Role of gasification modelling in overall plant design

Flame Days 2013 seminarIlkka HannulaVTT Technical Research Centre of Finland

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Simplified block diagram of a BTL plant

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Simplified block diagram of a BTL plant

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www.vtt.fi/inf/julkaisut/muut/2010/Hannula1.pdf

508/04/2013

www.vtt.fi/inf/julkaisut/muut/2011/Hannula301210.pdf

608/04/2013

Simplified block diagram of a BTL plant

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Experimental conversions as a function of reactor temperature(G = T gasif, R = T reforming)

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Most importantnon-equilibrium phenomena

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With reformer, main componentscome very close to eq. and modelresults are usually satisfactory

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Model validation based on raw gas- Fairly good resultsreached

- Expected experimentalerror ~5 %

- Even better matchreached with reformedgas

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Hydrocarbons & tar

Residualmethane

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Product gasHot gas filtration

Reforming of the filtered product gas

T = 850 °C

T = 550 °C

T = 950 °C

Product gasHot gas filtration

Reforming of the filtered product gas

T = 850 °C T = 850 °C T = 850 °C

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Liquid transportation fuels via large-scale fluidised-bedgasification of lignocellulosic biomass

(I. Hannula and E. Kurkela, 2013)

• Feedstock input 300 MWth (50 wt%, LVH) to dryer for all simulated designs• 4 end-product considered: methanol, DME, FT liquids and MTG• 5 individual plant designs simulated• 20 cases compared:

• Overall thermodynamic efficiency (on LHV basis)• Economics (capital cost estimates & levelised production costs)

CASE 1 2 3 4 5 Front-end Currently proven Further R&D required Steam system Condensing CHP CHP CHP CHP Filtration 550 °C 550 °C 850 °C 850 °C 850 °C Gasification 5 bar 5 bar 5 bar 22 bar 22 bar CO2 Vent Vent Vent Vent CCS

1808/04/2013

Liquid transportation fuels via large-scale fluidised-bedgasification of lignocellulosic biomass

(I. Hannula and E. Kurkela, 2013)

• Feedstock input 300 MWth (50 wt%, LVH) to dryer for all simulated designs• 4 end-product considered: methanol, DME, FT liquids and MTG• 5 individual plant designs simulated• 20 cases compared:

• Overall thermodynamic efficiency (on LHV basis)• Economics (capital cost estimates & levelised production costs)

CASE 1 2 3 4 5 Front-end Currently proven Further R&D required Steam system Condensing CHP CHP CHP CHP Filtration 550 °C 550 °C 850 °C 850 °C 850 °C Gasification 5 bar 5 bar 5 bar 22 bar 22 bar CO2 Vent Vent Vent Vent CCS

