Biomass specialisation course

Review of Gasification Plants

Jess Arauzo, Alberto Gonzalo, Jos L. Snchez (jlsance@unizar.es) Chem.&Environ. Eng. Dpt. C.P.S. www.cps.unizar.es/~proter

Gasification Plants Configuration of a gasification plant depends on: - Fuel to be used - Type of reactor: - fixed/moving bed - fluidized bed - entrained flow - combination - Operation pressure (near atmospheric or pressurired) - Method to deliver the heat needed for reaction - End use of producer gas gas cleanup There are so many different configurations possible, that it is difficult to find two similar plants in the world

Gasification Plants Review of some of the most representative plants/projects, sorted by the kind of reactor used:

- Fixed bed gasifiers Updraft Downdraft - Fluidized bed gasifiers Bubbling FB Circulating FB - Entrained bed gasifiers - Special Plants with a combination of reactors: Compact Power process Carbo V process

Fixed Bed FB UPDRAFT GASIFICATION Babcock & Wilcox Vlund ApS Put into operation in 1993, in the city of Harbore, to supply heat to 560 homes and municipal buildings. Fuelled by wood chips. Initially the producer gas was burnt in a boiler. After several years of research on gas cleaning, in 2000 two 750 kWe Jenbacher gas engines were set in operation

Gasification Plants

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

OIL/TAR FUELLED DISTRICT HEATING BOILER

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

UPDRAFT WOOD GASIFIER

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

FUEL AND ASH HANDLING SYSTEM

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

PRODUCER GAS FIRED DISTRICT HEATING BOILER

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

GAS CLEANING SYSTEM

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

HEAVY TAR SEPARATION SYSTEM

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

GAS ENGINES

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

TARWATC (FINAL WATER CLEAN UP)

Fixed Bed

Gasification Plants Babcock & Wilcox Vlund ApS

Fixed Bed

Gasification Plants FB DOWNDRAFT GASIFICATION

Combined Cycle Heat and Power Plant Project TU Bergakademie Freiberg PPS Pipeline Systems GmbH The technology is result of the research at the TU Bergakademie Freiberg in cooperation with the Institute for International Forestry and Wood Management at the TU Dresden

Fixed Bed

Gasification Plants

Project TU Bergakademie Freiberg - PPS Pipeline Systems GmbH

Based on a IGCC concept Producer gas is burned in a combustion chamber Combustion flue gas is used in a high temperature heat exchanger to heat fresh air, which is used to move the gas turbine Thus, gas cleaning and the technical risk for gas turbine operation are minimised

Fixed Bed

Gasification Plants

Project TU Bergakademie Freiberg - PPS Pipeline Systems GmbH

Fixed Bed

Gasification Plants

Project TU Bergakademie Freiberg - PPS Pipeline Systems GmbH

Clean wood consumed: 2500 kg/h Heating value of wood: 13.6 MJ/kg Heating value of producer gas: 5 MJ/kg Combustion chamber temperature: 980C Hot air temperature: 800C Gas turbine power generation: 1.3 MW Steam turbine power generation: 0.7-1 MW Heat output: 4.5 MW

Fluidized Bed

Gasification Plants

BUBBLING FLUIDIZED BED GASIFICATION Plastics Gasification Plant Poligas Ambiente Biosyn Technolgy developed by Kemestrie (spinoff company of the University of Sherbrook, Canada) The plant is located in Ribesalbes (Castelln). Gasifies 15000 ton/year of plastic residues from the ceramic industry

Fluidized Bed

Gasification Plants

Plastics Gasification Plant Poligas Ambiente Gasifier feed rate: 3000 kg/h Raw material: PE and PP residues Start-up finished at the end of 2002 Gasifying medium: O2-enriched air (40% O2) Fuel gas composition: 30-55% N2 16-30% CO2 12-30% CO 2-10% H2 Gas HHV: 12 MJ/Nm3 8.4 MWe are generated by 11 760-kWe Jenbacher Engines Solid residues are vitrified with natural gas

Fluidized Bed

Gasification Plants

Plastics Gasification Plant Poligas Ambiente

Fluidized Bed

Gasification Plants

Plastics Gasification Plant Poligas Ambiente

Fluidized Bed

Gasification Plants

CIRCULATING FLUIDIZED BED GASIFICATION

Atmospheric air CGB gasification for heat production: Lahti Gasifier at Kymijrvi CHP Power Plant

Pressurised air IGCC producing hot fuel gas: Sydkraft Project at Vrmano
Atmospheric air IGCC producing cold fuel gas: ARable Biomass Renewable Energy (ARBRE) Dual bed atmospheric steam IGCC: FERCO-Silvagas plant at Vermont

