1 Biomass gasification technologies for advanced power systems and synfuels - Status and Present R&D activities in Finland Esa Kurkela FINNISH – SWEDISH FLAME DAYS Naantali, January 29, 2009 VTT TECHNICAL RESEARCH CENTRE OF FINLAND 2 Biomass and waste gasification for boilers and kilns
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Biomass gasification technologies foradvanced power systems and synfuels
- Status and Present R&D activities in Finland
Esa Kurkela
FINNISH – SWEDISH FLAME DAYSNaantali, January 29, 2009
VTT TECHNICAL RESEARCH CENTRE OF FINLAND2
Biomass and waste gasificationfor boilers and kilns
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND3
CFB GASIFIER
REACTOR
850 °C
900 °CBIOFUEL FEED
BOTTOM ASH COOLING SCREW
HOT LOW CALORIFICGAS (750 - 650 °C)
AIR PREHEATER
RET
UR
N L
EGGASIFICATION AIR FAN
UNIFLOW CYCLONE
Atmospheric-pressure CFB/BFBgasification for kilns and boilers• Commercial lime-kiln gasifiers
were constructed in 1980’s byAhlström Oy
• New development by FosterWheeler in 1990’s for boilerapplications
• Gasifiers are now offered by• Foster Wheeler• Carbona/Andritz• Metso Power
• Feasible in size range 15-150 MW• Fuel drying is often neededto achieve required flame properties
From: Foster Wheeler
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Efficient utilisation of wastes and biomassresidues in existing power plants
a cost-effective way to reduce CO2 emissions of power plants
CFB gasifier of 60MW
Main boiler360 MWth
Gasifier feedpreparation
- in operation since 1998- no commissioning problems- 50 000 operating hours- gasifier availability > 95 %- boiler emissions decreased- payback time ca. 8 years
CFB gasifier of 60MW
Main boiler360 MWth
Gasifier feedpreparation
- in operation since 1998- no commissioning problems- high fuel flexibility- gasifier availability > 95 %- boiler emissions decreased-
From: Foster Wheeler
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND5
Source: T.Anttikoski, Foster Wheeler Energia Oy
Plastic reject materialwith 10 % aluminium
Corenso gasifier in Varkaus, Finland• gasification of aluminium containing plastic reject material• complete recycling of liquid cartoons (milk & juice packaging)• 50 MW gas to boiler, 2100 t/year aluminium for re-use• developed by VTT & Foster Wheeler Energia Oy in 1998 - 2000
in operation since autumn 2001
From: Foster Wheeler
VTT TECHNICAL RESEARCH CENTRE OF FINLAND6
Gas cleaning: gas cooling followed by filtration
Gascooler
Filter
Fuelfeeding
Gasburner
Coalburners
Bed material/Ca-basedadditive
Sorbent
4
VTT TECHNICAL RESEARCH CENTRE OF FINLAND
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
Na K Cl Al Ca Hg Sn Sb As Cd Pb V Mn Co Ni Cu Zn Mo Cr Si Mg
Demonstration by Lahti Energia Oy (Lahti, Kymijärvi)- SRF fuelled gasification based WtE plant (CHP)- 2 x 80 MWth gasification & gas cleaning trains- 160 MWth gas fired boiler
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND9
LahtiStreams IP (Advanced Integrated Waste Management and WtE Demonstration)
( Lahti Energia/FI, VTT/FI, L&T/FI, Dong Energy/DK, FZK/D; total budget 23.5 M€) )- Demonstration of complete advanced waste management chain including:
> waste processing> material recovery> SRD/RDF production> advanced high efficiency WtE plant> further treatment of ashes
-R&D of - waste processing and material recovery- improved hot gas cleaning- advanced ash treatment- new gasification based high efficiency WtE technologies
EU-BigPowerBiomass Gasification for High Efficiency Power
October 2005 – December 2008Overall Budget for the project: 2 943 k€ - Financed in part by EU FP6
