9th International Freiberg Conference

Transcription

1 9th International Freiberg Conference Techno-Economic Analysis of Syngas and Electric Power Production in FOAK Industrial Gasification Plant fed by Biomass and Agro-industrial Residues G. Calì 1, P. Deiana 2, E. Maggio 1, C. Bassano 2, S. Meloni 1 Sotacarbo S.p.A. 1 c/o Grande Miniera di Serbariu, Carbonia, ITALY ENEA 2 Italian National Agency for New Technologies, Energy and Sustainable Economic Development Via Anguillarese 301, Rome, ITALY Berlin - 6 June 2018

2 Summary Introduction Description of Demonstration Plant Experimental Activities Economic Analysis Conclusions

3 Sotacarbo S.p.A. Low Carbon Advanced Technology Company Sustainable Energy Research Center Company structure: 50% ENEA e 50% RAS Plants, Laboratories and Study Activities for Gasification, CO 2 Capture, Utilization and Storage SW Sardinia Into the area of Sulcis Coal Basin

4 Introduction The Energy Roadmap 2050 (EU) Shows that energy from renewable sources should reach the objective of 20% in 2020 (Renewable Energy Directive, 2009/28/EC). This requires R&I to reduce technology and non-technology cost, improve performance and promote technology deployment to market. ITALY National Energy Strategy defines objectives, key policies and priority measures in the energy sector. In particular it is expected that renewables will become the primary source in the Italian electricity sector together with gas, accounting for 34-38% at 2020 of consumption. Italian government has outlined an incentive scheme (Green Certificates) to support the production of energy from Renewables (e.g. biomass). Typically one certificate represents the generation of 1 MegaWatthour of electricity and it s a tradable commodity that producers and importers of electricity generated from non-renewable sources must annually purchase covering 2% of their total production.

5 Description Demostration plant

6 Description Demostration plant NORTH SOUTH

7 Description Demostration plant The gasifier Fixed bed with rotative grate Wellman-Galusha based technology Up-Draft Reactor Design Pressure Operating Pressure Syngas Outlet Temperature Fuel Feed Water Jacket and Stirrer Start up Dry Ash Discharging On line Syngas Analisys 3 bar bar g C Biomass/Coal Ceramic Irradiators

8 Description Demostration plant Sampling and analysis system Continuous monitoring of syngas composition: 1. Multi module industrial gas analysis system: H2, CO, CO2, CH4, H2S and O2 2. Portable Micro GC dedicated to: H2, CO, CO2, CH4, H2S, O2 N2, COS, C2H6 e C3H8 3. Sampling line for Tar and Dust

9 Sperimental Activities and Results Several sperimental test are performed Gasification of only wood chips Characterization of tested fuels Fuel fed Colombian coal Wood chips Wood chips Mix 10% coal and 90% Wood chips Gasification of blend of coal and Wood Chips Gasification of only coal Classification Sub-bituminous Eucalyptus Pinus Pinea Sub-bituminous - Pinus Pinea Origin Colombia Siurgus Donigala (Sardinia - Italy) Ortacesus (Sardinia Italy) Bulk density (kg/dm3) Density 0,85 0,28 0,36 Proximate analysis (% wt) Fixed Carbon 60,33 19,25 21,87 25,60 Moisture 1,96 7,84 9,56 8,86 Volatiles 36,37 63,03 67,25 64,26 Ash 1,34 0,92 1,33 1,29 Ultimate analysis (% wt) Total Carbon 76,30 39,4 57,27 61,48 Hydrogen 5,54 4,94 6,148 6,09 Nitrogen 1,42 0,18 0,40 0,48 Sulphur 0,59 0,01 0,09 0,13 Oxygen n.d. Moisture 1,96 0,84 9,56 8,86 Ash 1,34 0,92 1,33 1,29 Calorimetric analysis (MJ/kg) Lower Heating Value 32,47 13,25 17,09 18,97

