AN OVERVIEW OF CHEMREC PROCESS CONCEPTS

AN OVERVIEW OF CHEMREC® PROCESS CONCEPTS Mats Lindblom, Chemrec AB Presentation at the Colloquium on Black Liquor Combustion and Gasification May 13-...
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AN OVERVIEW OF CHEMREC® PROCESS CONCEPTS Mats Lindblom, Chemrec AB

Presentation at the Colloquium on Black Liquor Combustion and Gasification May 13-16, 2003, Park City, Utah

AN OVERVIEW OF CHEMREC® PROCESS CONCEPTS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

CHEMREC - Major Applications Development Milestones of CHEMREC Gasification Technology Principles Atmospheric Black Liquor Gasification system The Chemrec Booster in New Bern Atmospheric BLG Performance The Pressurized Black Liquor Gasification system The BLG Process – Mill Integration Flow Scheme BLGCC concept Performance - Chemrec BLGCC BLGMF concept Performance - Chemrec BLGMF BLGMF Process Biomass to Fuel Efficiency Technical Development

1. CHEMREC® - MAJOR APPLICATIONS Ready for commercialisation: • Booster (atmospheric air blown gasification) – Relieve overloaded recovery boilers – Capacity expansion projects Continued development: • BLGCC - Black Liquor Gasification Combined Cycle (pressurised oxygen-blown gasification) – Replacing recovery boiler – Increasing green power production – Improved pulp cooking liquors •

BLGAMF - Black Liquor Gasification with Methanol/DME Production as Motor Fuels for Automotive Uses – Replacing recovery boiler – Introducing new profitable green product line – Improved pulp cooking liquors

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2. CHEMREC® DEVELOPMENT MILESTONES • • • • • • •

Atmospheric pilot plant, 3 tDS/24 h, SKF, Hofors, 1987 Booster demonstration plant, 75 tDS/24 h, AssiDomän, Frövi, 1991 Pressurized air-blown pilot plant, 6 tDS/24 h, Stora Enso, Skoghall, 1994 Commercial Booster plant, 300 tDS/24 h, Weyerhaeuser, New Bern, 1996 Pressurized oxygen-blown rebuilt pilot, 10 tDS/24 h, Stora Enso, Skoghall, 1997 Piteå Development Plant 1 engineering starts 2001 Start-up of the rebuilt, second generation Booster plant, Weyerhaeuser, New Bern, June 2003.

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3. GASIFICATION TECHNOLOGY PRINCIPLES Black Liquor

GAS COOLER C.W

Atomizing medium

BFW Clean Cooled Syngas

Oxygen

LP-Steam GASIFIER

Raw Syngas QUENCH

HX Green Liquor

MP-Steam

Condensate

Weak wash

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4. ATMOSPERIC, AIR-BLOWN BLACK LIQUOR GASIFICATION SYSTEM Black Liquor

Gasification

Steam

Particulate removal / Gas cooling

Air

Oxidized w hite liquor Reactor

Stack Spray cooler Venturi scrubber

Fuel gas

Steam

Sulphur removal

Weak w ash

Gas cooling and dissolving of chemicals

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Quench

Gas firing

Liquor recycle Green Liquor

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5. THE CHEMREC BOOSTER IN NEW BERN

6. PERFORMANCE - CHEMREC BOOSTER Black Liquor throughput: Operating temperature: Pressure: Carbon conversion: Thermal efficiency: Syngas LHV: -”-

Composition:

H2 CO CH4 CO2 N2

Na & Sulphur Separation

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200 - 400 tDS/d 950 oC 0.7 bar(g) >99 % 45 % 2.5 -3.5 MJ/ Nm3 10-15 8-12 0.2-1 15-17 55-65

%vol -”-”-”-”-

15% of incoming S found in syngas.

