1 Biomassasta ja jätteestä synteesikaasua - suomalainen ratkaisu liikenteen biopolttoaineille sekä kotimaahan että vientimarkkinoille Esa Kurkela, Pat McKeough & Pekka Simell VTT II LIEKKI-päivä 24.1.2006, Turku
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3 Tankkausta 2010-luvulla EU: 5,75 % biopolttoaineita 2010 jälkeen
4 Kaikki biomassat Kaasutuksen avulla konversio hyvällä hyötysuhteella Kaikki lopputuotteet
5 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Suomalaisen synteesikaasutusprosessin kehitys VTT kehittää toisen sukupolven kaasutusprosessia synteesikaasun valmistukseen biomassasta: leijukerroskaasutus, soveltuu lajalle polttoainepohjalle puupolttoaineet ja turve olki, ruokohelpi ja muut peltobiomassat kierrätyspolttoaineet innovatiivinen katalyyttinen kaasunpuhditus reformoidun tuotekaasun hienopuhdistus Yrityskumppanit: Foster-Wheeler, Neste Oil, Andritz ja Vapo, kokeellinen T&K yhdessä TKK:n kanssa T&K-hanke 2004-07: 4M, 500 kw prosessinkehityslaitteisto Otaniemessä Uuden kaasutusprosessin teollinen demonstrointi 2008 2010; 30-50 MW Tavoitteena kaupallinen kokoluokka 200-300 MW feed ; mieluiten integroituna energiaa kuluttavaan teollisuuteen, kuten paperitehtaaseen
6 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Peat from MoDo steam dryer HTW gasifier Steam SYNGAS FROM PEAT AND WOOD HTW-PLANT AT OULU KEMIRA AMMONIA PLANT, 120 MW fuel Peat crush moisture 15 % 10bar 750-950 C Waste heat boiler Benzene from naphthalene extraction Benzene scrubber Gas to amisol scrubber 1500 k mol/h 29 bar Steam Oxygen Recycle gas Water scrubber To naphthalene extraction Improvements to the process: Ash Pressurised steam/o 2 -blown gasifier Dust 1st generation technology was successfully demonstrated in late 1980 s (Oulu, Berrenrath) Single gasifier train 100-300 MW feasible Sludge separation Optimised gasifier design - fuel flexibility, high availability Reforming of hydrocarbons - high syngas yield - no tar-related problems - optimal H2/CO ratio - conventional final gas cleaning unit operations can be applied Advanced gas filtration, gas cooler design and ash oxidation
7 UCG-process development unit at VTT, 0.5 MW new innovative technology Fuel-Flexible Fluidised-Bed Gasification - steam/oxygen (indirect heating) Gas Cleaning - tar & hydrocarbon reforming - chlorine & metal removal & filtration - dirty shift Ultra Cleanup -sulphur, NH3, HCN, halides, etc. - conventional processes available, optimisation needed FT-diesel CH3OH Hydrogen SNG clean fuel gas to fuel cells Gasifier targets: - no ash-related problems - simple design and high reliability - high C-conversion to gas + tars - no need for tar decomposition - low oxygen consumption Gas cleaning targets: - complete tar and benzene decomposition - over 95 % methane reforming -H 2 /CO ratio suitable to FT-synthesis - reliable operation - minimum overall gas cleanup train costs
8 Fuel-Flexible Fluidised-Bed gasification Required feedstock basis - different wood residues - straw, other agricultural residues - energy crops and short rotation wood - MSW and other solid waste streams Industrial-scale experiences - pressurised gasification and filtration for IGCC; two processes were developed in 1990 s - wood & waste gasification in Lahti since 1998 - gasification of aluminium containing plastics in Varkaus since 2001 - pilot-scale R&D with different waste-derived feedstocks (gasification & gas cleaning) - in operation since 1998 - no commissioning problems - 35 000 operating hours - gasifier availability > 95 % - boiler emissions decreased - payback time ca. 8 years Main boiler 360 MW th Gasifier feed preparation CFB gasifier of 60MW
