Chemrec pilot DP-1 and BioDME projtject & Chemrec industrial developments
Ragnar Stare Project Manager
IEA Task Meeting 2011 1 October 18-20, 2011 CHEMREC Energy to Succeed Overview
• This is Chemrec & Black Liquor • Chemrec pilot DP-1 and BioDME project – DP-1 – BioDME • Coffee break • Industrial development – Scale-up – Domsjö
IEA Task Meeting 2011 2 October 18-20, 2011 CHEMREC Energy to Succeed Core technology: Black liqu or gasification
Core competence: Process and equipment design Plant integration PjProject d evel opment
IEA Task Meeting 2011 3 October 18-20, 2011 CHEMREC Energy to Succeed Black liquor - Liquid biomass with properties uniquely suitable for gasification • Its available in existing industrial facilities in large quantities – About 600 TWh/year globally equal to • 30 million tons/yyqear diesel equivalent or • 16 billion gal/year of ethanol equivalents • Approx • It is a liquid – Easy to feed to a pressurized gasifier – CbtidtfidCan be atomized to fine dropl ltfets for rapid gasification rates • Uniquely high reactivity due to high Na/K content
IEA Task Meeting 2011 4 October 18-20, 2011 CHEMREC Energy to Succeed RS1 Typical Black Liquor Data
Example Kraft liquor composition mass/mass
HHV MJ/kg DS 13.3 C kg/kg DS 33.0% H kg/kg DS 3.3% S kg/kg DS 5.5% O kg/kg DS 35. 7% Na kg/kg DS 19.9% K kg/kg DS 2.4% Cl kg/kg DS 0.1% N kg/kg DS 0.1% DS kg/kg wet 71.9%
Note: A liquid biomass feedstock with a 3 Density: ~ 1.4 kg/dm consistent and higher dry solids content then Viscosit y: ~100 cp @ 125 ˚C most woods when harvested ! Note also that it correspond to 18.6 MJ/dm3 HHV ! pH ~13 IEA Task Meeting 2011 5 October 18-20, 2011 CHEMREC Energy to Succeed Folie 5
RS1 Den här kommer jag inte prata om, enbart säga "for the the hand-out version I enclude a coarse spec of our feedstock" Ragnar Stare; 25.08.2011 Black liquor - Liquid biomass with properties uniquely suitable for gasification
These properties allows gasification in a silingle st ep without t ar or meth ane reforming to high-quality syngas and green liquor
Gasification in an entrained flow high- temperature mode gives – FllFull carb on conversi on – No tar formation – Low methane formation – Small reactor volume (~25 m3/1000 t BLS/d) – Simple gas clean-up
IEA Task Meeting 2011 6 October 18-20, 2011 CHEMREC Energy to Succeed KEY TECHNOLOGY DRIVERS -WHY GO AHEAD WITH A CHEMREC PROJECT?
IEA Task Meeting 2011 7 October 18-20, 2011 CHEMREC Energy to Succeed Inherently more efficient, lower cost syngas production
• Ready-to-gasify liquid biomass feedstock available in existing industrial plants • Dual service – syngas production and black liquor recovery • Full heat integration with host plant significantly increases overall energy efficiency • Single-stage gasification without need for secondary tar or methane reduction • Location at industrial sites with existing efficient biomass logistics & existing utilities system • Low quality requirements on supplemental biomass for steam and ppgower generation Reduced investment cost Low variable cost
IEA Task Meeting 2011 8 October 18-20, 2011 CHEMREC Energy to Succeed Highest efficiency, lowest emissions
400 Conventional gasoline Conventional diesel Biodiesel: Glycine as chemical )) Fuels from coal Biodiesel: Glycine as animal feed Syndiesel: Coal to liquid 300 Syndiesel: Gas to liquid
quv. / km quv. Syndiesel: Farmed wood ee
