BioEnergy in Manitoba. Gasification Myths. Gasification Workshop Truths, Myths & Opportunities. Dr. Eric Bibeau

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1 BioEnergy in Manitoba Gasification Myths Dr. Eric Bibeau Mechanical & Industrial Engineering Dept Manitoba Hydro/NSERC Chair Alternative Energy Gasification Workshop Truths, Myths & Opportunities Greenwood Inn, Winnipeg, Manitoba, Nov 15, 2004

2 Gasifier Terms Used Distributed power (< 5 MWe) applicable to Manitoba Gasification for producing power direct = syngas indirect = hot flue gas Gasifier types discussed gasifier to produce a syngas to make power (direct) gasifier or gasifier/combustor to produce a hot flue gas to make power (indirect) Gasifier for heat (not covered) similar aspects apply focus on power generation

3 Why Look at Myths Need strong focus on realization of BioPower energy rather than on developing a technology gasification is favored in the public eye gasification is in news the EERC has completed over 100 hours of continuous operation of a biomass gasifier firing wood chips The process converts wood chips into gas (similar to natural gas) that can be fired in a small gas turbine (microturbine), diesel, or conventional combustion engine.

4 Why Look at Myths Need to be able to question information Experience from the Second World War shows, however, that properly designed wood gasifiers, operated within their design range and using fuels within the fuel specifications (which may differ between designs), can provide a sufficiently tar free gas for trouble-free operation From Mechanical Wood Products Branch, Forest Industries Division FAO Forestry Department large scale applications (500 kw and above): US$ 1000 per installed kw and upwards medium scale applications ( kw): US$/kW (gasifier only) small-scale applications (7-30 kw): 150 US$/kW, extremely reliable and should need no special operation and maintenance skills

5 Why Look at Myths Required to improve BioPower technology continuously questioning statements and findings a positive (negative) way to move forward understanding pitfalls allows solutions to be put forward many gasification projects have failed some types of gasification projects have succeeded understand how this technology could be effectively applied in Manitoba compares to other forms of biomass conversion technologies export market potential for Manitoba

6 BioPower is Gasification No air Limit air Excess air Add air No air Add air direct Add air direct indirect indirect Add air Add air Add air

7 BioPower is Gasification Air Heater 56.7% recovery Bio-oil (direct) 315 C 650 C 108 kpa 185 C combustion air 101 kpa 15.6 C 367 kpa 258 C 377 kpa 127 C Compressor Recuperator 111 kpa 315 C 336 kpa 483 C 58.3% cycle energy Brayton Air Cycle (indirect) Turbine / Expander 13.1% cycle eff. 7.4% overall eff Superheater Economizer 3 Boiler 2% blowdown Feed Pump 8 4 Attemporator Small steam CHP (indirect) Deaerator 5 Turbine 6 7 Co-generation process 1 Condensate return and makeup 1000 C Input 310 C Heater 59.9% recovery 300 C Thermal Oil Heat Transfer 250 C TURBODEN srl synthetic oil ORC Conversion 17% 60 C 80 C ORC (indirect) Air heat dump Liquid Coolant 1000 C Input 215 C Heater 68.2% recovery 400 C Entropic Fluid Heat Transfer 170 C ENTROPIC power cycle Conversion 17.6% 60 C 90 C EHC (indirect) Air heat dump Liquid Coolant

8 Gasifiers are Scalable Scalability issues surrounding gasifiers are more complex than combustion devices thermo-chemical conversion depends on the geometry of the gasifier affects the thermal properties of the fuel impacting reactions General rule small scale updraft/downdraft large scale bubbling fluidized bed/indirect Follow load change direct approach must not affect HHV of syngas indirect approach decoupled Biomass Reaction Mechanism Primary Pyrolysis Biomass Primary Tar (CH x O y ) + H CO 2 + CH 4 + C 2 H 4 + C s Secondary Pyrolysis Primary Tar Secondary tar (CH x O y ) + CO + CO 2 + C 2 H 4 + H 2 Homogenous Gas Phase Reactions Gaseous tar Secondary Tar C + CO + H 2 Hydrogen oxidation H 2 + ½ O 2 H 2 O MJ Water shift CO + H 2 O CO 2 + H MJ CO oxidation CO + ½ O 2 CO MJ Methane oxidation CH 4 + ½ O 2 CO + 2 H MJ Dry reforming CH 4 + CO MJ 2 CO + 2 H 2 Steam reforming CH 4 + H 2 O MJ CO + 3 H 2 Water-gas shift CO 2 + H 2 CO + H 2 O MJ Methane formation CO + 3H 2 CH 4 + H 2 O MJ Heterogeneous Reactions (solid and gas phase) Partial oxidation of carbon C s + O 2 CO MJ Methane formation C s + 2 H 2 CH MJ Steam gasification C s + H 2 O MJ CO + H 2 Oxidation of char and hydrogen C s + 2 O 2 + H 2 CO H 2 O MJ Boudouard char C s + CO MJ 2 CO

