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Refurbishment of catalytic tar reformer and projecton green gasoline
John Bøgild Hansen, Haldor Topsøe A/SIEA Meeting, Skive, October 25, 2017
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We have been committed to catalytic process technologyfor more than 70 years
• Founded in 1940 by Dr. Haldor Topsøe• Revenue: 700 million Euros• 2400 employees• Headquarters in Denmark• Catalyst manufacture in Denmark and
the USA
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Tar reforming – Enabling technologyfor biomass gasification
• Gasification of biomass results in a syngas that contains tars andcontaminants• 1000 -2500 ppm tar• 50 – 100 ppm S, particulates• 850-930°C, 1-30 bar g• Ammonia decomposition BIOMASS
ASH
GASIFIERTAR REFORMER
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“Dusty” tar reforming
PROCESSING& UTILIZATION
TARREFORMER
BIOMASS-FEED
ASH
GASIFIER
“Dusty” tarreforming10-30 g dust / Nm3
HOT GAS FILTER
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Skive Fjernvarme a.m.b.a. (Skive CHP)
Location Skive, Denmark
Capacity 21 MWth, Max 28 MWth
Operational year 2009
Fuel consumption 100 TPD
Fuel Biomass, wood pellets
Gasification techn. Air blown, bubbling fluidized bed
Pressure range 1 – 3 bar g
Power generation Gas engines
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GASIFIER
GAS FILTERGAS COOLER
3 GAS ENGINES
TAR REFORMER
BIOMASS(pellets)20 MWth
Fuel input
AIR & STEAM
ASH (C<2%)
FLY ASH
2 BOILERS
TO STACK
WATER
GAS SCRUBBING
GAS BUFFER TANK(pressure stabilizer)
DISTRICTHEATING11 MWth
POWER6,0 MWe
Copyright Carbona INC Finland
Temperature: 875 °C
200 °C
40 °C
30 °C
Cyclone
900 °C
Pressure: 2 bargBed material: olivine
Biomass Gasification Gas Engine
Tar reforming reactor before revamp 2014:
• Poor control ®Unstable operation
• Damaged internals
• Troublesomecatalystreplacement
• Poor workingenvironment.
Lower productivity
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7
The rebuild tar reformerhas several advantages…
Improvements:• Improved design of reactor internals• Faster and easier catalyst replacement• Much better working environment• Efficient dust blowing• Improved design of catalyst• Better dust handling ® increased utilization• Improved process control• Robust long-term activity ® longer lifetime
Increased stableoperation hours
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GASIFIER
GAS FILTERGAS COOLER
3 GAS ENGINES
TAR REFORMER
BIOMASS(pellets)20 MWth
Fuel input
AIR & STEAM
ASH (C<2%)
FLY ASH
2 BOILERS
TO STACK
WATER
GAS SCRUBBING
GAS BUFFER TANK(pressure stabilizer)
DISTRICTHEATING11 MWth
POWER6,0 MWe
Copyright Carbona INC Finland
Temperature: 875 °C
200 °C
40 °C
30 °C
Cyclone
900 °C
Pressure: 2 bargBed material: olivine
Biomass Gasification Gas Engine
Tar reformer revamp:
• Pressure shellmaintained
• New reactorinternals
• New catalystdesign
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The robust tar reformer
The new design of the reformerhas led to• less dust deposition• better dust blasting• controlled regeneration of the
monolithsIncreased operation hours andlonger lifetime of the monoliths.
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“Clean” tar reforming
PROCESSING& UTILIZATION
TARREFORMER
BIOMASS-FEED
ASH
DUST
HIGH TEMPERATUREHOT GAS FILTER
QUENCHGAS “Clean” tar reforming
1 -10 mg dust / Nm3
GASIFIER
Nickel-based
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Gas Technology Institute, Chicago
Location Chicago, USA
Capacity ~ 4 MWth
Fuel consumption 18 TPD
Fuel Biomass, wood pellets
Gasification techn. Oxygen blown, bubbling fluidized bed
Pressure range 1-9 bar g
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Gas Technology Institute, Chicago
• Tar reformer ~ 1150 run hrs
• No soot formation
• 15 min. lack of oxygen
• No deactivation!
