demartini energy in thermal conversion 2010 - Åbo...
TRANSCRIPT
Energy in Thermal ConversionEnergy in Thermal Conversion
Nikolai DeMartini
The Forest Based Biorefinery, 3‐7 May 2010
IntroductionIntroduction
• Many mass and energy balances aroundMany mass and energy balances around various ”scenarios” for the biorefinery
• All scenario’s have technical challenges and• All scenario s have technical challenges and there are nth plant assumptions
E di ib i f d• Energy, distribution of energy needs, reduction in carbon footpring all variables that h ld b id dshould be considered
Overview• Opportunities• Energy use in Finland• Energy use in Finland• Energy distribution in pine & birch• ”Minimum” value of ligninMinimum value of lignin• Example: energy use in BL gasification to liquid fuels
• Example: pyrolysis and catalytical hydrogenation of pyrolysis oilG l t i t ti• General comments on integration
• Well to wheel analysis
Opportunities in EnergyOpportunities in Energy
• Increasing world‐wide energy demandg gy• Increasing pressure for reduced CO2 emisisonsFinland not only has the possibility to produce more bio‐energy, but more importantly has the potential to export more of the technology to produce itproduce itKnowledge based economyThis is a growth industry – existing technologies g y g ghave not been proven/optimized for biomassEntrepreneurial opportunities
Energy Use in Finland 2008Energy Use in Finland 2008
• TotalNatural Total• 1.45x1018 J/y
• Chemical
Olja22,9 %
Vindkraft0,1 %
Naturgas10,9 %
Oil22.9%
Gas10.9%Wind
0.1%
energy bound in tree growth Nettoimport
Träbaserade bränslen21,9 %
Import
Tree based combustion 21.9%
in Finland• ~9x1017 J/y (100 Mm3 500
av el3,3 %
Kärnkraft
Vattenkraft4,4 %
Electricity3.3%Water power
4.4%Nuclear (100 Mm3, 500
kg/m3, 18 MJ/kg)
Kärnkraft17,4 %
Kol10,3 %
Övriga2,9 %
Torv5,9 %
Peat5.9%
Coal10.3%
Nuclear17.4%
Other2.9%
Chemical composition of pine (Pinus sylvestris) and birch (B t l d l ) % d b t(Betula pendula), % dry substance
100 % Extractives < 5%< 5%
80 % Lignin
< 5%
20-25%25-30%
< 5%
60 %Hemicelluloses
d ti
30-35%25-30%
40 %and pectins
0 %
20 %Cellulose
40%40%
0 %
Pine Birch
Approx. Lower Heating Values of Biomass Components
Component Heating ValueComponent Heating Value (MJ/kg)
Carbohydrates 13 6Carbohydrates 13.6Softwood lignin 26.9Hardwood lignin 25.1Resins, fatty acids 37.7
Pine BirchPine
Extractives 3 % %Extractives
BirchLHV 18 MJ/kg LHV 17 MJ/kg
29 %42 %
3 % 6 %
Lignin
Extractives
24 %35 %
3 % 7 %
Lignin
29 %
21 %Hemicellulose
34 %27 %Hemicellulose
40 % 30 %Cellulose 40 % 32 %Cellulose
Mass Energy Mass Energy
Fractionation followed by ConversionFractionation followed by Conversion
Harvesting + preparation
CelluloseProcessing Materials,
chemicals fuels
Solid Bi Hemicellulose
Processing
chemicals, fuels
Materials, h i lBiomass Hemicellulose
Materials
chemicals
P i
These scenarios alternative
Lignin Fuels/ChemicalsProcessing
Heat & Energy
energy needed
Heat & Energy for Process
700160Minimum Value of Lignin –M t i l E
600
120
140
lacemen
t
)
Materials vs. Energy
400
500
100
120
on oil rep
ton)
($/barrel)
*LHV 25.8 MJ/kg lignin
300
400
60
80
nin ba
sed
$/metric t
rice fo
r oil
20040
60
alue
of Lig (
Spot pr
0
100
0
20
Fuel Va
okt 28, 1995 jul 24, 1998 apr 19, 2001 jan 14, 2004 okt 10, 2006 jul 06, 2009 apr 01, 2012
Lindgren, Karen. Potential lignin applications beyond energy 2nd Nordic Wood Biorefinery Conference. Helsinki, Finland Sept. 2‐4, 2009.
