Refurbishment of catalytic tar reformer and project on green gasoline. John Bøgild Hansen, Haldor Topsøe A/S IEA Meeting, Skive, October 25, 2017

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1 Refurbishment of catalytic tar reformer and project on green gasoline John Bøgild Hansen, Haldor Topsøe A/S IEA Meeting, Skive, October 25, 2017

2 We have been committed to catalytic process technology for more than 70 years Founded in 1940 by Dr. Haldor Topsøe Revenue: 700 million Euros 2400 employees Headquarters in Denmark Catalyst manufacture in Denmark and the USA

3 Tar reforming Enabling technology for biomass gasification Gasification of biomass results in a syngas that contains tars and contaminants ppm tar ppm S, particulates C, 1-30 bar g TAR REFORMER Ammonia decomposition GASIFIER BIOMASS ASH

4 Dusty tar reforming BIOMASS -FEED GASI FIER TAR REFOR MER Dusty tar reforming g dust / Nm 3 HOT GAS FILTER ASH PROCESSING & UTILIZATION

5 Skive Fjernvarme a.m.b.a. (Skive CHP) Location Capacity Skive, Denmark 21 MW th, Max 28 MW th Operational year 2009 Fuel consumption Fuel Gasification techn. Pressure range Power generation 100 TPD Biomass, wood pellets Air blown, bubbling fluidized bed 1 3 bar g Gas engines

6 Biomass Gasification Gas Engine BIOMASS (pellets) 20 MWth Fuel input TAR REFORMER GASIFIER 900 C Cyclone Temperature: 875 C Pressure: 2 barg Bed material: olivine GAS COOLER 200 C Tar reforming reactor before revamp 2014: GAS FILTER FLY ASH GAS SCRUBBING 30 C 2 BOILERS GAS BUFFER TANK (pressure stabilizer) 40 C TO STACK Poor control Unstable operation Damaged internals Troublesome catalyst replacement Poor working environment. DISTRICT HEATING 11 MW th AIR & STEAM WATER POWER 6,0 MWe ASH (C<2%) Copyright Carbona INC Finland 3 GAS ENGINES Lower productivity

7 The rebuild tar reformer has several advantages Improvements: Improved design of reactor internals Faster and easier catalyst replacement Much better working environment Efficient dust blowing Improved design of catalyst Better dust handling increased utilization Improved process control Robust long-term activity longer lifetime Increased stable operation hours 7

8 Biomass Gasification Gas Engine TAR REFORMER GAS COOLER Tar GAS FILTER reformer revamp: TO STACK BIOMASS (pellets) 20 MWth Fuel input 900 C Cyclone 200 C FLY ASH 2 BOILERS ASH (C<2%) Temperature: 875 C Pressure: 2 barg Bed material: olivine GASIFIER AIR & STEAM GAS SCRUBBING 30 C WATER Pressure shell GAS BUFFER TANK (pressure maintained stabilizer) 40 C New reactor internals New catalyst 3 GAS ENGINES design DISTRICT HEATING 11 MW th POWER 6,0 MWe Copyright Carbona INC Finland

9 The robust tar reformer 9 The new design of the reformer has led to less dust deposition better dust blasting controlled regeneration of the monoliths Increased operation hours and longer lifetime of the monoliths.

10 Clean tar reforming QUENCH GAS HIGH TEMPERATURE HOT GAS FILTER Clean tar reforming 1-10 mg dust / Nm 3 BIOMASS -FEED DUST GASI FIER TAR REFOR MER Nickel-based ASH PROCESSING & UTILIZATION

11 Gas Technology Institute, Chicago Location Capacity Fuel consumption Fuel Gasification techn. Pressure range Chicago, USA ~ 4 MW th 18 TPD Biomass, wood pellets Oxygen blown, bubbling fluidized bed 1-9 bar g

12 Gas Technology Institute, Chicago C Tar reformer ~ 1150 run hrs Nm 3 /h ppmv H 2 S No soot formation 15 min. lack of oxygen No deactivation! Full tar conversion

13 TIGAS MTG Topsøe Integrated Methanol To Gasoline Synthesis Synthesis Gas Methanol Synthesis Day Tank (Raw Methanol) MeOH/DME Synthesis C 3 -C 4 MeOH DME Gasoline Synthesis Separation Gasoline Water

