CHP plants based on advanced biomass gasification January, 2006
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1 VTT TECHNICAL RESEARCH CENTRE OF FINLAND CHP plants based on advanced biomass gasification - EU BiGPower project 2005 - 2008 Esa Kurkela VTT – Technical Research Centre of Finland January, 2006 Esa.Kurkela@vtt.fi 24.1.2006 2 VTT TECHNICAL RESEARCH CENTRE OF FINLAND CHP plants based on biomass gasification - most potential gasification technologies z Smallest size range: < 500 kWe + 1 MWheat z z z Medium size range: 0.5 – 15 MWe + 1 – 15 MWheat z z z z z z Different gasification systems available: Modified updrafts, fluidised-bed, staged proceses Turbo-charged gas engines Gas cleaning is most critical process step Fuel cell plants or small gas turbines also possible in future Competition with fluidised-bed combustion with steam turbine cycle at > 3-5 MWe Large-scale biomass power plants: 15–150 MWe + 15-150 MWheat z z z z downdraft gasifiers and gas engines (naturally aspirating) new types of downdrafr gasifier? Pressurised fluidised-bed gasification with hot filtration Combined Gas and Steam Turbine Cycle or engine-steam turbine cycle? Competition with CFB and BFB boilers with steam cycles Co-firing in coal or natural gas power plants, gasifiers > 50 MWfuel z z z Esa.Kurkela@vtt.fi Fluidised-bed gasification No gas cleaning with clean biomass in PC boilers Filtration and chlorine removal with waste fuels 24.1.2006 3 VTT TECHNICAL RESEARCH CENTRE OF FINLAND GE Jenbacher, Itävalta VTT:n kaasutustutkimus v. 2006 aihe: Korkean hyötysuhteen CHP-tekniikat EU-BiGpower – Advanced Biomass Gasification for High-Efficiency Power – VTT:n koordinoima EU/Tekes-projekti 1.10.2005 – 30.9.2008 – 13 partneria, Suomesta VTT, TKK, Carbona ja Condens – VTT:n volyymi v. 2006 noin 330 k€ – kaasutukseeen perustuvat moottorivoimalat, polttokennovoimalat ja kombivoimalat – kaasun puhdistus em. käyttökohteisiin (katalyytit ja suodatus) – koetoimintaa: Otaniemen prosessikoesali, Kokemäki, UCG-PDU – kaasutus CHP:n systeemitarkastelut CATDEMO- Katalyyttisen kaasunpuhdituksen tuotteistaminen ja demonstrointi – – – – Esa.Kurkela@vtt.fi Volyymi v. 2006 noin 300-400 k€ Kokemäen demonstraatioprojekti ja tutkimusasema Skiven demonstraatiohanke Katalyyttivalmistuksen tuotteistaminen ja IPR:n vahvistaminen 24.1.2006 MTU FCS, Saksa 4 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Requirements for real success stories in medium-to-large-scale gasification • Fuel flexibility with respect to particle size, ash composition and moisture content • Elimination of tars without waste water problems • Effective final gas cleaning to protect gas engines, turbines or other downstream equipment • Automatic operation, good reliability and low service costs • High power production efficiency of 30 – 50 % in order to be competitive with boilers and steam cycles 5 VTT TECHNICAL RESEARCH CENTRE OF FINLAND UPDRAFT GASIFIER “BIONEER” - developed in 1980’s, 10 plants for boilers and kilns, 5 MW scale tar containing gas high carbon conversion robust, flexible, fully automated Hot gas District heating Fuel silo Electricity Ash 5 MW district heating plant, Jalasjärvi, Finland, in operation since 1987; 145 000 operating hours Gas boiler 6 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Novel – an improved updraft gasifier PRODUCT GAS FORCED FUEL FEEDING -high temperature & low tars - use of low density fuels possible -700-850 oC, 1-4 g/m3n tars TWO-STAGE OPERATION - counter-current bottom bed - tars decomposed above the bed by additional air feeding OXIDISING ZONE - complete carbon conversion humidifier and fully oxidised bottom ash gasification air cooling 7 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Novel power plant: 1.8 MWe + 3.3 MW heat - Kokemäki, Finland plant under comissioning total investment 4.8 M€ electric efficiency 30 % Tar reformer Optimal plant: - biomass moisture 50 % drying to 15 % by waste heat power efficiency up to 35 % suitable to 0.5 - 5 MWe power production cost < 5 c/kWh Scrubber Novel gasifier Gas cooler and Filter 3 Gas engines 8 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Time table of the Kokemäki Novel CHP plant Construction work: completed in April 2005 Commissioning and Testing periods Gasifier and the gas boiler: April - May Gas cleaning and heat recovery: May – August Start-up with one JMS 316 engine (520 kW): November Operation with one gas engine and gas boiler: 2006 performance and emission measurements tests with different fuels & plant optimisation 2nd and 3rd gas engines: 1.8 MWe: end 2006 Further R&D activities EC BiGPower: slip stream testing of 2nd generation catalytic gas clean-up and scrubbing water recycling (Oct. 2005 … Sept 2008) Testing with waste-derived fuels and agrobiofuels within other projects SKIVE PROJECT, DENMARK (by Carbona Oy, Salo, Patel & Horvath) PRODUCT GAS FILTER TO STACK GAS COOLER TAR CRACKER BOILER BIOMASS FLY ASH PRODUCT GAS COOLING (Heat Recovery) DISTRICT HEATING 11.5 MWth FLUE GAS HEAT RECOVERY PRODUCT GAS BUFFER TANK GASIFIER PRODUCT GAS SCRUBBING (Heat Recovery) AIR STEAM POWER 5.4 MWe ASH WATER TREATMENT GAS ENGINES Biomass-CHP-Plant-Güssing CHP-Plant Güssing Start up in November 2001 • • • • • • Fuel Fuel Power Electrical Power Thermal Power Electrical Efficiency Total Efficiency Wood chips 8 MW 2 MW 4,5 MW 25 % 80 % • • Investment Optimisation 9 1 Mill. EURO Mill. EURO 12 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Large-scale Power with Integrated Gasification Combined-Cycle - IGCC ¾ Fluidised-Bed Gasification at 20 bar, 800-950 oC ¾ Gas filtration at 400 - 600 oC ¾ Combined Gas Turbine and Steam Turbine Process • Developed and demonstrated in 1990’s • • • • • Electric efficiency 40 - 50 % Requires large-scale > 15 MWe Best global potential for CO2 reduction New R&D activities 2005 -> New demonstration projects will come – when and by which companies? Esa.Kurkela@vtt.fi 17.1.2006 Biomass IGCC Demonstration Plant, Värnamo, Sweden Biomass – IGCC power plant design (by Carbona Oy; K.Salo & A.Horvath) Small CHP plant • Power production: 7.4 MWe • District heat: 8.5 MJ/s • Electric efficiency: 40 % Large IGCC power plant • Power production: 116 MWe • Electric efficiency: 50 % 14 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 15 VTT TECHNICAL RESEARCH CENTRE OF FINLAND 2nd generation BIGCC Plants - efficiency 45-50 % - size range 15-100 MWe gas gas turbine turbine development development activities activities BIG-MCFC Plants - efficiency 40-50 % - size range 0.5-5 MWe MCFC MCFC HotModule HotModule development development for for natural natural gas gas applications applications 2nd generation engine plants - power efficiency 35-40 % - size range 1 - 15 MWe Pressurised Pressurised gasification gasification pilot/demo pilot/demo Värnamo Värnamo & & Tampere Tampere Gas Gas engine engine demonstrations demonstrations Bioneer Bioneer gasifier gasifier (heating (heating appl.) appl.) 1985 1995 Kokemäki, Kokemäki, Skive Skive Gussing Gussing 2005 Gas Gas cleaning cleaning R&D R&D Novel Novel gasifier gasifier Press. Press. FB FB gasifier gasifier Bioneer Bioneer R&D R&D in in Finland Finland gasifier gasifier R&D R&D Dual Dual Fluid Fluid Bed Bed Gasifier Gasifier R&D R&D in in Austria Austria Esa.Kurkela@vtt.fi 17.1.2006 MCFC MCFC pilot/demonstration pilot/demonstration Agrofuels Agrofuels & & waste demonstration waste demonstration 2nd 2nd generation generation engine engine plant plant demos demos EU-BiGPower 2010 -- Advanced Advanced catalytic catalytic gas cleaning gas cleaning -- New New Filters Filters -- 2nd 2nd generation generation gasifiers gasifiers -- Improved Improved gas gas engines engines -- MCFC MCFC concepts concepts 2015 New New R&D R&D activities activities 2020 2025 16 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Advanced Biomass Gasification for high-Efficiency Power BiGPower – project no. 019761 Targets for the gasification power plants Technology Present status Target 2010 - 2015 Target 2015 - 2020 Elect.Eff. Specif.Invest. Elect.Eff. Specif.Invest. Elect.Eff. Specif.Invest. % €/kWe % €/kWe % €/kWe Gasifier-engine (1-15 MWe) 20-30 3500-6000 30-35 2500-4000 35-40 2000-3000 Gasifier-MCFC (0.5-5 MWe) na (> 10 000) 35-40 < 10 000 45-50 2500-3000 Biomass IGCC (15-100 MWe) Combustion and steam turbine 35-40 3000-4500 40-45 2000-3500 45-50 1500-2000 Elect.Eff. % Specif.Invest. €/kWe 1-5 MWe 10-50 MWe na = not available yet Esa.Kurkela@vtt.fi 17.1.2006 17 - 25 3000-4000 only very limited development potential 25 - 37 2000-3500 (mature technology, thermodynamic limitations)
