7. Bush - R&D Platform for Systems Integration Researchwhitty/blackliquor/colloquium2003... · Vann Bush, Bob Dahlin ... Richard Hurley, George Stewart, Bipin Patel, Hank Aigner,

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An R&D Platform for Systems Integration Research

DOE Cooperative Agreement No. DE-FC36-02GO12024

Vann Bush, Bob Dahlin, Bill Farthing, Larry Felix, and Todd Snyder, Dick Del Bueno

Richard Hurley, George Stewart, Bipin Patel,Hank Aigner, and Perry Pierce

Dave Bowen and Francis Lau

Peter Walsh

James Spaeth

An R&D Platform for Systems Integration Research

Technical Advisory Panel

Kerry Bowers, Tom Johnson

Esa Kurkela, Pat McKeough

Les Reardon, Martha Rollins

Scott Sinquefield

Hasan Jameel

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BL Colloquium 14may033

• Contribute to energy independence & security

Increase renewable energy supply¤ 87% of non-hydro renewables from biomass

(76% from wood/wood wastes, including black liquor)

Increase energy efficiency of existing biomass users

Produce syngas from biomass to make liquid fuels, hydrogen, etc.

• Improve environmental performance, lower carbon intensity

• Preserve domestic Forest Products industry… 3rd most energy intensive industry… 4th largest industrial user of fossil fuels

National Incentives


National Bioenergy VisionBiomass gasification technologies are currently in place. However, there remain a number of technical and economic hurdles to improve their cost competitiveness with other technologies. Specifically, research is needed to reduce the capital costs and improve the operating efficiencies of gasification systems. In addition, research should be performed to enable a wider range of resources, such as forest and agricultural residues as well as to expand the development and application of black liquor gasification. Gasification technologies should be designed for integration with generating turbines and biorefineries.

from Roadmap for Biomass Technologies in the United States, Biomass Research and Development Technical Advisory Committee, Dec 2002.

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• Southeastern US is rich in biomass energy resource

Industrial KWhrs generated by wood/wood wastes:

#1 Alabama, #2 Georgia, #3 Louisiana, #5 Mississippi, #6 Florida, #7 Arkansas = over 50% of national total *

• Alabama #1 in nation in total net generation from wood/wood wastes (>4M MWhrs) *

• Forest products industry is Alabama’s #1 employer* Source: EIA Renewable Energy Annual 2001

Regional Incentive


SSoouutthhwweessttRReegg iioonn

33

NNoorrtthhwweessttRReegg iioonn

1155MMiiddwweessttRReegg iioonn

1122

NNoorrtthheeaassttRReegg iioonn

1133

SSoouutthheeaassttRReegg iioonn

8800

Kraft Pulp & Paper Mills

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• IGCC systems are unproven - operational risks are high

• Industry competition and low margins inhibit adopting speculative technical solutions - capital risks are high

• Integration issues are beyond the scope of technology companies - performance risks are high

Development Hurdles

Process-based Research & Development is needed to reduce these risks.


Key Benefits of Black Liquor GasificationDepend on Effective Process Integration

• Increased Electrical Power Production -gas cleanup for turbine protection

• Higher Overall Thermal Efficiency -integrated, efficient gas cleanup

• Separation of Sulfur and Sodium to Increase Pulp Yield -precise gasifier and gas cleanup tandem operation

• Autocausticizing or Direct Causticizing -catalyst delivery, solids separation, recycle systems

• Improved Environmental Performance -integration of separation/control systems for particles, alkali vapors, sulfur, NOx, and other pollutants plus ‘waste’ stream characterization

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Process Integration is not a substitute for Mill Integration.

It is a prerequisite.

Basic R&D

Equip. Development

System Development

Demo


Technical Issues

• Reliable solutions for feeding fuels into a gasifier• Temperature & residence times for optimum carbon conversion• Fluid dynamics in gasifiers, gas cleanup systems• Tar ‘management’ - prevention, decomposition, destruction• Durable refractory design, materials evaluation • Char and gas properties of different fuels• Gas cleanup options

… technologies… temperatures

• Process integration… sensors and controls evaluation and development… operational reliability of process… optimize BL chemical recovery (causticizing, S, Na separation,…)… synthesis gas quality, stability, and conversion efficiency

• Gas processing systems for multiple uses of syngas

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R&D Platform for Gasification System Testing And Integration

Testing and Verification of Enabling Technologies Required for Integrated Biomass Gasification Systems:

• Materials Handling

• Gasification

• Gas Cleanup/Conditioning

• Sensors and Process Controls

• Interface Issues and System Integration

• Power Generation (gas turbines, fuel cells, etc.)

• Synthesis Gas Processing (biorefinery technologies)


Advantages of a Pilot-Scale R&D Platform

• Affordable tests

• Parametric testing enabled by good process control

• Detailed characterization permits a mechanistic understanding of processes

• Believable scale to identify and resolve systems integration issues

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Biomass Gasification Facility Priorities

High-Efficiency Power for Forest Products Industry

Woody Biomass, Bark, SludgesBlack Liquor

Fluidized Bed Gasifier, moderate temperature (875°C)Pressurized Operation, air or oxygenHot Gas CleanupIntegrated Energy Conversion

TurbineIC EngineSolid Oxide Fuel Cell

Biomass Combined Heat & Power / Distributed GenerationRenewable Syngas Production

Industrial Fuel Gas SupplyNatural Gas Substitution, Hydrogen Production

Focus:

Fuels:

Features:

Future:


Biomass Gasification Research TeamSouthern Research Institute• prime contractor• hot gas cleanup expertise• host site, operations staff

Gas Technology Institute• RENUGAS® process equipment• gasification expertise• operations consulting

BE&K Engineering• facility engineering design• construction management• pulp & paper applications expertise

UAB• CFD process modeling

Technical Advisory Panel• Southern Company Services • Tennessee Valley Authority• Institute of Paper Science & Technology• VTT Finland• North Carolina State University

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Flexibility - The Facility’s purpose is to evaluate the design and integration of various energy conversion systems based on renewable fuel (biomass) gasifier equipments and processes

Fuels - The Facility will handle a variety of renewable fuel types focusing on wood chips and pulp mill black liquor.

