Alternative Heating Oil from Wood Residues - Industrial · PDF file ·...

Alternative Heating Oil from Wood Residues -

Industrial Demonstration

Reyhaneh Shenassa, Metso Power

Joakim Autio, Metso Power

Jukka Heiskanen, Fortum Power & Heat

tcbiomass2013, Chicago

© Metso

Presentation Outline

Company presentation - Biotechnology overview in Metso

The first integrated pyrolysis plant - Project development

- Process overview

- New analytical equipment for conversion processes

- Demonstration project status

2

© Metso

Sustainable technologies and services for the process industries

Metso’s key features:

• Customer industries include mining,

construction, pulp and paper, power, oil and

gas

• Global player with leading market positions

in its businesses

• Strong presence in the fast-growing

emerging markets

• Large installed base

• Strong focus on environmental solutions

and sustainable technologies

• Emphasis on implementing strategic

approach to sustainability

3

Net sales in 2012

EUR 7.5 billion

Services

44% of net sales

© Metso

Pulp, Paper and Power

At Metso, biorefining means the

sustainable processing of biomass into

marketable products, such as pulp, paper,

heat, power, fuels, chemicals and

materials.

• Extensive experience in processing

various kinds of biomass into recyclable

products and energy

• Our offering covers the entire life cycle

of biorefining processes, including new

installations, rebuilds and services

• Strong local presence at customer

sites, backed up by a global network of

experts

4

More value from biomass with Metso’s biorefining technologies

Metso’s PPP in 2012

• Net sales: 3,014 Me

• Orders received: 2,434 Me

• Personnel: 12 440

© Metso

Power industry – our eco-efficient solutions

• Fluidized bed and biomass boilers

• Biograte combustion systems

• Waste-to-energy solutions

• Multifuel combustion systems

• Gasification and pyrolysis solutions

• Flue gas cleaning systems

• Process automation solutions

5

FACT: Automated by Metso, the UK’s largest energy-from-waste plant will process on average 585,000 t/a of municipal and commercial waste generating 72 MW electricity

FACT: A brown-coal-fired power plant

converted to biomass technology by Metso

reduced their carbon footprint by 200,000 t,

SO2 emissions by 2,500 t and NOx

emissions by 200 t annually

© Metso

Metso develops new bioenergy solutions

6

heat

steam Combustion

electricity

waste

wood

peat

fossil

agro

2010

heat

steam

Bio gas

Bio oil

Bio coal

Lignin

New bio

products

Gasification

Pyrolysis

Steam explosion

Lignoboost

Combustion F

ue

l h

an

dlin

g

and pre

-pro

cessin

g

electricity agro

waste

wood

peat

fossil

2020

© Metso

Frontrunner in new conversion technologies

• Gasification

- Lahti Energy: CFB gasifier for waste

- GoBiGas: syngas gasifier for

biomass

- Vaskiluodon Voima: CFB gasifier for

biomass

• Pyrolysis

- Pilot at Metso R&D Center

- Fortum, Joensuu demonstration

plant start-up in fall 2013

• Bio-coal

- Steam explosion technology

- Commercially available

7

© Metso

Pyrolysis Integrated pyrolysis project development

• Metso, UPM, Fortum and VTT have developed a

biomass-based bio-oil production concept to provide

an alternative to fossil fuels

• Integrated fast pyrolysis process is identified as an

economically viable liquid biofuel concept to

reduce CO2-emissions in several different studies

• Pilot equipment operational since 2009

• Support from Tekes Biorefine-program

• Demonstration plant project ongoing

8

© Metso

Integrated pyrolysis Cost efficient bio-oil production concept

• Integrated pyrolysis process =

pyrolysis process + fluidized bed boiler

- Boiler bed material used as heat source

- Residual matter from pyrolysis process is

combusted in the boiler

• Contributing to electricity, steam and

DH production

- Simultaneous heat, power & bio-oil

production building the basis of feasible

operation

- Waste heat utilization for feedstock drying

9

0 %

100 %

Wood Liquid Char Gas

© Metso

Pyrolysis pilot unit

10

• In operation since 2009

• Production exceeds 100 tons

• Feedstocks:

- Sawdust

- Forest residues

- Crushed pellets

© Metso

35

40

45

50

55

60

65

70

75

70 75 80 85 90

Volatiles wt%

Org

an

ic y

ield

wt%

PDU Brown

PDU GreenPDU Sawdust

Pilot FR1

Pilot pine 1

Pilot pine 2Pilot FR 2

Pilot pine 3

Organic Yield Metso pilot / PDU (VTT)

11

© Metso

Pyrolysis oil utilization

• Testing at Fortum’s district

heating plant in Masala,

Finland

• Modified for pyrolysis oil

combustion by replacing the

1,5 MW burner

• Over 40 tons of pyrolysis oil

has been combusted

successfully

12

© Metso

First integrated pyrolysis plant being built Fortum, Joensuu

13

• Feedstock: woodchips, forest residues,

sawdust

• Annual production 50 000 tons pyrolysis oil

• Helps reduce CO2 emissions by 59,000

tons per year

• Reduces sulphur emission by 320 tons per

year

• Turnkey delivery by Metso, start-up in

autumn 2013

© Metso

Pyrolysis oil production technology

14

Metso DNA automation system High pressure steam Turbine

Electricity

Non-condensible gas

District heat

Condenser Crusher

Drying

Sand and

coke 500 ºC

Sand

800 ºC

Forest residue

Fluidized bed boiler Pyrolyzer Bio-oil

© Metso

Main Issues in Pyrolysis Oil Production

• The most important challenge is to make pyrolysis oil production

competitive in combustion applications

• Operating in the margin between the price of the reference fuel and

the price of the feedstock

• Reduce both CAPEX and OPEX

• Process integrations through the whole value-chain

• Maximize pyrolysis oil yield

• Maximize energy recovery

• Primary emissions and emission control of pyrolysis oil

combustion

© Metso

Feedstock Processing

© Metso

Challenges Associated with the Feedstock Processing

• Quality control of the feedstock procurement

• Several different suppliers - quality control

• Sustainability issues (EU) – traceability of feedstock

• Cost of feedstock

• Demanding and energy consuming requirements for pyrolysis inputs

• Low moisture content and very small particle size

• Cost competitive fuel processing including transportation

• Where are the best preconditions for the processing?

• Process integrations to maximize energy efficiency (for example

utilization of secondary process heats for drying in pulp mill)

© Metso

Water Content Product water content vs. feedstock moisture

18

4

6

8

10

12

14

20

25

30

35

40

45

Fee

d m

ois

ture

wt-

%

Pro

du

ct

mo

istu

re w

t-%

Product Feed

New analytical equipment for conversion processes

Feedstock moisture

19

© Metso

• Metso MR Moisture is a compact

and mobile unit that is setting the

new standard for efficiency, ease

and reliability in moisture analysis

• The Magnetic Resonance (MR)

technology combined with a

compact design mean that you can

now get laboratory-quality results in

field conditions

• Water content is analyzed through

the MR-signal induced by water

molecule hydrogen atoms placed in

magnetic fields

Metso MR Moisture for feedstock moisture analysis

20

© Metso

Metso MR Moisture

Results are reported

as moisture or solid

content

• It’s fast

- Measuring time 30 sec. ~ 2 min.

