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BTL2030Project presentation
VTT Technical Research Centre of Finland LtdEspoo, October 2016
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Timetable: 1.1.2016 – 31.12.2017Total budget: 2.7 M€ (Tekes 1.5 M€, Industrial partners 0.5 M€, VTT 0.7 M€)Industrial partners:
Fortum Oyj, Gasum Oy, Helen Oy, Kumera Corporation, Gasification TechnologiesOy, Oy Brynolf Grönmark Ab, ÅF-Consult Oy, Oy Woikoski Ab, Dasos Capital Oy,Kokkolanseudun Kehitys Oy, MOL Group
BTL2030 project Website: http://www.vtt.fi/sites/BTL2030
Timetable: 1.1.2016 – 31.12.2017Total budget: 2.7 M€ (Tekes 1.5 M€, Industrial partners 0.5 M€, VTT 0.7 M€)Industrial partners:
Fortum Oyj, Gasum Oy, Helen Oy, Kumera Corporation, Gasification TechnologiesOy, Oy Brynolf Grönmark Ab, ÅF-Consult Oy, Oy Woikoski Ab, Dasos Capital Oy,Kokkolanseudun Kehitys Oy, MOL Group
BTL2030 project Website: http://www.vtt.fi/sites/BTL2030
BTL2030-project
Copyright © VTT 2016
Project title: Production of transport fuels from biomass bygasification-based concepts integrated to energy consumingindustries and district heat power plants – pilot tests and feasibilitystudiesAcronym: BTL2030
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Government Program of Finland
VTT-VATT Traffic 2030 study
” To increase the share of renewable transport fuels to 40 % by 2030””To stop using coal in energy production and to halve the use ofimported oil for domestic use”
http://www.transsmart.fi/files/248/Tutkimusraportti_VTT-R-00752-15_liitteineen.pdf
Project backgroundand R&D need
Copyright © VTT 2016
Solutions for biofuel production from domestic feedstocks in FinlandTarget for renewable energy use of 40 % by 2030
Kokkola-Case
Regulation, sustainability,cascade-use etc.
Ethanol
International influencing,EU 2030 policy,
EU SET-Plan, new exports
Government’s policy:the share of renewablefuels to 40% by 2030
Myl
lyko
ski
90.0
00m
3 /aHVO
Kaja
ani
10.0
00m
3 /a
Oth
er
Naa
ntal
iap
pr.4
0kt
oe
Sköl
dvik
appr
.400
ktoe
Lapp
eenr
anta
100
ktoe
Pyrolysis
Ther
mal
pyro
lysi
sR
epla
ceof
heav
yoi
lBo
ilers
,fur
nace
s
Cat
alyt
icpy
roly
sis
Blac
kliq
uor,
ligni
n,m
oist
biom
ass
Gasification
Stea
mga
sific
atio
n,C
HP-
inte
grat
edBT
L,SN
G,H
2
O2-
gasi
ficat
ion,
larg
eBT
L-pl
ants
NER
300,
Che
mre
c
Biogas(not SNG)
Fuel
gas
for
furn
aces
and
boile
rs
VTT-pilot+ Industrial Demo
Forestindustry cases
CHP-integrates
Seve
rals
mal
lpl
ants
Limited raw-material basis - not very suitablefor forest residues, black liquor or bark
LiquefactionHTL
Hydrogen treatmentfor transport fuels
Co-feeding in refineries
Gasification with black liquorPulp industry integration
Suitable for wide range of domestic woody raw material,Additional production capacity of 600-900 ktoe/a by 2030
Project backgroundand R&D need
Copyright © VTT 2016
Energy use of wood in Finland
Energy Sector
Source: Jaakko Jokinen, Pöyry Management Consulting Oy. Integrating biofuels and newproducts in Forest Bioeconomy. VTT 2G 2020 Seminar, 26.5.2015 Espoo, VTT Bioruukki.