10 Sperimental Activities and Results Operating procedures include the following main phases: 1. Testing and start-up of the auxiliary systems 2. Start-up of the plant 3. Operational phase 4. Shut-down of the plant Gasification process parameters Gasification parameters and performans for different experimental test Fuel fed Colombian coal Wood chips Pinus Pinea Wood chips Pinus Pinea Mix 10% coal and 90% Wood chips Flow fuel fed (kg/h) Flow air (kg/h) Steam (kg/h) Syngas composition (molar fraction on a dry basis) CO 0,170 0,295 0,297 0,271 CO 2 0,097 0,060 0,062 0,038 H 2 0,106 0,084 0,120 0,099 CH 4 0,02 0,018 0,210 0,016 H 2 S 0, ,0007 N 2 0,597 0,542 0,497 0,544 O 2 0,0008 0,001 0,003 0,003 Lower Heating Value (MJ/kg) Raw syngas properties (molar fraction on a dry basis) 3,41 5,05 5,6 5,03 Flow syngas (kg/h) Cold gas efficiency ,68 0,8 0,8 0,79

11 Sperimental activities and results Syngas composition trend

12 Economic Analysis Method: COE and cash flow analysis Estimation BEC (Bare Erected Cost) Estimation TPC (Total Plant Cost) Includes: Engineering, Procurement and Construction Cost Estimation COE (Cost of Electricity) Estimation NPV (Net Present Value)

13 COE Calculation and Assumptions COE( /kwh e ) Capital Cost FixedO & M cost Variable O & M kwh e cost Personnel cost Tax Capital Cost= CRF*TPC Assumptions BEC 1.8 M Contingency (5% BEC) 0.1 M TPC 2.08 M Capital Recovery Factor (CRF) 7.1 % Load factor 80% (7000 h) Annual electric energy kwh e Fixed O&M cost 1 % TPC Variable O&M cost 2 % TPC Personnel 0.19 M TAX 30 %

14 BEC results BEC 100% 80% 60% 40% 20% 0% water treatment BOP Civil work clean up MCI ICE gasifier

15 COE results COE /kwhe Fuel cost Variable O&M Fixed O&M Personell Capital cost Tax

16 COE analysis and sensitivity Sensitivity analysis to investigate the most influencing factors +/-15% input variables has been changed Sensitivity analysis results load factor capital cost biomass cost Biomass Cost is the parameter that most influence the COE COE variation

17 NPV Calculation and Assumptions Parameter / Assumption Value Construction Period 3 years Incurred capital in: year 1 10% year 2 60% year 3 30% Debt Equity Ratio 50:50 Capacity factor 80% (7000 h) Plant lifetime 25 years Electricity price 0.20 /kwhe

18 NPV results Biomass Cost 50 /t Biomass Cost 30 /t NPV (25 y) 1.73 M 2.62 M IRR (%) pay back period 9 y 7 y

19 Ongoing activities The work of the ENEA/Sotacarbo task force is progressing: New experimental tests on different types of biomass and agricultural residues, and their mixtures with a strong effort focused on the characterization of the syngas production process Design and implementation of a Mild Combustion System to burn and enhance the tar contained in the syngas and eliminate the costs related to its disposal. Design and implementation of automatic feedstocks loading system. Improve plant automation to reduce personnel costs for plant management. Future developments include: The optimization and the complete automation of the process. The declared objective is to demonstrate a full concept 1MWe sized gasification plant, fed by coal and biomass, connected to the grid for power generation. This complete plant would be the FOAK running facility, which could be happily replicated by patenting and commercial activity, but also open to future research projects and programs in the field of coal and biomass gasification.

20 Conclusions A task force dedicated to the start up and management of the gasification demonstration plant was set up with the participation of ENEA and Sotacarbo Staff. The purpose of this work is to evaluate the financial and economic parameters Economic results can be improved by new technical developments in order to reduce the capital cost (economically sustainable project) and operation cost. The cost of fuel has an important influence on the COE costs of the plant, for this reason tests will be carried out with agricultural residues and other products (screws, rice husk, digestate) The ultimate objective is to bring the process of R&D on a new level and to demonstrate the technical, operational and, definitely, economic feasibility of a complete 1 MWe Unit for energy generation based on biomass gasification

21 Thank you for your attention