SNG aus Biomasse am Beispiel Göteburg Bioenergy 2020+ - Biomassetag November 2017

Slide 2

Overview

Graz (Head office)

Güssing

Wieselburg

Pinkafeld

Tulln

WHAT Austrian competence centre for

biomass utilization since 15+ years

WHERE 3 offices and 2 technical research

sites across Austria

WHO ~100 researchers from all academic

career levels (mostly engineers)

HOW National and international research

funding + industry partners (~9 Mio EUR turnover per year)

Research Areas

Slide 3

Biomass combustion

Gasification Systems Biological Conversion & Integration

Three main research areas:

1. Combustion

2. Gasification

3. Bioconversion

Plus a number of additional departments: microgrids,

simulation, automation and supply chain.

BIOENERGY 2020+ GmbH, a limited company is owned mostly by public ins-

titutions like universities, ministries and similar public bodies. The single biggest

owner is an association of enterprises with commercial interest in the field.

Bioenergy 2020+ enterprise and ownership

Slide 4

~20 individual firms

Gasification & Synthesis Value Stream

Slide 5

Gasification + Synthesis

Waste, feedstock

byproducts

• Wax

• Kerosene

• Alcohols

• Diesel

• Electrical

• Thermal

• Hydrogen

• Gas - SNG

Optional: Peak-wind energy

Sh

ifti

ng

Re

se

arc

h F

oc

us

Energy

Gases

Substances

Shifting the reseach focus towards higher-value products

Slide 6

Product range

Including recycling

of phosphorus from

sewage sludge and

agricultural sources. Biofuels

Energy & Heat

Chemicals

Feed

& Food

Health

& Cos-

metics

incre

asin

g m

ark

et va

lue

Dual Fluidized Bed (DFB)

Steam Gasification Technology

Slide 7

Slide 8

Production of Synthesis Gas: Starting point for SNG

to stack gas motor, H2, CH4, fuel, wax, …

Biomass is converted into

mostly hydrogen and carbon

monoxide – a so-called

synthesis gas.

Synthesis gas is the starting

point for a number of

downstream conversion

processes, like SNG

production.

Slide 9

DFB Reactor and System Integration

Güssing Plant Layout

Slide 10

Syngas via Steam Gasification: State of the Art

Gasification

Electricity (Gas engine)

Heat (District heating)

Synthesis gas H2 + CO

Cooling (optional) (via absorption refrigeration)

Green chemistry

Carbon source

Biomass (wood, …)

Agricultural-residues

Municipial waste (plastic, sewage sludge…)

The DFB gasification system achieved several

100,000 hours of operating experience with sev-

eral plants in the range of 0.5 to 32 MW thermal

power. The demonstration plant in Güssing

achieved more than 100,000 hours of operation.

As alternative to CHP,

the synthesis gas can

be used to produce

fuels and chemicals via

catalytic synthesis.

State of the art is synthesis gas utilization

in a gas engine for the generation of elec-

tricity, as well as waste heat utilization for

district or process heat. Via absorption

chillers, also cooling is possible.

Slide 11

Syngas: Synthetic Production Routes

Liquids & Waxes Gases

Synthetic Natural Gas (SNG)

Hydrogen

Ammonia

FT Fuels & Chem-icals (diesel, wax,

kerosene, …)

Mixed alcohols

Synthesis gas H2 + CO

Methanol

Isosynthesis - Isobutane

Oxosynthesis -

Aldehyde

Carbon source (biomass, residues, waste)

Gasification

A number of different routes for synthesis of

gaseous and liquid chemicals is possible

starting from the generated synthesis gas.

Methanation: SNG from Syngas

Slide 12

CHxOy H2 + CO + CH4 + CO2

3H2 + CO CH4 + H2O Methanation takes place

at 300-400°C with a

nickel catalyst with some

pre- and after-treatment

of the gas.

SNG to grid

Syngas from gasifier Must be separated

Methanation: SNG from Syngas - Details

Slide 13

Syngas

from

gasifier

Tar

removal

Compre

ssion

Pre-

heating

H2S

removal

2nd H2S

removal

Heat

recovery

NH3

removal

Compre

ssion

CO2

removal

H2O

removal

H2

removal Bio-SNG to grid

Status of SNG Production

Slide 14

Overview of Gasification Plants

Slide 15

Location Usage / Product Fuel / Product

MW, MW Start up

Supplier /

Engineering Status

Güssing, AT Gas engine 8.0fuel / 2.0el 2002 AE&E, Repotec End of demonstration life

time reached

Oberwart, AT Gas engine /

ORC / H2

8.5fuel / 2.8el 2008 Ortner

Anlagenbau On hold / restart?

Villach, AT Gas engine 15fuel / 3.7el 2010 Ortner

Anlagenbau On hold / restart?

