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Syngas to Electricity - Martin van 't Hoff
- 1. Syngas to Power Advanced Gasifica5on, Gas Cleaning and Product Gas u5liza5on Alkmaar, The Netherlands October 2nd 2014 Presented by: Mar5n van ‘t Hoff Biomass Gasifica5on Europe 2014
- 2. Presenta5on contents •Co-‐opera5on Royal Dahlman -‐ ECN • MILENA gasifica5on • OLGA product gas cleaning • Electricity via gas engines and gas turbines • Waste to Energy project • Gaseous and liquid fuels • Research opportuni5es at Investa
- 3. ECN & Royal Dahlman • Applied R&D; Transfer from fundamental research to a system which is ready for the market • Scien5sts, lab & pilot facili5es • Process modelling • Measurements and analysis • Patent holder of MILENA & OLGA technology • Coopera5on with Royal Dahlman on biomass and waste gasifica5on since 2001 • Engineering and produc5on of technology based equipment • Commercial system design • Technology delivery to the market • License holder of MILENA and OLGA technology • OLGA commercial demonstrated • MILENA is launched on the market based on ECN license and Royal Dahlman marke5ng & engineering
- 4. Biomass vs. Coal gasifica5on Syngas vs. product gas, reason for confusion! • Highly reac5ve fuels such as coal or tar-‐oil are gasified with oxygen at temperatures above 1200 °C and produce a ‘syngas’ CO – H2 and CO2 – H2O. • Biomass or waste gasifica5on has a reac5on temperature of 700 -‐ 950 °C and produce a ‘product gas’ (syngas + hydrocarbons) CO – H2 – CH4 – C2H6 – tars and CO2 – H2O.
- 5. Biomass vs. Coal gasifica5on (2) • Coal gasifiers have a very large scale of economy • Coal (entrained flow) gasifiers need fine powders or slurries, they are not suitable for biomass or waste (chips, fluff) • We aim for high efficiencies on a scale of 5 to 50 MWe • Our fuel: wood, waste & agricultural residues Examples (L to R): Waste wood Soya Stalk RDF from MSW
- 6. The MILENA gasifier MILENA an indirect gasifier • Both reactors in one refractory lined reactor vessel • 100% carbon to gas ra5o o Resul5ng in carbon free ash, less waste, cleaner waste & safer waste o Resul5ng in a higher cold gas efficiency (5 to 15% higher on LHV basis) • Separate flue gas exhaust, no or minimized nitrogen dilu5on of the product gas o Compared to air blown gasifica5on a 3 to 4 5mes higher hea5ng value. o Compared to oxygen/steam blown gasifica5on a much higher efficiency (no ASU parasi5c), while s5ll having 60% more hea5ng value o Very suitable for cataly5c upgrading & gas turbines
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- 8. Gasifica5on product gas cleaning Simplified… • Solid par5culates • Organic impuri5es (tars, dioxins) mainly dependant upon gasifier type and opera5onal characteris5cs • Inorganic impuri5es (H2S, HCl, NH3 etc.) mainly dependant upon feedstock composi5on • Other impuri5es (heavy metals, HCN, COS etc.) mainly dependant upon feedstock composi5on • A dirty feedstock (waste) is alrac5ve, but results in more cleaning efforts
- 9. The tar problem 1. Heavy tars • Condensa5on leads to fouling < 400 -‐ 450°C • Tar dew point is cri5cal parameter Deactivation of catalyst (SNG production) Fouling of equipment (gas cleaning) Plugging of an intercooler (gas engines/turbines)
- 10. The tar problem 2. Light tars • Heterocyclic compounds (phenol) are water soluble, condensate & scrubber water is poisoned • Naphthalene can cause crystalliza5on problems Phenol Naphthalene
- 11. Naphthalene crystals on gas engine control valve The tar problem
- 12. OLGA Tar removal Portugal: CFB gasifier, OLGA gas cleaning, Caterpillar 3516A+ gas engine OLGA, a tar/oil based gas scrubber • OLGA captures tars with high efficiencies, well within specifica5on for gas engines, gas turbines and cataly5c processes (SNG, FT-‐diesel). • OLGA does not convert the tars by using electricity or combus5ng part of the product gas. OLGA captures tars and recycles these as fuel to the gasifier. • OLGA has low pressure drop and only consumes some electricity for pumps and tracing < 0,1 MW for a 10 MW gross electric plant (1%). • OLGA does not change the main gas composi5on, high energy carriers like methane, ethene and the bulk of the benzene and toluene stay in the product gas. • OLGA is able to handle very high tar loads, up to 50 g/Nm3 allowing us to op5mize the MILENA.
