BTL2030 Project presentation VTT Technical Research Centre of Finland Ltd Espoo, June 2017
BTL2030-project Project title: Production of transport fuels from biomass by gasification-based concepts integrated to energy consuming industries and district heat power plants pilot tests and feasibility studies Acronym: BTL2030 Timetable: 1.1.2016 31.8.2018 Total budget: 2.7 M (Tekes 1.5 M, Industrial partners 0.5 M, VTT 0.7 M ) Industrial partners: Fortum Oyj, Gasum Oy, Helen Oy, Kumera Corporation, Gasification Technologies Oy, Oy Brynolf Grönmark Ab, ÅF-Consult Oy, Oy Woikoski Ab, Dasos Capital Oy, Kokkolanseudun Kehitys Oy, MOL Group BTL2030 project Website: http://www.vtt.fi/sites/btl2030 2
Government Program of Finland To increase the share of renewable transport fuels to 40 % by 2030 To stop using coal in energy production and to halve the use of imported oil for domestic use VTT-VATT Traffic 2030 study http://www.transsmart.fi/files/248/tutkimusraportti_vtt -R-00752-15_liitteineen.pdf Project background and R&D need 3
Solutions for biofuel production from domestic feedstocks in Finland Target for renewable energy use of 40 % by 2030 Regulation, sustainability, cascade-use etc. Government s policy: the share of renewable fuels to 40% by 2030 International influencing, EU 2030 policy, EU SET-Plan, new exports Biogas (not SNG) Ethanol HVO Gasification Pyrolysis Liquefaction HTL Several small plants Kajaani 10.000 m 3 /a Myllykoski 90.000 m 3 /a Other Sköldvik appr. 400 ktoe Naantali appr. 40 ktoe Lappeenranta 100 ktoe Steam gasification, CHP-integrated BTL, SNG, H2 O2-gasification, large BTL-plants NER300, Chemrec Fuel gas for furnaces and boilers Thermal pyrolysis Replace of heavy oil Boilers, furnaces Catalytic pyrolysis Black liquor, lignin, moist biomass Limited raw-material basis - not very suitable for forest residues, black liquor or bark VTT-pilot + Industrial Demo Hydrogen treatment for transport fuels Project background and R&D need Kokkola-Case Forestindustry cases CHP-integrates Co-feeding in refineries Gasification with black liquor Pulp industry integration Suitable for wide range of domestic woody raw material, Additional production capacity of 600-900 ktoe/a by 2030
Energy use of wood in Finland Project background and R&D need Energy Sector Additional potential of wood 20 TWh Corresponds to for 900 ktoe production of transport fuel (appr. 25 % of present fuel consumption) 4 TWh heat as by-product (district heat/industry) Gasification-BTL plants 18 plants of 50 ktoe/a capacity Investment 150-200 M /plant Total appr. 3 billion euro Potential elsewhere Sweden Central Europe (agrobiomass) Brazil (bagasse, eucachips) Source: Jaakko Jokinen, Pöyry Management Consulting Oy. Integrating biofuels and new products in Forest Bioeconomy. VTT 2G 2020 Seminar, 26.5.2015 Espoo, VTT Bioruukki.
Huge EU market 2030 - How Can Be Satisfied 5 %? What would mean e.g. 5 % of EU market? 15 Mtoe/a in road transport 300 gasification-synthesis plants of 150 MW feed e.g. 25 plants/year at 2030 => 5 B /year investment Aviation fuels: 4 % target 2 Mtoe/a by 2020? 40 gasification-synthesis plants Source: European Biofuels Technology Platform, SRA Jan. 2008 Project background Sustainability and ILUC GHG reduction > 60 % (Gasification-BTL > 80 %) Residues are the main feedstocks of gasification BTL 6 and R&D need
World markets and export potential are enormous Project background and R&D need Possible products via Gasification & Synthesis technologies Source: http://www.iea.org/publications/freepublications/publication/name-3976-en.html 7
Heat-integrated medium-scale BTL process via piloting and demonstration to industrial use P0: Concept development PRECHEM- Kokkolan Biorefinery project (2015) P1: Piloting at VTT Bioruukki and system studies 2016-18, 2.5 M P2: Industrial demonstration at Kokkola or forest industry site 2017-19, 40 M P3: First production plant, 220 M Capacity 50 ktoe/a, Design 06/17-06/19 Investment decision 06/2019, Commissioning 2021 P4: Several plants in operation 2025-30, investments 150-200 M /plant 2025: 5 plants, total 250 ktoe/a 2030: 10 plants, total600 ktoe/a Phase 1: Piloting and evaluation project, on-going as national project, VTT as a co-ordinator Phase 2: Demonstration project, will be planned togerher with industrial partners 2017-2019 Phase 3: Industrial Flagship project 8
BTL2030-project The target of this project is a medium-scale BTL concept, which can be integrated to different kind of energy intensive industries and district heating power plants The new gasification process is being developed at the DFB pilot plant of VTT Bioruukki and the feasibility of the process is studied together with industrial partners representing different potential applications and roles in the value chain. 9