2 Gasoline and Fuels from Syndiesel: Waste wood, black liquor diesel natural gas DME: Coal to liquid DME: Gas to liquid 200 s (g CO DME: Farmed wood nn DME: Waste wood, black liquor EtOH: Wheat, straw CHP, DDGS as AF Ethanol and EtOH: Sugar cane (Brazil) biodiesel EtOH: Wheat, straw CHP, DDGS as AF G emissio 100 EtOH: Farmed wood EtOH: Wheat straw DME and syndiesel EtOH: Wheat, lignite, CHP, DDGS as AF WtW GH from black liquor EtOH: Wheat, lignite, CHP, DDGS as fuel 0 EtOH: Wheat, NG GT+CHP, DDGS as AF EtOH: Wheat, NG GT+CHP, DDGS as fuel 100 200 300 400 500 600 Biogas: Municipal waste Optimum fuel Total WtW energy (MJ / 100 km) Biogas: Dry manure
Source: WtW study Eucar/Concawe/JRC 2005, 2010 Vehicles IEA Task Meeting 2011 9 October 18-20, 2011 CHEMREC Energy to Succeed DP-1
IEA Task Meeting 2011 10 October 18-20, 2011 CHEMREC Energy to Succeed Oxygen-blown high pressure gasifier
• Located at the Smurfit Kappa mill in Piteå, Sweden • UdfdUsed for devel opment and dthild technical demonst ttiration • Oxygen-blown and operated at 30 bar(g) • Cit20tBLS/d(3Capacity 20 t BLS/d (3 MWth), ~13 000 operati ng hours • Provides BioDME plant with syngas
IEA Task Meeting 2011 11 October 18-20, 2011 CHEMREC Energy to Succeed DP-1 - The Gasifier and Gas Cooler
Pre- GAS COOLER STEAM GENERATOR Black heater Liquor Cooling water Cooled Pre- raw Oxygen heater BFW syngas
REACTOR LP- steam
Raw syngas
CoolingMP- water QUENCH steamreturn
Green Liquor Condensate Weak Wash
IEA Task Meeting 2011 12 October 18-20, 2011 CHEMREC Energy to Succeed DP-1 Key systems
• Black Liquor day tank • Black liquor two stages pumping and preheating • Oxygen Stora ge & supp ly , incl. Preheating • Burner system • Gasification reactor with quench and dissolver sections • CtCCounter Curren t GliGascooling (ht(no heat recovery) • Green Liquor system • Supporting media systems (N2, various water systems) • Cool Raw Syngas transferred to BioDME inlet IEA Task Meeting 2011 13 October 18-20, 2011 CHEMREC Energy to Succeed DP-1 Accumulated Operating Hours
BioDME Start-up summer 2011
BioDME Installation & old flare system disconnect ed
Break- through! Excellent carbon con- version and GL
First Start Sept 30 2005
IEA Task Meeting 2011 14 October 18-20, 2011 CHEMREC Energy to Succeed DP-1 operating data per October 2008
BL load [t/day] Operation time/day t/d hours 25 30 Outcome Target Maintenance and probings Operation Target Condensate pump No BL from Kappa 25 20
20 15 15 10 10
5 5
0 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 135791113151719212325272931
bar Operating pressure [bar] hours Operation time [last 12 months] 35 Outcome Target 700 Total accumulated time 7,353 h 30 600 25 500 20 400 15 300
10 200
5 100
0 0 1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 Nov Dec Jan Feb Mar Apr MayCHEMREC Jun Jul Aug Sep Oct IEA Task Meeting 2011 15 October07 18-20,07 08 201108 08 08 08 08 08 08 08 08 Energy to Succeed Raw gas – Pilot Plant Data
H2
CO
CO2
• 50-70 ppm benzene CH • < 5ppm naphthalene 4 • Zero or close to zero higher tars • Very little fouling in heat exchangers • Particulates ”non-detectable”
IEA Task Meeting 2011 16 October 18-20, 2011 CHEMREC Energy to Succeed Plant activity today • Syngas provider for BioDME downstream train • Development and optimization of process parameters – Atom izati on – Further optimize quench operation • Component development & testing – New designs tested for core components – Materials testing • Gain experience of operating , to see what is needed to achieve a high availability • Marketing, sales and educational purpose • Test potential clients spent cooking liquors
The knowledge base needed for scale-up to a larger plant!
