btl2030 project presentation - · pdf filebtl2030 project presentation ... european biofuels...

BTL2030Project presentation

VTT Technical Research Centre of Finland LtdEspoo, June 2017

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Timetable: 1.1.2016 – 31.8.2018Total budget: 2.7 M€ (Tekes 1.5 M€, Industrial partners 0.5 M€, VTT 0.7 M€)Industrial partners:

Fortum Oyj, Gasum Oy, Helen Oy, Kumera Corporation, Gasification TechnologiesOy, Oy Brynolf Grönmark Ab, ÅF-Consult Oy, Oy Woikoski Ab, Dasos Capital Oy,Kokkolanseudun Kehitys Oy, MOL Group

BTL2030 project Website: http://www.vtt.fi/sites/BTL2030

Timetable: 1.1.2016 – 31.8.2018Total budget: 2.7 M€ (Tekes 1.5 M€, Industrial partners 0.5 M€, VTT 0.7 M€)Industrial partners:

Fortum Oyj, Gasum Oy, Helen Oy, Kumera Corporation, Gasification TechnologiesOy, Oy Brynolf Grönmark Ab, ÅF-Consult Oy, Oy Woikoski Ab, Dasos Capital Oy,Kokkolanseudun Kehitys Oy, MOL Group

BTL2030 project Website: http://www.vtt.fi/sites/BTL2030

BTL2030-project

Copyright © VTT 2016

Project title: Production of transport fuels from biomass bygasification-based concepts integrated to energy consumingindustries and district heat power plants – pilot tests and feasibilitystudiesAcronym: BTL2030

http://www.vtt.fi/sites/BTL2030

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Government Program of Finland

VTT-VATT Traffic 2030 study

§ ” To increase the share of renewable transport fuels to 40 % by 2030”§ ”To stop using coal in energy production and to halve the use of

imported oil for domestic use”

http://www.transsmart.fi/files/248/Tutkimusraportti_VTT-R-00752-15_liitteineen.pdf

Project backgroundand R&D need


http://www.transsmart.fi/files/248/Tutkimusraportti_VTT-R-00752-15_liitteineen.pdf

Solutions for biofuel production from domestic feedstocks in FinlandTarget for renewable energy use of 40 % by 2030

Kokkola-Case

Regulation, sustainability,cascade-use etc.

Ethanol

International influencing,EU 2030 policy,

EU SET-Plan, new exports

Government’s policy:the share of renewablefuels to 40% by 2030

Myl

lyko

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er

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ntal

iap

pr.4

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oe

Sköl

dvik

appr

.400

ktoe

Lapp

eenr

anta

100

ktoe

Pyrolysis

Ther

mal

pyro

lysi

sR

epla

ceof

heav

yoi

lBo

ilers

,fur

nace

s

Cat

alyt

icpy

roly

sis

Blac

kliq

uor,

ligni

n,m

oist

biom

ass

Gasification

Stea

mga

sific

atio

n,C

HP-

inte

grat

edBT

L,SN

G,H

2

O2-

gasi

ficat

ion,

larg

eBT

L-pl

ants

NER

300,

Che

mre

c

Biogas(not SNG)

Fuel

gas

for

furn

aces

and

boile

rs

VTT-pilot+ Industrial Demo

Forestindustry cases

CHP-integrates

Seve

rals

mal

lpl

ants

Limited raw-material basis - not very suitablefor forest residues, black liquor or bark

LiquefactionHTL

Hydrogen treatmentfor transport fuels

Co-feeding in refineries

Gasification with black liquorPulp industry integration

Suitable for wide range of domestic woody raw material,Additional production capacity of 600-900 ktoe/a by 2030



Energy use of wood in Finland

Energy Sector

Source: Jaakko Jokinen, Pöyry Management Consulting Oy. Integrating biofuels and newproducts in Forest Bioeconomy. VTT 2G 2020 Seminar, 26.5.2015 Espoo, VTT Bioruukki.