BTL2030-project The aim is to develop a new gasification process for heat integrated production of transport fuels and to demonstrate the technical feasibility of this process by carrying out pilotscale tests. Project objectives Develop a new gasification process for heat integrated production of transport fuels Demonstrate the technical feasibility of this process with various biomass feedstocks by carrying out pilot-scale tests. Carry out system studies to study the economic feasibility of the process in different integration cases. Follow-on industrial projects will be preliminarily planned together with participating companies. 10
BTL2030-project Target results of the project: To operate the DFB gasifier with various biomass feedstocks To estimate the performance of an industrial plant Hot gas filtration, catalytic reforming and sulphur removal has been developed and validated in the pilot-test runs Production concepts for FT, H 2 and SNG have been developed and evaluated in different cases of energy integration. The economic feasibility and the potential of this biofuel production route have been reliably estimated. Proposal(s) for industrial follow-on projects have been prepared 11
BTL2030 The advantages of the new production concept Can be integrated to different energy intensive industries and CHP plants Pressurized O2-blown gasifier is replaced by a steam gasifier operated at a low pressure Gasification can be carried out a lower temperature Low contents of heavy tars is reached already in the gasifier and filter Fuel feeding into a low-pressure gasifier is easier The gasifier design is similar to the air-blown CFB gasifier The expensive Rectisol-type of gas cleaning is replaced by simpler gas cleaning system The synthesis technology of the basic concept is also a once through system Synthesis off-gas is used to heat the gasifier 12
BTL2030 project Work packages WP 1: Pilot-scale development of the new gasification process WP 2: Feasibility studies WP 3: Preparation and planning of follow-up projects WP 4: International co-operation, reviews of competing technologies WP 5: Publications, seminars and information exchange 13
Gasification process principle Steam gasification & hot filtration & reforming Raw gas 700-800 o C Filter Fly ash to combustion Gas to reformer 600-800 o C Flue gas to steam generation O 2 or Air + Steam Staged reformer Fuel Steam (+ air/o2/co2) Air Gas to gas cooler and further cleaning 850 o C
WP 1: Pilot-scale development of the new gasification process Feedstock basis of the gasification process PDU and laboratory tests with selected feedstocks Pilot-tests with potential feedstocks and feedstock mixtures TIMETABLE 2016 2017 2018 WP1: PILOT DEVELOPMENT Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 BFB-PDU tests with selected feedstocks Gas cleaning R&D Costruction of slip stream unit 1st DFB pilot campaign - DFB 16/20 & 16/24 - DFB 17/06, 17/10 and 17/17 Modification of DFB pilot plant - new hot filter vessel - CFB oxidizer - modified slip stream 2nd DFB pilot campaign - 2-3 test weeks with modified design WP1 The largest WP of the project Development of gas cleaning concept, validation of the whole gasification process Hot filtration Reforming of tars and hydrocarbon gases Design of the bulk sulphur removal unit and testing, sorbent optimization R&D, final gas cleaning studies and tests in a slip stream unit Data for process modelling 15
DFB gasificationt Pilot-plant, VTT Bioruukki The DFB pilot plant will be modified and fine-tuned for the need of each test campaign
BFB100 atmospheric pressure fluidised-bed gasifier, VTT Bioruukki TAR SAMPLING N 2 FUEL GASIFIER BED MATERIAL/ ADDITIVE FILTER STEAM / O 2 / AIR / N 2 / CO 2 PURGE-N 2 TAR SAMPLING, GAS ANALYSER, MICRO GC TO GAS BOILER 17
WP 2: Feasibility studies General feasibility studies Evaluation of different synthesis technologies and contacts to technology suppliers Design of the production concept for several applications (FT, SNG, H 2 ) Biomass pre-treatment, gasification process, synthesis technology and energy integration Material and energy balances, energy efficiencies, possible feedstock basis, capital and operation costs, economic feasibility Specific case studies for participating investor companies Realised in co-operation with participating companies TIMETABLE 2016 2017 2018 WP2: EVALUTION Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Preliminray concept planning Synthesis technology review Concept calculation - 1st round Concept calculation - Final Case-studies 18