Example – BL Gasification to Liquid lFuels
• Energy from BL used to supply the pulp mill withEnergy from BL used to supply the pulp mill with electricity and steam
• Modern stand alone pulp mill is capable ofModern stand alone pulp mill is capable of producing excess energy in the recovery boiler
• BLG to liquid fuels would result in an export of• BLG to liquid fuels would result in an export of energy from the mill
• In future BLG to liquid fuels may make sense• In future BLG to liquid fuels may make sense relative to biomass gasification in this sense –combust biomass in biomass boiler and gasify BLcombust biomass in biomass boiler and gasify BL
SteamTurbine
Bark Biomass
Syngas recycle
Fusel Oil
ctricity
Syngas to Synthesis235.4 MWt (67%)
15.2 MWe
Air Separation
MeOH synthesis
ZnO guard bed
Boiler
Woo
d
Power
Steam
Syngas purge for inerts
O2 N2
CO2 toPulp mill
Elec
O2
Supply
BLG1
Syngas compression to
~60 bar
BLG2
CCC1
CCC2
DME synthesis
Solvent Stripper
Pulp Mill
BL Storage Rectisol
– CO2
removal
Water‐
MeOH/DME distillation
d
BLG3
BLG4
CCC3
CCC4Lo‐Sulfur
Stripper
DME168 MWt
GL Storage
WL bb
Rectisol –H S/COS
WaterGas shift reactor
Product storage
Lo‐SulfurWhite Liq.
Green Liq.
Solvent Stripper
S rich solvent + tars
S rich gasClean gas
t(48%)
For BL to FTD33% di lscrubber
for Sulfur capture
H2S/COS removal
High‐SulfurWhite Liq.
StripperRegen. solvent
BLG: black liquor gasification(950 °C, 32 bar, 4 units – 33% capacity each)CCC: counter current condenser
33% diesel17% naphtha
1430 metric tons/d Bone dry Pulp
CCC: counter current condenser(~29 bar, ~225 °C)BLin
350 MWt
Ekbom, et al. (2003); Larson, et al., (2006)
Steam also produced, but not enough for mill w/o boiler
Integration Example: Impact of Gasifier d lPressure on Steam Production in Cooler
Scale for FinlandScale for Finland
• If all of the BL in Finland was gasified theIf all of the BL in Finland was gasified, the analysis by Ekbom et al. (2003) estimates that ~50% of Finland’s transportation fuels could50% of Finland s transportation fuels could be replaced (based on 1999 fuel consumption and 2000 BL production)and 2000 BL production)
• Technology not yet proven
R b il i Fi l d l i l• Recovery boilers in Finland are relatively new
Economy of ScaleEconomy of Scale
Feedstock to Liquid Liquids Capacity Capital IntensityFeedstock to Liquid Transporation Fuels
Liquids Capacity(barrels/d diesel equiv.)
Capital Intensity($/ barrel/d)
Petroleum refining ~150 000 15 000Gas to liquid fuels ~100 000 to 150 000 25 000 to 50 000Gas to liquid fuels 100 000 to 150 000 25 000 to 50 000Coal to liquid fuels ~100 000 to 150 000 50 000 to 70 000BL/Biomass to liquidf l
~1 000 to 7 000 60 000 to 150 000fuels
Larson, E.D.; Consonni, S.; Katofsky, R.E.; Iisa, K.; Frederick, W.J. Jr. A cost‐benefit assessment of gasification‐based biorefining in the Kraft pulp and paper industry Vol 1 Main Report Final Report DE FC26 04NT42260 21 Dec (2006) 152 ppthe Kraft pulp and paper industry. Vol. 1: Main Report. Final Report DE‐FC26‐04NT42260, 21 Dec (2006), 152 pp.