Additional potential ofwood 20 TWh
Corresponds to for 900 ktoeproduction of transport fuel(appr. 25 % of present fuelconsumption)
4 TWh heat as by-product(district heat/industry)
Gasification-BTL plants18 plants of 50 ktoe/a capacityInvestment 150-200 M€/plantTotal appr. 3 billion euro
Potential elsewhereSwedenCentral Europe (agrobiomass)Brazil (bagasse, eucachips)
Project backgroundand R&D need
Copyright © VTT 2016
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What would meane.g. 5 % of EU market?
15 Mtoe/a in road transport300 gasification-synthesis plantsof 150 MW feede.g. 25 plants/year at 2030=> 5 B€/year investment
Aviation fuels: 4 % target2 Mtoe/a by 2020 ?40 gasification-synthesis plants
Sustainability and ILUCGHG reduction > 60 %(Gasification-BTL > 80 %)Residues are the main feedstocksof gasification BTL
Source: European Biofuels Technology Platform, SRA Jan. 2008
Project backgroundand R&D need
Copyright © VTT 2016
Huge EU market 2030- How Can Be Satisfied – 5 %?
7Source: http://www.iea.org/publications/freepublications/publication/name-3976-en.html
World markets and export potential are enormous
Possibleproducts viaGasification& Synthesistechnologies
Project backgroundand R&D need
Copyright © VTT 2016
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Heat-integrated medium-scale BTL process viapiloting and demonstration to industrial use
Phase 1: Piloting and evaluation project, on-going as national project, VTT as a co-ordinatorPhase 2: Demonstration project, will be planned togerher with industrial partners 2017-2019Phase 3: Industrial Flagship project
P0: Concept development – PRECHEM-Kokkolan Biorefinery project (2015)P1: Piloting at VTT Bioruukki andsystem studies 2016-17, 2.5 M€P2: Industrial demonstration at Kokkolaor forest industry site 2017-19, 40 M€
P3: First production plant, 220 M€Capacity 50 ktoe/a, Design 06/17- 06/19Investment decision 06/2019, Commissioning 2021
P4: Several plants in operation 2025-30,investments 150-200 M€/plant
2025: 5 plants, total 250 ktoe/a2030: 10 plants, total600 ktoe/a
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BTL2030-project
The target of this project is a medium-scale BTL concept, which canbe integrated to different kind of energy intensive industries anddistrict heating power plants
The new gasification process is being developed at the DFBpilot plant of VTT Bioruukki and the feasibility of the processis studied together with industrial partners representingdifferent potential applications and roles in the value chain.
Copyright © VTT 2016
1010
Develop a new gasification process for heat integrated production oftransport fuelsDemonstrate the technical feasibility of this process with variousbiomass feedstocks by carrying out pilot-scale tests.Carry out system studies to study the economic feasibility of the processin different integration cases.Follow-on industrial projects will be preliminarily planned together withparticipating companies.
BTL2030-project
Project objectives
The aim is to develop a new gasification process for heatintegrated production of transport fuels and to demonstratethe technical feasibility of this process by carrying out pilot-scale tests.
The aim is to develop a new gasification process for heatintegrated production of transport fuels and to demonstratethe technical feasibility of this process by carrying out pilot-scale tests.