- Plug-and-play setup

- No transportation of samples from source to laboratory

• It’s reliable

- +/- 1 moisture % measuring accuracy with 10-90% range. ≥ 20 g (0.7 oz) of water in sample

- Reliable calibration with water

- Challenges oven drying method in accuracy, sample volume and speed

• It’s easy to use

- Insert sample in provided container

- Easy touch-screen user interface

- Low maintenance – no moving or wearing parts

- Ethernet Modbus to DCS or plant systems

- Plug and play integration to Metso DNA Fuel Data Manager

21 © Metso

© Metso

Metso MR Moisture Accuracy

22

Metso MR Moisture Analyzer vs. oven dry method; wood based fuels

4.0

12.0

20.0

28.0

36.0

44.0

52.0

60.0

68.0

76.0

4.0 12.0 20.0 28.0 36.0 44.0 52.0 60.0 68.0 76.0

Oven dry method moisture reading (m-%)

MR

mo

istu

re r

ea

din

g (

m-%

)

MR-reading, 3 measurements averaged Optimum response

Fuels:

-Sawdust (n=12)

-Pine bark (n=3)

-Wood chips (n=15)

-Shavings (n=7)

-Recycled wood (n=5)

-Pellets (n=18)

© Metso

Pyrolysis Oil Production

© Metso

How to Make Pyrolysis Oil Production Feasible?

• It is not all about maximizing

the pyrolysis oil production, as

significant amount of by-

products are produced in any

case

• Utilisation of these by-products

is therefore also as critical

0.0

0.5

1.0

1.5

2.0

kg

/s

Conversion of Carbon in Non-Catalytic Pyrolysis45 MW of Wood

© Metso

Challenges Associated with the Production of Pyrolysis Oil

• Production of relatively homogenous feed to pyrolysis reactor (particle

size, moisture)

• Plugging of process parts

• Online cleaning methods

• Reducing the amount of solids in the oil (especially the ash)

• Design of systems and separation devices

• Permitting, lack of standards and specifications, HSE-issues

• The oil classification has an effect on almost everything

• New process and new people → extra care is needed

• Expensive materials needed for condenser, oil piping and oil tank

• Cost effective materials, coatings

© Metso

Challenges Associated with Combustion

• Cost-efficient combustion concept

• Everything from the storage and piping to the gaskets and

burner needs to be designed to fit the purpose

• Primary emissions and emission control concepts (especially

for particulates)

• Importance of feedstock quality

• Incombustible material should be minimized

• Pre-heating of pyrolysis oil is needed (just like HFO)

• Design of burner system if many different fuels are used

• Support fuel for pyrolysis oil firing is not necessary

• Continuous 100 % pyrolysis oil combustion tested in Masala,

Finland (even unmanned)

© Metso

Burner systems for pyrolysis oil

• Metso has developed and optimized burner

types especially for pyrolysis oil

• Pyrolysis oil atomization and flame differs

from that of HFO

• Burners need fixed ignition point and stable

flame root for reliable flame monitoring

• The whole end use chain from tank to

stack can be quoted

• CASE JOENSUU

• BFB boiler and a multifuel burner, 8 MW

• Pyrolysis oil, - gas, landfill gas and bioslurry

• Special Metso model multifuel bio burner

with all fuels in one burner

27

A partner’s view Fortum’s background for the bio-oil project

© Metso

New CHP+ concepts (Combined Heat and Power) Integrated production adding value

Key rationale and potential

• CHP is the most efficient way for converting fuels to power and heat

• CHP enables utilization of variety of different fuels, waste and industrial side products

• Stable heat loads enabling better utilization of assets

• New business through wider product range; new products in addition to electricity, heat and cooling

• New sustainable solutions for decreasing emissions by replacing fossil fuels and further improving energy efficiency

29

© Metso

The production and usage of bio oil is one route to low-carbon energy production

Bio-oil production integrated with electricity and heat production is not only highly energy

efficient but also a progressive alternative because of its investment and operating costs

Fuels of the power plant =

the raw materials of bio-oil

CHP plant

• electricity production

• heat production

• bio-oil production

Final consumption

of bio-oil

Low-carbon production

of heat and steam

30

A new chapter opens As of January 2014, Metso’s Pulp, Paper

and Power business will serve its’ customers

as an independent, listed company,

Valmet corporation*

*pending Metso EGM approval

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