SECTOR - Production of Solid Sustainable Energy Carriers ...€¦ · Production with available pilot scale facilities Typical test runs 50-100 hours Typical production per test few

This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration

under grant agreement n° 282826

New results of the SECTOR Project: Solid Sustainable

Energy Carriers from Biomass by Means of Torrefaction

A European R&D Project funded within the Seventh Programme for

research, technological development and demonstration by the

European Union

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Helsinki, 16.09.2014

D. Thrän, K. Bienert, M. Carbo, J. Kiel, U. Wolfesberger-Schwabl

Bionergy from Forest Topic 3: Processes for Solid Fuels from Forest Biomass

© 1,5,6: ECN; 2-4 Jasper Lensselink



The SECTOR project

Collaborative project: SECTOR

Project start: 01.01.2012

Duration: 42 months

Total budget: 10 Mio. Euro

Participants: 21 from 9 EU-countries

Coordinator: DBFZ

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© DBFZ



SECTOR objectives

Support the market introduction of torrefaction-based bioenergy carriers as a commodity renewable solid fuel

Further development of torrefaction-based technologies (up to pilot-plant scale and beyond)

Development of specific production recipes, validated through extensive lab-to-industrial-scale logistics and end-use performance testing

Development and standardisation of dedicated analysis and testing methods for assessment of transport, storage, handling logistics and end-use performance

Assessment of the role of torrefaction-based solid bioenergy carriers in the bioenergy value chains and their contribution to the development of the bioenergy market in Europe

Full sustainability assessment of the major torrefaction-based biomass-to-end-use value chains

Dissemination of project results to industry and into international forums (e.g. EIBI, EERA, CEN/ISO, IEA and sustainability round tables)

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project structure


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© DBFZ



Torrefied biomass properties in perspective

Wood chips Wood pellets Torrefied wood

pellets

Charcoal Coal

Moisture content (wt%) 30 – 55 7 – 10 1 – 5 1 – 5 10 – 15

Calorific value (LHV, MJ/kg) As received

7 – 12 15 – 17 18 – 22 30 – 32 23 – 28

Volatile matter (wt% db) 70 – 84 75 – 84 55 – 80 10 – 12 15 – 30

Fixed carbon (wt% db) 16 – 25 16 – 25 22 – 35 85 – 87 50 – 55

Bulk density (kg/l) 0.20 – 0.3 0.55 – 0.65 0.65 – 0.80 0.18 – 0.24 0.80 – 0.85

Vol. energy density (GJ/m3) 1.4 – 3.6 8 – 11 12 – 19 5.4 – 7.7 18 – 24

Hygroscopic properties Hydrophilic Hydrophilic (Moderately)

Hydrophobic

Hydrophobic Hydrophobic

Biological degradation Fast Fast Slow None None

Milling requirements Special Special Standard Standard Standard

Product consistency Limited High High High High

Transport cost High Medium Low Medium Low

Abbreviations: db = dry basis LHV = Lower Heating Value wt% = weight percentage


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© ECN

© OFI © 1 and 3: ECN; 2: Thomas Siepmann/ PIXELIO; 4: ofi; 5: Gabi Schönemann/PIXELIO



© DBFZ

TORREFACTION

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Torrefaction (WP3)

Activities: Execute series of lab/batch and pilot tests in different torrefaction facilities in order to:

• Further optimise torrefaction technologies (ECN, Umea Univ, CENER, Topell) • Broaden the feedstock range • Produce solid sustainable bioenergy carriers with properties that meet

requirements set by subsequent densification, logistics and end use



Torrefaction technologies


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Production with available demo plant Continuous operation

Production of 100-200 tons Specific feedstock

Production with available pilot scale facilities Typical test runs 50-100 hours

Typical production per test few tons 3-6 different feedstocks

Moving bed* (ECN) pilot

Rotary drum (Umeå University)

pilot

Rotary drum (CENER)

pilot

Toroidal (Topell) demo

Different technologies

* And the resulting Andritz/ECN technology, successfully demonstrated in Denmark at a scale of 1 ton/h



© DBFZ

DENSIFICATION

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Densification Process (WP4)

Activities: Lab-scale densification

• Testing of torrefied biomass provided by SECTOR partners

• Parametric study

• Data collection and analysis Feedback and process optimisation

Bench-scale/industrial-scale densification

• Production in pilot plants of CENER, UMU, ECN and Topell

• Data collection and analysis Process improvement



Densification - Example: Single Pellet Tests – Torrefied Spruce

(DTI)

with increasing torrefaction temperature:

• Friction and max. force are increasing

• Unit density is decreasing


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Energy to push pellet 1 cm in pellet die

Maximum force to initiate pellet movement

© DTI

© DTI © DTI © DTI



Densification: Pilot-scale tests (CENER)

Optimisation of densification process


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Image © Andritz © Image from Andritz