Fluidized Bed

Gasification Plants

Atmospheric air gasification in CFB for heat production: Lahti Gasifier at Kymijrvi CHP Power Plant The plant is located near the city of Lahti (Finland) The 350 MW power plant runs on pulverized coal combustion The 60 MWth gasifier was added in 1998, supplied by Foster Wheeler Energia Oy Fuelled by: waste wood, packaging wastes, tyres, forest residues, replacing 15% of fossil fuel Producer gas is fed into the coal boiler, to produce heat and steam Investment of 14 M

Fluidized Bed

Gasification Plants

Lahti Gasifier at Kymijrvi CHP Power Plant

Fluidized Bed

Gasification Plants

Lahti Gasifier at Kymijrvi CHP Power Plant

Gas composition (at 50% feed moisture): CO2 12.9% H2 5.9% N2 40.2% CO 4.6% CxHy 3.4% H2O 33% LHV 2.2 MJ/Nm3

Fluidized Bed

Gasification Plants

Pressurised air IGCC producing hot fuel gas: Sydkraft Project at Vrmano The plant was built between 1991 and 1993. Demonstration programme concluded in October 1999 First IGCC installation which worked at near commercial scale The plant run on gasifying operation for more than 8500 hours and the gas turbine run on producer gas for more that 3600 hours Fuels tested include: bark Wood chips Salix Straw RDF

Fluidized Bed

Gasification Plants

Sydkraft Project at Vrmano - The gasification technology has been developed in cooperation between Sydkraft AB and Foster Wheeler Energy International - The gas turbine was supplied by Alstom Power, with an electrical output of 4.2 MWe. A steam turbine produces 1.8 MWe - Thermal output 9 MWth - Biomass feed rate: 4300 kg/h - Air flow rate: 6500 kg/h - Pressure of operation: 18-22 bar - Hot gas cleaning system to avoid tar condensation

Fluidized Bed

Gasification Plants

Sydkraft Project at Vrmano

Fluidized Bed

Gasification Plants

Sydkraft Project at Vrmano

Feeding a mixture of bark, logging residues & waste wood at 5-25% moisture content: LHV of 18,9 MJ/kg. Carbon conversion in the gasifier: 97-98%. Gas LHV: 4.2-4.6 MJ/kg (does not include benzene and tar content) Gas composition (% in volume): H2 - 11 % CO - 16 % CO2 -12 % CH4 -5 % H2O - 12 % N2 - 44 % 1300-1700 ppm NH3 , 9000 mg/m3 benzene, 3500 mg/m3 light tar, 500 mg/m3 heavy tar Ash from the cyclone: 15-20% de unburned carbon and 65-75% bed material Ash from the bed: 0,2-0,5 % UC and 75-80% BM.

Fluidized Bed

Gasification Plants

Atmospheric air IGCC producing cool fuel gas: ARBRE Project The gasifier is an atmospheric pressure, air-blown circulating fluidized bed system, developed by TPS of Sweden Construction began in 1998 Feed material: wood (from conventional forestry and short-rotation plantation sites) Electrical output of 8 MWe, overall electrical eficiency of 31% Cool clean producer gas is compressed to feed the gas turbine

Fluidized Bed

ARBRE Project

Gasification Plants

Fluidized Bed

Gasification Plants

Dual circulating fluid bed steam gasification: FERCO-SilvaGas Process Plant at Vermont The SilvaGas process was developed by Batelles Columbus Laboratories in 1970s-80s Future Energy Corporation (FERCO) comercialices and has further depeloped the technology After more than 20000 hours of gasifying experience in a Process Research Unit (PRU) of 10 ton per day, FERCO constructed a 200 ton/d plant, located at Burlington Electrics McNeil Power Station in Vermont In a first phase, producer gas was burned in the station boiler . In a second phase, gas is cleaned and compressed in a gas turbine

Fluidized Bed

Gasification Plants

FERCO-SilvaGas Process Plant at Vermont

Gasification is carried out in two CFB:
Steam is the fluiding/gasifying agent of the CFB where biomass is fed Solids (sand +char) entrained from this bed are transported to the 2nd CFB where the char is combusted with air, producing the heat to carry out gasification. Hot sand from this bed is transported to the 1st CFB, acting as the heat Carrier. The advantage of the process is producing a medium heating value gas, as the product gas is not diluted with nitrogen from the air

Fluidized Bed

Gasification Plants

FERCO-SilvaGas Process Plant at Vermont

Fluidized Bed

Gasification Plants

FERCO-SilvaGas Process Plant at Vermont Gas cleaning includes a catalytic FB cracking, scrubbing and final refining in a wet ESP. Gasifier temperature: 800-850C Gas heating value: 11-14 MJ/Nm3 Gas composition:

Entrained Bed

Gasification Plants

ENTRAINED BED GASIFICATION SVZ Schwarze Pumpe waste gasification plant Originally, SVZ produced town gas from lignite. Since 1995 SVZ gasifies different residues (plastics, contaminated wood, sewage sludge, shredded materials from automovile recycling, MSW, waste oil, tar, ) with a total capacity of 560000 ton/y Three types of reactors: Entrained flow UD with solid discharge BGL (UD with molten discharge of ash)

Entrained Bed

Gasification Plants

SVZ Schwarze Pumpe waste gasification plant

Entrained Bed

Gasification Plants

SVZ Schwarze Pumpe waste gasification plant

Feed material: liquid wastes

Reaction temperature: 1600-1800C

Capacity: 15 ton/h
Gasifying agent: O2 and steam

CO and H2 are the main gas products

Entrained Bed

Gasification Plants

SVZ Schwarze Pumpe waste gasification plant

Feed material: solid wastes

Reaction temperature: 800-1300C

Operation pressure: 25 bar

Capacity: 12 ton/h

Gasifying agent: O2 and steam

CO and H2 are the main gas products

Entrained Bed

Gasification Plants

SVZ Schwarze Pumpe waste gasification plant

Feed material: solid and liquid wastes

Reaction temperature: 1600C

Operation pressure: 25 bar

Capacity: 35 ton/h

Gasifying agent: O2 and steam

CO and H2 are the main gas products

Entrained Bed

Gasification Plants

SVZ Schwarze Pumpe waste gasification plant Synthesis gas is used for methanol (120000 ton/y) and power production (75 MWe gas/steam turbine)

Gasification Plants

Special plants, with a combination of different reactors: Carbo V process: pyrolysis + thermal cracking + char gasification Ebara-Ube process: FB + Entrained flow Compact Power process: pyrolysis + UD char gasification + combustion

Carbo V process CARBO V PROCESS CHOREN Industries A 1 MWth pilot unit was constructed at the Freiberg (Germany), commissioned in 1998. The process has been tested with a variety of feed materials over a period of 3 years and ran for a total of 5,000 hours. The feed material includes: coal, sewage sludge, wood, ...

Gasification Plants

Carbo V process

Gasification Plants The Carbo-V Process is a threestage gasification process incorporating the following steps: - Low temperature gasification. working between 400C-600C. - High temperature gasification. Temperatures between 1300C and 1500C. - Endothermic entrained bed gasification. The temperature drops from more than 1,300 C to 800 C in a matter of seconds as a result of endothermic reactions.

Carbo V process

Gasification Plants

The capacity of the pilot unit in Freiberg is 1 MWth.

A 150 kW gas engine from the Caterpillar company was installed in 2001 and was operated and optimized for a total of more than 600 hours.

Carbo V process

Gasification Plants

Special Plants

Gasification Plants

ENTRAINED FLOW GASIFICATION EBARA-UBE Process

Placed in Yamaguchi (south of Japan). Completion date: 30 November 1999. Since this date the plant has been working for 3500 hours.

Special Plants

Gasification Plants

The EBARA-UBE is a process of two-stage gasification under pressure. - Preparation of plastic: The plastics are compressed and molted (50 to 100 mm diameter, 100 to 200 mm length). - Low temperature gasification: 600C-800C. - High temperature partial oxidization of gas from low temperature gasifier.

Special Plants Raw material: Waste plastics PCS: 9000 kcal/kg. Plant capacity: 30 Ton/d (as waste plastic). They are building a 240 Ton/day plant. Product: 3500 Nm3/h of gas, Equivalent to 26 ton/d NH3 Hydrogen in gas is 49.9 vol%. By-product: Ammonium Cloride 1Ton/day. Gas composition: H2 49.9 % CO 33.6 % CO2 15.2% H2S 2.3 %

Gasification Plants

Special Plants

Gasification Plants

Compact Power Process

Gasification Plants

COMPACT POWER PROCESS Compact Power is a British company which has developed a three-stage process to valorize difficult wastes (as clinical wastes The stages are: Rotary kiln pyrolysis Updraft gasification High temperature combustion Valorization is performed through a steam cycle

Compact Power Process

Gasification Plants

COMPACT POWER PROCESS

Biomass specialisation course

Review of Gasification Plants

Jess Arauzo, Alberto Gonzalo, Jos L. Snchez (jlsance@unizar.es) Chem.&Environ. Eng. Dpt. C.P.S. www.cps.unizar.es/~proter