
sensitivity cases):
– feedstock: 10 EUR/MWh (LHV)
– electricity: 30 EUR/MWh
e
– HP steam: 16 EUR/MWh of transferred heat
– MP and LP steam: 13 EUR/MWh of transferred heat
– fuel gas: 14 EUR/MWh (LHV)
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Modelling of Bio-Syngas Conversion
Comparison of Costs; Effect of Feedstock Price
Current
refinery-gate
price for
gasoline, diesel
(excl.
distribution and
taxes)
Production costs, EUR/GJ
22
20
18
16
14
Feed 0 EUR/MWh
Feed 5 EUR/MWh
12
Feed 10 EUR/MWh
10
8
Feed 15 EUR/MWh
Feed 20 EUR/MWh
6
4
2
0
FT
FT/R
CH3OH
SNG
H2/trad H2/PSA
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Synthesis gas from biomass to liquid biofuels,
hydrogen, synthetic methane and chemicals
- liquid biofuels or H2 in medium-to-large scale plants
Biorefineries at pulp and
paper mills or at oil refineries
fluid-bed gasifiers
100-400 MW
Other
Other pilot/demo
pilot/demo plants
plants
Berrenrath,
Berrenrath, Hawai,
Hawai,
Studsvik,
Vermonth,
Studsvik, Vermonth, Gussing
Gussing
HTW
HTW
plant
plant
in
in Oulu
Oulu
Air-blown
Air-blown biomass
biomass
&
& waste
waste gasifiers
gasifiers
1985
Synthesis
Synthesis gas
gas
R&Din
1980’s
R&Din 1980’s
Sweden,
Sweden, Germany;
Germany;
USA,
USA, Finland
Finland
1995
2000
Catalytic
Catalytic
reforming
reforming
know-how
know-how
2005
Hydrogen
technologies
Demonstration
Demonstration
100-200
100-200 MW
MW
2010
2015
2020
2025
Industrial
Industrial
demontsr.
demontsr.
VTT-UCG
VTT-UCG
Waste-to
Optimised
Optimised Waste-to
synfuel
syngas
syngas R&D
R&D synfuel
R&D
R&D
PDU-scale
PDU-scale
Development
Development
R&D
R&D on
on Hydrogen
Hydrogen technologies
technologies
2030
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Paperitehtaasta puunjalostamoksi
Paperi
sellu
Prosessihöyry ja sähkö
Voimalaitos
Sellu- ja paperitehdas
Kuivausenergia
Puu, peltobiomassat
ja kierrätyspolttoaineet
Biomassan
käsittely ja
kuivaus
Kaasutus ja
kaasunpuhdistus
polttokaasua
+ höyryä
synteesi
-kaasu
kuori,
metsätähteet
muu biomassa
FT-synteesilaitos
happi + höyry
PuuDiesel
Theoretical Potential in European Forest Industry Platforms
- 100 sites out of 1300 mills ¾ for IGCC plants: 4 000 MWe ~ 33 TWhe/a of additional electricity
from 4500 MW (37 TWh/a) ~ 3 Mtoe/a of solid biomass residues
¾ for FT-liquids plants: 14 500 MW (120 TWh/a ~ 11 Mtoe/a) of FT liquids
from 18 000 MW (150 TWh/a) ~ 14 Mtoe/a of solid biomass residues
¾ Forest residues would be available, < 20 €/MWh price, up to 6 – 10 Mtoe/a.
Solid recovered fuels (SRF) and straw/annual crops should be
supplementary fuels
¾ The forest industry platform offers up to 20 – 30 % lower production cost
than in traditional stand alone option.
¾ The EU biofuel demand in 2010 is 18 Mtoe/a according to the Biofuel Directive
- total investment ~ 25 Billion € and
- 8 Billion €/a motor fuel market on biofuels
by: Sipilä, VTT Clean World 27.10.2005
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Yhteenveto ja johtopäätökset
¾ Kaasutustekniikalla
keskeisen
tärkeä
merkitys
uusissa
energiajärjestelmissä halvan öljyn aikakauden jälkeen
¾ Suomalaisella biomassan ja jätteiden kaasutustekniikalla hyvät
mahdollisuudet saavuttaa huomattavia markkinaosuuksia
¾ Paineistettu leijukerroskaasutus ja hiilivetyjen katalyyttinen reformointi
valittu suomalaisen synteesikaasuprosessin perustaksi
¾ Uusi prosessi kehitetään ja testataan vuosina 2005-07 VTT:n 500 kW:n
PDU-laitoksella
¾ Uuden prosessin teollinen demonstrointi noin 50 MW:n kokoluokassa
energian tuotantosovelluksessa (esim. paperi & sellutehdasympäristössä tai öljynjalostamolla) 2008-10
¾ Kaupallinen tuotanto näyttäisi erittäin kilpailukykyiseltä muihin
Euroopassa kehitettäviin vaihtoehtoihin verrattuna kokoluokassa 150300 MW– ensimmäiset laitokset 2012-15
¾ Vuoden 2006 aikana haetaan sopivat kohteet ensimmäiselle ja toiselle
demolaitokselle – edettävä ripeästi ja määrätietoisesti jotta kiritään
saksalaisten ja ruotsalaisten edelle !
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Kiitos kuulijoille !
ja
UCG-projektin rahoittajille ja yhteistyötahoille
• VTT:n Puhdas Maailma teema
• Tekes – ClimBus-ohjelma
• Teknillinen korkeakoulu
• Neste Oil Oyj
• Foster Wheeler Energia Oy
• Andritz Oy
• Vapo Oy