Senden/Ulm,DE Gas engine /

ORC 14fuel / 5el 2011 Repotec Operational

Burgeis, IT Gas engine 2fuel / 0.5el 2012 Repotec,

RevoGas On hold

Göteborg, Sweden BioSNG 32fuel/20 BioSNG 2013 Repotec/ Valmet Operational / On hold

California R&D 1 MW fuel 2013 GREG Operational

Gaya, France BioSNG R&D 0,5 MW fuel 2016 Repotec Operational

Thailand Gas engine 4MW fuel / 1MWel 2016 GREG Operational

Overview

Slide 16

Key figures:

• 32 MW fuel power

• 20 MW SNG output

Performance target:

• Efficiency: >65%

• Time efficiency: 8000 h/a

Status:

Operational but intended scale-

up (4x) on hold due to perfor-

mance issues.

Plant Complexity: SNG vs. Heat and Power

Slide 17

SNG plant

(GoBiGas) Heat & Power

(Güssing)

SNG Efficiency (Vesta process)

Slide 18

Biomass to SNG

efficiency: 65%

>60% demonstrated in GoBiGas

ISBL1 CAPEX vs. Feed Capacity for Various DFB Projects

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0

5

10

15

20

25

30

35

40

45

50

0 5 10 15 20 25 30 35 40

Senden

To

tal

CA

PE

X [

Mio

EU

R]

Feed capacity [MWth]

Güssing

Oberwart

Nongbua

GoBiGas

1 ISBL – Inside Battery Limit

Estimated CAPEX for

various DFB projects

(only gasification parts

considered here) show

that GoBiGas CAPEX is

above expectations.

CAPEX here is

estimated for ISBL,

which does not include

auxiliary installations.

CAPEX Learning Curve

Slide 20

Corrected for the annual

plant cost index (steel

price, inflation, …) and

in the order of the

cumulated fuel power, a

certain learning effect is

evident.

* Estimated values, gasification part only

-

500.000

1.000.000

1.500.000

2.000.000

2.500.000

0 20 40 60 80 100 120

Specific

CA

PE

X*

(2016)

in E

UR

MW

-1

Cumulated fuel power in MW

Güssing

Oberwart Villach

Senden

GobiGas

Economic viability: Production costs for SNG

Slide 21

Raw materials

Operating labor

Utilities

Employee benefits

Supervision

Laboratory

Maintenance

Insurance and taxes

Operating supplies

Plant overhead

Depreciation

Approx 50%

of the prod-

uction costs

are CAPEX-

related costs

(fixed costs). Production costs

raw materials

labour

utilities maintenance

insurance &

tax

depreciation

Approx 50% of

the production

costs are

operating costs

(variable costs). operating

supplies

Time Efficiency: yearly operating hours

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0

5.000

2016 2014 2015 2017

Ø 2.506

7.708

0

5.000

2008 2010 2007 2002 2003 2005 2004 2006 2009 2011 2012 2013 2014 2015

Ø 6.356 op

era

tin

g h

ou

rs / y

ea

r [h

/a]

GoBiGas

(SNG)

Güssing

(Heat&Power)

0

5.000

2012 2013 2014 2015

Ø 3.746

2016

Senden

(Heat&Power)

Target

On average: ~30%

of target operating

hours achieved

Economic viability: A sensitivity analysis

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Values Units

Investment costs (incl. startup expenses)

29 700 000 EUR

Expenses 9 921 840 EUR a-1

SNG selling price for NPV = 0 130 EUR MWh-1

20 MWth plant

Natural Gas in Austria: ~50 EUR MWh-1

Economic viability: A sensitivity analysis

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-40%

-30%

-20%

-10%

0%

10%

20%

30%

40%

-30% -20% -10% 0% 10% 20% 30%

SNG

pri

ce v

aria

tio

n

Variable variation

Capital

Wood price

Operating hours

How fuel cost,

CAPEX and operat-

ing hours influence

the cost of SNG.

Highest sensitivity:

Operating hours!

Conclusions: Main Challenges for SNG

Slide 25

1

2

3

Complexity

and Reliability R&D must not only focus on energetic efficieny, but strife

for simplicity and reliability of plant layout and operation.

CAPEX &

Investment Investors need to plan for realistic time frames and

targets. Big players + funding with good stamina needed!

Learning &

Experience

(Almost) none of the shown plants have been build by

the same consortium, there are improvements, but there

could be more.

Contact

Slide 26

Bioenergy2020+ GmbH

Biomass Gasification Systems

Wienerstraße 49

7540 Güssing

Austria

Research Area Manager

Gasification Systems

markus.luisser@bioenergy2020.eu

T + 43 (0) 3322 42606-151

Unit Head | Syngas Processes

gerald.weber@bioenergy2020.eu

T + 43 (0) 3322 42606-154

Unit Head | Gasification

matthias.kuba@bioenergy2020.eu

T + 43 (0) 3322 42606-156