final meeting presentation ecn torrefactionbus final meeting, wageningen, 20 november 2007 2 bo...
TRANSCRIPT
1
ECN BO2-technology for biomass upgrading
Jaap Kiel
BUS final meeting, Wageningen, 20 November 2007
2 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Presentation overview
• Torrefaction principles• ECN BO2-technology
• Economics• Development status and
market implementation
2
3 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Biomass – a diverse energy source
Waste Wood (agricultural) residues energy corps
• Biomass = all organic material of non-fossil origin, meant for energy or chemicals/materials production
4 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
• Harvesting, collection• Handling
Biomass is a difficult energy source• Production
• Transport
• Storage• Pre-treatment (e.g., milling)
• Feeding• Conversion
3
5 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Torrefaction for biomass upgradinggeneral process description
Torrefaction
mass energy
Gas
Biomass
Torrified
biomass
1 0.7
0.3
1 0.9
0.1
0.7
0.9= 1.31Energy densification (E/kg)
Temperature: 200-300 °C
Pressure: near atmospheric
Heating rate: <50 °C/min
Absence of oxygen
Product: solid fuel
Residence time 10-30 min
Particle size < 4 cm thickness
6 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Friable and less fibrous
19 - 22 MJ/kg (LHV, ar)
Hydrophobic
Preserved
Homogeneous
Torrefaction and pulverisation
Fuel powder
From biomass/waste to commodity fuels
Superior fuel properties:
• Transport, handling, feeding
• Milling
• Combustion/gasification
• Feedstock range
• Standardisation
Tenacious and fibrous
10 - 17 MJ/kg (LHV, ar)
Hydrophilic
Vulnerable to biodegradation
Heterogeneous
Agricultural residues
Mixed
waste
Woody biomass
Pelletisation
Fuel pellets
Bulk density 750-850 kg/m3
Bulk energy density 15-20 GJ/m3
4
7 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Starting points ECN BO2-technology development (1)
• Torrefaction (combined with pelletisation) has the potential of becoming a key unit operation in biomass upgrading schemes for a wide range of applications, including:
− Biomass storage and (long-distance) transport – biomass import
− Co-firing in pf boilers
− (Co-)firing in entrained-flow gasifiers for producing power (IGCC) or transportation fuels (e.g., Fischer-Tropsch diesel)
− Small-scale pellet boilers and stoves
⇒ Torrefied biomass pellets may become a biomass commodity fuel
8 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Starting points ECN BO2-technology development (2)
• Torrefaction principle not new, but many aspects relevant to application for upgrading biomass into biomass fuel for thermal conversion processes were not addressed, including:
− Scale of operation in relation to reactor technology and processlayout
− Characterisation and quantification of product quality and how this relates to process conditions
− Nature and quantity of emissions
− Prospects of heat integration including utilisation of the energy containing torrefaction gases
− The economic viability of torrefaction as a biomass upgrading technique for bulk applications
⇒ 2002 start ECN BO2-technology development
5
9 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Proof-of-concept approach
Continuous screw
reactor (pyromaat)
Batch reactor
TGA analysis
Pellet press (batch)
Torrefied
biomassBiomassCutting mill
Lab-scale combustion
Simulator (LCS)Torrefaction
gas
Sampling methods
Analysis methods
Product distribution (M & E yields)
Pellet quality
Grindability
Combustibility
Torrefaction
database
Process
simulation
&
design tools
20 l batch reactor
5 kg/h screw reactor
10 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
TorrefactionTypical experimental results
Torrefaction
32 min, 260 ºCFeed: Willow
Size: 10 - 30 mm
LHV = 14.8 MJ/kg (ar)
MC = 14.4%
Fixed carbon: 16.8 %
Torrefied Willow
Size: 10 - 30 mm
LHV = 18.5 MJ/kg (ar)
MC = 1.9%
Fixed carbon: 22.1%Mass yield: 75.3% (ar)
Energy yield: 94.3% (ar)
Gas phase composition
CO 0.1 %
CO2 3.3 %
H2O 89.3 %
acetic acid 4.8 %
furfural 0.2 %
methanol 1.2 %
formic acid 0.1 %
remainder 1.0 %
Tad = 1045 ºC
6
11 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Grindability of (torrefied) biomass
-
40
80
120
160
200
240
280
320
360
- 0.2 0.4 0.6 0.8 1.0
average particle size (mm, volume based)
chip
per
ca
pac
ity (
kWth
)-
10
20
30
40
50
60
70
80
90
- 0.5 1.0 1.5
average particle size (mm, volume based)
Pow
