Industrial Gasificatio n Implementation for Biomass Presentation to Mosaic Company 22 May 2006
Jan 16, 2016
Industrial Gasification
Implementation for Biomass
Presentation to Mosaic Company
22 May 2006
Presentation Objectives
• Industrial Gasification – Wellman Galusha (commercial industrial gasifier reference )
• HMI Background– MIFGA Project Capital Steam Plant Study (USDOE)
• HMI/ARI Collaboration– MIFGA Project HMI/ARI Heads of Agreement, 1998
• Coal gasification to MN Peat & Faggio wood gasification
• Vision 21 Proposal Recap– HMI/ARI/CPM/Coen/EPRI
Desired Outcome
• Mosaic commit to Industrial Biomass Gasification for drying processes (displacing high cost natural gas)
• Define Objectives and begin Site specific Feasibility Study – June 2006
• Develop Hot-Raw Wood Gasification plant to be on-line in early 2007 fueling Mosaic’s dryers
Industrial Gasification
• Wellman Galusha gasifier reference• HMI personnel have 50+ years of industrial
operational experience with W-G gasifier• W-G gasifier operated worldwide commercially
from 1930’s to 1960’s (principally gasifying coals)
• MIFGA project (1981-85) quantified gasifier performance, efficiency & gas cleaning
Justification for Small Industrial Gasifiers
• Cost and availability of waste wood in Florida
• Cost of HMI wood Gasification system applied to industrial dryers & other thermal processes
• Clean utilization of industrial waste (will further enhance the economics)
MIFGA Project1981-1984
• ScopeDriven by the energy economics and gas curtailments in the mid 70’s and early 80’s, industry and the US DOE needed to demonstrate the gasification performance of US coals in a proven industrial gasifier (single-stage fixed bed gasifier)
MIFGA ProjectProcess Flow Schematic
MIFGA ProjectCoals Gasified
MIFGA ProjectOperations
• Continuous 10-day runs (minimum) for each fuel gasified
• Continuous process monitoring and raw fuel gas sampling
• Process operations limits quantified throughout each test
• 203 days of continuous gasifier operation on 15 different coals/fuels
MIFGA ProjectContinuous Gas Sampling
MIFGA ProjectTar Droplet Size Distribution
MIFGA ProjectTar/Oil Yield Correlation
MIFGA ProjectTar/Oil Quality (HHV)
MIFGA ProjectBarrel Quantities of Tar
• Enlarged tar removal and collection system was designed and operated to recover gallon-quantities of tar and oil
• Tar/oil collection efficiency greater than 99.99%
• Established foundation for complete gas cleanup system with 99.99% removal efficiency
MIFGA ProjectSingle Stage Gasifier Schematic
MIFGA ProjectImpact on Capital Steam Plant Study
• KY coal gasification performance quantified
• Product gas quality known• Coal liquids quantified• System performance & economics
quantified• Environmental impact known• O&M known
Capital Steam PlantHMI Gasification Economics
Gasifier Island$18.8 million
Net Power 40.3 MWe
Gasifier Island installed @ $466/KW
MIFGA ProjectARI selected HMI Gasifier
• Gasifier design and performance demonstrated (fuel flexible)
• High gasification conversion efficiency (80-85%, gas+liquids)
• Simple and reliable gasifier operation • Flexible fuel experience and knowledge• HMI O&M capabilities desired by ARI• HMI gas cleaning technology & experience
Ansaldo RicercheContracts/Collaboration
• Early 1998
ARI began evaluating mild gasification technologies worldwide
• Late 1998
ARI selected HMI, Inc. as technical partner
• December 1998
Signed HEADS of the AGREEMENT
Ansaldo RicercheContracts/Collaboration
• Q1 2000 HMI, Inc. Biomass Gasifier design completed
• Q2 2001 HMI/ARI gasifier fabrication and installation
