Advanced Biomass Gasification
for High-Efficiency Power - BiGPower
Liekkipäivä, Otaniemi 31.1.2007
Esa Kurkela
Focus of BiGPower project
C
A
R
B
O
N
Oil
Coal
Gasification
EntrainedFlow
1000…1500 oC
Syngas
H2+CO
Biomass
Waste
Fixed-Bed
Fluid-Bed
700…900 oC
O2
A
i
r
S
t
e
a
m
Liekki-päivä
Otaniemi 31 January 2007
Fuel gas
Chemicals
Hydrogen
SNG
Liquid fuels
Engines
Fuel cells
Gas Turbines
Boilers
Kilns
2
1
BIGPower - General Information
Duration: 36 months (October 2005 – September 2008 )
Overall Budget for the project: 2 943 k€
Financed in part by EU FP6
Gasification systems
Power production equipment
8
8
8
8
8
8
8
Condens Oy, Finland
Carbona Oy, Finland
Repotec GmbH, Austria
Biomasse Kraftwerk
Güssing, Austria
(Kokemäki & Skive sites)
GE Jenbacher, Austria
MTU CFC Solutions GmbH, Germany
Catalytic Gas Cleaning and filtration
8
8
8
MEL Chemicals, United Kingdom
NortaUAB, Lithuania
Madison Filter Ltd, United Kingdom
R&D organisations supporting industrial development
8
8
8
8
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
Liekki-päivä
Otaniemi 31 January 2007
3
Objectives
8 To develop reliable, cost-effective and fuel flexible
gasification technologies for high-efficiency small-tomedium scale (1-100 MWe ) power production from
biomass.
8 To create the fundamental and technical basis for
successful industrial follow-up developments and
demonstration projects aiming to commercial
breakthrough by 2010-20.
8 To carry out in pre-competitive manner well-focused
R&D activities on the key bottlenecks of advanced
biomass gasification power systems.
Liekki-päivä
Otaniemi 31 January 2007
4
2
Novel air-blown fixed-bed gasifier
(Condens Oy and VTT)
- Kokemäki, Finland
- 1.8 MWe + 3.3 MW distrcit heat
- total investment 4.8 M€
- electric efficiency 30 %
Optimal plant:
-
Tar
reformer
biomass moisture 50 %
drying to 15 % by waste heat
power efficiency up to 35 %
power + heat > 85 % efficiency
suitable to 0.5 - 5 MWe
Scrubber
Novel
gasifier
Gas cooler
and Filter
3 Gas engines
Liekki-päivä
Otaniemi 31 January 2007
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Novel air-blown fixed-bed gasifier
BiGPower Tasks & Results from WP3
Recycling of scrubber effluents
- characterisation of waste waters
from Kokemäki demo plant
- recycling of effluents to the gasifier
Replacement of nickel monoliths
by more robust & cheaper catalysts
- slip-stream testing – started in May 2006
- testing in full gas stream – also on-going
- new materials from WP1 also in 2007
In-situ catalytic tar reforming
Slip-stream catalyst testing at Kokemäki
- construction of testing equipment
- single element testing at Kokemäki
Optimised concept design
- for engine plants
Liekki-päivä
Otaniemi 31 January 2007
6
3
Dual Fluidised-Bed Steam Gasification
(Repotec, TUV & Biomasse Kraftwerk Güssing)
Biomass-CHP-Plant-Güssing, 2 MWe + 4.5 MW heat
Liekki-päivä
Otaniemi 31 January 2007
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Dual Fluidised-Bed Steam Gasification
Tasks and Results of WP2 of BiGPower
Increased fuel flexibility
- Feeding system development
- Ash-containing biomass and bed
material optimisation
- Improved in-bed tar decomposition
by active bed materials
- Lab and PDU tests at TUV
and verification at Güssing plant
Improved gas cleaning
- on-going activities in previous projects
- modifications of slip-stream facility
- testing of new BiGPower catalysts
in 2007-2008
Optimised concept design
- for engine plants
- for fuel cell plants
Liekki-päivä
Otaniemi 31 January 2007
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4
Biomass – IGCC power plant
(Carbona, VTT, TKK and CERTH, Madison Filter)
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 %
Liekki-päivä
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Otaniemi 31 January 2007
Biomass – IGCC power plant
BiGPower Tasks and Results from WP4