750 – 950 °C
1050 – 1375 Nm3/h
Full tar conversion
30 – 160 ppmv H2S
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MethanolSynthesis
Gasoline
C3-C4
Water
MTGMethanol To Gasoline
MeOH↔DME GasolineSynthesis
Separation
Day Tank(Raw Methanol)
Synthesis Gas
MeOH/DMESynthesis
TIGASTopsøe Integrated Gasoline Synthesis
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TIGAS Demonstrationsanlæg
•1 T/d; > 7000 timer, Houston, Texas, USA
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T/d & kg/hPilots
H-ZSM-5
Historical Perspective
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25 bbl/d Demonstration Plant
OXYGEN
BIOMASS
ASH
GASIFIERTAR REFORMER
BIOMASS
ASH
GASIFIERTAR REFORMER
TARR
EFOR
MER
BIOMASS
GASIFIER
ASH
http://www.energy.gov/news2009/releases.htm
GasolineMeOH/DMEGas
CleaningOXYGEN
MeOH/DME
Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes
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Pseudo-Adiabatic Pilot, Ravnholm
• 290-430°C
• 15-20 barg
• WHSV = 0.8 – 2.6 h-1 fixed bed
• Gasoline reactor: ZSM-5
• Cycle length: 10-40 days
• Lifetime: 1-2 years
Methanol to gasoline (MTG)
GasolinereactorMeOH Gasoline
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Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes
OXYGEN
BIOMASS
ASH
GASIFIERTAR REFORMER
BIOMASS
ASH
GASIFIERTAR REFORMER
TARR
EFOR
MER
BIOMASS
GA
SIFIER
ASH
http://www.energy.gov/news2009/releases.htm
GasCleaning
OXYGEN
Entire value chain: biomass in à gasoline out
Biogasoline Demonstration Plant
MeOH/DME Gasoline
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• Gasification & Tarreforming (existing)
• Morphysorb® AGRunit (existing)
• Utility units & controlsystem (existing)
• Syngas compression(new)
• TIGAS synthesis unit(new)
• Gasoline & wastewater tanks (new)
Biorefinery facility
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Gasoline testing• Engine emissions testing at Southwest Research Institute
• Tested a 80/20 high biomass TIGAS/gasoline blend.• Emission levels better than for conventional gasoline.• Found to be ”substantially similar” to conventional gasoline
• Fleet test• Testing 8 vehicles (EPA Standard Road Cycle)
• 2 Camry (2.5 L PFI),• 2 Corolla (1.8 L PFI)• 2 F-150 (3.5 L V6 EcoBoost®),• 2 Fusion (1.5 L EcoBoost®)
• Commercial gasoline vs. 50% biogasoline blend
• Accumulate 75,000 miles per vehicle
• Engine inspections
• Engine emission tests @ 4000 & 75,000 miles
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GridPower
GasTurbine
Fuel gas and/or LPG fractionused for power generation
Economics
5 cases: Gasoline production cost, IRR, and GHG reduction
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Summary
• MTG: direct conversion of methanol to gasoline• Topsøe MTG: TIGAS is a versatile technology for conversion of syngas to gasoline• Escalating share of unpredictable renewable energy
• is a challenge to balancing supply/demand balance in the power grid• adds increasing demand to standby backup capacity• increases overflow frequency
• Co-production of power and fuel• is a feasible solution to counteract imbalances• improves overall system flexibility• maximizes operator revenue
• Simplicity and efficiency makes TIGAS suitable for co-generation• through integration with IGCC or traditional power plants• enabling air-blown gasification of biomass• providing fast response to load variations• and providing maximum fuel/power flexibility
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Thought experiment
TARREFOR
MER
Biomass
ASH
GASIFIER
N2 CO2
H2 CO
~16 MWth
~7 MWth
Metanol/DME Gasoline
Gasoline
~100 bbl/d
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Skive > 20.000 citizens
6.000 households6.000 cars30 km/d (180.000 km/day)11,3 km/l Gasoline
15.900 l Gasoline/day100 bbl./day
Skive
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Fuel Cell and Electrolyser
½O2
H2 H2O
½O2
H2O + 2e- → H2 + O2-
O2-
O2- → 2e- +½O2
H2 + O2- → H2O + 2e-
O2-
½O2 + 2e- → O2-
SOFC SOECH2H2O
H2 + CO + O2 H2O + CO2 + electric energy (∆G) + heat (T∆S)SOFCSOEC
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SOEC more efficient than present ElectrolysersInternal waste heat used to split water
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
0 100 200 300 400 500 600 700 800 900 1000
Deg C.
kWh
perN
m3
H2
Minimum Electricity Input
Waste heat which can be utilised to split water
Energy needed to evaporate water
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Biogas upgrade by means of SOEC
CH4 + CO2 + 3H2O + El 2CH4 +H2O + 2O2
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New EUDP project50 kW SOEC and 10 Nm3/h methane
Participants:Haldor Topsøe A/SAarhus University
HMN NaturgasNaturgas Fyn
EnergiMidtXergiDGC
PlanEnergiEa Energianalyse
Coordinator:
Duration:June 2013 -Dec. 2017
Project sum:5.3 mio €Location:Foulum
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Methanation and SOEC at Foulum
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GreenSynFuel Project
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Mass Flows in Wood to MeOH
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Mass Flows in Wood + SOEC to MeOH
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Effciencies: Stand alone wood gasifierand gasifier plus SOEC
LHVEfficiency %
WoodGasifier
alone
Wood gasifierPlus SOEC
Methanol 59.2 70.8District Heat 22.6 10.8Total 81.8 81.6