We accept the challenge!

Transcription

1 Synthesis Gas Generation for Transportation Fuel Production Gasification Technologies Conference 2014, October Washington, DC Andras I. Horvath / ANDRITZ Oy, Niels R. Udengaard /Haldor Topsoe Inc. We accept the challenge!

2 Synthesis gas generation for transportation fuels Content Thermo-chemical conversion of biomass into liquid or gaseous transportation fuels. ANDRITZ Carbona Gasification Plant process produces clean synthesis gas from woody biomass applying pressurized Bubbling Fluidized Bed gasification technology and Haldor Topsoe s catalysts based tar reforming technologies. The synthesis gas is converted to transportation fuels i.e. bio SNG and gasoline, with Haldor Topsoe s TREMP methanation and TIGAS processes. Gasification Plant process is in commercial operation in a biomass CHP plant. Integrated Gasification Plant and TIGAS process operation was demonstrated at the pilot plant of Gas Technology Institute / USA. Ongoing engineering of commercial size biorefinery projects. 2

3 From biomass to chemicals Transportation fuels (Gasoline, SNG) Air Air separation unit Sulfur recovery (WSA) Sulfuric acid O 2 H 2 S Biomass Gasification Sour Shift Acid Gas Removal Synthesis Gasoline SNG NH 3 MeOH H 2 DME Formaldehyde CO 2 ANDRITZ Carbona Gasification Plant incl. Haldor Topsoe catalytic reforming Haldor Topsoe synthesis processes 3

4 Synthesis gas for transportation fuels Gasification Plant process BIOMASS GASIFIER BOTTOM ASH OXYGEN STEAM GAS FILTER FLY ASH RECYCLE GAS TAR REFORMER OXYGEN/ STEAM GAS COOLER STEAM BFW GAS SCRUBBER SYNGAS CONDENSATE Process components: Oxygen blown BFB gasifier Hot gas filter Catalytic tar reformer Steam generating gas cooler Water scrubber with heat recovery Typical parameters: Capacity up to 200 MWth/unit Pressure 10 bar Feedstock: Woody 20% moisture Clean syngas of H2/CO Controlled methane content 4

5 Gasification Plant process Skive gasification based CHP plant Demonstration of Gasification Plant process Air blown, low pressure BFB gasifier Limestone based bed material Catalytic tar reforming (dusty reformer) Gas cooling and filtration Gas scrubbing System pressure 2 bar In commercial operation since 2008 Dusty monolith type catalysts in tar reformer by Haldor Topsoe since 2009 Test platform for catalyst development (slip stream reactor by Haldor Topsoe) and hot gas filter related testing Process equipment development to achieve higher availability Availability 90% BIOMASS, 20 MWth AIR/STEAM TAR REFORMER GASIFIER BOTTOM ASH GAS FILTER FLY ASH GAS COOLERS GAS SCRUBBER WATER 2 BOILERS TO STACK GAS BUFFER TANK 3 GAS ENGINES DISTRICT HEATING 11.5 MWth POWER 3x2 MWe 5

6 Skive gasification CHP plant Main parameters & equipment PRESSURIZED BFB GASIFIER 3 GAS ENGINES Biomass feed 20 MWth (66 MMBtu/h) Designed for 28 MWth (95 MMBtu/h) Power 6.0 MW (3x2MW GEJ620 gas engines) District heat as CHP 11.5 MW / 39 MMBtu/h Feedstock: Wood pellets & wood chips 2 GAS BOILERS 6

7 Syngas for transportation fuel production Process development ANDRITZ Carbona / Haldor Topsoe / GTI and UPM / Philips 66 (gasoline test) cooperation Pilot plant testing at GTI Further develop pressurized oxygen/steam gasification of biomass at the 5 MWth/17 MMBtu/h gasification pilot plant Develop tar reforming and gas clean up of syngas for BTL and SNG applications Demonstrate integrated Gasification Plant TIGAS operation on pilot scale 1 st test campaigns ( ) to demonstrate syngas production for BTL and SNG applications financed by UPM Finland and E.ON Sweden 2 nd test campaigns ( ) to demonstrate TIGAS based integrated biorefinery operation financed by DOE. 7

