Advanced Gasification, Gas Cleaning and Product Gas utilization

Transcription

1 Advanced Gasification, Gas Cleaning and Product Gas utilization Gasification and Energy from Waste and Biomass March 12 th, 2014 Presented by: Martin van t Hoff

2 Presentation contents Royal Dahlman & ECN, short introduction MILENA Gasification OLGA Product Gas Cleaning Products; electricity, heat and more Our major challenge Launching project

3 Introducing Royal Dahlman and ECN Royal Dahlman Established in 1886 Private owned Technology company, engineering, project management, production, commissioning, start-up and training. Delivering the Oil & Gas and Power market world wide License Holder of MILENA and OLGA technology Filtration of Fines from (Hot) gasification syngas

4 Introducing Royal Dahlman and ECN Energy research Centre Netherlands Largest Dutch energy research centre Highly regarded for its expertise on gasification, gas cleaning and catalytic conversion to gaseous and liquid fuels Patent holder of MILENA and OLGA technology Working with Royal Dahlman on biomass and waste gasification since 2001 OLGA gas cleaning in ECN lab

5 Biomass vs. Coal gasification Syngas vs. Product Gas, Reason for confusion! Highly reactive fuels like coal or tar-oil are gasified with oxygen at temperatures above 1200 C and produce a syngas CO H 2 and CO 2 H 2 O. Biomass or waste gasification has a reaction temperature of C and produce a product gas (syngas + hydrocarbons) CO H 2 CH 4 C 2 H 6 tars and CO 2 H 2 O.

6 Biomass vs. Coal gasification (2) Coal gasifiers have a very large scale of economy Coal (entrained flow) gasifiers need fine powders or slurries, they are not suitable for biomass or waste (chips, fluff) We aim for high efficiencies on a scale of 5 to 50 MW e Our fuel: wood, waste & agricultural residues Examples (L to R): Waste wood Soya Stalk RDF from MSW

7 Principle of gasification (1) combustion: fuel + air (l > 1) flue gas + heat 25% pyrolysis: fuel + heat gas + char + 75% gasification: fuel + air (l~0.3) gas

8 Principle of gasification (2) Direct vs. Indirect Gasification gas Direct gasification: All reactions in one vessel gasifier fuel air Indirect gasification: gas flue gas Pyrolysis and combustion fuel reactions are separated pyrolysis energy combustion fuel air

9 Principle of gasification (3) gas gasification: fuel + air (λ~0.3) gas gasifier fuel air combustion: fuel + air (λ > 1) flue gas + heat gas pyrolysis fuel energy flue gas combustion pyrolysis: fuel + heat gas + char fuel air

10 The MILENA gasifier MILENA an indirect gasifier Both reactors in one refractory lined reactor vessel 100% carbon to gas ratio o o Resulting in carbon free ash, less waste, cleaner waste & safer waste Resulting in a higher cold gas efficiency (5 to 15% higher on LHV basis) Separate flue gas exhaust, no or minimized nitrogen dilution of the product gas o Compared to air blown gasification a 3 to 4 times higher heating value. o o Compared to oxygen/steam blown gasification a much higher efficiency (no ASU parasitic), while still having 60% more heating value Very suitable for gas turbines

11 MILENA gasification scope

12 Gasification product gas cleaning Simplified Solids particulates Organic impurities (tars, dioxins) mainly dependant upon gasifier type and operational characteristics Inorganic impurities (H 2 S, HCl, NH 3 etc.) mainly dependant upon feedstock composition Other impurities (heavy metals, HCN, COS etc.) mainly dependant upon feedstock composition A dirty feedstock (waste) is attractive, but results in more cleaning efforts

13 The tar problem 1. Heavy tars Condensation leads to fouling < 400 C Tar dew point is critical parameter Deactivation of catalyst Fouling of equipment Plugging of an intercooler

14 The tar problem 2. Light tars Heterocyclic compounds (phenol) are water soluble, condensate & scrubber water is poisoned Naphthalene can cause crystallization problems

15 The tar problem Naphthalene crystals on gas engine control valve

16 OLGA & dew points T = 850 C Cooler Particle separation Actual temperature C Temperature C Tar dew point C Water dew point ± 75 C Dew points & process choices

17 Dew points are important! T = 850 C Cooler Particle separation Temperature C Tar dew point C OLGA Separation of: tars & fine particles Condensation Actual temperature Water dew point ± 75 C Absorption Tar dew point < 10 C) Dew points & process choices

18 Dew points are important! T = 850 C Do not mix tar & water! Cooler Temperature C Particle separation Tar dew point C OLGA Separation of: tars & fine particles Condensation Water dew point ± 75 C Absorption Water Quench, condenser & scrubber (inorganics) WDP 30ºC Tar dew point < 10 C Actual temperature Actual temperature Dew points & process choices

19 PFD - OLGA with cyclone OLGA; a waste free system!

20 OLGA Performance, gas analysis Component (values in mg/nm 3 ) Raw Gas After OLGA Efficiency Benzene (not a tar component) % Toluene % Ethylbenzene % m/p-xylene % o-xylene+styrene % Phenol % Indeen+o-cresol % m/p-cresol % Naphthalene % Quinoline % Isoquinoline 4-100% 2-methyl-naftalene % 1-methyl-naftalene % Biphenyl % Ethenyl-naphtalene % Acenaphtylene % Acenaphtene % Detection limit is 2,5 mg/nm 3