- 13. OLGA & dew points Temperature °C Dew points & process choices T = 850°C Cooler Particle separation Water dew point ± 75˚C Actual temperature 450 – 500°C Tar dew point 400-‐450˚C
- 14. Dew points are important! Condensation Temperature °C Dew points & process choices Tar dew point 400-‐450˚C Water dew point ± 75˚C Tar dew point < 10˚C) Absorption Cooler OLGA Separation of: tars & fine particles Particle separation T = 850°C Actual temperature
- 15. Dew points are important! Condensation Temperature °C Dew points & process choices Tar dew point 400-‐450˚C Water dew point ± 75˚C Do not mix tar & water! Tar dew point < 10˚C Absorption Cooler OLGA Separation of: tars & fine particles Particle separation T = 850°C Actual temperature Water Quench, condenser & scrubber (inorganics) WDP 30ºC Actual temperature
- 16. PFD -‐ OLGA with cyclone OLGA; a waste free system!
- 17. OLGA Performance, gas analysis Component (values in mg/Nm3) Raw Gas AWer OLGA Efficiency Benzene (not a tar component) 644 428 34% Toluene 439 101 77% Ethylbenzene 8 1 87% m/p-‐Xylene 68 2 97% o-‐Xylene+Styrene 551 4 99% Phenol 597 -‐ 100% Indeen+o-‐cresol 864 4 100% m/p-‐Cresol 36 -‐ 100% Naphthalene 2.822 2 100% Quinoline 14 -‐ 100% Isoquinoline 4 -‐ 100% 2-‐methyl-‐nasalene 287 -‐ 100% 1-‐methyl-‐nasalene 212 -‐ 100% Biphenyl 219 -‐ 100% Ethenyl-‐naphtalene 197 1 99% Acenaphtylene 1.070 1 100% Acenaphtene 70 0 100% Detec5on limit is 2,5 mg/Nm3
- 18. OLGA Performance, gas analysis Component (values in mg/Nm3) Raw Gas AWer OLGA Efficiency Fluorene 425 -‐ 100% Phenanthrene 1.076 -‐ 100% Anthracene 398 -‐ 100% Fluoranthene 505 -‐ 100% Pyrene 609 -‐ 100% Benzo(a)-‐anthracene 184 -‐ 100% Chrysene 167 -‐ 100% Benzo(b)-‐fluoranthene 123 -‐ 100% Benzo(k)-‐fluoranthene 47 -‐ 100% Benzo(e)-‐pyrene 71 -‐ 100% Benzo(a)-‐pyrene 148 -‐ 100% Perylene 24 -‐ 100% Indeno(123-‐cd)-‐perylene 73 -‐ 100% Dibenz(ah)-‐anthracene 18 -‐ 100% Benzo(ghi)-‐perylene 57 -‐ 100% Coronene 30 -‐ 100% Total known tar components 11.415 117 99% Total unknown tars 5.691 54 99%
- 19. OLGA Performance, gas analysis Parameter Unit Raw Gas AWer OLGA Efficiency Total tar mg/Nm³ (dry) 17.106 171 99,0% Total tar excl. BTX mg/Nm³ (dry) 16.040 63 99,6% Total tar excl. BTX & unknowns mg/Nm³ (dry) 10.349 9 99,9% Naphthalene (key-‐component) mg/Nm³ (dry) 2.822 < 2,5 > 99,9% Phenol (key-‐component) mg/Nm³ (dry) 386 < 2,5 > 99,9% Tar dewpoint ° C > 350 < 15 ° F > 660 < 59 Tar aerosols (incl. dust) mg/Nm³ (dry) -‐-‐ 10
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- 21. Clean Product Gas specifica5on Clean Product Gas MILENA MILENA Air blown CFB Oxygen / Steam blown CFB Specifica[on Olivine bed Sand bed Sand bed Sand bed Refuse Derived Fuel (RDF), 25% moisture, 16% ash, 21,6 MJ/kg LHV daf >> Carbon to Gas efficiency 100% 100% 95% 95% Cold Gas efficiency (excl. tars) ~ 80% ~ 80% 70 -‐ 75% 70 -‐ 75% Product gas composi[on (vol%) Clean product gas downstream OLGA & water condensa[on @ 6% water CO 15,0 22,0 12,5 28,0 H2 21,3 14,2 11,3 21,6 CO2 22,6 15,8 13,1 29,7 O2 0,0 0,0 0,0 0,0 H2O 6,0 6,0 6,0 6,0 CH4 12,7 15,3 2,9 8,6 N2 (with air fluidiza5on) 9,4 10,9 51,2 0,6 CxHy (>CH4 & < toluene) 11,5 13,9 1,7 3,7 Total 98,5 98,1 98,7 98,1 LHV (wet) (MJ/Nm3) 17,1 19,8 4,8 11,3 LHV (wet) (Btu/ss) 427 495 130 303 Wobbe (LHV, MJ/Nm3) 18,6 21,8 5,1 12,0 Wobbe (LHV, Btu/scf) 464 545 137 321
