NSE Biofuels Oy
Wood Based BTL Diesel Development
2007 – 2011
IEA Workshop, Piteå 19.10.2011
Veikko Jokela, Stora Enso Oyj
NSE
NSE Biofuels Oy
y
50%/50% JV owned by
y Neste Oil Oyj
yj and Stora Enso Oyj
yj
Current business is to produce syngas from woody biomasses to
b used
be
d as ffuell iin St
Stora E
Enso V
Varkaus
k
pulp
l mill’s
ill’ lilime kil
kiln
Vehicle and test platform for owners’
owners BTL (Biomass
(Biomass-to-Liquids)
to Liquids)
development (NOSE- project)
Future goal is implementation of first commercial BTL plant and
further develop profitable businesses based on experiences of it
and on market demands
NSE
15.10.2011
V Jokela
2
Backbone of NSE BTL concept
p
•
Combined competencies
p
of two different industries:
•
•
•
•
•
•
•
Forest industry has strong raw material supply and logistics know how
Oil refining has process, product and distribution know how
Forest based feed stock
stock, the technical concept allows high
tolerance on varying biomass properties
FT wax offers extension in renewable feed stock base for high
quality traffic fuels outside food supply chain
Efficient energy integration with host plant
More than 85 % GHG savings compared to fossil traffic fuel
New, potential business area for forest industry
NSE
15.10.2011
V Jokela
3
Simplified Process Block Diagram for Production of BTL fuels
Stora Enso
NSE Biofuels Oy
2
Neste Oil
Energy
Integration
to host plant
1
Biomass,
Forest residue
1,8 Mm3/a
3
Drying
Gasification
Reforming
&
Gas
wash
Fischer
145 000
–
t/a
Tropsch
4
Refinery
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15.10.2011
V Jokela
4
Renewable
Fuels
NOSE Project Objectives
To develop and verify BTL technology based on biomass
gasification route
To provide the overall commercial technology concept
To evaluate the techno-economic
techno economic feasibility of the
production concept
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15.10.2011
V Jokela
5
Stepwise BTL concept development
Key technical challenges: Purification of biomass based syngas and
catalyst life time.
2007-2011
Pilot trials in
VTT PDU
0,5 MW
Pressurized
steam/oxygen
gasification and
reforming
2009-2011
Varkaus
Scale-up;
engineering
Test plant
experiences
12/5 MW
Atmospheric
CFB gasifier
modeling
ca. 500 MW
ca. 1
ca
1,8
8 Mm3
biomass
Pressurized
system
Steam/oxygen
gasification
ifi i
145000 t/a wax
Reforming
Strong
gasification
know-how at
VTT
2011
Commercial BTL
concept
ca. 1,0 TWh
surplus heat
Gas washing
FT unit
Licensors’ know-how
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15.10.2011
V Jokela
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NSE Biofuels Oy’s current business at Stora
Enso Varkaus p
pulp
p mill
NSE Biofuels Oy’s
Oy s business
Supplies
Silos and
fuel crushing
Forest
biomass
Drying
Syn gas
Gasifier
12 MW
Boiler
K6
Steam
NSE
Lime kiln
NSE Biofuels and integrated test platform
NSE Biofuels Oy’s
Oy s business
Supplies
Raw syngas
Silos and
fuel crushing
Gasifier O2/
12 MW steam
FT unit
Forest
biomass
Drying
Boiler
K6
Final cleaning
Steam
Supplies
5 MW test plant
Heat to
saw mill
R&D project
NSE
Lime kiln
Development
p
partners
p
Research & piloting partner
Gasification supplier
P
Process
engineering
i
i
Feedstock procurement
Sustainability
Upgrading,
pg
g, distribution
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15.10.2011
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Typical
yp
feed stock
Origin
g
%
Chips from
gg g residues
logging
Tree branches and tops from final
cutting areas
40-50
Energy wood
chips
Small-dimension roundwood from
pre-commercial and first
commercial thinning wood
30-40
Bark and
sawdust
Residues from traditional forest
industry
10-20
The forest chips containing a lot of inorganic material (ash, alkali metals
and sulphur) are setting the design criteria for the gasifier and
downstream gas cleaning process
NSE
15.10.2011
V Jokela
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Examples
p
of typical
yp
feed stock
Energy wood chips
chips, 1
Logging residues
residues, mainly fresh
Logging residues, rotten
Energy wood chips 2
NSE
CFB steam/ oxygen gasification at Varkaus
t t plant
test
l t
•
•
•
•
•
•
Gasification temp.:
Bed material:
Oxygen/steam:
Pressure
Secondary gas:
Gas flow to slip stream
•
Typical raw gas composition:
CO
14 %
CO2
19 %
H2
18 %
CH4
5%
H 2O
34 %
H 2S
120-200 pp
ppm
870 - 890 °C
Blend of limestone and sand
O2 40 - 50 %
atmospheric
p
Steam
0,4 – 0,6 kg/s
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Syngas
y g cleaning,
g, key
y to success
Some highlights:
g g
•
•
•
•
•
•
Several innovative process steps and sections
New catalyst technology for catalytic reforming of heavy
hydrocarbons e.g. tars developed with VTT
Removal of some specific organic trace compounds in syngas
COS and HCN conversion catalytically
Removal of CO2 and H2S in a unique combined process
section
After final polishing H2S content is below 10 ppb
NSE
15.10.2011
V Jokela
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Fischer-Tropsh synthesis: old invention –
new application
Varkaus test plant has on
on-line
line FT unit allowing
long term testing activities.
High quality FT wax based on bio syngas has
been produced with good success
Both slurry and fixed bed technologies has been
evaluated for commercial BTL plant.
valoKuva
vahasta
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15.10.2011
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Readiness to start Basic Engineering is
achieved
hi
d
Commercial BTL process is modelled and
the key operational parameters have been
estimated
ti t d and
d verified.
ifi d
Technical concept is based on both NSE’s
NSE s
own and licensors’ technology.
Profitability analysis including CAPEX,
OPEX estimates is ready.
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15.10.2011
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Current status
Trials completed in Varkaus test plant at the end of August 2011.
Developed BTL- technology works and the life time of catalysts is long
enough for industrial use.
EIAs of commercial BTL plant have been completed at two potential
sites: Neste Oil Porvoo oil refinery and Stora Enso Imatra pulp and
board mill integrate.
integrate
Decision to start Basic Engineering is waiting for the outcome of NER
300 ffunding
di application,
li ti
expected
t d iin Q3
Q3-Q4/2012.
Q4/2012
To meet the p
profitability
y targets
g
of commercial BTL p
plant is a challence.
Biomass dryer and air-blown CFB- gasifier continue production of raw
syngas for mill’s
mill s lime kiln.
kiln
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15.10.2011
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Raw syngas
y g in the lime kiln to replace
p
HFO
PROS
pulp
p making
g
Lower CO2 emissions in p
Lower NOx, dust and TRS emissions
Less rings in the lime kiln ?
CONS
Tendency to dust fires in the dry fuel line just before the gasifier
High focus on safety issues, more tedious to operate
Kil capacity
Kiln
it iis sensitive
iti to
t biomass
bi
moisture,
i t
20
20-25%
25% iis ttoo much
h
Lower flame radiation decreases slightly kiln capacity
SOME REMARKS
NPE management and quality of reburned lime unaffected
Easy and flexible change of fuels
H d tto meett profitability
Hard
fit bilit due
d to
t narrow market
k t price
i difference
diff
between biomass and HFO
Biomass dryer and gasifier rather heavy investment
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15.10.2011
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Biomass-to-Liquids renewable diesel
NSE Biofuels Oy
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