Energinet dk ForskEL-projekt Demonstration of 500 kw E Two stage Gasifier. Final Report. March 2013

Transcription

1 Energinet dk ForskEL-projekt Demonstration of 500 kw E Two stage Gasifier Final Report March 2013

2 WEISS A/S Ved Stranden Hadsund Telefon Telefax Energinet dk ForskEL-projekt Demonstration of 500 kw E Two stage Gasifier Final report March 2013 Udgivelsesdato 18. march 2013 Udarbejdet Kontrolleret Godkendt JDB BT BS

3 1 Table of content 1 Project details 2 2 Executive summary 3 3 Project results Background R&D plants Upscale of the two stage gasifier kw E pilot plant Present 500 kw E demonstration project Location Hadsund The project in Hillerod Main activities in the project Initial test of the demonstration plant 11 4 Utilization of project results 12 5 Project conclusion and perspective Project conclusion Perspective 13 Appendix Appendix 1: Poster at Biomass conference in Lyon, Appendix 2: Article in Biopress

4 2 1 Project details Project title Demonstration of 500 kw E Two stage Gasifier Project identification Energinet.dk project no Name of the programme which has funded the project ForskEL-projekt (ForskVE, ForskNG or ForskEL) Name and address of the enterprises/institution responsible for the project WEISS A/S Ved Stranden 1 DK-9560 Hadsund Contact person: Bjarne Skyum CVR (central business register) Date for submission March 18, 2013 Other partners: DTU, COWI, Dall Energy

5 3 2 Executive summary A 500kWe two-stage gasification plant has been designed and built. The plant is situated in Hillerød a town about 40 km north of Copenhagen. The plant is an upscale of the 200 kwe pilot plant that was built and verified at the premises of Weiss, Hadsund during The 500 kwe demonstration plant is built so it can run continually and unmanned. The project has included Upscaled design of all components of the two-stage gasificaction process. A new control system, so the plant can run automatic and unmanned. Automatic system for sorting of fine particles. A turbocharged engine and a system so the engine can switch between operation on natural gas and gasification gas. A Hazop study. Getting all financing and permits in place Construction of the plant. Commissioning and long term operation will be done in a following project : ForskVE-project

6 4 3 Project results 3.1 Background R&D plants At the Technical University of Denmark the department DTU-MEK worked for several years on a novel concept for the gasification of Biomass. The technology has been named The Two Stage Process because it may be characterised by the processes of pyrolysis and the gasification are carried out in two distinct stages. At the Technical University (DTU) several small-scale implementations of the concept proved, that a combustible gas could be generated. Also, it was demonstrated that the tar and dust content in the product gas was extremely low and suitable for fuelling gas-motors for combined heat and power (CHP). Furthermore, the environmental impact was low and the power efficiency was very high. In the original Two Stage Process the processes of biomass drying and pyrolysis were carried out by externally heating an auger using exhaust gas from an associated gas-motor. However, this approach would be limited to smaller plants. Figure 1 20kWe pilot plant at DTU (Viking gasifier)

7 5 Figure 2 Principle diagram of the Viking gasifier 3.2 Upscale of the two stage gasifier In order to upscale to plants of 500 kwe and above, the two-stage gasification process was modified. In the upscaleable concept, flue gas from the gas engine used to dry the fuel. Drying by use of superheated steam in combination with fixed bed gasification gives several advantages: - Environment friendly drying: no contamination of condensate. - No fire hazards. - No loss of product - Improved drying rate. - Lower temperature in partial oxidation zone: The temperature in the partial oxidation zone decreases about 200C when gasifying with steam compared to gasification of dry fuels. - Lower soot production: The amount of soot particles are reduced considerably when gasifying with steam. This is partly due to lower maximum temperatures and partly due to higher concentration of OH radicals which reduce the soot production. - Lower emissions after engine: The gas composition is different when steam is added as a gasification agent. The H 2 content is increased, and the CO content is lowered. This results in a faster combustion and lower emissions of CO and NO x.

8 6 Figure 3 Principle diagram of the two stage gasifier with steam drying of the fuel. Short process description: Steam is re-circulated through the DRYER (upper left) and heated by the ENGINE exhaust heat exchanger (mid left). The dry fuel enters an auger PYROLYSER externally heated by the hot raw product gas discharged from the GASIFIER (lower right). The PYROLYSER discharges a mixture of carbon, tar and pyrolysis gases into the top of the gasification reactor. Initially the tar is burned in a PARTIAL OXIDATION zone and the carbon and the pyrolysis gas is entering the GASIFIER, where a complete gasification process is carried out. The hot air for the PARTIAL OXIDATION is prepared in the AIR PREHEATER using heat from the product gas. The product gas is further (dry-) cooled by the district heating grid, then cleaned in a baghouse filter and finally cooled (in a condensing cooler) before being used in the ENGINE kw E pilot plant With financial support of Energinet.dk (project #6529) a 600 kw woodchips fuel input pilot plant was built. Long-term operation and stable conditions was demonstrated successfully in in a subsequent project also supported by Energinet.dk (project #6325).

9 7 Figure 4 Project manager Bjarne Skyum, WEISS A/S at 200 kwe two stage gasifier. 3.4 Present 500 kw E demonstration project Based on the positive experiences from the pervious pilot plants, it was decided to demonstrate the concept at a 500 kw E scale. The demonstration plant was originally intended to be installed at Hadsund District Heating Company (in the home town of the industrial partner WEISS), but it was difficult to find an economic acceptable solution. Therefore, Hillerod District Heating Company (in the vicinity of Copenhagen) was approached and an agreement with Hilleod was made. 3.5 Location Hadsund The initial contact took place in the summer of The project was found interesting and a proposal for Energinet.dk (via PSO Public Service Obligation funding) was prepared. A total funding of 16 million DKK was required and in December million DKK from the ForskEL programme for establishing the facility and 5 million DKK from the ForskVE programme for start-up and initial system shake down were granted.