9 Catalytic gas treatment: recent developments at VTT Tar decomposition with nickel monolith - R&D at VTT since mid 1990 s - MW-scale demonstration at Kokemäki and Skive gas engine plants 2005-06 Tar decomposition by zirconia-based catalysts R&D since 2000 Selective oxidation of ammonia since 1990 s Catalytic reforming of natural gas and light fuel oil for SOFC, 2004 and Catalytic after burner for SOFC, 2005 New catalytic system for methane reforming and dirty shift conversion Tars CATALYST 500-900 C CO, CO2, H2, H2O N- compounds N2, H2, H2O Design basis for multifunctional catalytic cleanup process for the UCG-PDU plant
10 500 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 Oxygen Steam Air Nitrogen Bed removal Heating elements Ash removal FILTER Heating elements Furnace
11 VTT TECHNICAL RESEARCH CENTRE OF FINLAND UCG-prosessin teknistaloudelliset tarkastelut Eri prosessivaihtoehtojen ja lopputuoteiden hyötysuhteiden ja kustannusten alustava arviointi (2004) Kaasutusprosessin valinta (2004-05) toimintapaine happikaasutus vs. epäsuora höyrykaastus reformerin ja shift-reaktorn suorituskyvyn vaikutukset Kaasun loppupuhdistuksen merkitys (2004-05) Yksityiskohtainen prosessisuunnittelu ja kustannusten arviointi (2006) Ensimmäisen (30-50 MW) ja toisen (100-300 MW) demolaitoksen suunnittelu ja kustannusarvio (2006) Pulp & Paper Mill Biofuel production
VTT TECHNICAL PROCESSESRESEARCH CENTRE OF FINLAND 12 Basic Layout of Processes for Bio-Syngas Production and Conversion Biomass Gasification & Reforming HP Steam Gas Cleaning CO shift, CO 2 removal Gas Conditioning Possible synthesis loop Synthesis/ Separation MP/LP Steam Upgrading Off-gas Main Product CC, FCCC Applications 1 30 bar 1 30 bar 30 bar FT, SNG, H 2 : 20 30 bar CH 3 OH, DME: 100 bar 850 C 40-280 C (final) (IGCC: 500 C) 40-350 C (initial) FT, CH 3 OH, DME, SNG, H 2 /trad: 200 300 C H 2 /PSA: 40 C Abbreviations: CC Combined-Cycle energy production FCCC Fuel-Cell Combined-Cycle energy production FT Fischer-Tropsch liquid fuels SNG Synthetic Natural Gas (CH 4 ) DME Di-Methyl Ether H 2 /trad Traditional process for H 2 production from syngas H 2 /PSA H 2 production based on separation by Pressure Swing Absorption
13 Modelling of Bio-Syngas Conversion Applications Examined and their Abbreviations FT: FT/R: CH 3 OH: Fischer-Tropsch primary liquids (C 5+ ); once-through Fischer-Tropsch primary liquids (C 5+ ); with reforming loop Methanol; high-conversion gas-phase synthesis SNG: Synthetic natural gas; mainly CH 4 ; H 2 (e.g. 2 vol. %) and inerts (e.g. 1 vol. %) also present; delivered at 30 bar H 2 /trad: H 2 /PSA: Hydrogen via traditional method; CH 4 (e.g. 2 vol. %) and inerts (e.g. 1 vol. %) also present; delivered at 30 bar Hydrogen via separation by Pressure Swing Adsorption; high-purity; delivered at 30 bar
14 Modelling of Biosyngas Conversion Comparisons of Efficiencies of Base Cases LHV-Efficiency for Main Product, % 100 90 80 70 60 50 40 30 20 10 0 FT FT/R CH3OH SNG H2/trad H2/PSA FT: Fischer-Tropsch primary liquids, once-through process with reasonably high once-through performance FT/R: process with reforming loop; same once-through FT performance
15 Benefits of Integration with Energy Consumer Overall Efficiencies for Different Applications (Base Cases) LHV-Efficiency, % 100 90 80 70 60 50 40 30 20 10 0 to main product to main product, offgas and steam FT FT/R CH3OH SNG H2/trad H2/PSA Note: steam = HP and LP steam produced in gas cooling and MP/LP steam produced in synthesis/shift. Conclusion: overall efficiency of FT is exceptionally high (heat of condensation of product liquids and heat of condensation of part of product H 2 O recovered as LP steam) while overall efficiency of methanol is lower. Benefits of integration will vary accordingly.