Process block diagramme FT/Base case BIOMASS FEED 100 / 150 MW BELT DRYER LOCK HOPPER STEAM GASIFIER HOT FILTER TAR+HC REFORMER 1 2 3 4 5 6 SYNGAS COOLER FT-DIESEL PRODUCT 54 / 81 MW 15 16 BY-PRODUCT ENERGY 20 / 30 MW 7 HYDRO CRACKER OT FTL CO2 SCRUB COMPR END COOLER 17 13 12 10 9 8 ZINC S REMOVAL 14 11 Example of an integrated production plant producing hydro-treated FT- middle distillate for diesel production. Indirectly heated atmospheric steam gasification with 82 % carbon conversion Oxygen operated reformer (staged reformer concept of VTT) No shift reactor, H 2 /CO=2 by fluidising gasifier with: 88 % water & 12 % CO 2 Sulphur control with once-through zinc adsorbents Compression to 26 bar in one step Minor CO 2 removal with pressurised water scrubber to achieve CO 2 for gasifier purposes Once-through two-stage cobalt-based low-temp FT-synthesis Off-gases mostly combusted in the oxidiser to provide heat for gasification 19
WP 3: Planning of follow-on projects Demonstration plant of P2 Evaluation of different alternatives for this critical phase of commercialization Formation of the industrial consortium including technology suppliers Planning of financing alternatives Preliminary planning of the Flag-ship plant(s) Target is to find a way for making the investment of first-of-kind plant economically attractive for the plant owner TIMETABLE 2016 2017 2018 WP3 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 EU LCE PROPOSALS - COMSYN project on-going - LCE 07-2017 proposal - LCE08-2017 WASTEGAS proposal - LCE 19/2017 demo proposal? National demo-project planning 20
WP 4: International co-operation and review of competing technologies General technology follow-up and information exchange within the EERA alliance of large European Research organizations IEA special project on hybrid concepts integrating bio-syngas and electrolysis hydrogen Contacts to technology suppliers and research organizations outside Europe Co-operation with Sweden Contacts to Brazil related to gasification of bagasse TIMETABLE 2016 2017 2018 WP4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Status review x x x x x x 21
WP 5: Reporting, publications, seminars and information exchange Scientifically interesting results will be published in journals and conferences during and after the project TIMETABLE 2016 2017 2018 WP5 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Publications Seminars x x Stakeholder groups 22
Project organization TEKES the Finnish Funding Agency for Innovation Jukka Leppälahti, Chief Adviser VTT Technical Research Centre of Finland Ltd. Project leader: Esa Kurkela, Project Manager Steering group Tekes, VTT, Fortum, Gasum, Helen, ÅF, GasTech, Grönmark, Kumera, Woikoski, Dasos Capital, Kokkolanseudun Kehitys, MOL/Hungary WP1 WP2 WP3 WP4 WP5 New gasification process, Piloting Feasibility studies Preparation of follow-up projects International co-operation, Reviews Publications, Seminars Work groups (VTT & industrial partners) 23
Dual Bed Steam Gasification Pilot at Bioruukki New low-pressure process for 50-150 MW input Most suitable applications Hydrogen by PSA SNG or FT diesel with oncethrough synthesis Low-pressure process suitable also to bagasse and other low-density feeds
Gasification pilots at Bioruukki Key research and scale-up offering Excellent know-how on fuel chemistry and gasification processes Unique fluidized bed gasification, catalytic gas cleaning and hot filtration test facilities from laboratory to pilot scale Cutting-edge tools for techno-economic evaluations and modelling Main equipment at Bioruukki Dual Fluidized-Bed steam gasification pilot plant for syngas applications. Atmospheric pressure, feed capacity 80 kg/h. Hot filtration, catalytic reforming CFB gasification pilot plant for syngas and fuel gas. Air-blown operation, steam-o 2 gasification. Hot filtration, catalytic reforming Bench-scale BFB gasification, filter and reformer testing facilities, 5 kg/h Pressurized fixed-bed pilot plant (1-10 bar) for CHP and syngas applications, feed capacity 80 kg/h Development plans for Bioruukki New test possibilities for waste and recycling raw materials DFB Test facility BFB100 Test facility Gasification Platform is used for gasification process development, testing of new feedstocks and for the development of gas cleaning technologies. Pressurized Fixed Bed Pilot Plant 25
Bioruukki - New piloting ecosystem at Kiviruukki industrial area, Espoo VTT Bioruukki A centre for process industry scale-up and demonstrations. A former printing plant transformed to world scale R&D centre. 8000 m2, room for several pilot units and laboratories. Located close to Otaniemi campus. 26
NEW ERA BTL2030 project Website: http://www.vtt.fi/sites/btl2030