Carbona Gasification Technologies Biomass Gasification Plant in Skive

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1 Carbona Gasification Technologies Biomass Gasification Plant in Skive Gasification 2010 Swedish Gas Centre (SGC) October, Scandic Crown, Gothenburg, Sweden Carbona Inc. Kari Salo

2 ANDRITZ Carbona Carbona is a biomass gasification technology based company supplying plants for various applications Andritz Oy (Finnish subsidiary of Austrian based Andritz Group) acquired ownership in Carbona Inc. gradually from 2006 Andritz is one of the leading suppliers in P&P industry and has also biomass CFB gasification background from 1980 s as Ahlstrom Machinery Oy, Pyroflow Carbona has developed BFB biomass gasification technology since 1996 ANDRITZ Carbona now offers plants on combined ANDRITZ Carbona technology, for both BFB and CFB gasification technologies 2

3 Biomass Gasifier Applications Fuel gas for kilns (Co-)firing (boiler) Co-generation (gas engine) IGCC (gas turbine) Syngas production MWth MWth MWth MWth. 150 MWth/unit Atmospheric CFB (circulating fluidized bed) Fossil fuel replacement Atmospheric CFB Power by steam cycle Low pressure BFB (bubbling fluidized bed) Power by gas engine units Pressurized BFB (air blown) Power by gas/steam turbines Pressurized BFB (oxygen blown) Development phase Pulp and paper and cement industries Utilities and all industries with large fossil fuel fired boilers Municipal utilities New mid-size power plants with max power BTL producers (P&P & others) and utilities Fuel gas Green power Green power Green power Bio liquids 3

4 Feasible Fuels Bark, wood residues Forest residue Wood chips, pellets Saw dust ANDRITZ Carbona offers gasification plants for mainly wood based fuels today. New fuels like waste, rejects, sludge, etc. may require further development work on gasification and especially on gas cleanup. 4

5 Two Gasifier Product Lines Bubbling fluidized bed Atmospheric MWth Pressurized MWth Circulating fluidized bed Atmospheric MWth BFB CFB 5

6 CFB Gasification Technology Basis Wisaforest Norrsundet Location Year Size/Fuel Wisaforest MW/ bark/saw dust Finland Cumulative operational experience exceeds 70 years Norrsundet Bruk MW/bark/saw dust Sweden ASSI MW/bark/saw dust Karlsborg Bruk, Sweden Portucell MW/bark Rodao Mill, Portugal 6

7 ANDRITZ Carbona CFB Gasifier with Boiler CFB Gasifier producing fuel gas from Renewables to replacefossile boiler fuels CFB Gasifier for Biomass Renew able fuel Oil Coal Natural Gas Fuel Gas Gasifier/Boiler application with gas cleanup Air Filter Gas cooler Oil Coal Natural Gas 7

8 Gas for Kilns Typical Plant Arrangement CFB Gasifier Fuel screening/crushing Fuel receiving Dryer Lime Kiln 8

9 BFB Gasification Technology Basis Originally Licensed from the Gas Technology Institute, GTI GTI Old Pilot Plant Facility, Chicago High Pressure, Oxygen GTI New Pilot Plant, Chicago High Pressure, Oxygen Old Pilot Plant, Finland High Pressure, Air GTI Pilot Plant, Hawaii High Pressure, Air 9 Carbona Gasification Plant, Denmark Medium Pressure, Air

10 Skive Gasifier/Engine Plant in Denmark Gasification Hot w ater accum ulator Engines and boilers Fuel storage 10

11 Bubbling Fluidized Bed Gasification Plant for Engines (Also demonstration for IGCC and BTL) BFB GASIFIER Gasification Plant Process: Carbona air blown, low pressure bubbling fluidized bed gasifier Limestone based bed material Catalytic tar reforming Gas cooling and filtration Gas scrubbing System pressure barg Power Plant Process: 3 Gas Engines with heat recovery and 2 Gas Boilers BIOMASS, 28 MWth GAS FIL TER TO S TACK TAR REF OR MER 2 BOILERS GAS SCRUBBER 2x10 MWth DISTRIC T HEATING 11.5 MWth GAS ENGINES AIR/STEAM POWER 3x2 MWe GAS BUFFER TANK 3 GAS ENGINES GAS COOLERS Danish Skive CHP-plant flow sheet 11

12 Gasification Plant Gasification Plant Process: Carbona air blown, low pressure bubbling fluidized bed gasifier Limestone based bed material Catalytic tar reforming Gas cooling and filtration Gas scrubbing System pressure barg Typical dry gas composition after reformer: CO %-vol 20 CO2 %-vol 12 H2 %-vol 16 CH4 %-vol 4 N2 balance LHV MJ/m3n

13 CHP Plant Plant Capacity: Nominal biomass feed 19.5 MWth, max. 28 MWth Power generation 6.0 MW (3x2MW GEJ620 gas engines) 11.5 MW district heat in CHP-mode Optional gas consumers 2x10 MWth gas boilers Plant Operation: Fully automated All combinations of gas consumers Load range % Fuel: 13 Wood pellets Plant design for wood chips

