1 Gasification Technologies for Fuel Production Tim Eggeman, Ph.D., P.E. June 29, 2009 Third Meeting of the International Sugarcane Biomass Utilization Consortium Shandrani Resort & Spa, Mauritius
Jan 04, 2016
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Gasification Technologies for Fuel Production
Tim Eggeman, Ph.D., P.E.
June 29, 2009
Third Meeting of the International Sugarcane Biomass Utilization ConsortiumShandrani Resort & Spa, Mauritius
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Gasification Can Be:
“Simple”
WWII Automobile
“Complex”
SASOL
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Fuel Gas Applications Are Simplest
Central Minnesota Ethanol Cooperative15 Million gal/yr Corn Dry Mill
$15 Million Gasifier Retrofit
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Another Fuel Gas Application
Retrofit a Pulverized Coal Boiler to Allow Co-firing BiomassLahti, Finland
50 MWth
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Why are Fuel Gas Applications “Simple”?
• Atmospheric Pressure Operation
• Air Blown:– Low Calorific Gas w/ N2 is OK
• Low Temperature– High Make of Methane and Tars is OK– Dry Ash…generally OK
• Moving Bed is Common
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Gasifier Flow Patterns
c) Entrained Flow
a) Moving Bed b) Fluidized Beds
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Fuel Capacity
Entrained Flow
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BIGCC Are More Complex
Värnamo, Sweden18 MWth Input as Wood
Gasifier: Circulating Fluid Bed,Air Blown,
18 bar, 950-1000 °C
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Repotec Gasifier
CONFIDENTIAL
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Repotec – Güssing 8 MWth
Year 2002 2003 2004 2005 2006
Gasifier 3182 4695 6137 7078 7191
Gas Engine 1251 4152 5463 6487 6826
Operating Hours Per Year
CONFIDENTIAL
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Not All Projects are Successful
• Many Fail to Get Funding– SIGAME (Eucalyptus BIGCC in Brazil)
• Technical and Management Problems
Paia, Hawai’iBagasse BIGCC
Had Problems withBagasse Supply/Feed
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Feedstock PropertiesHerbaceous
BiomassWoody
BiomassIllinois No. 6
Coal
UltimateAnalysis
C: 45%O: 40%
C: 50%O: 40%
C: 80%C: 10%
Proximate Analysis
Moisture: 15%
Volatile C: 80%Fixed C: 15%
Moisture: 50%
Volatile C: 80%Fixed C: 15%
Moisture: 11%
Volatile C: 45%Fixed C: 45%
Heating Value,MJ/Kg (dry)
18 20 29
Ash Minerals Si, K Si, K, Ca, Mg Si, Al, Fe, Ca
Ash PropertiesTInitial Deformation, °C
TFluid, °C
700-8501500
800-900 1000-11001200-1300
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Ash Properties
TInitial
Deformation
TFluid
StickyAsh
Regime
Forbidden Temperature
Range
Dry AshGasifiers
AgglomeratingGasifiers
SlaggingGasifiers
Raw Gas Quenching
Instantaneous Feed HeatingSlagging
Operations
T250
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Ash Properties
a) Coal AshFrom: www.ultrasys.com.au/bits.html#
b) Biomass AshFrom: Miles et. al. (1996)
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ThermodynamicsEffect of Pressure at T = 1000 °C Effect of Temperature at P = 30 Bar
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Fuel Footprint
a) Iso-lines of Cold Gas Efficiency b) Iso-lines of Syngas (H2 +CO) Yield
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Chemicals
Tail Gas(Heat, Steam/Power)
SynthesisGas
TarReforming
SyngasProcess
Gasification for Chemicals is Most Complex
Biomass
Producer Gas(Heat, Steam/Power)
Low Temperature Gasification
~800°C
High Temperature Gasification
~1300°C
Feed Conditioning
PyrolysisTorrefaction
Grinding
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Biomass to Liquids (BTL)
Gasification:
Fischer-Tropsch:
22 xHCOOBiomass
OHCHnHnCO n 222 )(2
Distribution of Products MeansAdditional Hydrotreating Is Needed
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Choren
Freiberg SiteBlue Stripe Building (Back) – Alpha PlantRed Stripe Building (Center) – Beta Plant
Open Space (Center Left) – Future Shell FT Plant
Installation of Entrained Flow Gasifier,Beta Plant
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Choren
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Mixed Alcohol Synthesis
OHnOHHCnHnCO Nn 2122 )1(2
222 HCOOHCO
Chemistry:
Shift Lowers H2:CO ~ 1Products Follow Flory DistributionRequires High Pressures
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Range Fuels
Demonstration Plant in Soperton, GA in Planning
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Syngas Fermentation
Same Chemistry asMixed Alcohol Synthesis!
