SNG aus Biomasse am Beispiel Göteburg Bioenergy 2020+ - Biomassetag November 2017
Overview WHAT WHERE WHO HOW Austrian competence centre for biomass utilization since 15+ years 3 offices and 2 technical research sites across Austria ~100 researchers from all academic career levels (mostly engineers) National and international research funding + industry partners (~9 Mio EUR turnover per year) Graz (Head office) Güssing Wieselburg Pinkafeld Tulln Slide 2
Research Areas Biomass combustion Three main research areas: 1. Combustion 2. Gasification 3. Bioconversion Plus a number of additional departments: microgrids, simulation, automation and supply chain. Gasification Systems Biological Conversion & Integration Slide 3
Bioenergy 2020+ enterprise and ownership BIOENERGY 2020+ GmbH, a limited company is owned mostly by public institutions like universities, ministries and similar public bodies. The single biggest owner is an association of enterprises with commercial interest in the field. ~20 individual firms Slide 4
Shifting Research Focus Gasification & Synthesis Value Stream Optional: Peak-wind energy Wax Kerosene Alcohols Diesel Substances Hydrogen Gas - SNG Gases Waste, feedstock byproducts Gasification + Synthesis Electrical Thermal Energy Slide 5
increasing market value Shifting the reseach focus towards higher-value products Product range Including recycling of phosphorus from sewage sludge and agricultural sources. Health & Cosmetics Feed & Food Chemicals Biofuels Energy & Heat Slide 6
Dual Fluidized Bed (DFB) Steam Gasification Technology Slide 7
Production of Synthesis Gas: Starting point for SNG Biomass is converted into mostly hydrogen and carbon monoxide a so-called synthesis gas. Synthesis gas is the starting point for a number of downstream conversion processes, like SNG production. gas motor, H 2, CH 4, fuel, wax, to stack Slide 8
DFB Reactor and System Integration Güssing Plant Layout Slide 9
Syngas via Steam Gasification: State of the Art Carbon source Biomass (wood, ) Agricultural-residues Gasification The DFB gasification system achieved several 100,000 hours of operating experience with several plants in the range of 0.5 to 32 MW thermal power. The demonstration plant in Güssing achieved more than 100,000 hours of operation. Municipial waste (plastic, sewage sludge ) Electricity (Gas engine) Synthesis gas H2 + CO Green chemistry As alternative to CHP, the synthesis gas can be used to produce fuels and chemicals via catalytic synthesis. Slide 10 Heat (District heating) Cooling (optional) (via absorption refrigeration) State of the art is synthesis gas utilization in a gas engine for the generation of electricity, as well as waste heat utilization for district or process heat. Via absorption chillers, also cooling is possible.
Syngas: Synthetic Production Routes Gases Carbon source (biomass, residues, waste) Liquids & Waxes Synthetic Natural Gas (SNG) Hydrogen Gasification FT Fuels & Chemicals (diesel, wax, kerosene, ) Mixed alcohols Slide 11 Ammonia Isosynthesis - Isobutane Synthesis gas H2 + CO A number of different routes for synthesis of gaseous and liquid chemicals is possible starting from the generated synthesis gas. Methanol Oxosynthesis - Aldehyde
Methanation: SNG from Syngas Syngas from gasifier Must be separated CH x O y H 2 + CO + CH 4 + CO 2 SNG to grid 3H 2 + CO CH 4 + H 2 O Methanation takes place at 300-400 C with a nickel catalyst with some pre- and after-treatment of the gas. Slide 12
Methanation: SNG from Syngas - Details Syngas from gasifier Tar removal Compre ssion H 2 S removal Preheating 2 nd H 2 S removal H 2 O removal CO 2 removal Compre ssion NH 3 removal Heat recovery H 2 removal Bio-SNG to grid Slide 13
Slide 14 Status of SNG Production
