Gasification of biomass - Biomass CHP Güssing Dr. Reinhard Rauch Institute for Chemical Vienna, University of Technology
Content Principle of FICFB gasification Results from biomass CHP Güssing CHP with Gas Engine Liquid Fuels by Fischer Tropsch Synthesis Gaseous Fuels by Methanation 2
Head: Ingo Marini Vice-Head: Hermann Hofbauer Mechanical Process Thermal Process & Simulation Chemical Process & Fluidisation Microbiology & Bio-chemical Gentechnology & Biochemistry Environmental Technology & Ecology Chemistry of Food and Natural Materials At the moment 100-120 scientific employes Turnover by research projects 2007: ~4.1 mill Euro More information under http://www.vt.tuwien.ac.at 3
Research Area Chemical Process & A. Reichhold, F. Winter, H. Hofbauer Research Group Fluidized Bed Systems & Refinery Technology Alexander Reichhold Research Group Reaction & Combustion Franz Winter Research Group Future Hermann Hofbauer Research Group Future works in: Biomass conversion (combustion, gasification, pyrolysis) Production of 2 nd generation biofuels (thermo chemical pathway) CLC (chemical looping combustion) 4
Equipment available FRU (Formation rate unit) Laboratory bubbling fluidised bed 100kW fuel input FICFB gasifier 50kW fuel input pressurised FB gasifier 120kW fuel input fixed bed gasifier 200kW fuel input CLC measuring equipment to measure gas composition, tar, and inorganic species simulation tools (IPSE pro for mass and energy balances, Fluent for fluid dynamics) 5
Content Principle of FICFB gasification Results from biomass CHP Güssing CHP with Gas Engine Liquid Fuels by Fischer Tropsch Synthesis Gaseous Fuels by Methanation 6
Gasification Systems Biomass Gasification Autothermal Allothermal Air O 2 /H 2 O H 2 O CO 2 Hu: low N 2 : high H 2 : low Hu: medium N 2 : zero H 2 : high Hu: medium N 2 : zero H 2 : high Hu: medium N 2 : zero H 2 : medium 7
The FICFB gasification technology Aims of the process: To produce a product gas with a high quality without the use of pure oxygen low nitrogen and tar content high calorific value Suitable for many different biomasses Usage of gas to produce electricity or upgrading to synthesis gas 8
Principle of the Process I product gas flue gas Heat Gasification Combustion biomass circulation steam air 9
Development steps 1993 Cold flow model Basic fluiddynamic research 1993 10 kw th laboratory plant Proof of principle 1995 100 kw th pilot plant Variation of process parameters and development of gas treatment 1998 500 kw th pilot plant Production of hydrogen rich gas, coupling with fuel cell 2001 8000 kw th demonstration plant Biomass CHP Guessing 2003 3 Nm³/h SNG Usage of product gas as synthesis gas for production of methane 2004 10 Nm³/h FT-Synthesis Usage of product gas as synthesis gas for production of FT-Diesel 10
History of 100kW FICFB gasifier 1995: 100kW 1993: 199410kW 1997 2000: 100kW 2000 flue gas fuel producer gas flue gas flue gas producer gas fuel producer gas steam air steam air air fuel steam 11
100kW FICFB gasifier Flow sheet of pilot plant III 12
Biomasses tested in the pilot scale FICFB gasifier Wood chips Wood pellets Saw dust Coal Sewage sludge pellets Animal residue Straw Willow All fuels can be used, if the ash melting point is above 1000 C as pure fuel. Fuels with lower ash melting point have to be used as mixture (e.g. 15% straw works well) 13
Change of bed material and influence on gas composition Bed material Olivine Calcite (AER- Process) Gasification temperature Catalyst (Nickel) 850 C 640 C 840 C H 2 [mol%] 37.7 67.5 43.9 CO [mol%] 29.1 3.3 27.2 CO 2 [mol%] 19.6 10.3 18.8 CH 4 [mol%] 10.4 13.1 8.3 C 2 H 4 [mol%] 2.8 1.7 1.3 C 2 H 6 [mol%] 0.3 3.0 < 0.1 HC (C 3 -C 5 ) [mol%] 0.1 1.1 < 0.1 14
Content Overview about energy situation in Austria Principle of FICFB gasification Results from biomass CHP Güssing CHP with Gas Engine Liquid Fuels by Fischer Tropsch Synthesis Gaseous Fuels by Methanation 15
Biomass CHP Güssing design data Start of construction September 2000 Start up January 2002 Fuel 2,2 to/h (Wood chips) Water content 15 % (35 %) Fuel power 8 MW Electrical power 2 MW Thermal power 4,5 MW Electrical efficiency 25 % (20%) Total efficiency 80 % Owner and operator Biomass Power Station Güssing Association
