Role of gasification modelling in
overall plant design
Flame Days 2013 seminar
Ilkka Hannula
VTT Technical Research Centre of Finland
08/04/2013
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Simplified block diagram of a BTL plant
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Simplified block diagram of a BTL plant
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www.vtt.fi/inf/julkaisut/muut/2010/Hannula1.pdf
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www.vtt.fi/inf/julkaisut/muut/2011/Hannula301210.pdf
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Simplified block diagram of a BTL plant
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Experimental conversions as
a function of reactor temperature
(G = T gasif, R = T reforming)
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Most important
non-equilibrium phenomena
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With reformer, main components
come very close to eq. and model
results are usually satisfactory
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Model validation based on raw gas
- Fairly good results
reached
- Expected experimental
error ~5 %
- Even better match
reached with reformed
gas
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Hydrocarbons & tar
Residual
methane
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Product gas
Hot gas
filtration
T = 850 °C
Reforming of the
filtered product gas
T = 950 °C
T = 550 °C
Product gas
Hot gas
filtration
Reforming of the
filtered product gas
T = 850 °C
T = 850 °C
T = 850 °C
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Liquid transportation fuels via large-scale fluidised-bed
gasification of lignocellulosic biomass
(I. Hannula and E. Kurkela, 2013)
•
•
•
•
Feedstock input 300 MWth (50 wt%, LVH) to dryer for all simulated designs
4 end-product considered: methanol, DME, FT liquids and MTG
5 individual plant designs simulated
20 cases compared:
•
Overall thermodynamic efficiency (on LHV basis)
•
Economics (capital cost estimates & levelised production costs)
CASE
Front-end
Steam system
Filtration
Gasification
CO2
1
2
Currently proven
Condensing
CHP
550 °C
550 °C
5 bar
5 bar
Vent
Vent
3
4
5
Further R&D required
CHP
CHP
CHP
850 °C
850 °C
850 °C
5 bar
22 bar
22 bar
Vent
Vent
CCS
08/04/2013
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Liquid transportation fuels via large-scale fluidised-bed
gasification of lignocellulosic biomass
(I. Hannula and E. Kurkela, 2013)
•
•
•
•
Feedstock input 300 MWth (50 wt%, LVH) to dryer for all simulated designs
4 end-product considered: methanol, DME, FT liquids and MTG
5 individual plant designs simulated
20 cases compared:
•
Overall thermodynamic efficiency (on LHV basis)
•
Economics (capital cost estimates & levelised production costs)
CASE
Front-end
Steam system
Filtration
Gasification
CO2
1
2
Currently proven
Condensing
CHP
550 °C
550 °C
5 bar
5 bar
Vent
Vent
3
4
5
Further R&D required
CHP
CHP
CHP
850 °C
850 °C
850 °C
5 bar
22 bar
22 bar
Vent
Vent
CCS
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CASE
1
2
3
4
5
Gasifier
Pressure
bar
5
5
5
22
22
Temperature
°C
850
850
850
850
850
Heat loss
%
1.2
1.2
1.2
1.3
1.3
Steam/O2
-
1.0
1.0
1.0
0.8
0.8
Carbon conversion
%
98
98
98
96
96
Recycle gas / O2
-
0.0
0.0
0.0
0.7
0.7
Recycle gas flow
kg/s
0.0
0.0
0.0
4.0
4.0
°C
203
203
203
210
210
°C
550
550
850
850
850
Outlet temperature
°C
957
957
957
957
957
Heat loss
%
1.6
1.6
1.5
1.6
1.6
Steam/O2
-
1.0
1.0
1.0
1.2
1.2
Methane in (dry)
mol%
8.8
8.8
8.8
9.1
9.1
Methane out (dry)
mol%
0.4
0.4
0.4
2.3
2.3
Methane conversion
%
95
95
95
70
70
S/O2 inlet temp
°C
206
206
206
291
291
mol%
1.1
1.1
1.1
1.1
1.1
S/O2 inlet temp
Filter
Temperature
Reformer
N2 out (dry)
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CASE
1
2
3
4
5
Gasifier
Pressure
bar
5
5
5
22
22
Temperature
°C
850
850
850
850
850
Heat loss
%
1.2
1.2
1.2
1.3
1.3
Steam/O2
-
1.0
1.0
1.0
0.8
0.8
Carbon conversion
%
98
98
98
96
96
Recycle gas / O2
-
0.0
0.0
0.0
0.7
0.7
Recycle gas flow
kg/s
0.0
0.0
0.0
4.0
4.0
°C
203
203
203
210
210
°C
550
550
850
850
850
Outlet temperature
°C
957
957
957
957
957
Heat loss
%
1.6
1.6
1.5
1.6
1.6
Steam/O2
-
1.0
1.0
1.0
1.2
1.2
Methane in (dry)
mol%
8.8
8.8
8.8
9.1
9.1
Methane out (dry)
mol%
0.4
0.4
0.4
2.3
2.3
Methane conversion
%
95
95
95
70
70
S/O2 inlet temp
°C
206
206
206
291
291
mol%
1.1
1.1
1.1
1.1
1.1
S/O2 inlet temp
Filter
Temperature
Reformer
N2 out (dry)
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For a plant having 300 MW biomass input
(LHV, AR @ 50 wt% moisture)
CH4 flow 3.8 MW
229 MW
250 MW
22.8 MW
242 MW
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Fischer-Tropsch design
Synthesis
• Shell Middle Distillate Synthesis
(Bintulu, Pearl)
• Cobalt-based (Co/Zr/SiO2) LTFT
• Very paraffinic syncryde, less alkenes and
oxygenates than in any other large-scale
industrial FT technology.