Parameters optimized: - Particle size of feedstock - Moisture content of feedstock - Torrefaction degree of feedstock - Die: diameter/length - Die rotation speed



Densification: Pilot scale densification (DTI)


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Briquetting tests:

Material torrefied at ECN: Spruce and Bamboo

Briquetting tests DTI in cooperation with CF Nielsen

Briquetting gets more challenging with increasing torrefaction degree

Keeping the briquette hot and under pressure for extended time improves quality

Good quality: Smooth surface, high density, stability but still optimization potential

Materials tested

Spruce

240 °C

260 °C

280 °C

Bamboo

245°C

255°C

265°C

300 kg each

material



© DBFZ

DEMONSTRATION TESTS (WP5)

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Demonstration Tests (WP5)

Proof of concept of Topell torrefaction system in 2013 at commercial scale for forest residues

Demonstrated continuous production of torrefied pellets with the product quality required by end users (biomass co-firing biomass)

Achieved and demonstrated full heat integration within the plant use of torgas to supply most of the heat demand of the plant, including drying and torrefaction

Production for successful co-firing trial (2300 tonnes, 5-25 wt% co-milling and co-firing in RWE/Essent Amer 9 power station) (conducted outside SECTOR)



© DBFZ

LOGISTICS

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Logistics (WP6)

Activities:

Characterise logistics performance:

• First by small-scale tests, later followed by larger-scale outdoor

storage and handling tests

• Assess various logistic aspects and produce optimised torrefaction-

based bioenergy carriers

• Test optimised pellets under real case conditions, e.g. in existing coal-

handling lines



Logistics - Outdoor storage and handling tests (EON)

Two outdoor storage piles were built in June 2013:


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Flat-topped pellets Model the formation of pellets after com-

paction (though no compaction has occurred)

3 tonnes

2.34 x 2.36 x 1.5 m

Peaked-topped pellets

Model the formation of pellets after it

has been delivered.

4 tonnes

2.34 x 2.36 x 1.5 m

© EON © EON




In-situ measurements

• Temperatures in piles

• Weather data (ambient temp, humidity, wind speed, wind direction, rainfall)

Sampling

• Surface and middle of each pile

Physical parameter tests

• Pellet durability

• Diameter

• Particulate size

• Particle distribution

Proximate Analysis

• Moisture

• Ash

• Volatiles

• Calorific Value


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Pellet durability as function of time


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60

65

70

75

80

85

90

95

100

105

0 10 20 30 40 50 60 70 80

Du

rab

ility

(%

)

Time (Days) Peak Middle Flat Middle Peak Surface Flat Surface



Logistics - Achieved results

Outdoor storage and handling tests (EON)

• Temperature profile in piles follows ambient temperature closely (few degrees C higher in piles)

• Continuously increasing moisture content of pellets observed on a monthly basis. Inside as well as close to the surface of the piles.

• Heating value of pellets (LHV, as received) has decreased due to the increased moisture content. On dry basis no difference observed indicating very minor losses due to biological activity or losses through leachate.

• Mechanical integrity of pellets close to surface has decreased; pellets close to the surface are porous and disintegrate easily. Updated mechanical durability tests to be carried out on final samples.

• Note: storage tests were conducted during 9-10 month period; strategic reserve at power plant is typically 2-3 weeks


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Image © Andritz © Image from Andritz



© DBFZ

END USE

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End use (WP7)

Activities:

End-use applications of torrefied biomass:

• Milling and feeding tests

• Medium-to-large scale firing and co-firing in pulverized-fuel boilers

• Medium-to-large-scale gasification and co-gasification in entrained-

flow gasifiers

• Small-scale combustion in commercial pellet boilers

• As feedstock or co-product for the production of bio-chemicals or bio-

materials



End Use - Milling & feeding

Milling tests performed at USTUTT in a hammer mill (200 kg/h):

Torrefied pellets from Topell (woodmix), ECN (Spruce), CENER (Beech and

Pine), and reference white wood pellets.

Preliminary results show significantly lower energy consumption for

torrefied pellets with finer and more spherical material output.

Preliminary results of feeding tests for both 20 kW and 500 kW PF

burners at USTUTT show no bridging and agglomeration problems.


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End use: Milling and feeding (ECN)

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Glass beads Coal

Raw Spruce Torrefied spruce chips Torrefied spruce pellets

Importance of particle morphology



End use: (Co-)gasification in EF gasifiers (Vattenfall)

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NUON/Vattenfall Buggenum IGCC Plant:

• 253 MWe power plant, entered service in 1993

as a coal gasification demonstration plant,

closed in 2013

• Hard coal as main fuel with continuous co-

gasification of saw dust up to 15 wt%

• Trial (outside SECTOR, but results brought in): • 1200 tonnes of torrefied fuel co-gasified with

hard coal in a 24 hours trial • Mixing rate ~70% on energy basis


Main observations during tests in 2012:

• No big technical challenges during conveying, sluicing and milling of torrefied

pellets/coal blend

• Estimated to be possible to achieve 90% of the plant nominal capacity without

major modifications in the fuel feeding system

• Higher heating value in the pellets connected to better milling properties but less

advantageous dust formation behaviour



End use: Commercial pellet boilers (TFZ, BIOS, BE2020)

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Torrefied pellets can be applied in commercial small-scale wood

pellet boilers and may provide the same or even higher combustion

efficiency as obtained with wood pellets, given the following

considerations:

• Slightly higher fixed carbon content in torrefied pellets vs. need for

burnout time (adaptations of grate and burnout zone possibly required)

• Air ratio and air-staging may require some adaptations

• Pollutant emissions (CO, VOC, NOx and PM) depend on wood resources

used, similar as for wood pellets. Higher expected fuel bed

temperatures may lead to higher fine particle emissions

• Ash and slag related problems may occur earlier due to higher ash

content

Experimental work is supported by CFD modelling



FUEL SPECIFICATION AND ANALYSIS

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© DBFZ

Fuel specification and analysis (WP8)

Activities:

Round Robin test 1 concluded: Validation of “standard” test methods for torrefied pellets:

• 43 participants, 18 countries, 11 parameters

• Ash, moisture content, chlorine and sulfur content, CHN analysis – comparable to solid biofuels performance in BIONORM II Round Robin test

• Net calorific value – reproducibility limit is higher than for solid biofuels

• Ash melting behaviour – reproducibility of deformation temperature is high; subjective method

Proposal for product standard for torrefied materials (thermally treated biomass):

• ISO 17225-1 publication date: April 2014

• ISO 17225-8 work item accepted Jan. 2014 – developed until 2016



© DBFZ

VALUE CHAINS AND

SUSTAINABILITY

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Value chains and sustainability (WP9)

Activities: assessment of the environmental and socio-economic impacts of torrefied

solid biomass in different value chains



WP9: Achieved results - Task 9.3 LCA


1.5 – 10.311.3 – 28.2 14.4 – 22.6

86.1 – 130.0

208.14

423.3 – 694.2

749.9

818.9

0

100

200

300

400

500

600

700

800

900

hydropower1

wind power

onshore1

wind power

offshore1

photovoltaics1

torrefied

pellets2

pellets2 biogas

2

(renewable

resources,

liquid manure)

natural gas1 hard coal

(ZA)2

Renewable energies Fossil fuels

co-firing

of tor. pellets2

GH

G e

mis

sio

ns in

g C

O2-e

q./kW

h

Range

99.0 – 286.0

175.8

685.7 – 752.3

co-firing

of pellets2

1 ecoinvent 2.1, gemis (profiles in annex A2)

2 DBFZ in-house calculations (profiles in annex A2)

93.8

wood-fired

CHP1

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Exemplary results: comparison of GHG mitigation potentials against reference options



CONCLUSION & OUTLOOK

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© DBFZ



Conclusion

EU-FP7 project SECTOR well underway (successful mid-term review)

Wealth of experimental lab-to-demo scale data generated on torrefaction,

densification, and product properties and performance in view of logistics and

end-use (co-firing, entrained-flow gasification and small-scale combustion),

and a lot more to come

Within SECTOR, over 100 tonnes of torrefied material produced and densified

This has allowed:

• Improved fundamental understanding of torrefaction and densification

• Improved performance of the torrefaction and densification technologies involved (e.g. in terms

of energy efficiency and availability)

• Gradual improvement of torrefied pellet properties and a better understanding of how to

optimise logistics and end-use

No show stoppers for torrefaction identified yet (but be realistic and do not

support the hype)

Product standardisation started

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Outlook

Expected future SECTOR results include:

• Full sustainability assessments (environmental, economic and social)

• Development of new “non standard” analysis methods for complete description of

torrefied material and proposals for standardisation

• Material Safety Data Sheets (MSDS)

• Data incorporation into ECN Phyllis/BIODAT biomass properties database

Torrefaction is ready for commercial market introduction, but:

• This appears more difficult (take more time) than initially anticipated

• Co-firing in European coal-fired power plants may not be the primary market

opportunity

• Other markets (e.g., gasification-based biochemicals and biofuels production,

distributed/industrial heat generation) and/or other regions (e.g. South-East Asia)

may be more attractive

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thank you very much for your attention

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Coordination & Speaker: Prof. Dr.-Ing. Daniela Thrän DBFZ gGmbH Torgauer Str. 116 04347 Leipzig Germany www.dbfz.de

SECTOR contact: Marlen Ristola t: +49 (0) 341 2434 588 e: [email protected] w: www.sector-project.eu

© Karl-Heinz Liebisch/PIXELIO


http://www.dbfz.de/

http://www.sector-project.eu/



SECTOR - Production of Solid Sustainable Energy Carriers ...€¦ · Production with available pilot scale facilities Typical test runs 50-100 hours Typical production per test few

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