9 Gasification is More Efficient Gasification is More Efficient What does the statement mean? high reaction efficiency as gasifier converts most of the fixed carbon caution: reduction reactions of the fuel may be affected by moisture content and this is not well understood BFB combustion devices covert most of the carbon produce more power using direct method vs indirect Gasifiers are often reported in the literature as being more efficient than combustion systems there is limited practical experience to support this claim Possible advantages of gasifiers are that burning syngas in a turbine allows for greater overall cycle efficiency gas turbine Brayton cycle with high efficiency gas turbines can theoretically outperform a steam-rankin cycle if properly implemented

10 Gasification is More Efficient Recent white paper on gasification reports plant efficiencies for integrated biomass gasification combined cycles of 35% to 50% these values are promising not achievable for small systems and for high MC fuels values seem higher than those achievable in practice by large fossil fuels power systems where fuel moisture is of minor important Rule of thumb No combined cycles under 20 MWe

11 Gasification is More Efficient At low MC Netley 1979 Area Harvest Moisture Biomass HHV Plant Available (Wet tonne) (Dry tonne) kj/kg Species (ha) min max (%) min max Dry Cattail , , ,070 98,043 18,229 Bulrush ,215 32, ,629 26,653 17,447 Reed Grass 650 1,112 1, ,020 17,285 Rushes, Sedges , ,819 15,838 Sum 9,806 13, ,659 11, ,535 Weighted average ,024 Vegetation maps Netley-Libau Marsh 2001 Small Condensing Steam Small steam with cogeneration Organic Rankine Cycle Air Brayton cycle Entropic cycle Gasification 1 Heat recovery loss (MW) Cycle loss (MW) Power generated (MWe) Cogeneration heat (MWth) Assumes Producer gas has heat value of 5.5 MJ/m 3 and cooled down to room temperature

12 Gasification is More Efficient Modeling distributed power systems with 50% MC feedstock realistic small size systems limit cycle improvement opportunities cost effective for technology for small size limit external heat/power to system adapt component efficiencies to scale model system as if building system today model actual conversion energy system ignore parasitic power for bio-oil & gasifier mass and energy balances account for every step in conversion exclude use of specialized materials

13 Bio-oil oil Overall Energy Balance Biomass Feed 50% moisture 21.5% energy loss Drying/Sizing to 10% / 2 mm 8% energy loss 18.5% 3% Power Pyrolysis 3% N 2 Sand 32% energy Char 60% energy Bio-oil Power 5% 45.6% energy loss Engine/ Generator 6.4% Electricity Electricity: 363 kwhr/bdtonne Pyrolysis heat: non-condensable gas + some char (no NG) Pyrolysis power: kwhr/bdtonne (335 or 5%) Engine efficiency: 28% (lower HHV fuel; larger engine; water in oil lowers LHV) Drying heat: MJ/kgh 2 0 New Hampshire experience Drying power: kwhr/bdtonne studying bio-oil What was learned? Sizing power: kwhr/bdtonne What information was missing? Limited useable cogeneration heat

14 Gasification Overall Energy Balance 15% energy loss 60% energy loss 17.25% energy loss Biomass Feed 50% moisture Drying to 25% Gasification 15% 40% energy Producer Gas Engine/ Generator 7.75% Electricity Electricity: 440 kwhr/bdtonne Assume require 25% MC and no sizing requirements (conservative) Ignore parasitic loads: dryer, gas cooler, gas cleaning, tar removal, fans (conservative) Heat to dry fuel comes from process (3.8 MJ/BDkg fuel ) 100% conversion of char to gas (conservative) HHV of syngas = 5.5 MJ/m 3 dry gas (16% of natural gas)

15 Gasification Overall Energy Balance 15% energy loss 60% energy loss 17.25% energy loss Biomass Feed 50% moisture Drying to 25% Gasification 15% 40% energy Producer Gas Engine/ Generator 7.75% Electricity Electricity: 440 kwhr/bdtonne Low HHV of gas affects efficiency of engine Assume ICE operates at 75% of design efficiency 15% heat from producer gas dries fuel No heat lost across gasifier boundary Limited useable cogeneration heat