BLGasification Combined CycleGenerationkWh/ADt
ConsumptionkWh/ADt
SaleskWh/Adt
/ fNew pulp mill w/ pressurized gasification
High Temp 2100 1050 1050
Low Temp 2100 920 1180
New pulp mill w/ RB
Conventional RB 1450 700 750
High power to heat RB 1700 730 970High power to heat RB 1700 730 970
Pulp Mill producing ~450 000 ADt/a → 70 Mwe gas turbine (GE6FA)~1 600 000 ADt/a → 250 Mwe gas turbine (GE7FA)~1 600 000 ADt/a → 250 Mwe gas turbine (GE7FA)
Poor turndown so need natural gas to substitute for syngas when production dropsFor gas valves on gas turbines (~500 °C is upper limit) so some gas cooling necessaryNa+K is manufacturer specific ~0.1 ppm in the syngas
Grigoray, M.Sc. LUT 2009; Vakkilainen et al. Pulp Pap Can, 2008
Sulfur ~10‐20 ppm depending on flue gas emissions control
Black Liquor Gasification – Current Status
MTRI f 600 °C 3• MTRI steam reformer, 600 °C, 3 atm– Norampac, Trenton, ON, June 2003
d /d– 100 tds/day
– This technology is no longer pursued
• Chemrec DP‐1: 30 bar; 950 °C; O2‐blown – Kappa Kraftliner in Piteå, Sweden (2005)Kappa Kraftliner in Piteå, Sweden (2005)
– 20 tDS/24h (3 MWth)
Bioraff 24 November 2009
Possible Mill DemonstrationPossible Mill Demonstration
• Domsjö Fabriker Örnsköldsvik SwedenDomsjö Fabriker, Örnsköldsvik, Sweden– Sulfite biorefinery producing specialty cellulose, lignin (lignosulfonate), ethanol( g )
– Plan to gasify 1100 t dry solids/day sulfite liquor
– Plan to use syngas to produce methanol (up to 450 tons/d) and/or dimethyl ether (DME) (up to 300 tons/d)
i i l f 0 $ f h– Decision on approval of a 70 M$ grant from the Swedish Energy Agency to be made by EU by the end of 2010of 2010
Thermal Conversion Routes w/o Fractionation
Oil to a Harvesting + Gas/Diesel
Pyrolysis
petroleum refinery
Pyrolysis Oil(acidic, high O2 content)
Hydrotreating
Catalytic
preparation
Gasification
Trasnport
Solid F l
+O2, hvGasification
CO, CO2, H H O
Fuels (MeOH, DME, FT)
Catalytic Upgrading
Gas cleaning, WGS, CO2removal CO, H2
Gasification
Fuel
Combustion
H2, H2OElectricityGas Turbine
removal
(alone or co‐combustion w/ coal)
CO2, H2O + heatSteam turbine
Electricity
IndustryIndustry, household, electric vehicles
Example – Pyrolysis of PoplarExample Pyrolysis of Poplar
100% of Energy In 60% of Energy In
Jones, SB; Holladay, JE et al. Production of Gasoline and Diesel from Biomass via Fast Pyrolysis, Hydrotreating and Hydrocracking: A Design Case. PNNL DOE Contract DE‐AC05 76RL 01830
BtL via pyrolysis + gasificationBtL via pyrolysis + gasificationAdvantage is transportation of biomass and larger scale of Gasification + Fischer‐Tropsch
Pyrolysis
PyrolysisPyrolysis
G ifi ti
y y
Gasification + Fuel Synthesis
PyrolysisPyrolysis
PyrolysisPyrolysis
Pyrolysis
IntegrationIntegration
• Gasification to Liquid Fuels/Chemicals→ userGasification to Liquid Fuels/Chemicals → user for steam produced from syngas cooling and catalytic processescatalytic processes
• Pyrolysis to liquid fuels → hydrogen source, refiner for bio oilrefiner for bio‐oil
• Integration improves the economy of the i l ll lcomparatively small scale
Well‐to‐Wheel Analysis11 % 11 % 11 %
10 % 9 % 9%10%
12 %
9 %
6%
8 %
10 %
4 %
6 %
0 %
2 %
DME di l GH2 FC h b M OH LH2 FC h b EtOH di l FTD di l
Ekbom T ; Lindblom M ; Berglin N ; Ahlvik P Technical and commercial feasibility study of black liquor gasification with methanol/DME
DME diesel‐hyb
GH2 FC‐hyb MeOH diesel‐hyb
LH2 FC‐hyb EtOH diesel‐hyb
FTD diesel‐hyb
Ekbom, T.; Lindblom, M.; Berglin, N.; Ahlvik, P. Technical and commercial feasibility study of black liquor gasification with methanol/DME production as motor fuels for automotive uses – BLGMF. (ALTENER programme of the European Union, Contract No. 4.1030/Z/01‐087/2001), (2003)Ahlvik, P., Brandberg, Å., Hådell, O., Gustafsson, P., “Well‐To Wheel Efficiency for alternative fuels from natural gas or biomass” Swedish National Road Administration, Vehicle Standards Division October 2001
Challenges• Batteries & Fuel Cells
– More environmentally benign batteries with adequate performanceF el cells that can handle more rob st f els– Fuel cells that can handle more robust fuels
– In long term could significantly alter electricity/fuels consumption• Catalysis
Pyrolysis oil upgrading (both post or in situ)– Pyrolysis oil upgrading (both post or in‐situ)– Pyrolysis + in‐situ chemical processing
• Materials– High temperature corrosion (oxidizing and reducing gas atmospheres)High temperature corrosion (oxidizing and reducing gas atmospheres)
• Gas turbines– For lower heating value syngas
• Process IntegrationProcess Integration– Maximize heat integration & use of existing infrastructure– Process integration when proceeded by some fractionation
• Installation and maturationInstallation and maturation