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Coskata
Working WithAlterNRG for
Plasma Gasification
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ZeaChem Technology
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HydrogenResidue to Gasifier
Sales
Biomass:• Hardwood• Softwood• Switch Grass• Corn Stover
EthanolSales
Ethyl Acetate
Sugar Solution
Acetic Acid
ZeaChem’s Core Technology
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Theoretical Yields
Cellulose, 40
HemicelluloseSugars, 18
HemicelluloseAcetate, 2
Lignin, 30
Other, 10
Biochemical OnlyYield: 78-112 gal(neat)/BDT
39-56
Biochemical Processing
100
Balance61-44
Thermochemical OnlyYield: 112 gal(neat)/BDT
56
100
Balance30
Mixed Alcohol Synthesis
Thermochemical Processing
Balance14
Syngas
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Values in Italics Indicate Chemical Energy Flow Normalized to Biomass = 100
Yield assumes 200 gal(neat)/BDT for 100% Chemical Efficiency
Syngas FermentationYield: 112 gal(neat)/BDT
56
100
Thermochemical Processing
BiochemicalProcessing
Balance30
Balance14
Syngas
70
ZeaChem HybridYield: 156 gal(neat)/BDT
78
100
60 40
Thermochemical Processing
Biochemical Processing
Hydrogenolysis
Balance4
Residue8
Balance18
Ester
52
H2
30
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Recommendations for ISBUC• Have Well-Defined Scope
– Start Simple then Build Complexity– Need a Strong Operating Partner with
• Form a High-Level Business Case Early– Incremental Economics for Addition of a BIGCC to a
“Typical” Mill– Refine as Progress is Made
• Project Plan– Sources of Funds– Location– Schedule
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Potassium ContentPotassium Content of Biomass
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Mixed waste paperFir mill waste
RFD - TacomaRed oak sawdust
Sugar Cane BagasseUrban wood waste
Willow - SV1-3 yrFurniture waste
Willow - SV1-1 yrAlder/fir sawdustSwitchgrass, MN
Hybrid poplarSwitchgrass, D Leaf, MN
Demolition woodForest residualsPoplar - coarse
Miscanthus, SilberfederWood - land clearing
Almond woodWood - yard waste
Danish wheat strawRice husks
Switchgrass, OHOregon wheat straw
Alfalfa stemsCalifornia wheat straw
Imperial wheat strawRice straw
Potassium Content (lb/MMBtu)
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Table 2.1 - Typical Feedstock AnalysesComplied from Phyllis (2006), US DOE Biomass Database (2006),
Neto (2005), Meyers (1981) and othersHerbaceous Biomass Woody Biomass Fossil
Corn Corn Hardwood CoalStover Stover Cane Cane Trash Cane Trash Cane Trash Hybrid Hardwood Hardwood Softwood Coal Illinois No. 6