Concept studies
PFB GASIFIER
• Gas turbine survey by Carbona
To
test
• Process modelling by CERTH
Bed
material
Additive
• Optimised concept
Advanced gas cleaning
CATR
Gas
cooler
c
Fuel feeding
equipment
• Increased filtration temperature
• New ceramic filter media
• Testing of catalytic filters
• Selective oxidation of ammonia
• Lab-scale testing by TKK
followed by tests at VTT’s new
500 kW pressurised gasifier
Heating
elements
FILTER
Oxygen
Ash
removal
Steam
Air
Nitrogen
Liekki-päivä
Otaniemi 31 January 2007
Heating
elements
Bed
removal
10
5
WP1: Advanced Gas Cleaning
(VTT, TKK, TUV, Madison Filter, MEL, Norta)
New monoliths, VTT & TKK
- new catalyst material and production method
Example of screening test results
80
70
C onversion (%)
New catalyst powders, MEL
- new materials and optimised production
- supply of tailored raw materials
to VTT, TKK & Norta
Toluene
A doped ZrO2
50
B doped ZrO2
40
30
C doped ZrO2
20
10
0
500
Metal substrate catalysts, Norta
- input from VTT, TKK and MEL
- improved plasma coating method
ZrO2
60
gamma-Al2O3
600
700
800
900
1000
Temperature (°C)
Catalytic filters, Madison Filter
- improved catalysts and production methods
Metal substrate catalysts by Norta
Testing of new catalysts
- laboratory-scale screening tests
- extended-time slip-stream tests
at Kokemäki and Güssing
- full-scale testing of selected catalysts
at Kokemäki
Liekki-päivä
Otaniemi 31 January 2007
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Advanced Gas Engines and MCFC
Tasks and Results of GE Jenbacher and MTU Fuel Cell Solutions
Increased Engine performance and
lower investment and operation costs
- higher efficiency and throughput
- evaluation of the effects of different design
parameters on engine performance with
BiGPower product gases
- materials optimisation and methods for
minimising tar-related problems
- CO and NOx emission control
- testing at GEJ and Güssing
MTU’s Fuel Cell HotModule
-
process calculation tool for gasification gases
MCFC process design for BiGPower gases
performance and costs of BiG-MCFC systems
design basis for demonstration project
Liekki-päivä
Otaniemi 31 January 2007
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6
Challenges and Future Plans
8 Project has been started according to work plan
8 Good new co-operation in WP1 for new catalysts
8 Traditionally effective co-operation in
9 WP1. VTT & TKK & MEL and now also with Norta and Madison Filter
9 WP2: Güssing, TUV, Repotec and GEJ
9 WP3: Condens & VTT and now also with GEJ
9 WP4: Carbona & VTT and now also with CERTH
8 New challenges with Fuel Cell integration
8 Promising expectations for Austrian-Finnish gasification
co-operation
8 Project objectives seem to be possible to reach
8 Timing of activities at demonstration plants is somewhat
challenging but should not create major problems
Liekki-päivä
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Otaniemi 31 January 2007
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
Bioneer
Bioneer
gasifier
gasifier
R&D
R&D
Kokemäki,
Kokemäki, Skive
Skive
Gussing
Gussing
1995
2005
Gas
Gas cleaning
cleaning R&D
R&D
Novel
Novel gasifier
gasifier
Press.
FB
gasifier
Press. FB gasifier
R&D
R&D in
in Finland
Finland
Dual
Dual Fluid
Fluid
Bed
Bed Gasifier
Gasifier
R&D
R&D in
in Austria
Austria
MCFC
MCFC
pilot/demonstration
pilot/demonstration
Agrofuels
Agrofuels &
&
waste
waste demonstration
demonstration
2nd
2nd generation
generation
engine
engine plant
plant demos
demos
EU-BiGPower
2010
-- Advanced
Advanced catalytic
catalytic
gas
gas cleaning
cleaning
-- New
New Filters
Filters
-- 2nd
2nd generation
generation
gasifiers
gasifiers
-- Improved
Improved gas
gas
engines
engines
-- MCFC
MCFC concepts
concepts
Liekki-päivä
Otaniemi 31 January 2007
2015
2020
2025
New
New R&D
R&D
activities
activities
14
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