14 Gas Parameters from Plant Control System Gasifier temperature 850 C CO ~20 % H2 ~16 % CO2 ~12 % LHV 4,8-5,0 MJ/kg p ~1,2 barg p ~ 0,7 barg CH4 ~ 5 % 14

15 General Operation Experience Gasifier (pressurized, bubbling fluidized bed, bed material dolomite, 850 C) Fuel feed is simple due to wood pellets, wood chips not used yet Gasifier generates stable gas with constant composition and LHV Tar content of the gas is low Tar Reformer (monolith catalysts, ºC, steam/nitrogen pulse cleaning) Reformer temperature auto control functions properly Reformer pressure drop stable (pulse cleaning) Reformer performance is under optimization (different catalysts) Gas Filter (bag house filter 200 ºC, nitrogen pulse cleaning) Filtration performance is good 15

16 Operation Experiences Gas Boilers (2x10 MJ/s) Utilizing gas from filter (200 ºC) and gas from scrubber (40 ºC) Clean heating surfaces (4000 h inspection) Gas Engines (3x2MW GEJ620) Gas engines like the stable quality gas Gas ramp filters and valves are clean 3000 h inspection) Full load (2 MW) operation of the engines Gas engine emissions under guarantee limits 16

17 Tar Reforming Experience after 7500 Operation Hours Tar Reformer (monolith catalysts, >900ºC, steam/nitrogen pulse cleaning) Reformer temperature control accurate Reformer pressure drop stable No soot formation Reformer performance is under optimization no tar (heavy) found after the reformer light hydrocarbon conversion satisfactory activated carbon filter needed in waste water stream ammonia conversion low in the beginning improved from 20% to 60% due to new catalyst 17 Mechanical improvements during last summer break and new catalyst Reformer outsourced to Haldor Topsoe

18 Future Plans Research & Development Tar catalyst development for dust containing gas Tar reforming to at least 95% Ammonia reforming at least 70% Carbona/Andritz and Skive Fjernvarme cooperate in catalyst testing and development Skive reformer is equipped with new type of HT catalyst since summer 2009 Testing of different gasifier bed materials to avoid dolomite re-carbonization during upsets to reduce dust amount from pellet fuel Testing of different fuels, mainly wood chips Optimization of process parameters also BTL in mind 18

19 Carbona Gasification Development Skive: R&D Platform for Clean Gas Power & BTL/SNG 150 MWfuel 30 MWfuel Skive Plant Heat 2 bar 10 bar Power Oxygen Air Skive Gasifier 19 GTI Pilot GTI Gasifier Biodiesel

20 Pilot Plant Demonstration Site GTI Energy & Environmental Technology Campus Des Plaines, Illinois Testing for BTL and Skive-processes (Bay 3) (Bay 2) (Bay 1) 1. Advanced Gasification Test Facility Bay 1: Carbona syngas conditioning system Bay 2: PWR, Coal Gasification System Bay 3: open 5-story test bay (available for TIGAS) Flex-Fuel Test Facility Carbona biom ass gasification system 3. Morphysorb Absorption/stripping for CO2 & H2 S rem oval 4. SulfaTreat Sorbent-based sulfur scavenger 5. High-pressure oxygen and nitrogen supply 5

21 Testing for Skive and BTL/SNG Testing Program at GTI Catalyst Test Facility - to evaluate different catalyst types Pilot Plant - pellets, wood chips, bark, logging residue and stump fuel and their mixtures - testing of different operation conditions for related equipment and sub-processes - testing of different reformer setups and catalysts - several test campaigns and set points already conducted during the program - long duration testing ongoing Bench Scale Unit - testing of fuels, bed materials, additives 21

22 BFB Gasifier for Synthesis Gas Applications High Pressure Oxygen Gasification Gas Conditioning Biomass (cooling, filtering, reform ing, etc. ) Gas Processing FischerTropsch Biodiesel Tigas Gasoline Synthesis Gas (shift, scrubbing, etc.) BioFermentation Ethanol Methanation Synthetic Natural Gas Gasifier Oxygen Oxygen Plant Air Steam Pipeline, Gas turbine, etc. Ash Typical plant size MWfuel 22

23 General Conclusion Good cooperation with plant owner and crew is essential The commitment and skill of the Skive Fjernvarme staff has been of special importance in plant implementation, operation and development Continuation on process development at site Cooperation concerning commissioning new plants has been agreed ANDRITZ Carbona sincerely thanks Skive Fjernvarme for cooperation 23

24 Legal Disclaimer All data, information, statements, photographs, and graphic illustrations contained in this presentation are without any obligation to the publisher and raise no liabilities to ANDRITZ AG or any affiliated companies, nor shall the contents in this presentation form part of any sales contracts, which may be concluded between ANDRITZ GROUP companies and purchasers of equipment and/or systems referred to herein. ANDRITZ AG All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ AG or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. 24

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