completed
• July/August 2001 HMI commissioned 1.3m HMI/ARI gasifier– Started on coke– Initial biomass faggio (beech wood) chips– Commissioning complete success
HMI/ARI Gasifier
Performance:
• 1.3 Meter Diameter• Coal throughput: 0.7-1.0 T/hr• Clean gas: 14-16 MM/BTU/hr• Electrical output: 0.7-1.0 MWe
HMI/ARI Gasifier
R&D Activities:• Flexible fuel pellet development
• Automatic bed level and fuel feed
• Automate grate drive and ash management
• Process control via continuous gas analysis
• Gas cleaning for both fuel cell & gas engine implementation
HMI/ARI GasifierFaggio Woodchip Feed
MN Peat pellets (MIFGA)
• Excellent gasification performance
• Hot-raw gas yields 92% conversion efficiency ( 60 MMBtu/hr/10-ft dia unit)
• Mosaic/HMI will establish integration and utilization of Hot-raw gases in dryers
• Degree of gasifier automation will be jointly defined by HMI & Mosaic
MN Peat Pellets Proximate & Ultimate Analyses
Proximate Analysis (%) Ultimate Analysis (%) Volatile Matter 42.20 Carbon 34.30Fixed Carbon 16.10 Hydrogen 3.50Ash 7.30 Nitrogen 1.60Moisture 34.40 Sulfur 0.20Sulfur 0.20 Oxygen 18.70
Ash 7.30Moisture 34.40
MN Peat Pellets Proximate & Ultimate Analyses
Heating Value: 6,092 BTU/lbAsh Fusion Temperatures (Deg F)
Oxidizing ReducingInitial deformation 2135 2050Softening 2155 2085Hemispherical 2205 2100Fluid 2220 2135
Free Swelling Index (FSI): 0
MIFGA ProjectMN Peat pellets Product Gas
Dry Gas Composition (Mol %)Hydrogen 17.20Carbon Monoxide 28.40Methane 1.46Ethane 0.10Ethylene 0.087Propane 0.024Propylene 0.04Carbon Dioxide 7.97Nitrogen & Argon 44.3
Dry Gas HHV 168 Dry Gas LHV 158
MIFGA ProjectMN Peat pellets Design Performance
MN Peat gasification throughput (120 lb/hr/sq-ft grate)Air/Peat 1.29 lb/lbSteam/Peat 0.19 lb/lbSaturation Temperature 139 ºFGas Offtake Temp 251 ºFGas Dewpoint 153 ºFTar Yield 7.9 lb/100 lb-peatTar HHV (dry) 15,552 Btu/lbTar Pour point 110 ºFTar Specific gravity (60/60 ºF) 1.0491
Vision 21
Overall US DOE Goal:
Effectively eliminate, at competitive costs, environmental concerns associated with the use of fossil fuels.
Vision 21 Goals
• Efficiency – Electrical generation 60% for coal-based systems
• Environmental – <0.01 lb/MMBtu sulfur & NOx
<0.005 lb/MMBtu particulate<50% emission rates organic compounds<1 lb/trillion Btu, Hg
50% reduction in CO2 via efficiency gains
• Costs – Must be cost competitive• Timing – Major improvements by 2007
Vision 21 Proposal Objectives
• Demonstrate fuel flexibility (coal & biomass)• Demonstrate nominal $0.00 cost for industrial fuel
pellets• Utilize air blown fixed-bed industrial gasifier• Clean gas for fuel cell or gas engine operation• Gas used for various power generation systems
(0.5 – 10MWe)• Demonstrate 50+% efficiency using fuel cells for
power generation
Vision 21 ProposalIndustrial Gasification Economic Objectives
• Coal/Biomass pellets cost < $0.00
• Industrial gasifier island installed for
< $500/KW
• Operational costs at industrial site
< $50/Kwyr
• Clean fuel gas cost < $3.00/MMBTU
Vision 21 ProposalThree Phase Project
• Phase I Coal/Biomass pellet development
• Phase II Demonstrate gasification performance of best
commercial pellets
• Phase III Demonstrate gas cleaning & fuel cell performance/efficiency
Vision 21 ProposalHMI/CPM Pellet Development
• Car fluff and coal pellet development
Action Plan(HMI & Mosaic)
• Scope & Begin Feasibility Study for waste wood by 12 June 2006 and complete by mid August 2006 (8 weeks)
• Begin Permitting Process by First of September 2006
• Deliver Hot-raw Gas to Mosaic’s dryer by end of August 2007