Kaasutustekniikkaan perustuva liikennepolttoaineiden valmistus METLA VTT tutkimusohjelman seminaari Espoo 4.6.2012 Esa Kurkela, VTT
2 Polttokaasua suoraan energiantuotantoon ja synteesikaasua polttoaineitten ja kemikaalien valmistukseen
3 Ilmanpaineinen leijukerroskaasutus voimalaitosten ja teollisuuden uunien yhteydessä - kaupallista teknologiaa, Suomessa kolme laitetoimittajaa -Lahti in operation 1: Connected since to 1998 PC-boiler - no in operation commissioning since 1998 problems - 50 high 000 fuel operating flexibilityhours - gasifier availability > 95 % - boiler emissions decreased - payback time ca. 8 years Main boiler 360 MW th Joutseno, CFB gasifier 48 MWth Connected to lime kiln Under construction From: Andritz Gasifier feed preparation CFB gasifier of 60MW New industrial CFB gasification plants constructed in 2011-12 two new gasifiers (2x80 MW) at Lahti waste-to-energy plant (supplier: Metso) one large gasifier (140 MW) in Vaasa (supplier: Metso) lime kiln gasifier (48 MW) at Joutseno (supplier Andritz) lime kiln gasifier (12 MW) at Varkaus was returned to air-blown operation mode after succesfull O 2 -blown test campaigns for Neste Oil and Stora Enso (Foster Wheeler)
4 Syngas Route to Biofuels Integrated Concept studied at VTT s UCG-project in 2004-07 VTT PDU Paper or pulp Process steam & power power plant Pulp and paper mill Energy to drying Gasification and gas treatment fuel gas + steam 50-150 MW Industrial Demo at Varkaus Forestry residues, mill residues, straw, energy crops, urban biowaste Biomass handling and drying 150-300 MW bark, forestry residues, other biomass steam & oxygen synthesis -gas Synthesis & upgrading 75-160 MW Hydrocarbon fuels (FT) or methanol, DME, SNG, H 2, etc. GTI Pilot
5 Suomesta kolmen konsortion NER-300 hakemukset puupohjaisen FT-dieselin tuotantolaitoksiksi Three consortiums are presently planning second-generation BTL biorefineries in Finland The planned capacities are 100 000 200 000 ton/a of diesel EU s NER300 funding has been applied - decisions expected at the end of 2012 Overall investment costs in order of 400-800 million? Complicated process concept Very large-scale is needed to achieve positive economics First plants will be more expensive than mature technology
6 Production of Transportation Fuels from Biomass 2G-Biofuels 2020 Project - 2012-14 Pilot-scale development of new innovative processes for improved efficiency and lower production costs Gasification-based systems Optimized high-pressure steam-oxygen gasification process aiming to improved fuel-to-syngas conversion efficiency and to wider feedstock basis (above 200 MW scale) Indirectly heated gasification for smaller size range (50-200 MW) Syntheses/catalysts with less stringent gas purity requirements compared with present processes Alternatives based on pyrolysis technology Pyrolysis oil production integrated to CHP Catalytic pyrolysis to improve oil quality Upgrading of pyrolysis oil for transportation fuels Co-production of fuels, heat and electricity integration to forest industries and district heating => high overall efficiency Total budget 7.3 M in 2012 14; second phase in 2015 17 Industrial partners: Andritz-Carbona, Foster Wheeler, Metso, UPM- Kymmene, NSE Biofuels, Fortum
7 Kaasutussovellusten asettamat polttoainevaatimukset Biomassojen laatuvaatimukset erilaisia eri sovelluksissa CFB kaasuttimet kattilakäytössä (Vaasa,Lahti) soveltuvat laajalle polttoainekirjolle BTL-sovellusten happi-höyrykaasutusprosessit hieman herkempiä - Tuhkan sulaminen, tervan muodostus - Paineellinen syöttö asettaa vaatimuksia palakoolle ym. BTL-sovellusten erityispiirteitä Laitoskoko erittäin suuri 300-400 MW vastaten yli 1 milj. m3, vuosi Kestävyyskriteerit tärkeitä Laaja polttoainekirjo: tehtaan sivutuotteet, metsätähteet, ensiharvennuspuu, agrobiomassat ja jätepolttoaineet? Metsäbiomassojen hankintaketjut tärkeitä logistiikkakulut korkeita Raaka-aine kuivataan alle 20 %:n loppukosteuteeen Tuhkan kierrätys ja muu loppukäyttöä tärkeitä Pääosa puun kaliumista ja kalsiumista päätyy lentotuhkaan ja karkea kiviaines pohjatuhkaan Lentotuhka sisältää reagoimatonta hiiltä tyypillisesti 20-40 %
Nopean pyrolyysin demonstrointi integrointuna Fortumin Joensuun lämpövoimalaan ForestEnergy2020 tutkimusohjelman tutkijaseminaari 4.6.2012 Espoo Yrjö Solantausta VTT
9 15.5.2012-9 Why Fast Pyrolysis Production Feasible at relatively small scale High yield of bio fuel oil from biomass Transport, storage Fluid product for logistics Energy density Challenging properties Utilisation Good control of feed/injection 20 to reach low emissions 15 At existing units Potential for upgrading to higher value products Energy Density MJ/l 40 35 30 25 10 5 0 LFO Bio-oil Wood pellets Wood chips
Development of Fast Pyrolysis Bio Oil Production Capacity MW 30 Envergent Fortum 10 Ensyn BTG BTG 1-5 Ensyn/ENEL UEF Fortum - Vapo FZK / KIT BTG Metso 0.1 Ensyn and others University of Waterloo and others 0.0005 University of Waterloo and others 1980 2000 2010 2020 15.5.2012-10 VTT experimental
11 VTT Has Participated into Operation of Four Different Fast Pyrolysis Pilot Plants During 1994-2012 WFPP - Union Fenosa, Spain, 1990 s Ensyn - ENEL, Italy, 1990 s Forestera Fortum, Finland, 2000 ITP - Metso, UPM, Fortum, Finland, 2009->
12 Fortum Joensuu: an Integrated Bio-Oil Demonstration Plant Bio-oil capacity 30 MW Annual production 50 000 t, 210 GWh Start-up 2013 Feedstock Forest residues, sawdust Reactor and pyrolysis oil recovery inside the boiler building Fuel receiving, drying and crushing Bio-oil tanks Source:
13 The Integrated Pyrolysis VTT Technology Heat and Power Fluid bed boiler Flue gases Fast pyrolysis Boiler fuel Pyrolysis fuel Sand + char Hot sand Bio oil
14 100 % Bio-Oil Combustion
Acknowledgements Kai Sipilä Anja Oasmaa Jani Lehto Eeva Kuoppala Kristian Lindfors Jaana Korhonen Matti Reinikainen Ville Paasikallio Sampo Ratinen Jouko Kukkonen Anssi Källi Pekka Saarimäki