▪ Additional potential ofwood 20 TWh▪ Corresponds to for 900 ktoeproduction of transport fuel(appr. 25 % of present fuelconsumption)▪ 4 TWh heat as by-product(district heat/industry)▪ Gasification-BTL plants

18 plants of 50 ktoe/a capacityInvestment 150-200 M€/plantTotal appr. 3 billion euro

▪ Potential elsewhereSwedenCentral Europe (agrobiomass)Brazil (bagasse, eucachips)



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What would meane.g. 5 % of EU market?§ 15 Mtoe/a in road transport§ 300 gasification-synthesis plants

of 150 MW feed§ e.g. 25 plants/year at 2030

=> 5 B€/year investment

Aviation fuels: 4 % target§ 2 Mtoe/a by 2020 ?§ 40 gasification-synthesis plants

Sustainability and ILUC§ GHG reduction > 60 %

(Gasification-BTL > 80 %)§ Residues are the main feedstocks

of gasification BTL

Source: European Biofuels Technology Platform, SRA Jan. 2008



Huge EU market 2030- How Can Be Satisfied – 5 %?

7Source: http://www.iea.org/publications/freepublications/publication/name-3976-en.html

World markets and export potential are enormous

Possibleproducts viaGasification& Synthesistechnologies



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Heat-integrated medium-scale BTL process viapiloting and demonstration to industrial use

Phase 1: Piloting and evaluation project, on-going as national project, VTT as a co-ordinatorPhase 2: Demonstration project, will be planned togerher with industrial partners 2017-2019Phase 3: Industrial Flagship project

P0: Concept development – PRECHEM-Kokkolan Biorefinery project (2015)P1: Piloting at VTT Bioruukki andsystem studies 2016-18, 2.5 M€P2: Industrial demonstration at Kokkolaor forest industry site 2017-19, 40 M€

P3: First production plant, 220 M€Capacity 50 ktoe/a, Design 06/17- 06/19Investment decision 06/2019, Commissioning 2021

P4: Several plants in operation 2025-30,investments 150-200 M€/plant

2025: 5 plants, total 250 ktoe/a2030: 10 plants, total600 ktoe/a


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BTL2030-project

The target of this project is a medium-scale BTL concept, which canbe integrated to different kind of energy intensive industries anddistrict heating power plants

The new gasification process is being developed at the DFBpilot plant of VTT Bioruukki and the feasibility of the processis studied together with industrial partners representingdifferent potential applications and roles in the value chain.


1010

§ Develop a new gasification process for heat integrated production oftransport fuels§ Demonstrate the technical feasibility of this process with various

biomass feedstocks by carrying out pilot-scale tests.§ Carry out system studies to study the economic feasibility of the process

in different integration cases.§ Follow-on industrial projects will be preliminarily planned together with

participating companies.

BTL2030-project

Project objectives

The aim is to develop a new gasification process for heatintegrated production of transport fuels and to demonstratethe technical feasibility of this process by carrying out pilot-scale tests.

The aim is to develop a new gasification process for heatintegrated production of transport fuels and to demonstratethe technical feasibility of this process by carrying out pilot-scale tests.


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BTL2030-project

Target results of the project:

§ To operate the DFB gasifier with various biomass feedstocks§ To estimate the performance of an industrial plant§ Hot gas filtration, catalytic reforming and sulphur removal has been

developed and validated in the pilot-test runs§ Production concepts for FT, H2 and SNG have been developed and

evaluated in different cases of energy integration.§ The economic feasibility and the potential of this biofuel production route

have been reliably estimated.§ Proposal(s) for industrial follow-on

projects have been prepared


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BTL2030The advantages of the new production concept§ Can be integrated to different energy intensive industries and CHP plants§ Pressurized O2-blown gasifier is replaced by a steam gasifier operated at a

low pressure§ Gasification can be carried out a lower temperature§ Low contents of heavy tars is reached already in the gasifier and filter§ Fuel feeding into a low-pressure gasifier is easier§ The gasifier design is similar to the air-blown CFB gasifier§ The expensive Rectisol-type of gas cleaning is replaced

by simpler gas cleaning system§ The synthesis technology of the basic concept is also a once through system§ Synthesis off-gas is used to heat the gasifier


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BTL2030 –projectWork packages

