large scale fischer-tropsch diesel production

www.ecn.nl

Large scale Fischer-Tropsch diesel production opportunities and challenges to shift from black (coal) to green (biomass)

Robin ZwartEnergy research Centre of the Netherlands (ECN)

5 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 ) www.ecn.nl

biofuels

natural gas

LPG

H2

Total

2010 2015 new proposal

2020 2020

5.75% 7%

2% 5%

- 2%

8%

10%

5%

7.75% 14% 23%

15%

10%

a few %

> 30%

5%

2005

2%

2%

biofuels

natural gas

H2

Total

2010 2015 2020

5.75% 7%

2% 5%

- 2%

8%

10%

5%

7.75% 14% 23%

2005

2%

2%

10%most recent

proposal 2010

The driving force for Fischer-Tropsch diesel production EU “biofuels” Directives and Proposals


2000 2010 2020 20402030

PJ/y

40

150min

912

Biomass (required) Biofuels (required) Biomass (available)

5

75 60

450max

Biomass availability and targets in the Netherlands

912 PJ in 2030 from “Rabou, Deurwaarder, Elbersen, Scott: Biomass in the Dutch Energy Infrastructure in 2030, January 2006”

Estimated biomass import:

> 450 PJth(hence over 15 GWth )

importinevitable


16 GW of biomass?!?

50 MWth plants

600 MWth plants

8 GWth plants(commercial GtL and CtL plants)

(commercial IGCC, planned Choren plant)

(commercial CFB, Choren β-plant)

IMPLEMENTATIONVIA

LARGE-SCALE PLANTS


System line-up of Fischer-Tropsch diesel production Biomass to liquids

Gas conditioning CC

Electricity(for use in plant)

Fischer-Tropsch synthesis

off-gas

Fischer-Tropsch Diesel

(ultra-pure high quality designer fuel)

light product

Biosyngas

GasificationPre-treatment

Biomass


•

High temperature (typically 1300-1500°C)•

Pure oxygen•

The ashes melt: slag •

Conversion: over 99%•

Conventional technology for coal on large-scale

Large-scale implementation?Shift from large-scale black (coal) to green (biomass)

but: small fuel particles needed

Option 1: Entrained Flow gasification


[Shell] [Siemens]Buggenum, Netherlands

Freiberg, Germany


•

Low temperature (typically 800-900°C)•

Pure oxygen, steam needed as moderator•

No melting: dry ash•

Conversion: typically 95%•

Hardly any fuel size restrictions•

Technology in development

Large-scale implementation?Shift from small-scale to large-scale green (biomass)

but: gas contains too much CH4 , gas needs treatment

Option 2: Fluidised Bed gasification


VTT pilot plant, Finland

Värnamo, Sweden

GTI pilot plant, USA


Options summary

entrained flow gasifier

pre- treatment

syngasbiomass

fluidised bed gasifier

catalyticreforming

• Proven (coal)• Large scale• 20%E biomass

• Under development• Small scale

• 100%E biomass

R&D on:• milling

• torrefaction• pyrolysis

• advanced feeding

R&D on:• tar cracking• Cx Hy reforming• deactivation

time

inst

alle

d ca

paci

ty

entrained flow

fluidised bed

LONG-TERM

SHORT-TERM


SeatransportBCF ROTTERDAMHUB

FT-synthesisPulverizing

PyrolysisPulverizing

Torrefaction

CFB

PyrolysisGrinding

Grinding

Chips

Chips

Chips

Chips

Pellets

Pellets

Pellets

Slurry

Pellets

FT-product

Chips

Chips

Chips

Chips

Pellets

Pellets

Pellets

Slurry

Pellets

Chips

PelletizingPulverizingChipping

Grinding

Chipping

PyrolysisChipping Pulverizing

PelletizingChipping

Chipping PelletizingPulverizing

Chipping PelletizingPulverizing

Chipping

Chipping

Chipping

Drying(7%)ChippingR1

R2

R3

R4

R5

R6

R7

R8

R9

R10

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

EF1300°C40 bar

FT-synthesis

FT-synthesis

FT-synthesis

FT-synthesis

FT-synthesis

FT-synthesis

FT-synthesis

FT-synthesis

Pulverizing

Pulverizing

Grinding

Torrefaction

Torrefaction

EF1300°C40 bar

FT-synthesisPulverizing

Drying(7%)

Drying(15%)

Drying(15%)

Drying(7%)

Drying(7%)

Drying(15%)

Drying(7%)

Drying(15%)

Drying(7%)

