Uusien liikenteen biopolttoaineteknologioiden kehitys Biorefine Loppuseminaari - innovaatioita ja liiketoimintaa Helsinki, 27.11.2012 Esa Kurkela
2 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
3 2G-Biofuels 2020 Project budget 7.3 M in 2012 14; second piloting phase in 2015 17 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) and simplified process schemes Syntheses 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 Industrial partners: Andritz-Carbona, Foster Wheeler, Metso, UPM- Kymmene, NSE Biofuels, Fortum. Main financier: Tekes
4 Detailed Techno-Economic Assessment of different processes O 2 -steam gasification, cost status of 2010 (results to be published in VTT Report by Hannula & Kurkela in early 2013) Biomass DRYING GASIFICATION REFORMING HP Steam Filtration Tar removal Scrubbing INITIAL GAS CLEANING CO shift, H 2 S removal CO 2 removal FINAL GAS CLEANING AND CONDITIONING MP Steam SYNTHESIS/ UPGRADING Off-gas Heat Steam + O 2 Steam Main Product Typical pressures 1-30 bar 30 bar 30-200 bar Main variables of the study Fuel input to the plant 300 MW in all 28 different cases Belt dryer with 20 % low-temp heat + 80 % hot water at 90 o C O 2 /steam gasification at 5 bar / 22 bar, filtration at 550 o C / 850 o C Synthesis alternatives: FT, methanol, DME, gasoline, ethanol, SNG-LT, SNG-HT Condensing steam cycle / district heat or industrial steam by back-pressure turbine Rectisol + guard beds in all cases as final gas cleaning
5 Arvioidut biomassan käytön hyötysuhteet Kuivurille tulevan puun syöttö 300 MW (LHV) CFB-kaasutus 5 bar, kuumasuodatus, tervojen ja metaanin reformointi Efficiency, % of Biomass feed (LHV)
6 mature technology no investment support no CO 2 credits no tax assumptions Gasoline @150$/bbl Before tax, incl. refining margin Gasoline @100$/bbl 5 bar / 550 o C Condensing steam cycle 5 bar / 550 o C District heat production 5 bar / 850 o C District heat production
7 Sec oxygen Biomass HIGH PRESSURE GASIFICATION OPTIONS 4-25 bar 850 o C Cooling or Pretreatment before filtration? High temp filtration Process improvements Increased pressure Increased filter temperature O 2 /air/ steam Improved Tar & methane reforming Lower cost acid gas removal Improved or simplified synthesis Additional feed gases Gas out 700-900 o C Gas to reformer 550-850 o C Staged reformer HT-Shift Fuel gas for energy production Transportation fuels SYNTHESIS FOR 200 MW SCALE FINAL GAS CLEANUP O 2 +H 2 O+ recycle gases
8 300 kw PDU-laitteisto on rakenteilla VTT:llä käyttöönotto keväällä 2013
9 Production of Biomass-Derived Synthesis Gas Initial step - two main approaches Main technical challenge: reforming of gas Biomass GASIFIER e.g. 850 ºC REFORMER 900 ºC catalytic Raw synthesis gas to cooling, clean-up and conditioning Typically: fluidised-bed gasifier, either oxygen-blown or indirectly heated Main technical challenge: prehandling, feeding of biomass Biomass BIOMASS PRE- TREATMENT Dry Pulver or Pyrolysis oil GASIFIER 1300 ºC + Raw synthesis gas to cooling, clean-up and conditioning Typically: oxygen-blown entrained-flow gasifier
10 JOHTOPÄÄTÖKSET Puun paineistettuun happikaasutukseen perustuva liikenteen polttonesteiden tuotantoprosessi on kehitetty valmiiksi kaupallista demonstrointia varten FT-dieselin ohella voidaan valmistaa metanolia, bensiiniä, DME:tä, metaania tai vetyä valmiit polttoaineet diesel ja bensiini kalleimmat mutta eivät vaadi jatkojalostusta tai omaa logistiikkaa Ensimmäisten tuotantomittakaavan laitosten talous on haasteellista monenlaista tukea tarvitaan Kypsän teknologian kannattavuuden edellytykset ovat melko hyvät ja julkisen tuen tarve kohtuullinen Jatkokehityksellä voidaan parantaa kokonaishyötysuhdetta, alentaa kustannuksia sekä toteuttaa laitokset hieman pienemmässä kokoluokassa tehokkaasti lämpöintegroituina Suomalaisen teknologian vientimahdollisuudet ovat merkittävät kunhan teknologian demonstrointi pystytään toteuttamaan