Role of gasification modelling in overall plant design

Flame Days 2013 seminar Ilkka Hannula VTT Technical Research Centre of Finland

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Simplified block diagram of a BTL plant

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Simplified block diagram of a BTL plant

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www.vtt.fi/inf/julkaisut/muut/2010/Hannula1.pdf

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www.vtt.fi/inf/julkaisut/muut/2011/Hannula301210.pdf

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Simplified block diagram of a BTL plant

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Experimental conversions as a function of reactor temperature (G = T gasif, R = T reforming)

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Most important non-equilibrium phenomena

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With reformer, main components come very close to eq. and model results are usually satisfactory

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Model validation based on raw gas

- Fairly good results reached - Expected experimental error ~5 % - Even better match reached with reformed gas

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Hydrocarbons & tar

Residual methane

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Product gas

Hot gas filtration

Reforming of the filtered product gas T = 950 C

T = 850 C T = 550 C

Product gas

Hot gas filtration T = 850 C

Reforming of the filtered product gas T = 850 C

T = 850 C

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Liquid transportation fuels via large-scale fluidised-bed gasification of lignocellulosic biomass

(I. Hannula and E. Kurkela, 2013)

Feedstock input 300 MWth (50 wt%, LVH) to dryer for all simulated designs 4 end-product considered: methanol, DME, FT liquids and MTG 5 individual plant designs simulated 20 cases compared: Overall thermodynamic efficiency (on LHV basis) Economics (capital cost estimates & levelised production costs)

CASE Front-end Steam system Filtration Gasification CO2

1 2 Currently proven Condensing CHP 550 C 550 C 5 bar 5 bar Vent Vent

4 5 Further R&D required CHP CHP CHP 850 C 850 C 850 C 5 bar 22 bar 22 bar Vent Vent CCS

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Liquid transportation fuels via large-scale fluidised-bed gasification of lignocellulosic biomass

(I. Hannula and E. Kurkela, 2013)

Feedstock input 300 MWth (50 wt%, LVH) to dryer for all simulated designs 4 end-product considered: methanol, DME, FT liquids and MTG 5 individual plant designs simulated 20 cases compared: Overall thermodynamic efficiency (on LHV basis) Economics (capital cost estimates & levelised production costs)

CASE Front-end Steam system Filtration Gasification CO2

1 2 Currently proven Condensing CHP 550 C 550 C 5 bar 5 bar Vent Vent

4 5 Further R&D required CHP CHP CHP 850 C 850 C 850 C 5 bar 22 bar 22 bar Vent Vent CCS

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CASE Gasifier Pressure Temperature Heat loss Steam/O2 Carbon conversion Recycle gas / O2 Recycle gas flow S/O2 inlet temp Filter Temperature Reformer Outlet temperature Heat loss Steam/O2 Methane in (dry) Methane out (dry) Methane conversion S/O2 inlet temp N2 out (dry) C % mol% mol% % C mol% C bar C % % kg/s C

5 850 1.2 1.0 98 0.0 0.0 203

5 850 1.2 1.0 98 0.0 0.0 203

5 850 1.2 1.0 98 0.0 0.0 203

22 850 1.3 0.8 96 0.7 4.0 210

22 850 1.3 0.8 96 0.7 4.0 210

550

550

850

850

850

957 1.6 1.0 8.8 0.4 95 206 1.1

957 1.6 1.0 8.8 0.4 95 206 1.1

957 1.5 1.0 8.8 0.4 95 206 1.1

957 1.6 1.2 9.1 2.3 70 291 1.1

957 1.6 1.2 9.1 2.3 70 291 1.1

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CASE Gasifier Pressure Temperature Heat loss Steam/O2 Carbon conversion Recycle gas / O2 Recycle gas flow S/O2 inlet temp Filter Temperature Reformer Outlet temperature Heat loss Steam/O2 Methane in (dry) Methane out (dry) Methane conversion S/O2 inlet temp N2 out (dry) C % mol% mol% % C mol% C bar C % % kg/s C

