Compact Gasification and Synthesis process for Transport Fuels

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Maud Beverley Elliott
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1 Compact Gasification and Synthesis process for Transport Fuels ETIP Bioenergy Workshop Emerging Technologies 4th June 2018 Dr Pasi Kauppinen VTT

Technology development Diversified feedstocks for DFB gasifier by VTT High temperature filtration by VTT and GKN Sulfur removal with adsobents by VTT Product upgrading by UniCRE Process

2 Technology development Diversified feedstocks for DFB gasifier by VTT High temperature filtration by VTT and GKN Sulfur removal with adsobents by VTT Product upgrading by UniCRE Process design & techno-economic studies & environmental assessments by DLR and Wood Market studies and business cases by ÅF Consult Improved reforming by VTT Intensified Fischer- Tropsch by INERATEC

3 HEAT FLY ASH Simplifications H 2 /CO ratio adjusted in the reformer - gasifier steam utilised WET BIOMASS BIOMASS DRYING FLUE GAS COMBUSTION AIR STEAM GASIFIER CHAR OXIDISER AIR FILTER REFORMER SYNTHESIS OFF-GAS FT WAX SYNGAS COOLING Filter operated at gasifier outlet temp FT SYNTHESIS WATER SCRUBBER GAS COMPRESSION 5 30 bar SULFUR REMOVAL GUARD BED 2 GAS COMPRESSION GUARD BED bar A combination of activated carbon + ZnO-based sorbents applied FT synthesis performance with high inert content! CO 2 REMOVAL SIMPLIFIED CONCEPT No need for an oxygen plant Intermediate cooling/reheating steps eliminated Separate WGS unit eliminated Simplified sulfur removal No CO 2 removal or partial removal by pressure water scrubbing Constructed in COMSYN project

Status of biomass gasification for synthesis applications MATURITY

CFB OXYGEN-BLOWN GASIFICATION Ready for commercialisation > 150 MWth

GASIFICATION Currently under development > 100 150 MWth PRESSURISED

4 Status of biomass gasification for synthesis applications MATURITY NSE Demo plant Varkaus, DFB pilot VTT Bioruukki PRESSURISED CFB OXYGEN-BLOWN GASIFICATION Ready for commercialisation > 150 MWth SXB pilot VTT Bioruukki LOW-PRESSURE DUAL FLUID-BED STEAM GASIFICATION Currently under development > MWth PRESSURISED FIXED-BED OXYGEN- BLOWN GASIFICATION Development started in 2016 < 50 MWth SCALE

5 Gasification gas cleaning OBJECTIVES Produce gasification gas suitable for Fischer-Tropsch synthesis Before filter After reforming CO vol% CO ,5 vol% H vol% N2 0 0 vol% Hydrocarbon conversion at reformer CH ,5 vol% C2 hydrocarbons vol% Benzene 11 Residuals g/m n3 (dry gas) Tar 15 Residuals g/m n3 (dry gas) H2O ,8 vol% (wet gas) H2S ppmv Partial removal at filter Adsorbent beds

Fischer-Tropsch Synthesis by INERATEC OBJECTIVES Testing intensified FT reactor integration with biomass gasification Compare single and two-stage synthesis Design module for 8-10 bpd capacity

6 Fischer-Tropsch Synthesis by INERATEC OBJECTIVES Testing intensified FT reactor integration with biomass gasification Compare single and two-stage synthesis Design module for 8-10 bpd capacity Produce total kg of FT products during project TECHNOLOGY Once-through FT synthesis Intensified reactor with cobalt catalyst 10 15% inerts (N 2, CO 2 and CH 4 ) allowed -> Simplifies the gas clean-up process

7 HEAT FLY ASH Current lab scale development WET BIOMASS BIOMASS DRYING FLUE GAS COMBUSTION AIR STEAM GASIFIER CHAR OXIDISER AIR FILTER REFORMER SYNTHESIS OFF-GAS FT WAX FT SYNTHESIS SYNGAS COOLING WATER SCRUBBER GAS COMPRESSION 5 30 bar SULFUR REMOVAL GUARD BED 2 GAS COMPRESSION 1 5 bar GUARD BED 1 CO 2 REMOVAL

Development for: Hot gas filtration OBJECTIVES Increasing filtration temperature to 800 850 o C Simultaneous decomposition of tars Development of catalytic coating for filters TECHNOLOGY Filtration

8 Development for: Hot gas filtration OBJECTIVES Increasing filtration temperature to o C Simultaneous decomposition of tars Development of catalytic coating for filters TECHNOLOGY Filtration based on GKN s metal filter elements Iron-chromium-aluminium alloy Corrosion resistant & withstand high temperatures and mechanical loads ALD coating of nickel added on lab filters for activity tests. PILOT SCALE FILTER CANDLE

9 Development for: Sulfur removal OBJECTIVES Produce gasification gas suitable for Fischer-Tropsch synthesis TARGETS FOR CLEAN SYNGAS H2S + COS < 0.1 ppm NH3 + HCN < 1 ppm O2 < 1 ppm HCl < 0.1 ppm Condensables: dew point < 10 C TECHNOLOGY Simple dry bed adsorption with: Metal oxides eg. ZnO at >150 C H 2 S + ZnO ZnS + H 2 O Activated carbon (AC) at C 2 H 2 S + O 2 2 S(s) + 2 H 2 O ZnO more effective H 2 S adsorber than AC Costs favor AC (<< 1000 /ton) over ZnO (> 3000 /ton) AC as bulk adsorbent

10 In construction: Gas ultra-cleaning process OBJECTIVES Test ultra-cleaning units as part of pilot test runs. The first test run in June. TECHNICAL DETAILS Design for 5 m3/h slip stream from the gasifier = about 10% of total product gas from gasifier Fitted into a 3x3x4 m (HxWxD) rack

11 Conclusions MAIN OBJECTIVE COMSYN project aims for a gasification-based concept which would allow reduction of the biofuel production cost of 35%. NEXT STEP Starting up gas cleaning line at the pilot and testing the entire process from biomass gasification to Fischer-Tropsch synthesis during June.

12 ACKNOWLEDGEMENTS COMSYN project has received funding from the European Union s Horizon 2020 research and innovation programme under grant agreement No VTT

13 ACKNOWLEDGEMENTS P. Simell, J. Kihlman, S. Tuomi, E. Kurkela, C. Frilund, V. Kivelä, VTT T. Böltken, INERATEC H. Balzer, GKN J. Hajek, UniCRE R.-U. Dietrich, DLR V. Tota, Wood V. Hankalin, ÅF Consult VTT

14 Thank you for your attention! YouTube: comsynproject.eu #vttpeople

Biomass gasification gas cleaning by reforming Energy Lab 2.0 meets Neo-Carbon Energy Noora Kaisalo

VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD Biomass gasification gas cleaning by reforming Energy Lab 2.0 meets Neo-Carbon Energy Noora Kaisalo Biomass gasification Autothermal reforming Hot-filtration