WP 1: Pilot-scale development of the new gasification process

WP 2: Feasibility studies

WP 3: Preparation and planning of follow-up projects

WP 4: International co-operation, reviews of competing technologies

WP 5: Publications, seminars and information exchange


Gasification process principle

Steam gasification & hot filtration & reforming

Fuel

Steam(+ air/O2/CO2)

Raw gas700-800oC

Fly ashto combustion

Filter

Gas to reformer600-800 oC

Stagedreformer

Gas to gas coolerand further cleaning850 oC

O2 or Air+ Steam

Air

Flue gas to steamgeneration


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WP 1: Pilot-scale development of the newgasification process WP1 →The largest WP of the projectWP1 →The largest WP of the project

Feedstock basis of the gasification process§ PDU and laboratory tests with selected feedstocks§ Pilot-tests with potential feedstocks and feedstock mixtures


TIMETABLEWP1: PILOT DEVELOPMENT Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4BFB-PDU tests with selected feedstocksGas cleaning R&DCostruction of slip stream unit1st DFB pilot campaign - DFB 16/20 & 16/24 - DFB 17/06, 17/10 and 17/17Modification of DFB pilot plant - new hot filter vessel - CFB oxidizer - modified slip stream2nd DFB pilot campaign - 2-3 test weeks with modified design

20182016 2017

Development of gas cleaning concept, validation of the wholegasification process§ Hot filtration§ Reforming of tars and hydrocarbon gases§ Design of the bulk sulphur removal unit and testing, sorbent optimization

R&D, final gas cleaning studies and tests in a slip stream unit§ Data for process modelling

DFB gasificationt Pilot-plant, VTT Bioruukki


The DFB pilot plant will bemodified and fine-tuned for the

need of each test campaign

The DFB pilot plant will bemodified and fine-tuned for the

need of each test campaign

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STEAM / O2 / AIR / N2 / CO2

PURGE-N2

TARSAMPLING

TAR SAMPLING,GAS ANALYSER,

MICRO GCTO GASBOILER

FUEL

N2

BED MATERIAL/ADDITIVE

FILTER

GASIFIER

BFB100 atmospheric pressure fluidised-bedgasifier, VTT Bioruukki

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WP 2: Feasibility studiesGeneral feasibility studies§ Evaluation of different synthesis technologies and contacts to technology

suppliers§ Design of the production concept for several applications (FT, SNG, H2)§ Biomass pre-treatment, gasification process, synthesis technology and

energy integration§ Material and energy balances, energy efficiencies, possible feedstock

basis, capital and operation costs, economic feasibilitySpecific case studies for participating investor companies§ Realised in co-operation with participating companies


TIMETABLEWP2: EVALUTION Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4Preliminray concept planningSynthesis technology reviewConcept calculation - 1st roundConcept calculation - FinalCase-studies

20182016 2017

1919

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BELTDRYER

STEAMGASIFIER

HOTFILTER

TAR+HCREFORMER

SYNGASCOOLER

ENDCOOLERCOMPR

ZINC SREMOVAL

OTFTL

CO2SCRUB

HYDROCRACKER

1 2 4 5 6

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101213

Process block diagramme – FT/Base case

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LOCKHOPPER

3

14

9

§ Indirectly heated atmospheric steam gasification with 82 % carbon conversion§ Oxygen operated reformer (staged reformer concept of VTT)§ No shift reactor, H2/CO=2 by fluidising gasifier with: 88 % water & 12 % CO2§ Sulphur control with once-through zinc adsorbents§ Compression to 26 bar in one step§ Minor CO2 removal with pressurised water scrubber to achieve CO2 for gasifier purposes§ Once-through two-stage cobalt-based low-temp FT-synthesis§ Off-gases mostly combusted in the oxidiser to provide heat for gasification

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BIOMASS FEED100 / 150 MW

FT-DIESEL PRODUCT54 / 81 MW

BY-PRODUCT ENERGY20 / 30 MW

Example of an integrated production plant producinghydro-treated FT- middle distillate for diesel production.