Basic Facility Criteria

Free Standing - The Facility will be free-standing, it will contain all process support and administrative functions.

Fuel receipt, processing, feedingSyn-gas cleaning, thermal oxidation, burningFlue gas cleaningHigh pressure nitrogen, oxygen, steamOperational controlSafety ControlData acquisition, computational analysisLaboratory analysis

Criteria (cont)

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Factors ConsideredSafetyEquipment change-out Potential for parallel testing/operationsMultiple fuelsMultiple forms of “users”- CT, fuel cell, F-TProcess scale-up planTest durationsFuel supply logisticsExpandability

Criteria (cont)

Criteria (cont)

Foundation-Starting Point—GTI RENUGAS®

• Single Stage Fluidized-Bed

• High efficiency, 80%

• High conversion, 98%

• Moderate temperature, 1600 F

• Air or Oxygen

• High or Low Pressure

• Fuel flexible

Bottom AshRemoval

Gasifier

Cyclone

AIR/O2

Fuel feed

AIR / STEAM

FluidizedBed

FreeboardDisengagingZone

SYNGAS

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Facility Scale

RENUGAS® Process Development Unit Size on Wood:

10.9 Metric Tons / Day @ 90% Dryness

21,600 #/ Day Dry Feed Rate

9000 Btu/# Dry

195 MM Btu/Day = “1 PDU”

26,500 SCF/Hr @ 137 Btu/SCF = 3.63 MM

Btu/Hr (88 MM Btu/Day)

45% GTCC Eff = 0.5 to 0.6 MWe


Gasification Facility Scaling

8.113.83.26.01.81.80.6Potential GTCCPower-MWe

13.623.25.310.03.03.01.0Thermal Ratio-PDU’s

2650451110351944584584195Heat In-MMBtu/day

62006200130006200620090009000HHV-Btu/#

Kraft BLKraft BLCoalKraft BLKraft BLWoodWoodFuel Feed Stock

40040072600079600314600946006479021600Fuel Feed RateDry #/Day

182330.0---143.043.0------Weight Rate MT/DayLiquor Dry Solids

------38.0------32.710.9Weight Rate-WetMet T/Day

MTCIBig Island

ChemrecNew Bern

PSDFWilsonville

10X PDU Step 4

3X PDU Step 3

3X PDU Step 2

GTI PDU Step 1

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Facility Scale

Conceptual Design is for the 3X or 585 MM Btu/Day capacity

Future scale-up would be to the 10X or 1950 MM Btu/Day

Large enough for systems integration but not too large to entail large risk

Design Elements Process DiagramsBasic Sizing CalculationsEquipment and construction specsEquipment & Support Services LayoutsDiagnostics and Controls ApproachEquipment List/DataSite LayoutSupplier Proposals

Major StructuresBasic Architecture

Cost Estimate

Facility Scope & Estimate Process Preliminary Design Definition

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sam

plin

gch

ambe

r1

LIBS

from gasifier

cycloneEPF 2

EC = environmental chamber for analytical instruments

CS = fuel gas conditioning system

to gas disposal

EC

TA = FID tar analyzer

CS

on-line PC/S = in situ particle counter/sizermicro GC = micro Gas Chromatograph

GC/MS = Gas Chromatography / Mass SpectrometryFTIR = Fourier Transform-InfraredMS = Mass Spectrometer

on-line PC/S

EPF = Extractive Particulate Filter

EPF 1

CS

CS

CS

sam

plin

gch

ambe

r2

LIBS = laser-induced breakdown spectrometer

CSTA, GC/MS,FTIR, MS,micro GC

CSTA, FTIR,MS, microGC

CO ,CO,O

2

2

CO ,

CO,O

2

2

BED

Free

boar

d


Component Range, vol %,or as noted

Methodof Detection

SampleConditioning*

Total No.of Units

O2 ~0 paramagnetism 4 2CO 4 - 8 NDIR 4 3CO2 12 - 17 NDIR 4 3H2O 0 - 100 dipole polarization 0 1

H2, N2, CO, CO2, H2S,COS, C1 to C6 HC

0.001 to 30 Micro GC withTC detector

4 2

H2O, CO,CO2, CH4, oil? 4 to 45 FT-IR 2 or 3 2H2, N2, Ar, HCN?, HCl? 3 to 30 MS 2 or 3 2Tar, oil, total HC 0.2 - 0.8 FID 2 2Tar and oil species ~0.001 GC/MS 2 or 3 1Particle concentration ~1 - 75 g/m3 triboelectric 0 2?Particle batch sample ~1 - 75 g/m3 filter 0 2Particle conc., size ~1 g/m3 light scattering 0 1Si, Al, Ca, Na ~0.1 g/m3 LIBS 0 1

* Sample conditioning: 0 - cooled to 1000 oF1 - particles removed, sample at 1000 oF2 - heavy tar removed, sample at ~550 oF3 - light tar removed, sample at ~300 oF4 - oil and water removed (~32 oF dewpoint), sample at room temperature

On-Line Analytical Instrumentation

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7. Bush - R&D Platform for Systems Integration Researchwhitty/blackliquor/colloquium2003... · Vann Bush, Bob Dahlin ... Richard Hurley, George Stewart, Bipin Patel, Hank Aigner,

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