Copyright © VTT 2016
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BTL2030-project
Target results of the project:
To operate the DFB gasifier with various biomass feedstocksTo estimate the performance of an industrial plantHot gas filtration, catalytic reforming and sulphur removal has beendeveloped and validated in the pilot-test runsProduction concepts for FT, H2 and SNG have been developed andevaluated in different cases of energy integration.The economic feasibility and the potential of this biofuel production routehave been reliably estimated.Proposal(s) for industrial follow-onprojects have been prepared
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BTL2030The advantages of the new production conceptCan be integrated to different energy intensive industries and CHP plantsPressurized O2-blown gasifier is replaced by a steam gasifier operated at alow pressureGasification can be carried out a lower temperatureLow contents of heavy tars is reached already in the gasifier and filterFuel feeding into a low-pressure gasifier is easierThe gasifier design is similar to the air-blown CFB gasifierThe expensive Rectisol-type of gas cleaning is replacedby simpler gas cleaning systemThe synthesis technology of the basic concept is also a once through systemSynthesis off-gas is used to heat the gasifier
Copyright © VTT 2016
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BTL2030 –projectWork packages
WP 1: Pilot-scale development of the new gasification process
WP 2: Feasibility studies
WP 3: Preparation and planning of follow-up projects
WP 4: International co-operation, reviews of competing technologies
WP 5: Publications, seminars and information exchange
Copyright © VTT 2016
Gasification process principle
Steam gasification & hot filtration & reforming
Fuel
Steam(+ air/O2/CO2)
Raw gas700-800oC
Fly ashto combustion
Filter
Gas to reformer600-800 oC
Stagedreformer
Gas to gas coolerand further cleaning850 oC
O2 or Air+ Steam
Air
Flue gas to steamgeneration
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WP 1: Pilot-scale development of the newgasification process
WP1 The largest WP of the projectWP1 The largest WP of the project
Feedstock basis of the gasification processPDU and laboratory tests with selected feedstocksPilot-tests with potential feedstocks and feedstock mixtures
Development of gas cleaning concept, validation of the wholegasification process
Hot filtrationReforming of tars and hydrocarbon gasesDesign of the bulk sulphur removal unit and testing, sorbent optimizationR&D, final gas cleaning studies and tests in a slip stream unitData for process modelling
Copyright © VTT 2016
TIMETABLEWP1 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4BFB-PDU tests with selected feedstocksGas cleaning R&DDFB pilot campaigns
20182016 2017
FUELTANK
BIOMASS
GASIFIER
BED FEEDER
OXIDISER
FILTER
AIR TO OXIDISER
REFORMER
PRODUCT GAS
CYCLONE
COOLERFLUE GAS
N2
DFB gasificationt Pilot-plant, VTT Bioruukki
The DFB pilot plant will bemodified and fine-tuned for the
need of each test campaign
The DFB pilot plant will bemodified and fine-tuned for the
need of each test campaign
Copyright © VTT 2016
FUELTANK
AIRO2STEAMCO2
AIRO2STEAMCO2
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STEAM / O2 / AIR / N2 / CO2
PURGE-N2
TARSAMPLING
TAR SAMPLING,GAS ANALYSER,
MICRO GCTO GASBOILER
FUEL
N2
BED MATERIAL/ADDITIVE
FILTER
GASIFIER
BFB100 atmospheric pressure fluidised-bedgasifier, VTT Bioruukki
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WP 2: Feasibility studiesGeneral feasibility studies
Evaluation of different synthesis technologies and contacts to technologysuppliersDesign of the production concept for several applications (FT, SNG, H2)Biomass pre-treatment, gasification process, synthesis technology andenergy integrationMaterial and energy balances, energy efficiencies, possible feedstockbasis, capital and operation costs, economic feasibility
Specific case studies for participating investor companiesRealised in co-operation with participating companies
Copyright © VTT 2016
TIMETABLEWP2 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4Concept evaluationSynthesis technologyConcept calculation - PreliminaryConcept calculation - FinalCase-studies
20182016 2017
1919
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BELTDRYER
STEAMGASIFIER
HOTFILTER
TAR+HCREFORMER
SYNGASCOOLER
ENDCOOLERCOMPR
ZINC SREMOVAL
OTFTL
CO2SCRUB
HYDROCRACKER
1 2 4 5 6
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101213
Process block diagramme – FT/Base case
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LOCKHOPPER
3
14
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Indirectly heated atmospheric steam gasification with 82 % carbon conversionOxygen operated reformer (staged reformer concept of VTT)No shift reactor, H2/CO=2 by fluidising gasifier with: 88 % water & 12 % CO2Sulphur control with once-through zinc adsorbentsCompression to 26 bar in one stepMinor CO2 removal with pressurised water scrubber to achieve CO2 for gasifier purposesOnce-through two-stage cobalt-based low-temp FT-synthesisOff-gases mostly combusted in the oxidiser to provide heat for gasification
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BIOMASS FEED100 / 150 MW
FT-DIESEL PRODUCT54 / 81 MW
BY-PRODUCT ENERGY20 / 30 MW
Example of an integrated production plant producinghydro-treated FT- middle distillate for diesel production.