5 850 1.2 1.0 98 0.0 0.0 203

5 850 1.2 1.0 98 0.0 0.0 203

5 850 1.2 1.0 98 0.0 0.0 203

22 850 1.3 0.8 96 0.7 4.0 210

22 850 1.3 0.8 96 0.7 4.0 210

550

550

850

850

850

957 1.6 1.0 8.8 0.4 95 206 1.1

957 1.6 1.0 8.8 0.4 95 206 1.1

957 1.5 1.0 8.8 0.4 95 206 1.1

957 1.6 1.2 9.1 2.3 70 291 1.1

957 1.6 1.2 9.1 2.3 70 291 1.1

For a plant having 300 MW biomass input (LHV, AR @ 50 wt% moisture) CH4 flow 3.8 MW 22.8 MW

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229 MW

250 MW

242 MW

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Fischer-Tropsch design
Synthesis Shell Middle Distillate Synthesis (Bintulu, Pearl) Cobalt-based (Co/Zr/SiO2) LTFT Very paraffinic syncryde, less alkenes and oxygenates than in any other large-scale industrial FT technology. 80 % per-pass conversion, ~ 0.90 Multitubular fixed-bed reactor at 200 C and 30 bar. Recovery & upgrade C5 recovered by condensation at 45 C and Psynth No cryogenic separation of C1-C2 Hydrocracker at 325 C and 40 bar with noble metal hydrocracking catalyst

Simplified layout of the FT synthesis, product recovery and refinery section, adapted SMDS design. From: Arno de Klerk (2011) Fischer-Tropsch refining, Wiley-VCH, 642pp, ISBN 9783527326051

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For a plant having 300 MW biomass input (LHV, AR @ 50 wt% moisture)

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What is the overall impact?

For a plant having 300 MW biomass input (LHV, AR @ 50 wt% moisture)

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- Detailed mass & energy balances used as a basis for equipment sizing - Chemical Engineers Plant Cost Index used to account inflation - Component costs scaled using individual exponents:

Cost estimation methods

CAPITAL COSTS, M Auxiliary equipment Buildings Oxygen production Feedstock pretreatment Gasification island Gasification Hot-gas cleaning CO shift Syngas cooling Compression Acid gas removal Power island Fischer-Tropsch synthesis FT reactor HC recovery plant H2 production (PSA system) Wax hydrocracking FT recycle compressor TOTAL OVERNIGHT CAPITAL TOTAL CAPITAL INVESTMENT

5BAR/550C 5BAR/850C 22BAR/850C 97.0 18.8 47.2 31.1 150.9 51.1 38.7 6.2 10.2 8.9 35.9 27.1 77.0 41.2 8.1 1.4 25.7 0.5 352.1 369.7 93.6 18.8 43.8 31.1 151.4 51.1 37.9 6.6 10.2 8.9 36.8 23.9 80.9 43.4 8.6 1.5 26.9 0.5 349.9 367.4 93.6 18.8 43.7 31.1 149.3 51.1 39.5 7.1 10.6 5.7 35.3 30.0 80.1 43.0 8.5 1.4 26.7 0.6 353.0 370.7

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Plant factors Total biomass use, MW, AR

Target year for costs

Annual peak load demand for heat, h/a Capacity factor

300 2010 5500 90 %

Investment cost factors Balance of Plant Indirect costs Contingency for standard components Contingency for less mature components Interest during construction, fraction of TPC Capital charges factor, (10%, 20a) O&M costs factor, fraction of TPC/a Public investment support, M
Prices Biomass, /MWh Electricity, /MWh District heat, /MWh

BOP instrumentation and controls, electrical connections, piping, insulation, and site preparation Indirect costs Engineering & head office costs 15 %, start-up costs 5 % and royalties & fees 2 % O&M Personnel costs 0.5 % Maintenance & insurances 2.5 % Catalysts & chemicals 1 %

30 % 22 % 20 % 30 % 5% 12 % 4% 0
17 50 30

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300 MW Biomass @ 17 /MWh, 0.12 CCF Electricity 50 /MWh, DH 30 /MWh@5500 h/a

Levelised production cost

Mature technology No investment support No CO2 credits No tax assumptions

Gasoline @150$/bbl

Before tax, incl. refining margin, 1 = 1.33 $ (2010)

Gasoline @100$/bbl

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VTT - 70 years of

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