• 80 % per-pass conversion, ~ 0.90
• Multitubular fixed-bed reactor at 200 °C and
30 bar.
Recovery & upgrade
• C5 recovered by condensation at 45 °C
and Psynth
• No cryogenic separation of C1-C2
• Hydrocracker at 325 °C and 40 bar with noble
metal hydrocracking catalyst
Simplified layout of the FT synthesis, product recovery and refinery section, adapted
SMDS design. From: Arno de Klerk (2011) Fischer-Tropsch refining, Wiley-VCH,
642pp, ISBN 9783527326051
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For a plant having 300 MW biomass input
(LHV, AR @ 50 wt% moisture)
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What is the overall impact?
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For a plant having 300 MW biomass input
(LHV, AR @ 50 wt% moisture)
Cost estimation
methods
- Detailed mass & energy
balances used as a
basis for equipment
sizing
- Chemical Engineer’s
Plant Cost Index used
to account inflation
- Component costs
scaled using individual
exponents:
CAPITAL COSTS, M€
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5BAR/550C 5BAR/850C 22BAR/850C
Auxiliary equipment
97.0
93.6
93.6
Buildings
18.8
18.8
18.8
Oxygen production
47.2
43.8
43.7
Feedstock pretreatment
31.1
31.1
31.1
Gasification island
150.9
151.4
149.3
Gasification
51.1
51.1
51.1
Hot-gas cleaning
38.7
37.9
39.5
CO shift
6.2
6.6
7.1
Syngas cooling
10.2
10.2
10.6
Compression
8.9
8.9
5.7
Acid gas removal
35.9
36.8
35.3
Power island
27.1
23.9
30.0
Fischer-Tropsch synthesis
77.0
80.9
80.1
FT reactor
41.2
43.4
43.0
HC recovery plant
8.1
8.6
8.5
H2 production (PSA system)
1.4
1.5
1.4
Wax hydrocracking
25.7
26.9
26.7
FT recycle compressor
0.5
0.5
0.6
TOTAL OVERNIGHT CAPITAL
352.1
349.9
353.0
TOTAL CAPITAL INVESTMENT
369.7
367.4
370.7
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Plant factors
Total biomass use, MW, AR
Annual peak load demand for heat, h/a
Capacity factor
300
2010
5500
90 %
Investment cost factors
Balance of Plant
Indirect costs
Contingency for standard components
Contingency for less mature components
Interest during construction, fraction of TPC
Capital charges factor, (10%, 20a)
O&M costs factor, fraction of TPC/a
Public investment support, M€
30 %
22 %
20 %
30 %
5%
12 %
4%
0
Target year for costs
Prices
Biomass, €/MWh
Electricity, €/MWh
District heat, €/MWh
17
50
30
27
BOP
instrumentation and
controls, electrical
connections, piping,
insulation, and site
preparation
Indirect costs
Engineering &
head office costs 15 %,
start-up costs 5 % and
royalties & fees 2 %
O&M
Personnel costs 0.5 %
Maintenance &
insurances 2.5 %
Catalysts &
chemicals 1 %
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Levelised production cost
300 MW Biomass @ 17 €/MWh, 0.12 CCF
Electricity 50 €/MWh, DH 30 €/MWh@5500 h/a
•
•
•
•
30
Mature technology
No investment support
No CO2 credits
No tax assumptions
Gasoline
@150$/bbl
Before tax, incl.
refining margin,
1 € = 1.33 $ (2010)
Gasoline
@100$/bbl
08/04/2013
VTT - 70 years of
technology for business
and society
31