Valorisation of Synthesis Gas from Biomass - the Piteå DME pilot. Esben Lauge Sørensen, May 2009

Transcription

1 Valorisation of Synthesis Gas from Biomass - the Piteå DME pilot Esben Lauge Sørensen, May 2009

2 Contents Presentation of Haldor Topsøe A/S Presentation of Chemrec AB The BioDME Project Lay-out of DME pilot Gasifier Performance Syngas Technologies today and tomorrow Conclusion: Anticipated Technological Conquests

3 Presentation of Haldor Topsøe A/S

4 Topsoe SynGas Technologies Ammonia Hydrogen Methanol Formaldehyde DME Gasoline - TIGAS Synthesis Gas SNG 15-20% of turn-over spent on R&D

5 Topsoe Pilot Plant Traditions

6 Presentation of Chemrec AB - Technology -

7 Generation of Motor Fuels at a Pulp Mill Valorisation of black liquor: Production of syngas for motor fuel production from internal stream in existing pulp-mill Steam generation from biomass is used to make up energy content of produced biofuel Biomass Biomass boiler Steam and power Black liquor Pulp wood Pulp mill Green liquor Steam Cellulose pulp Power Motor fuels plant Motor fuel

8 Why Black Liquor Gasification? Liquid Easy to feed to a pressurized gasifier Can be atomized to fine droplets Rapid gasification rates Highly reactive (high Na/K content) Full carbon conversion at ~1000 deg C No tar formation Low methane formation BL is available in large quantities About 270 MW of black liquor is generated at an average sized pulp mill (~ tons of pulp per year)

9 The BioDME Project An EU-sponsored bio-mass to liquid fuels project

10 The BioDME project 3G vehicle development Fuel injection development Vehicle production Vehicle field test Vehicle production Biomass Black liquor Syngas generation and cleaning Fuel properties DME production DME Distribution& filling Industrial use

11 BioDME project Consortium Partners - Plant engineering, construction and operation - Plant owner - DME injection system development - Laboratory support to plant operation - DME production technology provider - DME distribution - DME fuel specification - Fuel additives and lubricant developments BioDME Project Coordinator - Engine development - Vehicle manufacturing - Field test responsible

12 Pilot site: Piteå in Sweden Existing DP-1 DME Storage Planned DME Pilot

13 Pilot plant on location Architectural view of new plant

14 Process Technology Demonstration Timeline First EU-application filed: June 2007 Official Project Kick-off Sept 2008 Basic Engineering Complete: Mar 2009 Start of DME-production: June 2010 Test programme completed: Sept 2012

15 Pilot Plant: 5 MTPD DME from BLG

16 Overall Process Layout Existing unit

17 Performance of existing gasifier

18 Existing Gasification Pilot Plant, DP-1 Black Liquor Oxygen GAS COOLER STEAM GENERATOR Cooling water BFW * Cooled raw syngas REACTOR * QUENCH Raw syngas * LPsteam MPsteam Weak Wash Condensate * Cooling Water in DP-1

19 Raw gas Data from Development Plant H 2 CO CO ppm benzene < 5ppm naphthalene Zero or close to zero tar contents Very little fouling in heat exchangers Particulates non-detectable CH 4

20 Black Liquor Gasification Typical performance Example: Data for liquor at 73% DS content as fired. LHV: MW th(lhv) Black liquor feed 75 MP and LP Steam generated 23 Feedwater heating 2 Syngas 44 Gasifier thermal efficiency 92% Replaces low-efficiency Tomlinson boiler with high-efficiency biomass boiler Temperature of gas [ C] Effect from gas cooling/condensation [MW]

21 Topsoe Syngas Technologies - Now and in the future

22 Tailor-made catalysts and technologies Biomass gasification processes from 1 bar Slurry feed gasification At up to ~ 80 bar Process Variation

23 WGS a versatile reaction Steam/CO >2.5 IGCC H 2 S > 1% H 2 / CO >> H 2 T 0 ~240 C P ~80 bar Water Gas Shift (H 2 -CO)/(CO+CO 2 ) = 3 H 2 /CO = 1-2 NH 3 SNG (TREMP) MeOH/FT T 0 ~170 C P ~1 bar H 2 S < 0.01% CO/H 2 = 1 DME Gasoline (TIGAS) Steam/CO <1 23 Variety of Input Variety of Products

24 Water-gas shift catalysts from Topsøe Sweet shift catalysts High temperature shift: Fe/Cu/Cr Low to Medium temperature shift: Cu/Zn/Al SK LK-811 LK-821 Sour shift catalysts High and low temperature service: supported Co Mo sulphides SSK-10

25 Energy efficient H 2 Production - industrial lay-out Heat integration

26 Acid Gas Recovery Units in Topsoe Plants Many technologies commercially available Simple activated MDEA wash used for pilot plant. A sulphur slip in the order of 20 wt ppm is anticipated. Absorption beds used together with amine wash to reach syngas quality demand In industrial scale, an AGR with a sulphur slip lower than 1 ppm will be used

27 Deep Desulpurisation of Synthesis Gas Sulphur components in synthesis gas (CO, CO 2, H 2 ) H 2 S (ppm), COS (ppm), Organic S (ppb) Removal of sulphur HTZ Contains ZnO Removal of H 2 S + COS at some conditions Syngas: H 2 + CO + CO 2 + Sulphur ST-101 Contains Cu, Zn and Al oxides Removal of all sulphur compounds Cu also promotes the formation of MeOH Operation at low temperature to avoid MeOH formation Catalyst S-guard Clean Syngas

28 Optimal Desulphurisation Temperature Dependence on temperature Methanol formation Volume needed Temperature

29 Methanol synthesis loop - industrial lay-out Off-gas to fuel H 2 recovery unit LP steam DMW Purge gas scrubber Make-up gas Sulphur guard Methanol reactor Recycle Off-gas to fuel HP separator LP separator Raw MeOH product

30 Methanol Synthesis under condensing conditions Equilibrium curve Two-phase region Dewpoint curve No condensation

31 Comparison of key process data - industrial vs. novel MeOH technology Industrial lay-out New technology Methanol capacity, index M.U.-gas flow, (H 2 + CO), index Reactor inlet flow, index H 2 /CO inlet reactor ~ CO/CO 2 inlet reactor ~ Recycle ratio (!) Catalyst volume, index

32 DME synthesis - industrial lay-out Off-gas Recycle DME column DME product Waste water column Methanol Reactor Waste water MP steam Steam condensate

33 Conclusion: Anticipated Technological Conquests

34 Conclusion Demonstration of a process for production of DME as diesel substitute from biomass via black liquor from a pulp mill Validation of concept through demonstration of entire value chain from black liquor gasification to the use as diesel substitute New standards for deep desulphurisation of synthesis gas, sour shift conversion and once-through methanol production