IEA Task Meeting 2011 17 October 18-20, 2011 CHEMREC Energy to Succeed Plant Operation & Maintenance
• Facility budgeted and planned to operate in consecutive campai gns, each campai gn with a planned set-up of tasks as indicated • DP-1tdith5hiftf2lih1 operated with 5 shifts of 2 people in each shift handling all processes in both DP-1 and the BioDME downstream train (from inlet to black liquor day-tank to Biofuel product tanks) • Engineers and facility managment staff working day time/weekdays • Maintenance either done by operations team with wider range of skills or sub-contracted whenever heavyyqp equipment, licens-weldinggq etc is required.
IEA Task Meeting 2011 18 October 18-20, 2011 CHEMREC Energy to Succeed BIODME PROJECT
IEA Task Meeting 2011 19 October 18-20, 2011 CHEMREC Energy to Succeed BioDME consortium
• Chemrec builds and operates the BioDME plant based on Haldor Topsøe technology • Volvo Trucks develops, builds and places DME trucks with Delphi providing fuel injection system technology • ETC, the Energy Technology Centre in Piteå, contributes its technical expertise • Preem is responsible for BioDME distribution and builds fuel stations in Sweden • Total is responsible for fuel and lubricant specifications
• The project is financed by the participants, the EU and the Swedish Energy Agency
Starting date: 1 September 2008 Duration 48 months Total budget 28.4 M€ EU funding: 82M8.2 M€ Swedish Energy Agency: 9.6 M€
IEA Task Meeting 2011 20 October 18-20, 2011 CHEMREC Energy to Succeed Engineering, Procurement and Construction of BioDME Plant
Erection of main process modules May 2010
IEA Task Meeting 2011 21 October 18-20, 2011 CHEMREC Energy to Succeed Engineering, Procurement and Construction of BioDME Plant
DME Production 4 tons / day capacity: Pipe ~10 000 m installation: Hand valves & on off valves: ~1400 pieces
Instruments: ~450 pieces
Vessels: ~30 pieces
Heat ~25 pieces exchangers: Process Plant Foot Print 20 x 30 m
Construction ~ € 20 million cost:
IEA Task Meeting 2011 22 October 18-20, 2011 CHEMREC Energy to Succeed Black Liquor DP-1 Gasifier unit unit Oxygen
Gas Carbon CO Amine H2S / CO2 to filter shift wash pulp mill incinerator conditioning
MeOH Synthesis 2 First single-pass Syngas Sulphur MeOH MeOH synthesis Compressor guard Synthesis 1 featuring > 95% yield
MeOH (recycled)
Off gases DME Product
DME synthesis DME & synthesi s Product purification
Water IEA Task Meeting 2011 23 October 18-20, 2011 CHEMREC Energy to Succeed BioDME Production
First bio-methanol The plant has produced 7 m3 produced 2011-07-18 of bio-methanol
• First BioDME was produced 2011-07-27
IEA Task Meeting 2011 24 October 18-20, 2011 CHEMREC Energy to Succeed DP1+BioDME today 19th October
• The BioDME pilot plant successfully produced 7 m3f3 of biometh anol iJlin July and dttfthDME start of the DME section was initiated (2011-07-27) • The t urnaround of th e mill d uri ng A ugust/ September has been used to make some improvements and maintenance work . • The pilot is expected to be in full operation in November.