16 Small Steam Overall Energy Balance 40.5% energy loss 49.6% energy loss Biomass Feed 50% moisture Heat Recovery Steam Cycle 9.9% Electricity 4% power Electricity: 563 kwhr/bdtonne Limit steam to 4.6 MPa and 400 o C (keep material costs low) Use available turbines for that size: low efficiency (50%) No economizer 4% parasitic load Flue gas temperature limited to 1000 o C for NOx All major heat losses and parasitic loads accounted

17 Small Steam CHP Overall Energy Balance 40.5% energy loss 53.8% energy loss 115 C steam cogeneration Biomass Feed 50% moisture Heat Recovery Steam Cycle 5.7% Electricity Electricity: 324 kwhr/bdtonne Heat: 2936 kwhr/bdtonne Limit steam to 4.6 MPa and 400 o C (keep material costs low) Could use economizer to pre-heat combustion air Many ways to improve efficiency

18 Air Brayton Cycle 58.2% energy loss 14.9% 34.4% energy loss Biomass Feed 50% moisture Heat Recovery Brayton Cycle 7.4% Electricity Electricity: 420 kwhr/bdtonne Flue gas temperature inlet to heater limited to 650 o C for material requirements Recuperator with single-stage turbine No preheat of combustion air (34% increase in efficiency) Tube metal temperatures limited to 565 o C Turbine thermal efficiency 85%

19 ORC 49.7% energy loss 40.1% energy loss Biomass Feed 50% moisture Heat Recovery Turboden Cycle 80 C liquid cogeneration 10.2% Electricity Electricity: 580 kwhr/bdtonne Heat: 2713 kwhr/bdtonne Flue gas temperature limited to 1000 o C for NOx Cool flue gas down to 310 o C CHP heat at 80 o C All major heat losses and parasitic loads accounted

20 EHC Biomass Feed 50% moisture 31.8% energy loss Heat Recovery 56.2% energy loss Entropic Cycle 90 C liquid cogeneration 12.0% Electricity Electricity: 682 kwhr/bdtonne Heat: 3066 kwhr/bdtonne Flue gas temperature limited to 1000 o C for NOx Cool flue gas down to 215 C CHP heat at 90 o C Fluid limited to 400 C All major heat losses and parasitic loads accounted

21 Gasification is More Efficient At high MC Bio-oil Gasification Syngas Note: Results are for 50% moistures content CHP and Distributed Power Air Brayton Large Steam Overall Power Efficiency 6.6% 7.8% 7.4% 25.0% Electricity (kwhr/bdtonne) Heat (kwhr/bdtonne) Overall Cogen Efficiency 6.4% 7.8% 7.4% 25.0% Small Steam Direct Small Steam CHP Indirect Organic Rankine Indirect Entropic Overall Power Efficiency 9.9% 5.7% 10.2% 12.0% Electricity (kwhr/bdtonne) Heat (kwhr/bdtonne) - 2,936 2,713 3,066 Overall Cogen Efficiency 9.9% 53.9% 54.5% 67.5%

22 Gasifiers Have Low Emissions Biomass emissions in general CO 2 neutral CO Excess air and good mixing CH 4 active use can be better or worse than natural decay Particulate can be addressed Sulfur biomass (except for MSW) has low S NO x important in all biomass conversion technologies every time air is injected

23 Gasifiers Have Low Emissions Biomass emissions in general SO 2 no influence of technology Natural way has more NOx CH 4 is 21 times worst of a GHG than CO 2 ; biomass energy production is the ONLY option that makes sense CO 2 no change except for composting

24 Gasifiers Have Low Emissions Do gasifiers have lower emissions than combustion devices? direct? indirect? Gasifier should have less fly ash because of reduced carry over as less air flow is required Is there a real advantage using syngas? does this outweigh the complexity of the flue gas treatment, fuel preparation, low moisture content requirements, and loss of the latent heat of the gas indirect method: is it easier and cheaper to clean the flue gas?