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7. THE PRESSURISED BLG SYSTEM Black Liquor Atomizing medium

COUNTER CURRENT CONDENSER C.W BFW

Oxygen

Clean Cooled Syngas LP-Steam

GASIFIER

Raw Syngas QUENCH

HX Green Liquor

MP-Steam

Condensate

Weak wash

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8. THE BLG PROCESS - MILL INTEGRATION FLOW SCHEME Pressurized BLG Process Black Liquor

Gasifier/ Quench

Gas Cleanup Plant

Electric Power or Synfuel Plant

El. Power or Methanol/ DME

Low Sulfidity Green Liquor Oxygen Polysulfide Liquor Air

Oxygen Plant

Cooking Liquor Preparation

High Sulfidity Green Liquor SO2

Green/White Liquor Sulfur Conversion

H2SO4 Oxygen

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9. CHEMREC BLGCC PROCESS Oxygen

MP/LP Hot Steam w ater

Air separation

Gas Sulphur handling

Gasification Gas cooling

Pow er Black liquor

Gasifier

Weak w ash

Quench

Raw gas

Counter Current Condenser

Sulphur generation

Gas Clean-up Absorber

Polysulfid generation

Polysulfide

White Liquor

Stripper

Condensate

Green liquor

Fuel Gas HP Steam LP Steam Pow er and Steam in a Com bined Cycle

Air

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Gas Turbine

HRSG

BFW

Flue gas

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10. PERFORMANCE - CHEMREC BLGCC Black Liquor throughput: Operating temperature: Pressure: Carbon conversion: Total thermal efficiency: Syngas LHV: -”-

Composition:

H2 CO CH4 CO2 N2

Na & Sulphur Separation: 05/20/2003

>1000 950 30 >99 80 7 - 9.5

tDS/d oC bar(g) % % MJ/ Nm3

30-35 28-32 0.5-2 30-35 1-4

%vol -”-”-”-”-

55% of incoming S found in gas. 12

11. CHEMREC BLGMF CONCEPT (EXCL. BIOMASS BOILER) Electric Power

Air Separation unit

BFW preheat LPSteam

Oxygen

Pilot burner fuel

Combustible Purge +Flash gases 8

MPSteam

Black Liquor

~50%

MP+ LP 10 Steam

~50% 5 4

Gasifier 1 Quench

COshift

2

Raw Gas Cooler

3

Syngas Compr.

13 14

12

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Abs I

Methanol synthesis Absorber Regen. 6

H2S rich gas

Alt2

Alt1

Abs II

6

Prewash

Tars Green Liquor to the Pulp mill

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Claus Tail Gas

Claus unit

30 bar steam

x x

MeOH Distillation

Raw Methanol 16

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H2S absorption High S. Green Liq.

Liq. Sulphur

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CO2

Waste water

99.8% Methanol

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12. PERFORMANCE - CHEMREC BLGMF Black Liquor throughput: Operating temperature: Pressure: Carbon conversion: Total thermal efficiency:

As for BLGCC 80 - 90 %*)

*) depending on product purity and type.

Syngas LHV: -”- Composition:

As for BLGCC

Na & Sulphur Separation: Major Thermal Losses in BLGMF: - Cooling Water needs - Steam consumption: -Electric Power: 05/20/2003

Syngas cooler, Rectisol Unit MeOH Distillation, Rectisol-stripper, CO-shift ASU-, SG- and MeOH loop compressors 14

13. BLGMF PROCESS BIOMASS TO FUEL EFFICIENCY Pulp Wood

Heat / Power Boiler

Internal power and heat

Additional Renewable Energy

Pulp Mill Black Liquor

Black Liquor Gasification with Fuel Conversion

Methanol/DME

Green Liquor

Paper

Methanol/ DME = 65-75 % Production Efficiency = Additional Renewable Energy 05/20/2003

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14. CHEMREC DEVELOPMENT PLANTS DP-1 AND DP-2 Process Units

Plant

Location

DP1*)

Piteå, North Sweden

- Gasification - Gas Cooling - Gas Cleaning

DP2*)

Kappa Kraftliner Piteå

- Full BLGCC concept

Capacity tDS per d/ MWt

Pressure (bar)

Purpose

20 / 3

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- Verify Plant technical features. - Secure performance for DP-2

~300 / 45

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- Fully develop the BLGCC concept. - Net product approx .10 MWe and 35 t/h of steam.

*) Plant Investments Supported by a Grant from the Swedish Government of 238 MSEK, approx 25 Mill €

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