Doubling of synthetic biofuel production via H2 from RES
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Talk held in a seminar organised by Chalmers Technical University. Dec 5th 2014
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Doubling of synthetic biofuel production via H2 from RES
- 1. Doubling of synthetic biofuel production via H2 from RES Seminar presentation, Chalmers Dec 5th 2014 Ilkka Hannula VTT Technical Research Centre of Finland
- 2. 2 There are nearly 100 professionals working at VTT around the fluidised bed technology platform Combustion, gasification and pyrolysis processes share the common ”process heart” - fluidised bed The main differences between processes are mostly related to the temperature levels and gas atmosphere Process integrations, close co-operation with industry & excellent experimental capabilities Catalytic processes, CFD modeling and Techno-economic calculation competences to support thermal conversion process development COMBUSTION CATALYTIC PROCESSES GASIFICATION PYROLYSIS VTT competencies & capabilities
- 3. 301/03/2015 3 Industry Focus Biomass to 2nd generation biofuels Pretreatment and hydrolysis Fermentation Product recovery Ethanol and other alcohols Lipids Diesel, jet fuel BIOTECHNOLOGY Thermal or catalytic fast Pyrolysis Product upgrading Gasoline Diesel, jet fuel FAST PYROLYSIS Gasification Gas cleaning to syngas Liquid fuel synthesis Methanol, DME Gasoline Diesel, Jet Fuel Hydrogen SNGMethanation PSA GASIFICATION
- 4. 401/03/2015 4 Oil Coal Biomass Waste/SRF GASIFICATION 800 – 1400° C O2 A I R S T E A M Wide Feedstock Basis High-Quality Final Products SYNGAS (CO + H2) FUEL GAS Methanol, DME, Gasoline, jet-fuel, methane, hydrogen, Chemicals Industrial kilns Co-firing in boilers Gas turbines Engines Fuel cells Biomass gasification to high-value products G A S C L E A N I N G
- 5. 5 1995 2000 2005 2010 2015 20201985 2025 2030 LAHTI II, 160 MW WASTE-TO-ENERGY WASTE-TO-ENERGY PLANTS WITH MATERIAL RECOVERY o HIGH ELECTRIC EFFICIENCY o RECOVERY OF VALUABLE METALS WASTE-TO-ENERGY PLANTS WITH MATERIAL RECOVERY o HIGH ELECTRIC EFFICIENCY o RECOVERY OF VALUABLE METALS LIME-KILN GASIFIERS REPLACEMENT OF FOSSIL FUELS IN BOILERS AND KILNS o WOOD, AGROBIOMASS o 10-200 MW FUEL BIOMASS/WASTE GASIFIERS FOR POWER CBF/BFB GASIFICATION R&D AND PILOTING R&D on o HOT GAS FILTRATION o WASTE AND STRAW GASIFICATION R&D NEEDS 2013 - 17 o FILTER ASH UTILISATION o RECOVERY OF METALS o IMPROVED GAS CLEANING JOUTSENO LIME KILN 2012 Biomass and waste gasification for boilers and kilns LAHTI 60 MW
- 6. 601/03/2015 6 RECENT PROJECTS: Biomass and waste gasification for boilers and kilns
- 7. 7 Biomass gasification for fuels and chemicals PEAT AMMONIA PLANT OULU, FINLAND SYNGAS R&D FOR BIOFUELS o GASIFICATION PROCESS DEVELOPMENT o CATALYTIC REFROMING o FINAL GAS CLEANING o TESTING OF SYNTHESIS CATALYSTS GASIFICATION R&D AND PILOTING USA, GERMANY, SWEDEN, FINLAND 2010 2015 20201985 2005 203020001995 2025 BIO-DME PLANT PITEÅ, SWEDEN GTI PILOT, USA NSE BIOFUELS, FINLAND BIO-FUELS AND CHEMICALS o DIESEL, MeOH, DME, SNG, H2, GASOLINE o OLEFINS, OTHER CHEMICALS o FOREST & AGRO-INDUSTRY INTEGRATION o INTEGRATION TO HEAT AND POWER o INTEGRATION TO SOLAR & WIND ENERGY o NEW WASTE-TO-FUEL CONCEPTS SKIVE CHP, DENMARK CEGABTL 2015 - 2017 o IMPROVED LARGE-SCALE GASIFICATION PROCESS o NEW PROCESSES FOR SMALLER SCALE o SIMPLER, CHEAPER GAS CLEANING o NEW CONCEPTS FOR INTEGRATED PRODUCTION OF FUELS, POWER AND HEAT
- 8. 8
- 9. 901/03/2015 9 Production of Synthesis Gas from Solid Fuels Initial step - two main approaches
- 10. 1001/03/2015 10 2G-Biofuels 2020 Project budget 7.3 M€ in 2012–14; second piloting phase in 2015–17 Gasification task Pressurised O2-gasification >150 MW bio Industrial integ. Low-pressure steam gasification <150 MW bio Municipal integ. Hot Filtration & Catalytic Reforming Synthetic fuels and chemicals + heat - MeOH, DME - FTL, MTG - MTO SNG, H2 + heat Industrial partners: Andritz-Carbona, Foster Wheeler, Metso, UPM-Kymmene, NSE Biofuels, Fortum. Main financier: Tekes
