Scaling-Up Gasification and Pyrolysis Processes for Industrial Demonstration

Transcription

1 Scaling-Up Gasification and Pyrolysis Processes for Industrial Demonstration Bioruukin pilotointikeskuksen asiantuntijaseminaari Yrjö Solantausta, Esa Kurkela, Kai Sipilä VTT Technical Research Centre of Finland Ltd

2 Topics Two case examples on scale-up related to innovation Fluidized-bed gasification Fast pyrolysis Elements in scale-up for pre-feasibility of new processes Understanding of process chemistry, performance, products Process scale-up includes both modelling and experimental work Process scale-up for fluid feeds is carried out largely by modelling, solid feeds (biomass, wastes) require more experimental work CFD-, Apros, AspenPlus models applied to our materials Laboratory facilities for study pheneomena PDU/pilot for scale-up and for extended operation h Presence at customer demonstration and commissioning 19/03/2015 2

3 GASIFICATION

4 Biomass Gasification for Fuels and Chemicals DFB, GUSSING, AUSTRIA GTI PILOT, USA BIO-FUELS AND CHEMICALS o o o o o DIESEL, MeOH, DME, SNG, H 2, GASOLINE OLEFINS, OTHER CHEMICALS FOREST & AGRO-INDUSTRY INTEGRATION INTEGRATION TO HEAT AND POWER BIO-CCS EASY TO ADD, IF NEEDED PEAT AMMONIA PLANT OULU, FINLAND 1985 NSE BIOFUELS DEMO - VARKAUS, FINLAND GASIFICATION R&D AND PILOTING USA, GERMANY, SWEDEN SYNGAS R&D FOR BIOFUELS o GASIFICATION PROCESS DEVELOPMENT o CATALYTIC REFROMING o FINAL GAS CLEANING o TESTING OF SYNTHESIS CATALYSTS R&D NEEDS 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 4

5 O 2 -Blown CFB Gasification New Developments PFB GASIFIER INCREASED FILTRATION TEMPERATURE 2GBIOFUELS PROJECT IMPROVED REFORMER PERFORMANCE FOR SNG AND FOR BTL FEEDSTOCK - BARK - FOREST RESIDUE - WOOD PELLETS BED MATERIAL AND ADDITIVE COOLER FILTER PRODUCT GAS REFORMER GAS COOLER OXYGEN FILTER ASH STEAM BED REMOVAL 0.5 MW facility has been used for process development, > 4000 hours in operation Improved process concept was developed in 2GBiofuels project in

6 An Example of Experimental Innovation - Tar Reforming VTT s Core Technology Heavy tars and C 2 -hydrocarbons are decomposed in the Pre-Reformer Total tar reforming and partial reforming of methane (60-90 %) in the Final Reformer No soot formation in the reformer and stable pressure drop Developed and demonstrated during 4000 hours of operation at VTT s UCG PDU in Verified also at industrial demo plants, technology licensing to industrial partners Presently applied also for Dual Bed steam gasification process of VTT Clean syngas from biomass-process development and concept assessment, Simell, Pekka; Hannula, Ilkka; Tuomi, Sanna; Nieminen, Matti; Kurkela, Esa; Hiltunen, Ilkka; Kaisalo, Noora; Kihlman, Johanna, Biomass Conversion and Biorefinery. Springer. Vol. 4 (2014) No: 4,

7 FAST PYROLYSIS

8 Fast Pyrolysis for Bio-Fuel Oil - Scale-Up FORTUM, PORVOO, FINLAND FORTUM DEMONSTRATION - JOENSUU, FINLAND UNION FENOSA, SPAIN IEA BIOENERGY COLLABORATION ENEL, BASTARDO, ITALY VALMET, TAMPERE, FINLAND EARLY FAST PYROLYSIS BENCH-SCALE o CANADA, USA o IEA BIOENERGY ASSESSMENTS FIRST EUROPEAN PILOTS o TWO CANADIAN, ONE FINNISH TECHNOLOGY o CONTINUOUS OPERATION VERIFIED o OPERATED BY EUROPEAN UTILITIES SCALE-UP o ENSYN IN CANADA o BTG IN MALAYSIA o VALMET o FORTUM DEMONSTRATION 2014 o BTG DEMSONSTRATION

9 Scaling-up the VTT Integrated Biomass Fast Pyrolysis ( ) Three leading Finnish industries in their respective fields agree of scaling-up the VTT technology integrating a power boiler to biomass fast pyrolysis A 7 tpd bio-oil pilot plant built at the Valmet R&D center in Tampere Successful scale-up of technology achieved by 2010 Solantausta, Y, Oasmaa, A, Sipilä, K, Lindfors, C, Lehto, J., Autio, J., Jokela, P., Alin, J., Heiskanen,J Bio-oil production from biomass: Steps toward demonstration: ACS. Energy & Fuels, Vol. 26, No. 1, pp /03/2015 9

10 VTT New 0.5 tpd Fast Pyrolysis Pilot The innovation: A new value chain in bioenergy Integration of a CHP fluidized-bed boiler and fast pyrolysis Adaptation of existing components and a design for a new commercial bio-product Produced bio-oil is fired in modified district heat boilers to replace mineral fuel oil Fast Pyrolysis Facility in Otaniemi h of operation Next challenges: a stationary diesel power plant fuel, transportation fuels 48 tonnes of bio-oil produced An average on-stream time 85 % 10

11 Computational Fluid Dynamic (CFD) Modelling

12 Results of CFD Modelling of the Pyrolysis Reactor Particle and Chemistry Models Included Temperature (K) Release of bio oil and gas components from particles Particle tracks coloured with initial size

13 VTT THERMAL BIOMASS CONVERSION PLATFORMS WASTES RESIDUES BIOMASS STRAW COMBUSTION GASIFICATION PYROLYSIS POWER HEAT & COOLING GASOLINE DIESEL JET FUEL CHEMICALS BIO-AROMATICS INTERMEDIATES RECOVERY OF MATERIALS

14 Concluding remarks VTT has proven track record in two cases as an innovation partner to industry in bridging the gap from laboratory to industrial demonstration Utilisation of CFD/Aspen-models in interfacing VTT s pilots and industrial demonstrations, and eventual de-bottlenecking Bioruukki is a multi-discipline pilot center to verify models, to develop processes, and reduce the critical path of products to markets The Finnish innovation system by Tekes and TEM has paid dividends in cases, where industry first participates to public projects, and VTT participates to subsequent industrial scale-up efforts The Finnish innovation system is unique in producing results to the markets

15 TECHNOLOGY FOR BUSINESS