Catalytic Gas Cleaning and filtration• MEL Chemicals, United Kingdom• NortaUAB, Lithuania• Madison Filter Ltd, United Kingdom
R&D organisations supporting industrial development• VTT - Technical Research Centre of Finland• TUV - Technical University of Vienna, Austria• CERTH - Centre of Research & Technology Hellas,Greece• TKK - Helsinki University of Technology, Finland
Gasification systems• Condens Oy, Finland• Carbona Oy, Finland• Repotec GmbH, Austria• Biomasse Kraftwerk
Güssing, Austria• (Kokemäki & Skive sites)
Power production equipment• GE Jenbacher, Austria• MTU CFC Solutions GmbH, Germany
• pressurised gasification followed by catalytic reforming• 500 kW Process development Unit• studies for 150 – 400 MW plants integrated to pulp and paper industry
Pressurecontrol valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elementsFurnace
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
Pressurecontrol valve
Fuel feedingequipment
Bedmaterial
Additive
PFB GASIFIER
FILTER
Gascooler
CATR
Bedremoval
Ashremoval
Heatingelements Heating
elementsFurnace
Air
Nitrogen
Steam
Oxygen
To slip streamtesting facilities
Kemira’s peat ammoniaplant in 1990
VTT’s 500 kW PDUfor syngas andultraclean fuel gas
VTT TECHNICAL RESEARCH CENTRE OF FINLAND20
Wood, strawenergy crops,peat, RDF
FT-synthesis& upgrading
Gasification andgas treatment
Pulp andpaper mill
Biomasshandling
anddrying
powerplantProcess steam & power
Paper& pulp
WoodDiesel
Energyto drying
synthesis-gas
bark,forestresidues,otherbiomass
fuel gas+ steam
steam &oxygen
Integration of FT-synthesis plant to pulp and paper mill
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VTT TECHNICAL RESEARCH CENTRE OF FINLAND
Efficiencies with Industrial-Heat ProductionEfficiency = 100 x [LHV-energy of main product + high-grade byproduct energy - {electricity /
0.4}] / [LHV-energy of as-received feedstock]
-40
-20
0
20
40
60
80
100
FT CH3OH SNG H2
Ove
rall
Effic
ienc
y, % Primary
energy outMain product
(Electricity in)/ 0.4
Feedstock drying: from 50 % moisture to 30 % with secondary heat; from 30 % to 15 % with by-product steam
From: McKeough & Kurkela, NWBC, Stockholm 2008
VTT TECHNICAL RESEARCH CENTRE OF FINLAND22
VTT-UCGOptimised
syngas R&D& PDU-scaledevelopment
Industrial demon-stration: 15 MW
- replacement of oil/gas- start-up in 2009
Further R&D- process optimisation- waste gasification- hydrogen technologies
New applications- fuel cells, 2nd gen. IGCC- hydrogen or methane- renewable chemicals
R & D on hot filtrationand
catalytic gas cleaning
Biomass/wastegasification for power
(Lahti, Corenso,Värnamo, Kokemäki)
Peatammonia
plantOulu/Finland
Synthesis gasR&D in Europeand USA in 1980’s
First synfuel production plant- 200-250 MW feed capacity- 105 000 tons/a diesel fuel- 3 % Finnish transport fuel- start-up in 2012-14
1995 2000 2005 2010 2015 20201985 2025 2030
Biorefineries at pulp and papermills and at large CHP plants
- diesel production: 70 -150 000 tons/plant- by-product heat for process steam or
district heating- high overall efficiency
SYNTHESIS GAS FROMBIOMASS
FROM R&D TO INDUSTRIAL SUCCESS(road map made in VTT’s UCG project in 2006)
• Biomass characterisation for pressurised steam/oxygen-blowngasification: ash behaviour and reactivity
• Filter blinding and catalyst deactivation studies• Tar reactions in non-catalytic and catalytic processes• System studies on BTL-applications and hydrogen production• Development of measuring methods for tars and other gas
contaminants• IEA groups: ”Biomass thermal gasification” and ”Biomass Hydrogen”