- 11. 1101/03/2015 11 Gasification Hot gas filtration Reforming of the filtered product gas T = 850 °C T = 550 °C T = 950 °C Gasification Hot gas filtration Reforming of the filtered product gas T = 850 °C T = 850 °C T = 850 °C HOT GAS FILTRATION • Hot gas filtration R&D focused on filter blinding phenomenon. • Experimental work with a bench-scale pressurised hot gas filtration unit ALMA. • The main variables to be studied: • Filtration temperature and pressure • Particulate and tar concentrations • Use of different sorbents and additives
- 12. 1201/03/2015 12 -20 0 20 40 60 80 100 0 10 20 30 40 50 60 70 80 90 100 760 810 860 910 CH4conversion,% Conversion,% T, ºC Catalyst A - Tar Catalyst A – CH4 Catalyst B and C - Tar Catalyst C – CH4 Catalyst B – CH4 Reforming of tars and light hydrocarbon gases VTT’s reformer is based on staged reforming without soot formation Different catalysts from alternative suppliers can be used Complete tar and C2-hydrocarbon conversion CH4 conversion depends on temperature, catalyst type and reactor volume N.Kaisalo & P.Simell, Vetaani-project: laboratory results 2012
- 13. 1301/03/2015 13Source: Spath & Dayton, 2003, NREL/TP-510-34929
- 14. 1401/03/2015 14 Updated Techno- Economic Assessment Detailed evaluation of 20 individual plant configurations MeOH, DME, FTL & MTG Plant configurations technically proven at pre-commercial scale Impact of further R&D to the overall economics estimated Large scale: 300 MWth of biomass (~1500 mtpd, dry) Nth plant economics Available for download: http://bit.ly/192Vl3G
- 15. 1501/03/2015 15
- 16. 16 *Liquid transportation fuels via large-scale fluidised-bed gasification of lignocellulosic biomass, Hannula, Ilkka; & Kurkela, Esa 2013. VTT, Espoo. 114 p. + app. 3 p. VTT Technology: 91 • Mature technology • No investment support • No CO2 credits • No tax assumptions Gasoline @150$/bbl Gasoline @100$/bbl Before tax Ref.margin: 13.4$/bbl 1€ = 1.33$ (2010) Levelised production cost estimates* 300 MW biomass @ 17 €/MWh, 0.12 ann. factor Electricity 50 €/MWh, DH 30 €/MWh@5500 h/a
- 18. 1801/03/2015 18 Base case layout for synthetic biofuels production allows: • 50 – 60 % fuel efficiency and • up to 80 % overall efficiency. These numbers are among the best in the industry. GASIFICATION SYNTHESISGAS CLEAN-UP UPGRADING Biomass residues Synthetic fuel Purge gasRecycle CO2
- 19. 1901/03/2015 19 Despite the high energy efficiency, about half of the feedstock carbon needs to be rejected from the process, as there is not enough hydrogen to convert it into fuels. The traditional conversion route is therefore hydrogen constrained. GASIFICATION SYNTHESISGAS CLEAN-UP UPGRADING Biomass residues Synthetic fuel Purge gasRecycle CO2
- 20. 2001/03/2015 20 Feed carbon Surplus carbon Feed hydrogen FuelBiomass feedstock However, by adding hydrogen from external source, the surplus carbon could be hydrogenated to fuel as well.
- 21. 2101/03/2015 21 Feed carbon Surplus carbon External hydrogen Feed hydrogen FuelBiomass feedstock However, by adding hydrogen from external source, the surplus carbon could be hydrogenated to fuel as well.
- 22. 2201/03/2015 22 Feed carbon Fuel Surplus carbon External hydrogen Feed hydrogen FuelBiomass feedstock However, by adding hydrogen from external source, the surplus carbon could be hydrogenated to fuel as well.
- 23. 2301/03/2015 23 But the surplus carbon is in the form of CO2, instead of CO! Implications: - Only methane and methanol have reaction route via CO2 - More H2 is required to produce one mole of fuel from CO2 than from CO. - CO2 has higher activation energy than CO => more catalyst needed - Byproduct water from CO2 hydrogenation inhibits methanol catalysts CO Fuel CO2 H2 H2 FuelBiomass feedstock
- 24. 2401/03/2015 24 Despite challenges related to CO2 hydrogenation, the potential increase in fuel output is enormous: Fuel output can be easily doubled from the base case… and in some cases almost tripled! CO Fuel CO2 H2 H2 FuelBiomass feedstock
- 25. 2501/03/2015 25 • Fuel output when CO fully hydrogenated with internal hydrogen via water-gas shift
- 26. 2601/03/2015 26 • Fuel output when CO fully hydrogenated with internal hydrogen via water-gas shift • Fuel output when CO fully hydrogenated using internal and then external hydrogen source
- 27. 2701/03/2015 27 • Fuel output when CO fully hydrogenated with internal hydrogen via water-gas shift • Fuel output when CO fully hydrogenated using internal and then external hydrogen source • Fuel output when CO and CO2 fully hydrogenated using internal and then external hydrogen source
- 28. 2801/03/2015 28