16 Typical Investment Breakdown Capacity: about 300 MW input 67 % 33 % Pretreatment Gasification Reforming Gas cleaning O 2 plant In addition: Gas conditioning Synthesis Upgrading +10 % to +30 % Energy production
17 Modelling of Bio-Syngas Conversion Important Bases of the Cost Estimates Capacity of plant: 300 MW of feedstock (LHV basis) Annual operating time: 8000 h/a Interest on capital: 10 % for 20a O&M costs: 4 % of investment Base values for purchased/sold energy (other values applied in sensitivity cases): feedstock: 10 EUR/MWh (LHV) electricity: 30 EUR/MWh e HP steam: 16 EUR/MWh of transferred heat MP and LP steam: 13 EUR/MWh of transferred heat fuel gas: 14 EUR/MWh (LHV)
18 Modelling of Bio-Syngas Conversion Comparison of Costs; Effect of Feedstock Price Current refinery-gate price for gasoline, diesel (excl. distribution and taxes) Production costs, EUR/GJ 22 20 18 16 14 12 10 8 6 4 2 0 FT FT/R CH3OH SNG H2/trad H2/PSA Feed 0 EUR/MWh Feed 5 EUR/MWh Feed 10 EUR/MWh Feed 15 EUR/MWh Feed 20 EUR/MWh
Synthesis gas from biomass to liquid biofuels, hydrogen, synthetic methane and chemicals - liquid biofuels or H 2 in medium-to-large scale plants 19 Other pilot/demo plants Berrenrath, Hawai, Studsvik, Vermonth, Gussing HTW plant in Oulu Air-blown biomass & waste gasifiers Demonstration 100-200 MW Biorefineries at pulp and paper mills or at oil refineries fluid-bed gasifiers 100-400 MW Hydrogen technologies 1985 1995 2000 2005 2010 2015 2020 2025 2030 Synthesis gas R&Din 1980 s Sweden, Germany; USA, Finland Catalytic reforming know-how VTT-UCG Optimised syngas R&D PDU-scale Development Industrial demontsr. Waste-to synfuel R&D R&D on Hydrogen technologies
Paperitehtaasta puunjalostamoksi 20 Paperi sellu Prosessihöyry ja sähkö Voimalaitos Sellu- ja paperitehdas Kuivausenergia Kaasutus ja kaasunpuhdistus polttokaasua + höyryä Puu, peltobiomassat ja kierrätyspolttoaineet Biomassan käsittely ja kuivaus kuori, metsätähteet muu biomassa happi + höyry synteesi -kaasu FT-synteesilaitos PuuDiesel
Theoretical Potential in European Forest Industry Platforms - 100 sites out of 1300 mills - for IGCC plants: 4 000 MW e ~ 33 TWh e /a of additional electricity from 4500 MW (37 TWh/a) ~ 3 Mtoe/a of solid biomass residues for FT-liquids plants: 14 500 MW (120 TWh/a ~ 11 Mtoe/a) of FT liquids from 18 000 MW (150 TWh/a) ~ 14 Mtoe/a of solid biomass residues Forest residues would be available, < 20 /MWh price, up to 6 10 Mtoe/a. Solid recovered fuels (SRF) and straw/annual crops should be supplementary fuels The forest industry platform offers up to 20 30 % lower production cost than in traditional stand alone option. The EU biofuel demand in 2010 is 18 Mtoe/a according to the Biofuel Directive - total investment ~ 25 Billion and - 8 Billion /a motor fuel market on biofuels by: Sipilä, VTT Clean World 27.10.2005
22 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Yhteenveto ja johtopäätökset Kaasutustekniikalla keskeisen tärkeä merkitys uusissa energiajärjestelmissä halvan öljyn aikakauden jälkeen Suomalaisella biomassan ja jätteiden kaasutustekniikalla hyvät mahdollisuudet saavuttaa huomattavia markkinaosuuksia Paineistettu leijukerroskaasutus ja hiilivetyjen katalyyttinen reformointi valittu suomalaisen synteesikaasuprosessin perustaksi Uusi prosessi kehitetään ja testataan vuosina 2005-07 VTT:n 500 kw:n PDU-laitoksella Uuden prosessin teollinen demonstrointi noin 50 MW:n kokoluokassa energian tuotantosovelluksessa (esim. paperi & sellutehdasympäristössä tai öljynjalostamolla) 2008-10 Kaupallinen tuotanto näyttäisi erittäin kilpailukykyiseltä muihin Euroopassa kehitettäviin vaihtoehtoihin verrattuna kokoluokassa 150-300 MW ensimmäiset laitokset 2012-15 Vuoden 2006 aikana haetaan sopivat kohteet ensimmäiselle ja toiselle demolaitokselle edettävä ripeästi ja määrätietoisesti jotta kiritään saksalaisten ja ruotsalaisten edelle!
23 VTT TECHNICAL RESEARCH CENTRE OF FINLAND Kiitos kuulijoille! ja UCG-projektin rahoittajille ja yhteistyötahoille VTT:n Puhdas Maailma teema Tekes ClimBus-ohjelma Teknillinen korkeakoulu Neste Oil Oyj Foster Wheeler Energia Oy Andritz Oy Vapo Oy