8 BTL / SNG pilot plant tests at GTI Gasification plant tests (1 st campaign) Gasification Plant testing Participants: UPM; E.ON; ANDRITZ Carbona; Haldor Topsoe; GTI; PALL Filtration Four feedstock types (3 from Finland, 1 from USA) tested at different operating conditions 800 hours of oxygen blown gasification and clean syngas production Different process arrangement tested acc. catalytic tar reformer concepts Dusty reformer for dust containing gas Clean reformer for filtered gas Recycle of scrubbed product gas tested H2/CO ratio between 1 to 1.5 Slip stream testing of hot gas filter Catalytic tar reformer development by Haldor Topsoe A/S: Catalyst and catalyst operation parameter development % reforming of tars & lighter hydrocarbons Controlled reforming of methane 0.5 to 6.0 vol% Reducing ammonia in reformed gas 8

9 TIGAS pilot plant tests at GTI Integrated biorefinery operations (2 nd campaign) Wood to green gasoline using ANDRITZ Carbona (AC) gasification and Topsoe TIGAS processes DOE Award No. DE-EE Demonstration of Thermochemical Conversion of Woody Biomass to Gasoline at GTI s Pilot Plant (FFTF / AFTF) Project Team: Haldor Topsoe; ANDRITZ Carbona; UPM Oy, Phillips 66; GTI Pilot plant capacities: Feedstock: Pelletized aspen (6% moisture, 0.9% ash) Capacity: 19.2 tpd wood 13.5 tpd sweet syngas 685 gal/d gasoline Gasoline yield: bbl/ton (maf) Gasification Plant (AC) AGR (GTI) TIGAS (Haldor Topsoe) 9

10 TIGAS pilot plant tests at GTI Conversion and product properties Pilot Plant Results Biomass * fed, lb Gasoline made, lb LP gas made, lb 5513 Energy conversion, biomass to fuels Octane (R+M)/ Aromatics, vol% * 6 wt% moisture, 0.9 wt% ash Engine emissions from 80% bio-gasoline blend were substantially similar to standard gasoline Fleet test with 50% bio-gasoline blend logging miles on each of 4 vehicle pairs Pilot results reduce technical risk sufficiently for licensors to offer commercial package 10

11 Benefits of Topsoe TIGAS technology World leader in syngas and methanol technologies Highly successful operation of gasoline catalyst GSK-10 High quality gasoline in compliance with ASTM D-4814 Optional Gasoline Upgrading Unit (GUU) resulting in higher octane number Experience reliability and combination of catalyst & technology in both refinery and synthesis gas areas 11

12 ANDRITZ Gasification Plant & HT TIGAS based biorefinery 7120 tpd wood to 730 tpd gasoline WOOD (50% moisture) 7120 MEDIA 44 H2O 2670 Biomass Drying & Gasification Particulate Removal Tar Reforming Heat Recovery & Steam Generation CO Cooling & Condensation Compression CO 2 O 2 Oxygen Plant ASH 310 Power Generation STEAM Water Treatment Acid Gas Removal RECYCLE TO GASIFIER TAIL GAS Separation Gasoline Synthesis MeOH/DME Synthesis Polishing GASOLINE LPG WATER Self-sufficient on power and all water recycled GHG Reduction of 92 % compared to petroleum-based gasoline Ongoing basic engineering in frames of the DOE project 12

13 Topsoe s TREMP SNG technology TREMP SNG technology is characterized by: High temperature stable catalysts High T per pass enabling low recycle flow High utilization of reaction heat This results in: High quality SNG product (high HHV) Max. production of super-heated steam Low CAPEX and OPEX The most energy-efficient SNG process The world s largest SNG plant (Qinghua in China) is based on TREMP. 13

14 E.ON Bio2G project Biomass to Bio-SNG (Biomethane) Facts Production capacity 200 MW / 680 MMBtu/h + heat & electricity Forest residues as feed stock To be located in Malmö/Landskrona Awarded for EU / NER300 support of 203 M Technology Pressurized oxygen blown gasification (Andritz, FI) Gas cleaning and methanation, (Haldor Topsoe, DK) (source, E.ON) 14

15 E.ON Bio2G project mt/a wood to 168 MMm 3 n/a (6000 MMSCF/a) SNG Forest Transport Fuel Reception/Preparation/Storage Fuel Dryer Clean syngas Auxiliary systems Cooling water, District Heating, Bulk material, etc Compression Steam Electricity Air Separation Dry Gas Cleaning Boiler/Turbine Synthesis gas (CH 4 H 2 CO tar, etc.) Unit (ASU) Gasification Oxygen biofuel Gas conditioning CO 2 Removal Methanation CH 4 H 2 O Drying Compression Biogas (Biomethane) SNG efficiency 62-64% (excl. ASU); total efficiency 70-80% (source, E.ON) 15

16 ANDRITZ Oy Any questions? For further information please contact: Andras Horvath Andritz Oy, Finland