14 TIGAS Demonstrationsanlæg 1 T/d; > 7000 timer, Houston, Texas, USA

15 Historical Perspective T/d & kg/h Pilots H-ZSM-5

16 25 bbl/d Demonstration Plant Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes BIOMASS BIOMASS GASIFIER TAR REFORMER TAR REFORMER GASIFIER OXYGEN Gas Cleaning MeOH /DME MeOH/DME Gasoline ASH OXYGEN

17 Methanol to gasoline (MTG) MeOH Gasoline reactor Gasoline C barg WHSV = h -1 fixed bed Gasoline reactor: ZSM-5 Cycle length: days Lifetime: 1-2 years Pseudo-Adiabatic Pilot, Ravnholm

18 Biogasoline Demonstration Plant Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes BIOMASS BIOMASS GASIFIER TAR REFORMER TAR REFORMER GASIFIER OXYGEN Gas Cleaning MeOH/DME Gasoline ASH OXYGEN Entire value chain: biomass in à gasoline out

19 Biorefinery facility Gasification & Tar reforming (existing) Morphysorb AGR unit (existing) Utility units & control system (existing) Syngas compression (new) TIGAS synthesis unit (new) Gasoline & waste water tanks (new)

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23 Gasoline testing Engine emissions testing at Southwest Research Institute Tested a 80/20 high biomass TIGAS/gasoline blend. Emission levels better than for conventional gasoline. Found to be substantially similar to conventional gasoline Fleet test Testing 8 vehicles (EPA Standard Road Cycle) 2 Camry (2.5 L PFI), 2 Corolla (1.8 L PFI) 2 F-150 (3.5 L V6 EcoBoost ), 2 Fusion (1.5 L EcoBoost ) Commercial gasoline vs. 50% biogasoline blend Accumulate 75,000 miles per vehicle Engine inspections Engine emission 4000 & 75,000 miles

24 Economics 5 cases: Gasoline production cost, IRR, and GHG reduction Grid Power Fuel gas and/or LPG fraction used for power generation Gas Turbine

25 Summary MTG: direct conversion of methanol to gasoline Topsøe MTG: TIGAS is a versatile technology for conversion of syngas to gasoline Escalating share of unpredictable renewable energy is a challenge to balancing supply/demand balance in the power grid adds increasing demand to standby backup capacity increases overflow frequency Co-production of power and fuel is a feasible solution to counteract imbalances improves overall system flexibility maximizes operator revenue Simplicity and efficiency makes TIGAS suitable for co-generation through integration with IGCC or traditional power plants enabling air-blown gasification of biomass providing fast response to load variations and providing maximum fuel/power flexibility

26 Thought experiment Biomass GASI FIER TAR REFOR MER ASH N 2 CO2 H 2 CO ~16 MW th ~7 MW th Metanol/ DME Gasoline ~100 bbl/d Gasoline

27 Skive > citizens households cars 30 km/d ( km/day) 11,3 km/l Gasoline Skive l Gasoline/day 100 bbl./day

28 Fuel Cell and Electrolyser SOFC SOEC H 2 H 2 O H 2 O H 2 H 2 + O 2- H 2 O + 2e - O 2- ½O 2 + 2e - O 2- H 2 O + 2e - H 2 + O 2- O 2- O 2-2e - +½O 2 ½O 2 ½O 2 H 2 + CO + O 2 SOF C SOEC H 2 O + CO 2 + electric energy ( G) + heat (T S)

29 SOEC more efficient than present Electrolysers Internal waste heat used to split water Energy needed to evaporate water kwh per Nm3 H Waste heat which can be utilised to split water Minimum Electricity Input Deg C.

30 Biogas upgrade by means of SOEC CH 4 + CO 2 + 3H 2 O + El 2CH 4 +H 2 O + 2O 2

31 New EUDP project 50 kw SOEC and 10 Nm 3 /h methane Participants: Haldor Topsøe A/S Aarhus University HMN Naturgas Naturgas Fyn EnergiMidt Xergi DGC PlanEnergi Ea Energianalyse Coordinator: Duration: June Dec Project sum: 5.3 mio Location: Foulum

32 Methanation and SOEC at Foulum

33 GreenSynFuel Project

34 Mass Flows in Wood to MeOH

35 Mass Flows in Wood + SOEC to MeOH

36 Effciencies: Stand alone wood gasifier and gasifier plus SOEC LHV Efficiency % Wood Gasifier alone Wood gasifier Plus SOEC Methanol District Heat Total