Biomass to motor fuels over the black liquor route. · • Existing plant-internal liquid biomass...
Transcript of Biomass to motor fuels over the black liquor route. · • Existing plant-internal liquid biomass...
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CHEMREC Energy to Succeed
Biomass to motor fuels over the black liquor route. Status and requirements for demonstration Patrik Löwnertz 2009-01-22
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CHEMREC Energy to Succeed
Pulp mill integrated process with biomass feedstock swap • Existing plant-internal liquid biomass stream (black liquor) is
used as motor fuels plant gasification feedstock • Steam generation from biomass is used to make up energy
content of produced biofuel
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Biomass boiler
Motor fuels plant
Pulp mill
Biomass Steam and power
Black liquor
Motor fuel
Steam Green liquor Power
Pulp wood
Cellulose pulp
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CHEMREC Energy to Succeed
Black liquor is liquid biomass with properties uniquely suitable for gasification • It is a liquid
– Easy to feed to a pressurized gasifier – Can be atomized to fine droplets for rapid
gasification rates
• It is highly reactive due to high Na/K content Gasification in an entrained flow high-temperature mode can then give – Full carbon conversion – No tar formation – Low methane formation – Small reactor volume (~25 m3/1000 t BLS/d) – Simple gas clean-up
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CHEMREC Energy to Succeed
Feedstock swap gives full biomass feedstock flexibility • Any biomass that can be beneficially burned in
conventional high-performance steam generating boilers can be used – Forest logging residues (bark, tops, branches) – Saw mill, board mill and other wood waste – Agricultural residues (straw, corn stower, bagasse etc) – Mixed solid waste
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CHEMREC Energy to Succeed
Typical value chain
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Activity Characteristics Forestry Well-established, low non-renewable resource use Biomass extraction By-product from extraction of saw logs and pulp wood Feed stock preparation
Pulping to produce black liquor. Shredding /chipping of biomass for stream generation in conventional HP boiler
Gasification High-temperature entrained-flow gasifier, very short retention time. Novel technology.
Raw gas post-treatment
Only condensing cooling/steam generation, ~5 ppm tar, low methane content
AGR and sulphur handling
Well-established technologies
Synthesis and product distillation
Well-established technologies (MeOH and DME)
Product High flexibility - MeOH and DME preferred due to high conversion and vehicle efficiency, very good environmental performance, moderate investment cost.
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CHEMREC Energy to Succeed
Critical technologies
• Emphasis on using established technologies wherever possible: – ASU, AGR, sulphur recovery, synthesis and product distillation
• Scale-up of oxygen-blown, pressurized gasifier key challenge, in particular – Burner nozzle (atomizing efficiency, flame shape, flow patterns) – Quench (flow patterns, mechanical design) – Gas cooler steam generator (mechanical design)
• Special challenge from pulp mill integrated design: – Even higher demand for availability
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CHEMREC Energy to Succeed
The motor fuels plant – MeOH/DME case
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Well-proven technology
Critical technology
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CHEMREC Energy to Succeed
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The Gasifier - Core technology risk areas
Green Liquor
Raw syngas
Condensate
Black Liquor
GAS COOLER
REACTOR
QUENCH
Cooled raw syngas BFW
LP- steam
MP- steam
Weak Wash
Oxygen
Cooling water
BURNER
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CHEMREC Energy to Succeed
Critical performance / cost areas
• Low risk in technology except for scale-up related risks for gasifier and gas cooler
• Low risk in investment cost estimates; high percentage of cost from established technologies
• Low risk in conversion / consumption related costs; high confidence in conversion efficiency
• Higher risk in project execution; can be mitigated by extensive pre-engineering and selection of contractors and contracting form. Can be in conflict with time-to-market goals.
• Start-up curve and final availability critical to overall project financial performance; first plants pose higher risk
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CHEMREC Energy to Succeed
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First generation technology, > 55 000 h of full-scale operation • Commercial atmospheric, air-
blown gasifier to boost recovery capacity
• Capacity 300 t BLS/d, about 15% of total mill recovery capacity
• Installed in 1996, now operated more than 55 000 h
• Of great importance for development of refractory system and other components
• Has now reached 95% annual availability and 2 years refractory life
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CHEMREC Energy to Succeed
• Chemrec already runs the world’s only plant for oxygen-blown, pressurized gasification of black liquor to raw syngas
• Capacity 20t solids/d, 3 MWth • Oxygen-blown, 30 bar operating pressure • In continuous 24/7 operation with 15 operators • 8000+ hours of operation
Existing pilot plant
Ground floor of gasification plant Chemrec’s plant and ETC’s research facility
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CHEMREC Energy to Succeed
BioDME plant to be operational H1 2010
DME production 4-5 t/d
Amine Wash
Final S Removal
& Guard Bed
DME Process
Development Unit
Raw DME BFW LP-st
CO2/H2S
DME Storage
Existing syngas plant
Activated Carbon
CO2
CW DME
New DME pilot plant
MP-steam*
WeakWash
LP-steam*
Raw syngas
Green Liquor Condensate
Black Liquor
GAS COOLER
REACTOR
QUENCH
BFW*Oxygen
Atomisingmedium
Cooling water
* Cooling waterin DP1
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CHEMREC Energy to Succeed
BioDME Consortium
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CHEMREC Energy to Succeed
Demonstration plant next step
• Goals of demonstration plant – Show successful operation of near-commercial size plant
including scaled-up oxygen-blown gasifier – Demonstrate successful integration within motor fuels plant – Demonstrate successful integration with pulp mill
• Minimum plant size 500 t BLS/d or about 32 000 m3 gasoline equivalents/year
• Total investment cost €150 million of which 50% grant funding or equivalent required
• Pre-projects for two demonstration plants on-going
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CHEMREC Energy to Succeed
Demonstration plant partners needed • Host pulp mill • Motor fuels plant investors / operator • Technology suppliers • Product off-taker / Fuel distributor • (Vehicle manufacturer) • (Transportation buyers)
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CHEMREC Energy to Succeed
Sustainability
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☻ ☻ ☻ ☻ ☻
DME via black liquor scores high
on main criteria
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• Key environmental and economic sustainability issues for Chemrec black liquor gasification extensively evaluated within – EUCAR / Concawe / JRC WtW project – Renew project
• Very good scores for key variables including – WtW and conversion efficiencies – GHG emission reduction – Land use efficiency – Product cost
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CHEMREC Energy to Succeed
BioDME from Wood Waste over Black Liquor – Highest Efficiency, Lowest Emissions
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DME from wood waste over black liquor
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CHEMREC Energy to Succeed
High efficiency, simple system and plant integration synergies gives low product cost
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Lowest fuel production cost for Chemrec’s DME plant in RENEW’s 4-year, €20 million study
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CHEMREC Energy to Succeed
Thank you !