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

Transcription

1 Large scale Fischer-Tropsch diesel production opportunities and challenges to shift from black (coal) to green (biomass) Robin Zwart Energy research Centre of the Netherlands (ECN)

2 EU biofuels Directives and Proposals The driving force for Fischer-Tropsch diesel production new proposal 2020 biofuels 2% 5.75% 7% 8% 15% natural gas 2% 5% 10% 10% LPG 5% H 2-2% 5% a few % Total 2% 7.75% 14% 23% > 30% 10% most recent proposal nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

3 Biomass availability and targets in the Netherlands PJ/y Biomass Biofuels Biomass (required) (required) (available) 912 Estimated biomass import: > 450 PJ th (hence over 15 GW th ) 450 max import inevitable 150 min PJ in 2030 from Rabou, Deurwaarder, Elbersen, Scott: Biomass in the Dutch Energy Infrastructure in 2030, January nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

4 16 GW of biomass?!? 50 MW th plants (commercial CFB, Choren β-plant) 600 MW th plants (commercial IGCC, planned Choren plant) 8 GW th plants (commercial GtL and CtL plants) IMPLEMENTATION VIA LARGE-SCALE PLANTS 7 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

5 Biomass to liquids System line-up of Fischer-Tropsch diesel production Biosyngas off-gas Electricity (for use in plant) Biomass light product Fischer-Tropsch Diesel (ultra-pure high quality designer fuel) Pre-treatment Gasification Gas conditioning Fischer-Tropsch synthesis CC 8 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

6 Option 1: Entrained Flow gasification High temperature (typically C) Pure oxygen The ashes melt: slag Conversion: over 99% Conventional technology for coal on large-scale but: small fuel particles needed Large-scale implementation? Shift from large-scale black (coal) to green (biomass) 9 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

7 Freiberg, Germany [Shell] Buggenum, Netherlands [Siemens] 10 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

8 Option 2: Fluidised Bed gasification Low temperature (typically C) Pure oxygen, steam needed as moderator No melting: dry ash Conversion: typically 95% Hardly any fuel size restrictions Technology in development but: gas contains too much CH 4, gas needs treatment Large-scale implementation? Shift from small-scale to large-scale green (biomass) 11 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

9 GTI pilot plant, USA VTT pilot plant, Finland Värnamo, Sweden 12 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

10 Options summary R&D on: milling torrefaction pyrolysis advanced feeding Proven (coal) Large scale 20% E biomass installed capacity entrained flow fluidised bed time biomass pretreatment entrained flow gasifier SHORT-TERM syngas fluidised bed gasifier catalytic reforming LONG-TERM Under development Small scale 100% E biomass R&D on: tar cracking C x H y reforming deactivation 13 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

11 Case study 10 cases Published in Energy and Fuels, 20, 2006, pp R1 Chipping Drying (7%) BCF Land transport Chips HUB Sea transport Chips ROTTERDAM Pulverizing EF 1300 C 40 bar FTsynthesis R2 Chipping Drying (7%) Chips Chips Pulverizing Pyrolysis EF 1300 C 40 bar FTsynthesis R3 Chipping Drying (15%) Chips Chips Torrefaction Pulverizing EF 1300 C 40 bar FTsynthesis R4 Chipping Drying (15%) Chips Chips CFB EF 1300 C 40 bar FTsynthesis R5 Chipping Drying (7%) Pulverizing Pelletizing Pellets Pellets Grinding EF 1300 C 40 bar FTsynthesis R6 Chipping Drying (7%) Pulverizing Pelletizing Pellets Pellets Grinding Pyrolysis EF 1300 C 40 bar FTsynthesis R7 Chipping Drying (15%) Pelletizing Pellets Pellets Grinding Torrefaction Pulverizing EF 1300 C 40 bar FTsynthesis R8 Chipping Drying (7%) Pulverizing Pyrolysis Slurry Slurry EF 1300 C 40 bar FTsynthesis R9 Chipping Drying (15%) Torrefaction Pulverizing Pelletizing Pellets Pellets Grinding EF 1300 C 40 bar FTsynthesis R10 Chipping Drying (7%) Chips Pulverizing EF 1300 C 40 bar FTsynthesis FTproduct 4 /GJ wood chips ~200 PJ/y FT products 14 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

12 Case study Boundary conditions and assumptions (1) O 2 -blown entrained flow gasification, 40 bar Fischer-Tropsch process: - C 5+ hydrocarbons are assumed to be upgraded to products Power production/consumption included in cost calculations [Shell SCGP] 15 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

13 Case study Boundary conditions and assumptions (2) wood-rich region sea the Netherlands wood chips in collection facility 4 /GJ collection facility (80x) hub/harbour (8x) Rotterdam (1x) ~200 PJ/y Fischer-Tropsch products in Rotterdam 200 PJ/y = 2% of EU15 fuel consumption 16 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

14 Case study Transport Fischer-Tropsch products Wood chips Wood pellets Wood oil/char slurry Torrefied wood pellets (TOP) Publications on torrefaction ( Combined torrefaction and pelletisation: The TOP process (ECN-C ) Torrefaction for entrained flow gasification of biomass (ECN-C ) Torrefaction for biomass upgrading (ECN-C ) green biomass waste demolition wood TOP fuel powder TOP fuel pellets 18 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

15 Case study Resulting biomass price ( /GJ bm ) at the gate of the FT plant wood chips 7.2 /GJ bm wood pellets 7.3 /GJ bm bio-slurry 7.9 /GJ bm TOP pellets 6.7 /GJ bm FT-products --- wood-rich region sea the Netherlands 19 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

16 Case study Fischer-Tropsch products costs 20 chips sea transport wood pellets sea transport other sea transport /GJ FT-products 15 ADV ADV slurry TOP ADV slurry TOP slurry TOP 10 slurry: pyrolysis oil/char-slurry feeding TOP: torrefied biomass powder feeding ADV: advanced FT-products 14 /GJ diesel = 0.50/ltr diesel (crude oil $ 80/barrel) 20 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

17 Conclusions on case 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! 22 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

18 Conclusions in general 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 23 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

19 Short-term implementation of biosyngas The largest existing biosyngas plant 600 MW th Buggenum IGCC Co-gasification of biomass with coal (up to 20% E ) Syngas production via Entrained Flow gasification 24 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

20 Short-term options in the Netherlands NUON Buggenum IGCC: - Shell Entrained Flow gasifier - Startup Co-gasification up to 34% wt or 20% E of renewables MW th,input / 250 MW e, output - Currently ± 7500 hours / yr on syngas NUON Magnum IGCC: - Copy of the Buggenum IGCC - Startup Co-gasification similar to Buggenum IGCC % of current consumption of 500 PJ - 3x600 MW th,input / 750 MW (+450 MW e, output e from natural gas) - Planned > 7500 hours / yr on syngas 2011 Biobased FT diesel potential: PJ (based on proven co-gasification percentages) PJ (based on maximum capacity available) 25 2nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )

21 Thank you for your attention ECN For more information, please contact: Ir. Robin Zwart phone fax ECN Publications can be found on: Visit also: Phyllis - internet database for biomass, coal, and residues: Thersites internet model for tar dewpoint calculations: nd International Freiberg Conference on IGCC & XtL technologies ( 8th - 12th May 2007 )