25 Gasifiers Have Low Emissions Gasification is seen as being the environmental choice is this justified? what are the physical mechanism to justify this? what about CHP; GHG offsets Look at designs combustors gasifiers Particulate levels are not low enough to use the syngas directly in an engine How emissions change with the type of fuel and moisture content is also not certain

26 Gasifiers Have Low Emissions Note: Gasification systems using the direct approach have two sources of emissions NOx, Sox, CO, PM need to be looked at from gasifier and engine Emissions need to be reported after the engine Cannot stop at energy from product or intermediate form Examples of multi-step energy conversion systems bio-oil renewable hydrogen ethanol from fermentation

27 Gasifiers Have Low Emissions BTG 2001 study of emissions from 21 gasifiers in Europe 4 out of 21 gasifiers met the NOx limit 5 out of 21 met CO limits 8 out of 21 met particulate limits Consider that gasifiers in these studies operated possibly with dryer fuel California study (From National Renewable Energy Laboratory, NREL/SR , 1999)

28 Gasifiers Can Handle Any Fuel Most gasifiers sensitive to the fuel properties Cannot support high moisture fuel content what gasifier manufacturers mean is that the fuel can be pre-processed to make the feedstock acceptable to their gasifiers requirements for this preprocessing are often not well understood economically or from an energy efficiency point of view little attention given in drying the fuel and evaluate the impact on gasification performance, efficiency, and costs fuel drying consumes heat and power and increases capital and operating costs alternatively higher moisture fuel can be mixed with lower moisture feedstock or with waste hydrocarbon fuels In traditional combustion biomass boiler systems fuel variations lead to boiler upsets

29 Gasifiers & Energy Crops are Favorable Consensus for marginal lands grow high yield crops use entire plant and weeds limit fossil fuel use use proven and economical conversion method Manitoba has unused waste biomass forest biomass wood residues from sawmills agriculture residues straw from grain animal wastes swine, poultry, bovine municipal wastes organic residues non-mainstream biomass cattails and peat moss See Gasification Workshop, Gimli, Manitoba, September 30, 2004

30 Gasifier Performance is Well-Known Need to develop the technical and economical aspects of gasification Determine if biomass syngas could be co-fired into power boilers in the province Determine if gasifiers can economically pre-dry high moisture content fuel Investigate the co-generation potential of gasifiers for direct and indirect conversion double the economic return displaces natural gas important in Manitoba for GHG offsets Syngas cleanup and conditioning technology

31 Gasifier Performance is Well-Known Methods to condensate the moisture and tars Biomass plant economics are poor compared to fossil based power systems important to achieve a simplified system that is troublefree gasifier need to operate at very high capacity factor BTG, Inventory of biomass gasifiers manufacturers and installations, Final Report, EWAP program, October 2001.

32 Gasifier Concentrates Heavy Metals This has been shown in Manitoba for MSW Mechanism of how the fixed bed interacts with the oxidizing agent is not well understood If gasifiers perform better than a deep bed combustion system, it is not known why

33 Gasifiers are a Low Cost Solution Gasifiers are low cost has yet to be demonstrated practically for all scales Need to demonstrate the cost advantages as require additional equipment: fuel: sizing & drying direct: tar, water, PM, latent heat removal to inject syngas into engine engine: production versus low BTU engine Cost for biomass turnkey installations for gasifiers should not exceed (high side) Base Power ($/kw installed) Capital Cost 5 MWe 3,000 1 MWe 3, MWe 4,000

34 Gasifiers are a Low Cost Solution Cost estimates vary according to industry, region, and the payback time required payback period can be reduced by up to 50% if the waste heat can be use productively payback for different capital cost and power rates Capital Electrical rates (c/kw hr) Cost /kw Pay back (years)

35 Gasifiers are a Low Cost Solution CHP Revenue Chart Electical Power Nartural Gas $0.060 per kwhr $0.025 per kwhr Canadian Dollars Revenue per BDTon Biomass Power (85% use) Heat (40% use) Total Bio-oil $19 $19 Gasification Syngas $22 $22 Air Brayton $21 $21 Large Steam $72 $72 Small Steam $29 $29 1 Small Steam CHP $17 $29 $46 Organic Rankine $30 $27 $57 Entropic Hybrid $35 $31 $65 *Revenue for distributed biopower systems using 50% MC biomass

36 Gasifier Has Limited Operator Requirements This point is crucial in the use of this technology for distributed power Gasifiers need to function with little operator assistance or they will potentially fail in the market place Steam engineer (cost?) indirect approach Impact of system on automation and operator requirements direct approach (focus on gas quality and hard to control) indirect approach (decoupled)