- 22. Set up CHP – IGCC plant with OLGA 1-‐10 MWe Gas engines + ORC 6-‐50 MWe IGCC Gas turbine combined cycle
- 23. Engine or Turbine? Gas engines • Available for product gas in 1-‐2 MWe per engine • Loss with ac5ve cooling • Typical availability 85% • Lower power output on product gas vs. on natural gas (10% -‐ 50% dera5ng) • Lower capex, higher opex 1-‐10 MWe Gas turbines • Available Gas engines + ORC for product gas in 6 MWe per turbine and larger capaci5es • Very low loss but compressor parasi5c • High availability, typical 96% • Higher power output on product gas vs. on natural gas (expansion advantage +10%) • Higher capex, lower opex 6-‐50 MWe IGCC Gas turbine combined cycle
- 24. MILENA-‐OLGA CHP-‐IGCC efficiencies Net plant efficiency to useful low quality heat Net plant efficiency to high quality heat Net plant efficiency to power 26% 32% 17% 31% 25% 39% 32% 48% 47% 13% 13% 16% 16% 21% 21% 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Gas Engine Gas Engine + ORC GT single cycle GT comb. cycle GT single cycle GT comb. cycle 24 MWth 24 MWth 160 MWth 155 ton/day RDF 153 ton/day RDF 1035 ton/day RDF
- 25. Waste to Energy -‐ ETI selec5on Worlds most efficient waste to energy technology contest • The UK based Energy Technologies Ins5tute (ETI) selected Royal Dahlman with two UK companies to compete in this challenge • In January ‘14, we completed a FEED study which included extensive tests on UK waste • In the coming months the winner will be announced, which will receive an ETI investment for the demonstra5on plant
- 26. The Grimsby Renewable Power facility Project Sta[s[cs Project loca5on Moody Lane, Grimsby, Lincolnshire, UK Plant commercial feedstock Flexible: RDF -‐ SRF -‐ Biomass Waste input (at MRF) 60.000 to 80.000 tpa (based on typical MRF opera5on) Plant RDF/SRF input 37.000 tpa SRF or 47.000 tpa RDF Plant input energy 22-‐23 MW (LHV) at nominal capacity Plant gross electricity genera5on 8,8 MW Plant net electricity sales 7,0 MW (op5misa5on to 7,6 MW possible)
- 27. MILENA – OLGA Most Efficient EFW MRF The GRP facility receives RDF/SRF in bales, but also has MRF func5onality for flexibility and robustness. Two shredders, a sieve and magnet belts MILENA The MILENA scope includes flue gas treatment, coolers and the cyclones OLGA -‐ AQUA OLGA (green) captures tars and dust and recycles these to the MILENA. Downstream OLGA (blue) water is condensed out and components such as HCl and NH3 are removed Power Block A Solar/Caterpillar Taurus60 gas turbine, heat recovery steam generator and a steam turbine that also receives steam from the MILENA coolers
- 28. Waste to Energy -‐ ETI selec5on 22 MW RDF from UK waste, to 7 MW net electricity
- 29. Waste to Energy -‐ ETI selec5on MILENA gasifier Power block OLGA – AQUA gas cleaning
- 30. MILENA-‐OLGA to gaseous and liquid fuels MILENA-‐OLGA delivers a clean nitrogen free gas suitable for cataly[c conversion to several gaseous and liquid fuels • CH4 – SNG – “green gas” • Fisher-‐Tropsch diesel • H2 • Methanol • Ethanol • Jet fuels • Mixed alcohols, Etc.
- 31. Research opportuni5es at Investa MILENA – OLGA – SNG line-‐up Tie-‐in for full or slip stream tests the plant capacity, ≈ 4 MWth Clean product gas at 18-‐20 MJ/Nm3 (540-‐600 Nm3/hr) Available at 1 bara, 6 bara or 40 bara
- 32. Thank You! Mar5n van ‘t Hoff m.vanthoff@dahlman.nl www.renewableenergy.nl