Syngas routes to alternative fuels - John Bogild Hansen

John Bøgild Hansen - Haldor Topsøe Alkmaar, October 2, 2014

Syngas Routes to Alternative Fuels from Renewable Sources

We have been committed to catalytic process technology for more than 70 years

¡  Founded in 1940 by Dr. Haldor Topsøe ¡  Revenue: 700 million Euros

¡  2700 employees

¡  Headquarters in Denmark

¡  Catalyst manufacture in Denmark and the US

Gasification process

Biomass Coal

Natural gas etc.

Raw materials for gasification

Hydrogen

Methanol

Power

Ammonia

Products

Synthesis gas

CO, H2, CO2, CH4

Building blocks

etc.

SNG

Tar removal

Tar reforming – Enabling technology for biomass gasification ¡  Gasification of biomass results in a syngas that contains

tars and contaminants –  1000 -2500 ppm tar –  50 – 100 ppm S, particulates

–  850-930°C, 1-30 bar g

–  Ammonia decomposition

BIOMASS

ASH

GASIFIER TAR REFORMER

Topsoe Tar Reforming in Skive ¡  Topsoe monolithic tar

reforming catalyst was started up late August 09

¡  Low ammonia slip

¡  Low methane exit

¡  Low dP

“Dusty” tar reforming

PROCESSING & UTILIZATION

TAR REFOR

MER

BIOMASS-FEED

ASH

GASIFIER

“Dusty” tar reforming

10-30 g dust / Nm3

HOT GAS FILTER

Skive Fjernvarme a.m.b.a. (Skive CHP)

Location Skive, Denmark

Capacity 21 MWth, Max 28 MWth

Operational year 2009

Fuel consumption 100 TPD

Fuel Biomass, wood pellets

Gasification techn. Air blown, bubbling fluidized bed

Pressure range 1 – 3 bar g

Power generation Gas engines

Skive Fjernvarme a.m.b.a. (Skive CHP)

“Clean” tar reforming

PROCESSING & UTILIZATION

TAR REFOR

MER

BIOMASS-FEED

ASH

DUST

HIGH TEMPERATURE HOT GAS FILTER

QUENCH GAS “Clean” tar reforming

1 -10 mg dust / Nm3

GASIFIER

Nickel-based

Gas Technology Institute, Chicago

Location Chicago, USA

Capacity ~ 4 MWth

Fuel consumption 18 TPD

Fuel Biomass, wood pellets

Gasification techn. Oxygen blown, bubbling fluidized bed

Pressure range 1-9 bar g

Gas Technology Institute, Chicago

¡  Tar reformer ~ 1150 run

hrs

¡  No soot formation

¡  15 min. lack of oxygen

–  No deactivation!

750 – 950 °C

1050 – 1375 Nm3/h

Full tar conversion

30 – 160 ppmv H2S

DME the versatile fuel

TIGAS

Con

vers

ion

(H2+

CO

)

Pressure (bar g)

0

20

40

60

80

100

0 20 40 60 80 100

MeOH

MeOH / DME

Syngas to MeOH/DME Equilibrium

0.5 1 1.5 2 2.5

H2/CO

0%

Equi

libriu

m, m

ol%

20%

40%

60%

80%

100%

H2

CO

CO2

DME MeOH

H2O

T = 250°C

H2 = 51 CO = 48 CO2 = 1

Optimum ratio at H2:CO ≈ 1

Methanol from sustainable sources

BioDME Black Liqour to Green DME Demo

CO2 Black Liq.

Water

WGS Sulphur

Guard

MeOH Synthesis

AGR DME

Unit

Methanol Synthesis

Gasoline

C3-C4

Water

MTG Methanol To Gasoline

MeOH↔DME Gasoline Synthesis Separation

Day Tank (Raw Methanol)

Synthesis Gas

MeOH/DME Synthesis

TIGAS Topsøe Integrated Gasoline Synthesis

25 bbl/d Demonstration Plant

OXYGEN

BIOMASS

ASH

GASIFIERTAR REFORMER

BIOMASS

ASH

GASIFIERTAR REFORMER

TAR

REFO

RM

ER

BIOMASS

GA

SIFIER

ASH

http://www.energy.gov/news2009/releases.htm

Gasoline MeOH/DME / N

2

Gas Cleaning OXYGEN

MeOH /DME

Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes

Fuel Cell and Electrolyser

½O2

H2 H2O

½O2

H2O + 2e- → H2 + O2- O2-

O2- → 2e- +½O2

H2 + O2- → H2O + 2e- O2-

½O2 + 2e- → O2-

SOFC SOEC H2 H2O

H2 + CO + O2 H2O + CO2 + electric energy (∆G) + heat (T∆S) SOFC

SOEC

SOEC more efficient than present Electrolysers Internal waste heat used to split water

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

0 100 200 300 400 500 600 700 800 900 1000

Deg C.

kWh

per N

m3

H2

Minimum Electricity Input

Waste heat which can be utilised to split water

Energy needed to evaporate water

Electrolysis

CO H2 CO2

Power Steam CO2

Hydrogen SNG Methanol DME Gasoline Diesel

Syngas

GreenSynFuel Project

Mass Flows in Wood to MeOH

Mass Flows in Wood + SOEC to MeOH

Effciencies: Stand alone wood gasifier and gasifier plus SOEC

LHV Efficiency %

Wood Gasifier

alone

Wood gasifier Plus SOEC

Methanol 59.2 70.8 District Heat 22.6 10.8 Total 81.8 81.6

Synergy between SOEC and fuel synthesis

SOEC Synthesis CO2

H2O

Syn Gas

Product

Steam

Using the gas system as a key integrator

Biogas in the future integrated energy system

0

200

400

600

800

1000

1200

1400

Wind Sun Wave Heat (sun, geo. and

heat pump)

Biomass and waste (incl.

slurry)

PJ p

er y

ear

Used today (2008)

Potential

2050 (recommendation)

26

Domestic renewable resources to reach 100 per cent renewable energy by 2050 Danish Commission on Climate Change Policy, 2010

Fluctuating power production

Gross energy consumption 2008

Gross energy consumption 2050

Energinet.dk analysed high wind scenario

Wind scenario

2012-04-23 Renewable gases as a flexibility provider for the power grid

Source:

Conclusions ¡  Dusty tar reforming is now commercially proven ¡  Clean tar reforming has been demonstrated in

connection with succesful meOH/DME and gasoline synthesis at 25 bbl/day

¡  Sustained black liquor to DME has been proven at 4 MTPD scale and truck operation as well

¡  Coupling SOEC with biomass gasification can double the biomass potential by converting excess carbon.