er c
onsu
mpt
ion
(kW
e/M
Wth
)
C(270,21)
C(280,18)
C(290,12)
W(290,24)
W(260,24)
Willow (MC=10-13%)
Willow (dried)
Cutter wood
AU bituminous coal
Borssele run
demolition wood
D(300,11)
-
10
20
30
40
50
60
70
80
90
- 0.5 1.0 1.5
average particle size (mm, volume based)
Pow
er c
onsu
mpt
ion
(kW
e/M
Wth
)
C(270,21)
C(280,18)
C(290,12)
W(290,24)
W(260,24)
Willow (MC=10-13%)
Willow (dried)
Cutter wood
AU bituminous coal
Borssele run
demolition wood
D(300,11)
C(270,21)
C(280,18)
C(290,12)
W(290,24)
W(260,24)
Willow (MC=10-13%)
Willow (dried)
Cutter wood
AU bituminous coal
Borssele run
demolition wood
D(300,11)
Torrefaction leads to a dramatic decrease in required milling power and increase in milling capacity
12 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Combustion reactivity of torrefied woodLab-scale Combustion Simulator experiments
0
10
20
30
40
50
60
70
80
90
0 500 1000 1500 2000 2500time [ms]
con
vers
ion
[%
] o
r L
OI [
% d
.b.]
100
high-volatile coal low-volatile coal torr. (300°C) demolition wood HVC (LOI) LVC (LOI) torr. (300°C) demolition wood (LOI)torr. (280°C) prune wood torr. (280°C) prune wood (LOI) torr. (280°C) demolition woodtorr. (280°C) demolition wood (LOI) prune wood (fresh) prune wood (fresh, LOI)
High reactivity for torrefied wood
7
13 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Semi-industrial pelletisation testsFeatures:
• 10 kg/h
• No automatic moisture supply
• Preliminary findings:− Easy pelletisation− Low energy input required
− Pellet quality strongly dependent on pelletisation conditions
14 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
BO2pellets – features
• High energy density (15-20 GJ/m3, >3x biomass, 1.5-2x wood pellets)
• Water resistant (no swelling or disintegration)
• No/less biological degradation and heating
• Excellent grindability (similar to coal)
• Good combustion and gasification properties
But how to produce them with a high energy efficiency and at low cost ?
8
15 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Pre-existing “torrefaction technology”Features:
• Derived from cooling or
pyrolysis technology
• Not fuel flexible / robust
• Limited scale-up
• High investment cost
• Difficult control of process
parameters
16 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
ECN directly heated torrefaction technology
Drying Torrefaction Cooling
Heat exchange
Biomass TOP pellets
Air
Utillity fuel
Flue gas
Combustion
ΔP
Torrefactiongas
Flue gas
Flue gas
Gasrecycle
Pelletisation
Features:
• High energy efficiency (> 90%)
• Heat integration
• Conventional drying and
pelletisation
• Compact moving bed
technology
• Cost effective
15-20% moisture
9
17 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
ECN torrefaction technologyInnovative moving bed reactor
• Compact reactor
• Small footprint
• High heat transfer rates
• Accurate T-control
• Uniform product quality
• Feedstock flexibility
• Low capital investment
Pilot-scale torrefaction reactor at ECN
18 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Total Capital Investment TOP and Pelletisation (Feedstock: 180 kton/a woodchips @ 50%mc)
0
1
2
3
4
5
6
7
8
TOP Process Conventional Pelletisation
TC
I (M
Eur
o)
Drying
Torrefaction
Size Reduction and Pelletisation
Storage
Indirect Cost
Working Capital
Total capital investment – study estimate(BO2pellets vs. wood pellets)
BO2-technology Conventional pelletisation
Total Capital Investment(Feedstock 180 kton/a woodchips @ 50% moisture)
10
19 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
Green Wood Pellets
Saw Dust Pellets
47 MW /75 kton/a
MC = 50%
47 MW / 75 kton/a
MC = 35%BASE CASE
47 MW /75 kton/a
MC = 25%
23 MW / 36 kton/aMC = 35%
71 MW /112 kton/aMC = 35%
Pro
duct
ion
Cos
t Ind
icat
ion
(E
uro/
GJ
prod
uct)
Total Cost Other PowerSupport Fuel Personnel MaintenanceDepreciation and Financing Feedstock (=0 Euro/tonne)
Total production cost – study estimate (BO2pellets vs. wood pellets)
20 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Chain study (BO2pellets vs. wood pellets)
BO2-technology
(South Africa)Logistics
Conventional
Pelletisation
(South Africa)Logistics
(Co-)firing
coal-fired power stations
or entrained-flow gasifiers
North-West Europe
Sawdust
Sawdust
2.0 EUR/GJ0.7 EUR/GJ <2.0 EUR/GJ
<4.7 EUR/GJ
2.3 EUR/GJ0.7 EUR/GJ 2.9 EUR/GJ
5.9 EUR/GJ
Higher co-firing capacity
Lower capital investment
Higher co-firing flexibility
and availability
Favourable
economics!