Biomass CHP Güssing Test plants Renewable Synthetic Natural Gas (SNG), Renewable Liquid Fuels Gas Engine Biomass gasification Biomass SNG-lab scale production FT liquid fuels 17
CHP-PLANT GÜSSING To synthesis gas applications electricity heat 18
Gas Composition (after gas cleaning) Main Components H 2 % 35-45 CO % 22-25 CH 4 % ~10 CO 2 % 20-25 Minor Components C 2 H 4 % 2-3 C 2 H 6 % ~0.5 C 2 H 2 % ~0,4 O 2 % < 0,1 N 2 % 1-3 C 6 H 6 g/m 3 ~8 C 7 H 8 g/m 3 ~0,5 C 10 H 8 g/m 3 ~2 TARS mg/m 3 20-30 Possible poisons H 2 S mgs/nm³ ~200 Mercaptans mgs/nm³ ~30 Thiophens mgs/nm³ ~7 HCl ppm ~3 NH3 ppm 500-1000 Dust mg/nm³ < 20 H 2 :CO = from 1.5:1 to 2:1 19
Increase of Availability of the Plant 8000 7000 6000 gasifier engine hours of operation 5000 4000 3000 2000 1000 0 2002 2003 2004 2005 2006 2007 20
Sulfur balance = Anlagenteile = H 2 S S im Produktgas = S in Feststoffen = SO 2 S im Rauchgas = R-SH S im Produktgas = S in Biomasse 21
Lifetime of engine oil 3 2,5 Grenzwert Neutralisationzahl [mgkoh/g] 2 1,5 1 0,5 0 0 500 1000 1500 2000 2500 3000 3500 4000 Betriebsstunden 22
Optimisation CHP Integrated dryer h el = 34 %; h ges = 70 %; IGCC h el = 31 %; h ges = 75 %; Single Cycle h el = 25 %; h ges = 80 %; BWL = 8,8 MW f = 40 % Dryer BWL = 9,6 MW f = 15 % Gasifier Engine el = 2,4 MW el = 3,0 MW w = 5,3 MW ORC el = 0,6 MW w = 4,2 MW w = 3,2 MW 23
Biomass CHP Oberwart 24
The basic concept Green Chemistry Over 30,000 hours of operation Producer Gas (gas engine, gas turbine, fuel cell) Biomass Biomass Gasification Synthetic Natural Gas (SNG) FT-Fuels (FT-Diesel) Methanol Hydrogen others 25
Renewable liquid fuels Fischer-Tropsch Syntheses 26
Fischer Tropsch Syntheses Fischer-Tropsch BioFiT Slurry bed reactor Temperature 200-300 C Pressure 20-30 bar Capacity ~ 10 Nm³/h Catalyst 2005: Iron 2006: Cobalt 2007: commercial catalyst nco + 2nH 2 = nch 2 + nh 2 O Biomass gasification Biomass BioFiT liquid fuel production 27
Schema of FT Syntheses Fluidised bed 850 C biomass steam particel tar heat Gas engine electricity gasification Gas cleaning Gas utilisation Flue gas Sulphur Chlorine Gas Treatment and compression FT-Synthesis 240-280 C 20-30 bar catalyst Product separation gaseous products, Off-Gas liquid fuel 28
Properties of FT Diesel Properties Unit EN 590:2004 Results of FT Diesel min max Cetane number - 51,0-75-85 Density at 15 o C kg/m³ 820 845 770-790 Polycyclic aromatic hydrocarbons %(m/m) - 11 < 1 Total aromatics content %(m/m) - - < 1 Sulphur content mg/kg - 50 < 5 Flash point C >55-87 to 91 Carbon residue %(m/m) - 0,30 < 0,03 Ash content %(m/m) - 0,01 < 0,0015 Water content mg/kg - 200 200 to 300 Total contamination mg/kg - 24 2 to 4 Copper strip corrosion (3h at 50 C) rating class 1 class 1 a Oxidation stability g/m³ - 25 < 5 Lubricity, corrected wear scar diameter m m - 460 340 to 360 Viscosity at 40oC mm²/s 2,00 4,50 2.3 to 2.5 Oxidation stability g/m³ - 25 < 12 Cold Filter Plugging Point, (CFPP) C - -20-5 to 0 29
Renewable natural gas Synthetic natural gas (BioSNG) 30
Methanation Methanation (BioSNG) Fluidized bed reactor Temperature 300-350 C Pressure 1-5 bar Capacity ~ 10 Nm³/h Catalyst Nickel CO + 3 H 2 = CH 4 + H 2 O Biomass gasification Biomass BioSNG-lab scale production 31
Results BioSNG lab scale So far no deactivation In cooperation with PSI 32
Schema BioSNG demonstration Fluegas Fluegas Treatment Wood Power Gasification Gas Cleaning Gas Engine Ash H 2 Recycle Streams Energy, Liquid & Solid Waste Gas Treatment Methanation SNG Purification Energy, Water & other Materials CO 2 + H 2 S / Heavy HC CO 2 Product (to substitute N 2 ) SNG Fueling Station Rev. 4 / DU / 24.9.2006 Bio-SNG Fuel 33
1MW BioSNG demonstration plant 34
Current Status and Outlook Successful scale up of a dual fluidized bed steam gasification system from laboratory to industrial scale (within 10 years) Industrial plant available with High electrical efficiency (> 30 % with combined gas engine and ORC-process) No solid residues (without ash, carbon content <0,5 %) No liquid condensates European emission requirements are met High availabilities (>93 %) Next plant is under commissioning (10 MW fuel ) High potential for biofuels (BioSNG, BioFiT) BioSNG, most suitable, 1 MW (100 m 3 /h BioSNG), start up demonstration Summer 2008 BioFiT, research ongoing 35
Information http://www.ficfb.at Visits under +43 3322 9010 850 36