21 OLGA Performance, gas analysis Component (values in mg/nm 3 ) Raw Gas After OLGA Efficiency Fluorene % Phenanthrene % Anthracene % Fluoranthene % Pyrene % Benzo(a)-anthracene % Chrysene % Benzo(b)-fluoranthene % Benzo(k)-fluoranthene % Benzo(e)-pyrene % Benzo(a)-pyrene % Perylene % Indeno(123-cd)-perylene % Dibenz(ah)-anthracene % Benzo(ghi)-perylene % Coronene % Total known tar components % Total unknown tars %

22 OLGA Performance, gas analysis Parameter Unit Raw Gas After OLGA Efficiency Total tar mg/nm³ (dry) ,0% Total tar excl. BTX mg/nm³ (dry) ,6% Total tar excl. BTX & unknowns mg/nm³ (dry) ,9% Naphthalene (key-component) mg/nm³ (dry) < 2, 5 > 99,9% Phenol (key-component) mg/nm³ (dry) 386 < 2, 5 > 99,9% Tar dewpoint C > 350 < 15 F > 660 < 59 Tar aerosols (incl. dust) mg/nm³ (dry) -- 10

23 Commercial demonstration in France Blue flame indicates clean gas! Commissioning, start-up & success in 2006 France demo, wood & wine residue

24 Clean Product Gas specification Clean Product Gas MILENA MILENA Air blown CFB Oxygen / Steam blown CFB Specification Olivine bed Sand bed Sand bed Sand bed Refuse Derived Fuel (RDF), 25% moisture, 16% ash, 21,6 MJ/kg LHV daf Carbon to Gas efficiency 100% 100% 95% 95% Cold Gas efficiency (excl. tars) ~ 80% ~ 80% > 70-75% 70-75% Product gas composition (vol%) Clean product gas downstream OLGA & water 6% water CO 15,0 22,0 12,5 28,0 H 2 21,3 14,2 11,3 21,6 CO 2 22,6 15,8 13,1 29,7 O 2 0,0 0,0 0,0 0,0 H 2 O 6,0 6,0 6,0 6,0 CH 4 12,7 15,3 2,9 8,6 N 2 (with air fluidization) 9,4 10,9 51,2 0,6 C x H y (>CH 4 & < toluene) 11,5 13,9 1,7 3,7 Total 98,5 98,1 98,7 98,1 LHV (wet) (MJ/Nm 3 ) 17,1 19,8 4,8 11,3 LHV (wet) (Btu/sft) Wobbe (LHV, MJ/Nm 3 ) 18,6 21,8 5,1 12,0 Wobbe (LHV, Btu/scf)

25 MILENA-OLGA to gaseous and liquid fuels MILENA-OLGA delivers a clean nitrogen free product gas suitable for catalytic conversion to several gaseous and liquid fuels Fisher-Tropsch diesel Methanol CH 4 SNG green gas H 2 Etc.

26 MILENA-OLGA SNG (green gas) efficiencies 75% 70% LHV conversion biomass to CH4 LHV (net; plant paracitic deducted fom produced CH4) 70.3% 65% 66.8% 63.5% 64.3% 60% 60.8% 58.1% 55% 50% 52.7% 54.3% Torrefaction pretreatment Entrained Flow gasifier 30 bar Steam/oxygen blown CFB gasifier 10 bar OLGA tar removal FICFB gasifier 1 bar RME scrubber MILENA gasifier 1 bar OLGA tar removal

27 OLGA Experience & scale-up Lab scale pilot ECN Industrial Pilot ECN France Portugal Caterpillar 3516 A+ engines

28 MILENA experience & scale-up Scale up developments 4 MW demonstration in India lab pilot MILENA at ECN Industrial pilot MILENA at ECN Two 22 MW IGCC projects in Europe

29 Waste to Energy - ETI selection Worlds most efficient waste to energy technology contest The UK based Energy Technologies Institute (ETI) selected Royal Dahlman with two UK companies to compete in this challenge. We just completed a FEED study which included extensive tests on UK waste. In the coming months the winner will be announced, which will receive an ETI investment for the demonstration plant.

30 MILENA-OLGA CHP efficiencies 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Net plant efficiency to useful low quality heat Net plant efficiency to high quality heat Net plant efficiency to power 13% 32% 13% 48% 26% 32% Gas Engine Gas Engine + ORC 16% 17% 16% 21% 47% 31% 25% 21% 39% GT single cycle GT comb. cycle GT single cycle GT comb. cycle 24 MWth 24 MWth 160 MWth 155 ton/day RDF 153 ton/day RDF 1035 ton/day RDF

31 Set up CHP plant with OLGA 1-10 MW e Gas engines + ORC 6-50 MW e IGCC Gas turbine combined cycle

32 Waste to Energy - ETI selection 22 MW RDF from UK waste, to 7 MW net electricity

33 Waste to Energy - ETI selection

34 Thank You! Martin van t Hoff m.vanthoff@dahlman.nl