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0  a2 jim frederick 0 a2 jim frederick Presentation Transcript

  • Jim Frederick Table Mountain Consulting, LLC TMC
  • • Utilize the whole tree • Produce a variety of forest-derived products – Cellulose fiber – Synthetic fuels and chemicals (e.g. methanol-to-gasoline, dimethyl DME, Fischer Tropsch diesel,…) – Lignin-derived products – Pharmaceuticals, neutraceuticals – Electrical power • Utilize forest materials for energy
  • • Plant economic optimization and market demand for products determine the optimal product mix • Constraint: steam generated must meet mill steam demands
  • Kraft pulp mill Methanol to Gasoline FT Diesel DME
  • Gasification – Biomass => CO, CO2, H2, H2O – CO + H2 => liquid fuels and chemicals Pyrolysis – Biomass => organic liquids, gases, char – Organic liquids are refined to liquid fuels and chemicals
  • Gasification – Biomass => CO, CO2, H2, H2O – CO + H2 => liquid fuels and chemicals Pyrolysis – Biomass => organic liquids, gases, char – Organic liquids are refined to liquid fuels and chemicals
  • Choices – Gasification/pyrolysis feedstock can be biomass OR black liquor (OR both) – Products can be power OR both liquid fuels and power – Fuel products can be chosen independently – Ratio of fuel products to power is determined through process design and management of heat utilization Constraints – No change in pulp production rate and pulp quality – Steam production must meet pulp mill requirements
  • Black liquor concentration and combustion Biomass boiler Residual biomass Pulping operations Pulp HP steam From the EU BLGMF (Altener) report, Dec 2001 Import or export power Fiber Power and steam
  • Pulp HP steam Export power Liquid fuels or chemicals Steam turbine Biomass boiler Biomass fuel Pulping operations BL gasification and liquids synthesis plant From the EU BLGMF (Altener) report, Dec 2001 Pulp
  • 1. Produce dimethyl ether (DME) and power a. Maximize DME from BLG syngas (DMEa) i. Recycle unconverted syngas ii. Burn wood residues and unconverted syngas to generate process steam and power b. Increase power production (DMEb) i. Recycle unconverted syngas ii. Gasifiy wood residue to fire gas turbine for power iii. HRSG downstream of gas turbine generates power and process steam Based on Larson, Consonni, Katofsky, Iisa, Frederick, A Cost-Benefit Assessment of Gasification-Based Biorefining in the Kraft Pulp and Paper Industry v. 1-4, report to the USDOE and AF&PA, 2006.
  • 1. Produce dimethyl ether (DME) and power c. Single pass syngas for increased power (DMEc) i. Single pass for syngas through DME synthesis reactor ii. Burn wood residues and more unconverted syngas to generate process steam and power iii. HRSG downstream of gas turbine generates power and process steam
  • 2. Produce Fischer Tropsch diesel and power a. Maximize DME from BLG syngas (FTa) i. Syngas from black liquor gasification only ii. Syngas once-through the FT synthesis reactor iii. Power island includes a biomass gasifier, syngas cooler, and combined cycle power plant with process steam extraction iv. Unconverted syngas is burned in power island b. Maximize power generation (FTb) i. Similar to FTa but with a larger biomass gasifier and gas turbine for more power generation
  • 2. Produce Fischer Tropsch diesel and power c. Maximize FT diesel production (FTc) i. Syngas from both black liquor and biomass gasification ii. Syngas once-through the FT synthesis reactor iii. Power island burns only unconverted syngas; otherwise the same as in FTa and FTb ; combined cycle power plant with process steam extraction plus a condensing turbine to utilize excess steam
  • 1. Gasification of both black liquor and biomass to produce syngas for biofuels 2. Power and steam generation using combined unconverted syngas plus syngas from gasified biomass plus heat recovered from exothermic syngas processing steps
  • Fuel synthesis option Incremental biomass for fuel & energy, dry t/d Net incremental biomass to mill, % Syngas from biomass goes to: DMEa 700 5.4% None produced DMEb 1,326 24% Gas turbine DMEc 678 4.8% Gas turbine FTa 829 9.2% Gas turbine FTb 2,246 51% Gas turbine FTc 2,704 64% Synthesis Based on 1725 ADt/d unbl. pulp production and 2458 t/d dry BL solids.
  • 0 20 40 60 80 100 120 140 Steam,kg/s Liquid fuels processes Additional steam from CHP plant Net steam generated in fuel plant Steam generated from recovery and power boilers Pulp mill steam requirement
  • • Adequate biomass supply • Separation and recovery of S and Na – Temperature and pressure effects – H2S recombined with green liquor => lime required • Changes in equivalent capacity of some standard pulp mill operations? • Configure the integrated plant for excellent heat utilization
  • • On pulping: none • On brownstock washing: none • On black liquor evaporation: none • On recovery boiler throughput:  gasification of all black liquor means no demand for a recovery boiler
  • Sulfur separates from sodium during gasification (and pyrolysis) • Recapture of H2S, followed by causticizing: H2S + Na2CO3 => NaHS + NaHCO3 NaHCO3 + Ca(OH)2 => NaOH + H2O + CaCO3 • Causticizing of conventional green liquor: Na2CO3 + Ca(OH)2 => 2NaOH + CaCO3 2 CaO per 2 NaOH 1 CaO per 2 NaOH
  • Lime consumption and causticizer volume requirement and can be doubled when H2S has to be recaptured  55% release at 950oC, pressurized O2 (30 bar) gasificationa  15% release at 950oC, atmospheric pressure air gasificationa  100% release at 700oC, atmospheric pressure steam gasification a Lindblom, M. An Overview of the Chemrec Process Concepts (2003).
  • Oxidant T, C P, bar % of S to H2S Increase in lime and causticizer volume required O2 950C 30 bar 55% 55% Air 950C 1 bar 15% 15% Steam 700C 1 bar 100% 100%
  • Biomass FT crude Power t/d t/d MWe (net) a. burn biomass for 1,659 238 88 steam & power, OR b. gasify biomass for 4,493 238 230 steam & power, OR c. gasify biomass 5,374 783 78 for syngas Based on Larson et al., 2006 Gasify black liquor for syngas AND: Basis: 1327 ODt pulp/day and 212 MWth process steam produced
  • Impact (as % increase) Gasification Biomass required to 225% Evaporation load none Rcovery boiler throughput -100% Recaust operations 0% to +100% Process steam generationa none Power generation 100% – 170% Biofuels production, % input LHV 18% - 42% a steam to pulp mill only
  • • Biomass: – Much technology development under way – Commercial pyrolysis technology is available • Black liquor: – no technologies under development
  • • Mass distribution (nominal, on an ash-free basis): – Pyrolysis gas: 15% – Pyrolysis oil: 70% – Pyrolysis char: 15% • Energy retained in pyrolysis oil: 65-70% • Integration issues: – Energy to drive pyrolyze – Utilization of pyrolysis gas and char
  • Source: K Mäenpää, Metso, 2012
  • Gases: CO, CO2, H2, H2O(v), methane, other light hydrocarbons Liquids: CxHyOz liquids from benzene to C20 + Char: carbon and inorganic matter 60-65% crude oil yield
  • Biomass Crude pyrolysis oil Hydrotreated oil C, wt-% 51.9 33.7 25.2 H, wt-% 6.2 5.2 4.2 O, wt-% 41.8 31.2 Total 100.0 70.0 29.5 Energy content, MJ/kg biomass 19.6 17.5 Fuel value retained, % 58.2
  • • To Dr. Kristiina Iisa for her guidance on the pyrolysis section of this presentation