10 8 It was assumed, that ForskVE would support later long-term operation tests. Hadsund District Heating Company (HDHC the Plant Host), WEISS (The Industrial Partner), COWI and Dall Energy (Consultants) and DTU (the Technical University of Denmark) would be partners in the project. First the relationship to the various authorities was reviewed and it was soon found, that the ownership would be somewhat complicated. The plant would be located at HDHC, but for reasons of legislations the gasifier itself would be operated by a neighbouring municipality (VSV Veddum Skelind Vesborg). For some reason the legislations stated that different laws control power production and heat production. WEISS prepared a rudimentary feasibility study, which indicated that the project should be favourable and would result in a reduction of heating costs for the customers in VSV. HDHC prepared an analysis of heat demand and heat production capability. COWI prepared a preliminary study based on these analyses. However, when the board of directors at VSV made their decision in the summer of 2009 it was ruled, that the reduction in heating cost was too low for the parties to enter the project. 3.6 The project in Hillerod When the reluctance from the VSV board of directors became apparent, the partners in the project WEISS, COWI, Dall Energy and DTU decided to focus on Hillerod Municipality. This was the result of a previous dialog with Hillerod Municipality (HM) concerning the possibility to establish a 200 kw E system in connection with a new housing area. HM was interested in changing the project and place the 500 kw E gasifier adjecent to a 5 MW T wood-chips boiler plant for district heating. This would be a perfect solution for the present Two-stage gasifier project. A contract was entered with HM and the up scaling of plant design from the 200 kw E pilot plant was initiated in January The original 5 MW T project was supported by a EU programme (acronym SORCER), where WEISS participated decided to leave that project and concentrate on the present PSO project.

11 9 3.7 Main activities in the project. The main activities in the project have been: Upscale All components have been revived and an updated design has been made Controll system The control system of the plant is more advanced than in the previous pilot plants. The new control system can operate the plant full automatic and unmanned Automatic sorting of fine particles. The pressure drop of the char bed may increase with there are very fine particles in the fuel. Therefore an automatic sorting system has been implemented. The system removes the fine dust and transports it to the 5 MW grate boiler Turbocharged engine A turbocharged engine have been installed by the company Fleco. Considerable work has been done to develop a system so the engine can switch between operation on natural gas and gasification gas Hazop study There has been held a number of HAZOP meetings attended by developers, consultant, producer, owner and operating personnel where the plant was systematically examined for risks in plant construction, management and operation, which led to a series of recommendations and actions Weiss has been incorporated in the plant, so the plant will be operated properly. The Hazop is documented with HAZOP tables, barrier charts and a worksheet. These appendices are confidential but may be sent separately to Energinet if desired Dealing with authorities There has been considerable dialogue and paper work with various authorities in order to get all permits to establish and run the plant Construction The plant has been constructed during There was several different incidents that caused delay in the construction of the plant, but in March 2012 could the system be pressure tested. The plant was ready for hot testing in the fall of 2012.

12 10 Photographs from the plant : Figure 5 The building with the gasifier system. Figure 6 The sorting system separating the fines Figure 7 Gas cooler + Pyrolysis reactor (right) Figure 8 Gas cooler + Pyrolysis reactor (right) Figure 9 Gasifier and cyclone Figure 10 Gasengine

13 11 Figure 11 3-D layout of the demonstration plant. 3.8 Initial test of the demonstration plant The commissioning and opertion will be done in a next project : ForskVEproject The initial tests have shown, that the plant can operate stable and unmanned. There are still some final adjustments to be made.

14 12 4 Utilization of project results This demonstration project was crucial for WEISS for entering the market with the two-stage gasification technology. The demonstration at a real end user is an important reference for WEISS to convince prospective customers. Furthermore, an operating full-scale demonstration plant is important to WEISS for confidential offering commercial guaranties to the customers. Even if WEISS are asked by foreign customers from countries, where larger subsidies are offered for electricity producing plant based on biomasses it is extremely important to have the first semi-commercial plant geographically close to the company. Therefore, WEISS hopes, that in a few years several plants can be build on normal commercial conditions.

15 13 5 Project conclusion and perspective 5.1 Project conclusion A two-stage gasifier with a nominal capacity of 500 kwe has been developed, designed and built. The project has included Upscaled design of all components. A new control system, so the plant can run automatic and unmanned. Automatic system for sorting of fine particles. A Turbocharged engine and a system so the engine can switch between operation on natural gas and gasification gas. A Hazop study. Getting all financing and permits in place Construction of the plant. The plant is now going into operation phase. The operation of the plant is supported by the project: ForskVE-project Perspective Based on historical results with the Viking gasifier, as well as pilot project in Hadsund, followed by various articles and participation in conferences meetings Weiss have big interests in the concept. Weiss is constantly approached by interested buyers from around the world who are very interested in buying a gasifier to produce electricity on wood chips. In fact, many are interested in producing power in many alternative fuels. The many inquiries show that there is a need for a power producing plant biomass in sizes kw el.

16 14 There are two main factors that give interest. Either there is a view to a high electricity price, or it is the aim to produce power in areas where there are no electricity. Generally, this is how the concept should be mass-produced to get the price far enough down. It will be possible, but it is associated with very high costs to get there. The concept must first be developed, which requires many hours yet. This is why Weiss currently focus on the basic components.

17 15 Appendix. 5.3 Appendix 1: Poster at Biomass conference in Lyon, Appendix 2: Article in Biopress 2012.

18 16 Poster at Biomass conference in Lyon, 2010

19 17 Article in Biopress 2012.