@ 2005
11
21 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
ECN BO2-technology – market potential……. some figures
• EU-27: coal-fired plants with 10% co-firing requires 70 Mton/a dry biomass ≅ 700 BO2-plants with plant-size 100 kton/a
• EU-15: 43 Mton/a dry biomass (agro-residues) available for energy purposes; substantial possible role of BO2-technology to increase efficiency and reduce cost of overall biomass-to-energy chain
• Current world-wide wood pellet production approx. 7.5 Mton/a, expected to increase rapidly in coming 5-10 years to tens of millions of tons, mostly coarse shavings and green wood. Thus good prospects for BO2-technology.
• EU-27: 10% biofuels in 2010, ≅ 1300 PJ/a, corresponding to approx. 110 Mton/a dry biomass (@ 60% conversion efficiency). BO2-technology is an enabling technology for HT gasification-based BtL.
22 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
ECN BO2-technology – status
• Pilot-scale testing (PATRIG) ongoing
− Validation of reactor and process concept− Optimisation of process conditions for a broad feedstock range (woody
biomass, agro-residues)
− Industrial pelletisation tests− Extensive quality evaluation BO2pellets
(e.g., hygroscopic nature, biodegradation, strength, milling characteristics, combustion/gasification reactivity)
• IP in BO2 Energy concepts bv
• Industrial partnership established aimed at demonstration and market introduction
• Continued basic R&D (in co-operation with institutes/universities) − E.g., contaminated biomass (residues) and waste
12
23 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
PATRIG torrefaction pilot-plantStatus November 2007• Construction and commissioning
(nearly) completed
• Biomass supply and pre-treatment arranged
24 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
ECN BO2-technology market introduction
Econcern/Chemfo
BO2RightsBO2GO BO2Unlimited
End users BO2-plants
End users
1st BO2-plant
13
25 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
ECN BO2-technology market introduction
• Partnership ECN – Econcern – Chemfo
• Design and construction 1st production plant BO2GO, scheduled for operation in 2009
• Start-up of BO2Unlimited for supply of commercial BO2-plants
− add-on to wood pellet plants
− residues food & feed sector
− agricultural residues
26 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
In conclusion
• ECN BO2-technology allows cost-effective production of commodity fuels from a wide range of biomass/waste feedstock with a high energy efficiency (>90%)
• 2nd generation BO2pellets show:− High energy density
− High water resistance
− No/Limited biological degradation
− Excellent grindability
− Good combustion and gasification properties
• Fields of application:− Long distance biomass transport
− Co-firing in pf boilers
− (Co-)firing in entrained-flow gasifiers− Small-scale pellet boilers/stoves
• Pilot-plant testing started, industrial partnership for 1st plant and commercialisation, strong market pull for BO2-plants and BO2pellets
14
27 BO2-technology for biomass upgrading into commodity fuels – Jaap Kiel
Thank you for your attention………
For more information, please contact:
Dr.ir. J.H.A. (Jaap) Kiel Publications can be found on:phone +31 224 56 4590 www.ecn.nl/publicationsfax +31 224 56 8487email [email protected]
and I will be happy to answer your questions!