IEA Task Meeting 2011 25 October 18-20, 2011 CHEMREC Energy to Succeed Fuel distribution
Piteå
200 m3 storage tank in Piteå
Stockholm
Göteborg 34 m3 trailer
Jönköping • Available LPG technology modified for DME • Low cost
CHEMREC IEA Task Meeting 2011 26 October 18-20, 2011 European Project BioDME 26 7th FrameworkEnergy Programme to Succeed Fuel Distribution
• Four filli ng st ati ons d edi cat ed f or th e 10 DME t ruck s i n S wed en • Technology based on LPG and modified for DME • Safety regulations based on LPG • Investment about 200.000 Euro per Filling Station
IEA Task Meeting 2011 27 October 18-20, 2011 CHEMREC 27 Energy to Succeed 10 Field test trucks
IEA Task Meeting 2011 28 October 18-20, 2011 CHEMREC Energy to Succeed COFFEE BREAK
IEA Task Meeting 2011 29 October 18-20, 2011 CHEMREC Energy to Succeed INDUSTRIAL DEVELOPMENT - SCALE-UP - DOMSJÖ
IEA Task Meeting 2011 30 October 18-20, 2011 CHEMREC Energy to Succeed Not the first scale-up! • The New Bern Booster gasifier, > 47 000 h of full-scale operation • Commercial atmospheric, air- blown ggyasifier to boost recovery capacity • Capacity 300 t BLS/d, about 15% of t ot al mill recovery
capacity (~47 MW Feedstock HHV) • Installed in 1996, operated >47 000 h until October 2008 • Reached 95% annual availability and 2 years refractory life • Of great importance for development of refractory system and other components IEA Task Meeting 2011 31 October 18-20, 2011 CHEMREC Energy to Succeed Chemrec Unit Scale-up strategy employed
• Break down into defined pieces to scale- up and manage the interfaces • Use analogies with knowledge from proven full-scale equipment whenever possible • Test/verifyyy all that reasonably can be tested in lab or pilot scale • Ensure thtthat multi ltilple sol ltiutions and dfll fall- backs are enabled in design
IEA Task Meeting 2011 32 October 18-20, 2011 CHEMREC Energy to Succeed Scale-Up – Operating experience a foundation
Air-blown , atmospheric Pressurised, O2-blown New Bern, DP-2 300 t DS/d, 500 t DS/d 47 000 op. h
Frövi 50-75 t DS/d DP-1 20 t DS/d 13 000 op. h
IEA Task Meeting 2011 33 October 18-20, 2011 CHEMREC Energy to Succeed Preparations for industrial scale plants
Chemrec Gasifier Unit Status: • Gasifier,,q quench and g as cooler scale-up work complete • Gasifier black liquor nozzle scale-up work ongoing • Process Design Package work well advanced in cooperation with key suppliers
IEA Task Meeting 2011 34 October 18-20, 2011 CHEMREC Energy to Succeed Equipment and plant design well advanced Steam Drum Reactor
Quench
Final Coolers
Gas Cooler Steam generator
Train #1 Train #2 Train #3
IEA Task Meeting 2011 35 October 18-20, 2011 CHEMREC Energy to Succeed INDUSTRIAL-SCALE PROJECTS
IEA Task Meeting 2011 36 October 18-20, 2011 CHEMREC Energy to Succeed The Domsjö Project
Location: Örnsköldsvik, Sweden Products and capacity: Dual product plant – 100 000 t DME or 140 000 t MeOH/year Full recovery boiler replacement
Project cost: Approx. € 300 million / $ 400 million minus €54 million grant Scheduled start-up: 2015
IEA Task Meeting 2011 37 October 18-20, 2011 CHEMREC Energy to Succeed Domsjö – already a biorefinery today
Biomass District Domsjö Local heat Örnsköldsvik Fiber Pulp Utility Community wood Steam Power Product kton/year Specialty cellulose 199 Lignosulfonate 71
Ethanol 8
IEA Task Meeting 2011 38 October 18-20, 2011 CHEMREC Energy to Succeed … and more so with BioMethanol and BioDME production
Biomass District Domsjö Local heat Örnsköldsvik Fiber Pulp Utility City wood Steam Power Product kton/year Specialty cellulose 255 Lignosulfonate ~60
Ethanol 10-15
DME/Methanol 100/140
IEA Task Meeting 2011 39 October 18-20, 2011 CHEMREC Energy to Succeed Biorefineryygp Throughput – Before & After
• A Biorefinery based on the Sulfite Pulping process