37 Gasification is Beyond Combustion Statement based in part on gasification being more environmentally friendly more efficient less costly in fashion Bias against combustion based on bad experiences in the past (older technology) time when their was no regulation doing the impossible: disposal of very wet biomass using combustion If all technology meets environment emissions, what is better? gasifier gasifier/combustion combustion incinerator fast and slow pyrolysis Low Capital, Operational, & Maintenance costs Which technology holds better promise for emissions reduction in the future? PM, CO, NOx, SOx, Ash disposal

38 Gasification Requires Efficiency Technical complexity direct indirect BioPower distributed technologies for 50% MC 25% Tampier M., Smith D.W., Bibeau E.L. and Beauchmin P., "Identifying environmentally preferable uses for biomass resources: Phase 2 report: life-cycle emission reduction benefits of selected feedstock-to product threads," Envirochem Services Inc. Project sponsored by the National Resource Canada, the National Research Council, and the Commission for Environmental Cooperation, 2004.

39 Gasifiers are Best at GHG Displacement Waste biomass application (residues) often no fuel usage attributed to biomass transportation (35% MC) kg fuel /km/bdtonne 3.2 kg CO2 released for 40 km from emissions point transportation of biomass very positive on CO 2 displaced < 1% CO 2 cost per 100 km economic limitation $65/BDtonne for 125 km

40 Gasifiers are Best at GHG Displacement Electricity (kw e -hr) displace electricity from various sources look at (1) location, (2) average electricity on the grid, (3) additional load favorable to displace fossil fuels generation only Electricity Emissions Average Marginal Provincial Emission CO2 CO2, CH4, N2O (tonnes/mwh) (tonnes/tj) (tonnes/mwh) (tonnes/tj) Newfoundland and Labrador Prince Edward Island Nova Scotia New Brunswick Quebec Ontario Manitoba Saskatchewan Alberta British Columbia Territories Marginal Canadian Emission Factor Remote communities CHP Impact

41 Gasifiers are Best at GHG Displacement Heat (kw th -hr) integrated areas displace oil, natural gas, electricity non-integrated area displace oil Northern Community: special case off-grid power from transported diesel off grid heat from transported oil very favorable to CHP ORC, EHC, and small steam CHP

42 Gasifiers are Best at GHG Displacement Scenario Description Emissions per kwe-hr 1 Low carbon intensity power CO 2 : 52 g generation: 90% of nuclear or large hydropower; 10% natural gas Typical Regions Québec, British Columbia, Manitoba; France; Norway; Sweden Power 2 Moderate carbon intensity power mix:65% nuclear/large hydro, 25% coal, 10% natural gas 3 High coal/oil content in power production (50%); nuclear/large hydro: 25%; natural gas: 25% CO 2 : 288 g CO 2 : 588 g Canadian average; Ontario; Atlantic Canada; Austria; Belgium United States average, Denmark; Germany; Mexico; Spain; U.K. 4 Very high coal/oil content 75%, nuclear/large hydro 15%, natural gas 10% CO 2 : 761 g Alberta, Saskatchewan, central U.S.; Greece; Ireland; Netherlands Heat GHG EMISSION (kgco2/bdtonne) CHP SYSTEMS Small Steam Turboden Entropic Heating Oil Natural Gas

43 Gasifiers are Best at GHG Displacement Distributed Systems and 50% MC Manitoba 0 Large Steam Pow er EMISSION REDUCTIONS for CHP SYSTEMS Sm all Steam Pow er Brayton Cycle Pow er Bio-oil Conver. Pow er Gasif. Conver. Pow er Sm all Steam CHP Turboden Cycle CHP Entr opic Cycle CHP GHG EMISSION (kgco2/bdtonne) Scenario 1 Scenario 2 Scenario 3 Scenario 4 Gasifiers direct Displacing oil for heat Gasifiers indirect

44 Gasifiers are Best at GHG Displacement BioEnergy in a Northern Manitoba Community Subsidized Power BioPower System Power: Diesel Fuel Manitoba Northern Community Power ~1 MWe-hr ~No GHG EHC CHP ~233 liters/ MWe-hr ~2.83 Kg CO2/ liter Heat: Oil ~93 liters/ MWth-hr ~2.83 Kg CO2/ liter Heat ~5 MWth-hr ~No GHG Gasifier Biomass (local or pellets) 2 BD tonne/mwe-hr 2 MWe Community Subsidized Power System BioPower System Power (2 MWe) tonne CO 2 0 tonne CO 2 Heat (10 MWth) tonne CO 2 0 tonne CO 2 Total 34,608 tonne CO 2 0 tonne CO 2

45 Acknowledgement Manitoba Hydro/NSERC Chair in Alternative Energy Presentation & Information

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