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CASE 1 2 3 4 5

Gasifier

Pressure bar 5 5 5 22 22

Temperature °C 850 850 850 850 850

Heat loss % 1.2 1.2 1.2 1.3 1.3

Steam/O2 - 1.0 1.0 1.0 0.8 0.8

Carbon conversion % 98 98 98 96 96

Recycle gas / O2 - 0.0 0.0 0.0 0.7 0.7

Recycle gas flow kg/s 0.0 0.0 0.0 4.0 4.0

S/O2 inlet temp °C 203 203 203 210 210

Filter

Temperature °C 550 550 850 850 850

Reformer

Outlet temperature °C 957 957 957 957 957

Heat loss % 1.6 1.6 1.5 1.6 1.6

Steam/O2 - 1.0 1.0 1.0 1.2 1.2

Methane in (dry) mol% 8.8 8.8 8.8 9.1 9.1

Methane out (dry) mol% 0.4 0.4 0.4 2.3 2.3

Methane conversion % 95 95 95 70 70

S/O2 inlet temp °C 206 206 206 291 291

N2 out (dry) mol% 1.1 1.1 1.1 1.1 1.1

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CASE 1 2 3 4 5

Gasifier

Pressure bar 5 5 5 22 22

Temperature °C 850 850 850 850 850

Heat loss % 1.2 1.2 1.2 1.3 1.3

Steam/O2 - 1.0 1.0 1.0 0.8 0.8

Carbon conversion % 98 98 98 96 96

Recycle gas / O2 - 0.0 0.0 0.0 0.7 0.7

Recycle gas flow kg/s 0.0 0.0 0.0 4.0 4.0

S/O2 inlet temp °C 203 203 203 210 210

Filter

Temperature °C 550 550 850 850 850

Reformer

Outlet temperature °C 957 957 957 957 957

Heat loss % 1.6 1.6 1.5 1.6 1.6

Steam/O2 - 1.0 1.0 1.0 1.2 1.2

Methane in (dry) mol% 8.8 8.8 8.8 9.1 9.1

Methane out (dry) mol% 0.4 0.4 0.4 2.3 2.3

Methane conversion % 95 95 95 70 70

S/O2 inlet temp °C 206 206 206 291 291

N2 out (dry) mol% 1.1 1.1 1.1 1.1 1.1

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CH4 flow 3.8 MW 22.8 MW

For a plant having 300 MW biomass input (LHV, AR @ 50 wt% moisture)

229 MW 250 MW 242 MW

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Fischer-Tropsch designSynthesis• Shell Middle Distillate Synthesis

(Bintulu, Pearl)• Cobalt-based (Co/Zr/SiO2) LTFT • Very paraffinic syncryde, less alkenes and

oxygenates than in any other large-scale industrial FT technology.

• 80 % per-pass conversion, ~ 0.90 • Multitubular fixed-bed reactor at 200 °C and

30 bar.Recovery & upgrade• C5 recovered by condensation at 45 °C

and Psynth• No cryogenic separation of C1-C2• Hydrocracker at 325 °C and 40 bar with noble

metal hydrocracking catalyst

Simplified layout of the FT synthesis, product recovery and refinery section, adapted SMDS design. From: Arno de Klerk (2011) Fischer-Tropsch refining, Wiley-VCH, 642pp, ISBN 9783527326051

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2408/04/2013For a plant having 300 MW biomass input (LHV, AR @ 50 wt% moisture)

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What is the overall impact?

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CAPITAL COSTS, M€ 5BAR/550C 5BAR/850C 22BAR/850C

Auxiliary equipment 97.0 93.6 93.6

Buildings 18.8 18.8 18.8

Oxygen production 47.2 43.8 43.7

Feedstock pretreatment 31.1 31.1 31.1

Gasification island 150.9 151.4 149.3

Gasification 51.1 51.1 51.1

Hot-gas cleaning 38.7 37.9 39.5

CO shift 6.2 6.6 7.1

Syngas cooling 10.2 10.2 10.6

Compression 8.9 8.9 5.7

Acid gas removal 35.9 36.8 35.3

Power island 27.1 23.9 30.0

Fischer-Tropsch synthesis 77.0 80.9 80.1

FT reactor 41.2 43.4 43.0

HC recovery plant 8.1 8.6 8.5

H2 production (PSA system) 1.4 1.5 1.4

Wax hydrocracking 25.7 26.9 26.7

FT recycle compressor 0.5 0.5 0.6

TOTAL OVERNIGHT CAPITAL 352.1 349.9 353.0

TOTAL CAPITAL INVESTMENT 369.7 367.4 370.7

Cost estimationmethods- Detailed mass & energy

balances used as abasis for equipmentsizing

- Chemical Engineer’sPlant Cost Index usedto account inflation

- Component costsscaled using individualexponents:

For a plant having 300 MW biomass input (LHV, AR @ 50 wt% moisture)

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Investment cost factorsBalance of Plant 30 %Indirect costs 22 %Contingency for standard components 20 %Contingency for less mature components 30 %Interest during construction, fraction of TPC 5 %Capital charges factor, (10%, 20a) 12 %O&M costs factor, fraction of TPC/a 4 %Public investment support, M€ 0

Indirect costsEngineering & head office costs 15 %, start-up costs 5 % and royalties & fees 2 %

O&MPersonnel costs 0.5 % Maintenance & insurances 2.5 %Catalysts & chemicals 1 %

BOPinstrumentation and controls, electrical connections, piping, insulation, and site preparation

PricesBiomass, €/MWh 17Electricity, €/MWh 50District heat, €/MWh 30

Plant factorsTotal biomass use, MW, AR 300Target year for costs 2010Annual peak load demand for heat, h/a 5500Capacity factor 90 %

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• Mature technology• No investment support• No CO2 credits• No tax assumptions

Gasoline@150$/bbl

Gasoline@100$/bbl

Before tax, incl. refining margin,

1 € = 1.33 $ (2010)

Levelised production cost300 MW Biomass @ 17 €/MWh, 0.12 CCF

Electricity 50 €/MWh, DH 30 €/MWh@5500 h/a

3108/04/2013

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