Overview of Gasification Plants Location Usage / Product Fuel / Product MW, MW Start up Supplier / Engineering Status Güssing, AT Gas engine 8.0 fuel / 2.0 el 2002 AE&E, Repotec End of demonstration life time reached Oberwart, AT Gas engine / ORC / H 2 8.5 fuel / 2.8 el 2008 Villach, AT Gas engine 15 fuel / 3.7 el 2010 Senden/Ulm,DE Gas engine / ORC Burgeis, IT Gas engine 2 fuel / 0.5 el 2012 Ortner Anlagenbau Ortner Anlagenbau On hold / restart? On hold / restart? 14 fuel / 5 el 2011 Repotec Operational Repotec, RevoGas On hold Göteborg, Sweden BioSNG 32 fuel /20 BioSNG 2013 Repotec/ Valmet Operational / On hold California R&D 1 MW fuel 2013 GREG Operational Gaya, France BioSNG R&D 0,5 MW fuel 2016 Repotec Operational Thailand Gas engine 4MW fuel / 1MW el 2016 GREG Operational Slide 15
Overview Key figures: 32 MW fuel power 20 MW SNG output Performance target: Efficiency: >65% Time efficiency: 8000 h/a Status: Operational but intended scaleup (4x) on hold due to performance issues. Slide 16
Plant Complexity: SNG vs. Heat and Power SNG plant (GoBiGas) Heat & Power (Güssing) Slide 17
SNG Efficiency (Vesta process) Biomass to SNG efficiency: 65% Slide 18 >60% demonstrated in GoBiGas
Total CAPEX [Mio EUR] 50 45 40 35 30 25 20 15 10 5 0 ISBL 1 CAPEX vs. Feed Capacity for Various DFB Projects Güssing Oberwart Nongbua Senden GoBiGas 0 5 10 15 20 25 30 35 40 Estimated CAPEX for various DFB projects (only gasification parts considered here) show that GoBiGas CAPEX is above expectations. CAPEX here is estimated for ISBL, which does not include auxiliary installations. Slide 19 Feed capacity [MWth] 1 ISBL Inside Battery Limit
CAPEX Learning Curve 2.500.000 Specific CAPEX* (2016) in EUR MW -1 2.000.000 1.500.000 1.000.000 500.000 Oberwart Güssing Villach Senden GobiGas Corrected for the annual plant cost index (steel price, inflation, ) and in the order of the cumulated fuel power, a certain learning effect is evident. - 0 20 40 60 80 100 120 Cumulated fuel power in MW Slide 20 * Estimated values, gasification part only
Economic viability: Production costs for SNG Approx 50% of the production costs are CAPEXrelated costs (fixed costs). operating supplies insurance & tax depreciation maintenance Production costs raw materials utilities labour Approx 50% of the Raw production materials costs are Operating labor operating Utilities costs (variable Employee costs). benefits Supervision Laboratory Maintenance Insurance and taxes Operating supplies Plant overhead Depreciation Slide 21
operating hours / year [h/a] Time Efficiency: yearly operating hours 5.000 0 2014 2015 2016 2017 Ø 2.506 Target On average: ~30% of target operating hours achieved GoBiGas (SNG) 5.000 0 2012 2013 2014 2015 2016 Ø 3.746 7.708 Senden (Heat&Power) 5.000 0 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Ø 6.356 Güssing (Heat&Power) Slide 22
Economic viability: A sensitivity analysis 20 MW th plant Values Units Investment costs (incl. startup expenses) 29 700 000 EUR Expenses 9 921 840 EUR a -1 SNG selling price for NPV = 0 130 EUR MWh -1 Natural Gas in Austria: ~50 EUR MWh -1 Slide 23
SNG price variation Economic viability: A sensitivity analysis Operating hours 40% 30% 20% 10% Wood price How fuel cost, CAPEX and operating hours influence the cost of SNG. Highest sensitivity: Operating hours! 0% -30% -20% -10% 0% 10% 20% 30% -10% Variable variation Capital Slide 24-20%
Conclusions: Main Challenges for SNG 1 2 3 Complexity and Reliability CAPEX & Investment Learning & Experience R&D must not only focus on energetic efficieny, but strife for simplicity and reliability of plant layout and operation. Investors need to plan for realistic time frames and targets. Big players + funding with good stamina needed! (Almost) none of the shown plants have been build by the same consortium, there are improvements, but there could be more. Slide 25
Contact Bioenergy2020+ GmbH Biomass Gasification Systems Wienerstraße 49 7540 Güssing Austria Research Area Manager Gasification Systems markus.luisser@bioenergy2020.eu T + 43 (0) 3322 42606-151 Unit Head Syngas Processes gerald.weber@bioenergy2020.eu T + 43 (0) 3322 42606-154 Unit Head Gasification matthias.kuba@bioenergy2020.eu T + 43 (0) 3322 42606-156 Slide 26