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2020
WP 3: Planning of follow-on projectsDemonstration plant of P2
Evaluation of different alternatives for this critical phase ofcommercializationFormation of the industrial consortium including technology suppliersPlanning of financing alternatives
Preliminary planning of the Flag-ship plant(s)Target is to find a way for making the investment of first-of-kind planteconomically attractive for the plant owner
Copyright © VTT 2016
TIMETABLEWP3 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4EU LCE PROPOSALS XXX XXX LCE08 LCE19
Demos, flag ship
20182016 2017
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WP 4: International co-operation and review ofcompeting technologies
General technology follow-up and information exchange within the EERAalliance of large European Research organizationsIEA special project on hybrid concepts integrating bio-syngas andelectrolysis hydrogenContacts to technology suppliers and research organizations outsideEuropeCo-operation with SwedenContacts to Brazil related to gasification of bagasse
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TIMETABLEWP4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4Status review x x x x x x
20182016 2017
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WP 5: Reporting, publications, seminars andinformation exchange
Scientifically interesting results will be published in journals andconferences during and after the project
Copyright © VTT 2016
TIMETABLEWP5 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 PublicationsSeminars x x xStakeholder groups
20182016 2017
23Work groups (VTT & industrial partners)
Steering groupTekes, VTT, Fortum, Gasum, Helen, ÅF, GasTech, Grönmark, Kumera,
Woikoski, Dasos Capital, Kokkolanseudun Kehitys, MOL/Hungary
VTT Technical Research Centre of Finland Ltd.Project leader: Esa Kurkela, Project Manager
TEKES – the Finnish Funding Agency for Innovation
Jukka Leppälahti, Chief Adviser
Project organization
Feasibilitystudies
Preparation offollow-upprojects
WP3
Internationalco-operation,
Reviews
Publications,Seminars
New gasificationprocess,Piloting
WP1 WP2 WP4 WP5
Copyright © VTT 2016
Dual Bed Steam Gasification Pilot at BioruukkiNew low-pressure process for 50-150 MW input
Most suitable applicationsHydrogen by PSASNG or FT diesel with once-through synthesisLow-pressure processsuitable also to bagasse andother low-density feeds
Most suitable applicationsHydrogen by PSASNG or FT diesel with once-through synthesisLow-pressure processsuitable also to bagasse andother low-density feeds
Copyright © VTT 2016
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Gasification pilots at Bioruukki
Key research and scale-up offeringExcellent know-how on fuel chemistry and gasification processesUnique fluidized bed gasification, catalytic gas cleaning and hot filtrationtest facilities from laboratory to pilot scaleCutting-edge tools for techno-economic evaluations and modelling
Main equipment at BioruukkiDual Fluidized-Bed steam gasification pilot plant for syngas applications.Atmospheric pressure, feed capacity up to 80 kg/h. Hot filtration, catalyticreformingCFB gasification pilot plant for syngas and fuel gas. Air-blown operation,steam-O2 gasification. Hot filtration, catalytic reformingBench-scale BFB gasification, filter and reformer testing facilities
Development plans for BioruukkiNew pressurized fixed-bed pilot plant for CHP and syngas applicationsNew test possibilities for waste and recycling raw materials
Gasification Platform is used for gasification process development, testing of newfeedstocks and for the development of gas cleaning technologies.
Gasification Platform is used for gasification process development, testing of newfeedstocks and for the development of gas cleaning technologies.
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Bioruukki - New piloting ecosystemat Kiviruukki industrial area, Espoo
VTT BioruukkiA centre for process industryscale-up anddemonstrations.A former printing planttransformed to world scaleR&D centre.8000 m2, room for severalpilot units and laboratories.Located close to Otaniemicampus.
Copyright © VTT 2016
NEW ERANEW ERABTL2030 project Website: http://www.vtt.fi/sites/BTL2030