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2020

WP 3: Planning of follow-on projectsDemonstration plant of P2§ Evaluation of different alternatives for this critical phase of

commercialization§ Formation of the industrial consortium including technology suppliers§ Planning of financing alternatives

Preliminary planning of the Flag-ship plant(s)§ Target is to find a way for making the investment of first-of-kind plant

economically attractive for the plant owner


TIMETABLEWP3 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4EU LCE PROPOSALS - COMSYN project on-going - LCE 07-2017 proposal - LCE08-2017 WASTEGAS proposal - LCE 19/2017 demo proposal?National demo-project planning

20182016 2017

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WP 4: International co-operation and review ofcompeting technologies§ General technology follow-up and information exchange within the EERA

alliance of large European Research organizations§ IEA special project on hybrid concepts integrating bio-syngas and

electrolysis hydrogen§ Contacts to technology suppliers and research organizations outside

Europe§ Co-operation with Sweden§ Contacts to Brazil related to gasification of bagasse


TIMETABLEWP4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4Status review x x x x x x

20182016 2017

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WP 5: Reporting, publications, seminars andinformation exchange

§ Scientifically interesting results will be published in journals andconferences during and after the project


TIMETABLEWP5 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 PublicationsSeminars x xStakeholder groups

20182016 2017

23Work groups (VTT & industrial partners)

Steering groupTekes, VTT, Fortum, Gasum, Helen, ÅF, GasTech, Grönmark, Kumera,

Woikoski, Dasos Capital, Kokkolanseudun Kehitys, MOL/Hungary

VTT Technical Research Centre of Finland Ltd.Project leader: Esa Kurkela, Project Manager

TEKES – the Finnish Funding Agency for Innovation

Jukka Leppälahti, Chief Adviser

Project organization

Feasibilitystudies

Preparation offollow-upprojects

WP3

Internationalco-operation,

Reviews

Publications,Seminars

New gasificationprocess,Piloting

WP1 WP2 WP4 WP5


Dual Bed Steam Gasification Pilot at BioruukkiNew low-pressure process for 50-150 MW input

Most suitable applications§ Hydrogen by PSA§ SNG or FT diesel with once-

through synthesis§ Low-pressure process

suitable also to bagasse andother low-density feeds

Most suitable applications§ Hydrogen by PSA§ SNG or FT diesel with once-

through synthesis§ Low-pressure process

suitable also to bagasse andother low-density feeds


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Gasification pilots at BioruukkiKey research and scale-up offering§ Excellent know-how on fuel chemistry and gasification processes§ Unique fluidized bed gasification, catalytic gas cleaning and hot filtrationtest facilities from laboratory to pilot scale§ Cutting-edge tools for techno-economic evaluations and modelling

Main equipment at Bioruukki§ Dual Fluidized-Bed steam gasification pilot plant for syngasapplications. Atmospheric pressure, feed capacity 80 kg/h. Hot filtration,catalytic reforming§ CFB gasification pilot plant for syngas and fuel gas. Air-blown operation,steam-O2 gasification. Hot filtration, catalytic reforming§ Bench-scale BFB gasification, filter and reformer testing facilities, 5 kg/h§ Pressurized fixed-bed pilot plant (1-10 bar) for CHP and syngasapplications, feed capacity 80 kg/h

Development plans for Bioruukki§ New test possibilities for waste and recycling raw materials

Gasification Platform is used for gasification process development, testing of newfeedstocks and for the development of gas cleaning technologies.

Gasification Platform is used for gasification process development, testing of newfeedstocks and for the development of gas cleaning technologies.

BFB100 Test facility

DFB Test facility

Pressurized Fixed Bed Pilot Plant

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Bioruukki - New piloting ecosystemat Kiviruukki industrial area, Espoo

VTT Bioruukki§ A centre for process industry

scale-up anddemonstrations.

§ A former printing planttransformed to world scaleR&D centre.

§ 8000 m2, room for severalpilot units and laboratories.

§ Located close to Otaniemicampus.


NEW ERANEW ERABTL2030 project Website: http://www.vtt.fi/sites/BTL2030

http://www.vtt.fi/sites/BTL2030

btl2030 project presentation - · pdf filebtl2030 project presentation ... european biofuels...

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