Landtransport

4 €/GJ wood chips ~200 PJ/y FT products

Published in Energy and Fuels, 20, 2006, pp. 2192-2197

10 casesCase study


•

O2 -blown entrained flow gasification, 40 bar

•

Fischer-Tropsch process:-

C5+ hydrocarbons are assumed to be upgraded to products

•

Power production/consumption included in cost calculations

[Shell SCGP]

Boundary conditions and assumptions (1)Case study


wood-rich region sea the Netherlands

collection facility(80x)

hub/harbour (8x)

Rotterdam (1x)

woo

d ch

ips

in c

olle

ctio

n fa

cilit

y 4

€/G

J

200 PJ/y = 2% of EU15 fuel consumption

~200

PJ/

y Fi

sche

r-Tr

opsc

h pr

oduc

ts in

Rot

terd

am

Boundary conditions and assumptions (2)Case study


•

Fischer-Tropsch products•

Wood chips

•

Wood pellets•

Wood oil/char slurry

•

Torrefied wood pellets (TOP)

TransportCase study

demolition wood

green biomass

waste

TOP fuel powder TOP fuel pellets

•

Fischer-Tropsch products•

Wood chips

•

Wood pellets•

Wood oil/char slurry

•

Torrefied wood pellets (TOP)

Publications on torrefaction (www.ecn.nl/bkm)

Combined torrefaction and pelletisation: The TOP process (ECN-C--05-073)

Torrefaction for entrained flow gasification of biomass (ECN-C--05-067)

Torrefaction for biomass upgrading (ECN-C--05-013)

http://www.ecn.nl/bkm


wood chips 7.2 €/GJbm

wood pellets 7.3 €/GJbm

bio-slurry 7.9 €/GJbm

TOP pellets 6.7 €/GJbm

FT-products ---

wood-rich region sea the Netherlands

Resulting biomass price (€/GJbm ) at the gate of the FT plantCase study


14 €/GJdiesel = € 0.50/ltrdiesel (crude oil $ 80/barrel)

€/G

J FT

-pro

duct

s

10

15

20chips sea transport

ADVADV

TOPslurry

wood pellets sea transport

ADV

TOPslurry

slurry: pyrolysis oil/char-slurry feedingTOP: torrefied biomass powder feedingADV: “advanced”

other seatransport

TOP

slurry

FT-products

Fischer-Tropsch products costsCase study


•

the entrained flow case study:-

biomass pre-treatment can significantly improve BtL economics:

reduced transport costs overweigh additional capital costs

-

pre-treatment there (near wood source) is preferred over pre-treatment here (next to gasifier plant):

making wood pellets is worthwhile, but pyrolysis or torrefaction is more attractive, but overseas Fischer-Tropsch is favorable!

Conclusions on case study


•

large-scale BtL has two main technology options:-

entrained flow gasification of pre-treated biomass torrefaction at ECN

-

fluidised bed gasification with subsequent reforming

•

the implementation path:-

entrained flow: from coal to biomass (large-scale) NUON, Elcogas?

-

fluidised bed: from small to large (100% biomass)

•

the main technological challenges:-

entrained flow: pre-treatment part of EU FP7 proposal

-

fluidised bed: catalytic reforming

Conclusions in general


600 MWth Buggenum IGCC• Co-gasification of biomass with coal (up to 20%E )• Syngas production via Entrained Flow gasification

The largest existing biosyngas plantShort-term implementation of biosyngas


Short-term options in the NetherlandsNUON Buggenum IGCC:- Shell Entrained Flow gasifier- Startup 1993- Co-gasification up to 34%wt or 20%E of renewables - 600 MWth,input / 250 MWe, output- Currently ± 7500 hours/yr on syngas

NUON Magnum IGCC:- Copy of the Buggenum IGCC- Startup 2011- Co-gasification similar to Buggenum IGCC - 3x600 MWth,input / 750 MWe, output (+450 MWe from natural gas)- Planned > 7500 hours/yr on syngas

2011 Biobased FT diesel potential:- 7.3 PJ (based on proven co-gasification percentages)- 36.3 PJ (based on maximum capacity available)

1.8-7.2%of current

consumptionof 500 PJ


For more information,please contact:

Ir. Robin Zwartphone +31 224 56 4574fax +31 224 56 8487email [email protected]

ECN Publications can be found on: www.ecn.nl/en/bkm

Visit also:

“Phyllis” - internet database for biomass, coal, and residues: www.phyllis.nl

“Thersites” – internet model for tar dewpoint calculations: www.thersites.nl

Thank you for your attention ECN

mailto:[email protected]

large scale fischer-tropsch diesel production

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