Domsjö Production 2010 With BFP kton/y kton/y Specialty Cellulose 199 255 Lignin (lignosulfonate) 71 ~60 Ethanol 8 10-15 BioMethanol (BioDME) 140 (100) Mass, sold products 278 470 (425) Thick liquor combusted 239 0
• Domsjjyppö with BFP will buy approx ~1.3 MJ of low grade biomass for every MJ sold as high quality biofuel
IEA Task Meeting 2011 40 October 18-20, 2011 CHEMREC Energy to Succeed Domsjö Project Time-line Pre-S(C&Studies , (Conceptual & Feasibility ) , 2008-2011
ThTechno logy an dEid Engineer ing con trac tor Selected 2010-2011
Environmental Permit Application, Prepared & handed in, 2011
Front End Engineering and Design , FEED, Start early 2012
Project Execution, start 2012/2013 (Conditional on financial close and Environmental pp)ermit awarded)
Plant Commissioning and Start-up 2014/2015
IEA Task Meeting 2011 41 October 18-20, 2011 CHEMREC Energy to Succeed Gasification unit for Domsjö project
Steam drum
Green liquor flash system
Green liquor Black liquor tanks Pipe bridge with all tanks connections to unit
IEA Task Meeting 2011 42 October 18-20, 2011 CHEMREC Energy to Succeed Options studied for actual clients with a commercial interest (scientific studies excluded) Multiple feedstocks to provide make-up steam Output Products demand for mill Choices
CHEMREC Mixed Alcohols/ Natural gas (√) Technology Ethanol
Coal CO2 Transportation Methanol √ Fuels DME (DiMethylEther) √ Petcoke Syngas or CO+H Gasification 2 Synthetic Diesel (FTD) √ Residual oil & Gas Chemicals PiProcessing Synthetic or Gasoline √ Biomass √ CbidCombined Hydrogen Heat & Power √ NG/Fuel oil Black Liquor Existing replacement in kiln (√) Processes IEA Task Meeting 2011 43 October 18-20, 2011 CHEMREC Energy to Succeed Wood-to-Weel efficiency….?
Source: Wikipedia, Adler Diplomat 3 GS mit Holzgasgenerator, 1941 IEA Task Meeting 2011 44 October 18-20, 2011 CHEMREC Energy to Succeed Thanks for your attention!
IEA Task Meeting 2011 45 October 18-20, 2011 CHEMREC CHEMRECEnergy to Succeed BACK-UP SLIDES
IEA Task Meeting 2011 46 October 18-20, 2011 CHEMREC Energy to Succeed Char gasification reactivity of different feedstocks
Source: Bürkle et al Source: Bürkle, 1998
IEA Task Meeting 2011 47 October 18-20, 2011 CHEMREC 11/1/2011 4 Energy to Succeed DME engine
• Ideal fuel for diesel process • 440 HP, 13 L engine • Minor technical modifications • E5ihEuro 5 without urea-SCR or Particulate filter
Small modifications in the engine
DME spray - No soot formed
IEA Task Meeting 2011 48 October 18-20, 2011 CHEMREC Energy to Succeed DME fuel system
200 - 400 bar 13 - 20 bar 1 - 15 bar
IEA Task Meeting 2011 49 October 18-20, 2011 CHEMREC Energy to Succeed The BioDME trucks are in operation today!
IEA Task Meeting 2011 50 October 18-20, 2011 CHEMREC Energy to Succeed Field test status 2011-09-12
• Trucks at customer: 7 • Mileage last week: 7 177 km • Accumulated mileage: 135 254 km
Field test mileage
200000 180000 160000 140000 120000
mm 100000 k 80000 60000 40000 20000 0 2011-01-07 2011-02-26 2011-04-17 2011-06-06 2011-07-26 2011-09-14 Date
IEA Task Meeting 2011 51 October 18-20, 2011 CHEMREC Energy to Succeed Volvo DME truck
• Standard Volvo truck • NfltNew fuel system • New engine control • Diesel enggyine with diesel efficiency • 440 HP, 13 L engine • Euro 5 without urea-SCR or Particulate filter DME fuel
EMS
Conventional diesel DME tank Pump engine system
IEA Task Meeting 2011 52 October 18-20, 2011 CHEMREC Energy to Succeed A High Temperature Pressurized Oxygen blown Entrained Flow Gasifier
Chemrec’s Black Liquor Gasifier
Examples of suspension gasifier technologies: *GE (ex-Texaco) (oil & coal-slurry) *Shell (oil & coal-slurry) *Chemrec (Black Liquor) *MPG/Lurgi (Bioliq)
IEA Task Meeting 2011 53 October 18-20, 2011 CHEMREC Energy to Succeed