(Whole) (Cob) Switchgrass Bagasse Dry Leaves Green Leaves Tops Poplar Eucalyptus Oak Pine Lignite Bituminous Pet Coke
Ultimate Analysis, wt% dry
C 46.80 46.60 47.39 44.60 46.20 45.70 43.90 50.20 49.50 49.90 51.30 65.70 70.00 88.24H 5.74 5.87 5.67 5.80 6.20 6.20 6.10 6.06 5.75 5.94 4.69 4.50 4.90 3.68N 0.66 0.47 0.55 0.60 0.50 1.00 0.80 0.60 0.14 0.38 0.51 1.20 1.40 2.18S 0.11 0.01 0.06 0.10 0.10 0.10 0.10 0.02 0.03 0.50 0.15 1.00 3.80 5.69O 41.40 45.50 39.13 44.50 43.00 42.80 44.00 40.40 44.00 41.30 40.30 18.40 10.70 0.51Cl 0.27 0.21 0.09 0.02 0.10 0.40 0.70 0.01 0.06 0.01 0.02 - - -Ash 5.10 1.40 6.54 2.20 3.90 3.70 4.30 2.70 0.50 2.40 3.00 9.20 9.20 0.30
Proximate Analysis, wt% dry
Moisture 6.1 8.0 13.9 50.2 13.5 67.7 82.3 50.0 50.0 50.0 50.0 35.5 11.2 7.0
Volatile Carbon 80.9 80.1 77.0 79.9 84.5 80.6 79.3 84.8 86.6 84.2 75.6 48.7 46.3 13.4Fixed Carbon 14.0 18.5 15.9 18.0 11.6 15.7 16.4 12.5 12.9 13.4 21.4 42.1 45.6 86.3Ash 5.1 1.4 6.5 2.2 3.9 3.7 4.3 2.7 0.5 2.4 3.0 9.2 8.1 0.3
Biochemical Analysis, wt% dry
Cellulose 37.3 40.2 36.9 39.1 43.2 48.5 38.6 44.2Galactan 0.9 1.7 1.4 0.4 0.8 0.9 2.1 2.0Mannan 0.5 0.0 0.3 0.3 2.5 1.0 0.0 12.3Xylan 16.4 23.6 23.0 20.2 16.4 11.6 17.7 5.2Arabinan 3.1 3.2 2.4 1.6 0.7 0.4 0.6 0.7Lignin 14.6 12.3 9.6 24.3 24.2 27.7 27.4 27.9Balance 27.2 19.0 26.4 14.0 12.3 9.9 13.6 7.7
Total Sugars 58.2 68.7 64.0 61.7 63.5 62.4 59.0 64.4
Heating Value
HHV, MJ/kg (dry) 18.10 18.77 18.90 18.10 17.40 17.40 16.40 19.02 19.22 20.45 20.59 25.52 29.20 35.64
Ash Composition, as Oxides wt% of Ash
Al2O3 2 6.98 2.3 3.5 1.4 0.5 0.8 7.9 0.9 10.9 13.6 17.9CaO 8.7 1.3 7.14 0.7 4.7 3.9 2.6 49.9 26.5 65 29 17.6 5.8CuO 0.00006 0.00006 0.00006Fe2O3 4.1 3.56 2.3 0.9 0.5 0.2 1.4 0.5 4.5 6.6 20.1K2O 20.7 2 7 1.7 2.7 13.3 29.5 9.6 7.2 9.9 13.1 0.1 1.8MgO 6.1 2.5 3.17 0.5 2.1 2.2 2.5 18.4 7.3 8.3 4.7 2.5 1MnO2 0.062 0.169 0.12 0.155
Na2O 0.2 1.2 1.03 0.045 0.123 0.128 0.119 0.1 5 0.8 0.6 0.6 0.4P2O5 8.7 6.9 2.8 0.5 0.5 2 2.5 1.3 29.1 7.5 5.3 0.1 0.1SiO2 54 40.3 65.42 5.9 17.8 2.3 46.1 41.8 47.5SO3 8.7 2 2 2.2 14.6 4.6
TiO2 0.34 0.3 0.1 0.2 1.5 0.8ZnO 0.009 0.015 0.035Balance -0.4 33 0.56 91.893 85.29894 76.43694 61.89094 10.3 -0.8 2.5 -14.4 1 0
Alkali, kg/GJ Feed (dry) 0.59 0.02 0.28 0.02 0.06 0.29 0.78 0.14 0.03 0.13 0.20 0.03 0.06
Ash Fusion Temperatures, C
Reducing ConditionsInitial Deformation 1129 1079 1093Spherical 1234 1166 1182Hemispherical 1414 1177 1193Fluid 1518 1227 1271
Oxidizing ConditionsInitial Deformation 1160 1132 1260Spherical 1266 1199 1332Hemispherical 1377 1210 1343Fluid 1500 1254 1432