Chemrec History and Future Plants Feb 03 2012
Mats Lindblom, Process manager Chemrec AB
CHEMREC 1
Energy to Succeed
Chemrec DP1 History - In Brief 2001: Piling for the new Chemrec DP1 lab
2002: Design of the Reactor
2002 -2003: The DP1 building 2004 Eng. & Mech. Construction
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Chemrec BLG Development Plant • • • • •
Located at the Smurfit Kappa Kraftliner mill in Piteå, Sweden
Oxygen-blown and operated at 30 bar(g) Capacity 20t BLS/d (3 MWth)
In operation since 2005, >14 500 accumulated operating hours Used for development and technical demonstration
CHEMREC 2/6/2012
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Energy to Succeed
What is Black liquor? BLACK LIQUOR
Biomass in liquid form Wood Type
Cellulose
Hemicellulose
Lignine
Extractives + others
Spruce
42%
28%
27%
3%
Fir
41%
28%
27%
4%
Birch
41%
34%
21%
4%
CHEMREC
2/6/2012
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Energy to Succeed
Why gasify Black liquor?
• Liquid – – – –
Easy to feed to a pressurized gasifier Can be atomized to fine droplets Rapid gasification rates Stable properties over time
• Efficient gasification – Full carbon conversion at ~1000 deg C – No tar formation – Low methane formation
• Available in large quantities – World BL capacity about 660 TWh – Corresponds to 340 TWh / 40 million m3 gasoline equivalents per year – Typically 250-300 MW of BL per pulp mill 2/6/2012
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CHEMREC Energy to Succeed
The Gasifier and the Gas Cooler Steam Black Liquor
Cooling water
Oxygen
BFW Steam
REACTOR
GAS COOLER
LPsteam
Cooled raw syngas
Raw syngas MPsteam
QUENCH
Green Liquor Weak Wash
Condensate
CHEMREC Energy to Succeed
THE PROJECT Supported by: *)
CHEMREC
*) The Swedish Energency 7
Energy to Succeed
Some facts about the BioDME project
Smurfitkappa Kraftliner Piteå
Chemrec DP1
The Solander Centre
Chemrec BioDME
Energitekniskt Centrum (ETC)
DME Production capacity:
4 tons / day
Pipe installation:
~10 000 m
Hand valves & on off valves:
~1400 pieces
Instruments:
~450 pieces
Vessels:
~30 pieces
Heat exchangers:
~25 pieces
Process Plant Foot Print
20 x 30 m
Construction cost: Kolugnsvägen
8
European Project BioDME 7th Framework Programme
~ € 20 million
CHEMREC Energy to Succeed
Chemrec DP1, and the new BioDME plant DP1 plant
Flare
CO-shift, MeOH-/DMEsynthesis, DMEdistillation
Aminewash
Carbon filters
CHEMREC 9
Energy to Succeed
Block flow diagram of the BioDME-project H2S / CO2 to mill MeOHSynthesis 2
ZnO-bed
MeOH Synthesis 1
Amine wash MeOH (fr recirc)
COshift
Waste gas
DMEProduct
Steam
DMEsynthesis
Raw MeOH (95%) Carbonfilter
Evaporator
~ 4 tpd of BioDME
Water
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CHEMREC Energy to Succeed
Amine Wash / Syngas Compressor / Condensate drum
CHEMREC 11
Energy to Succeed
BioDME Field Test • 10 Volvo DME trucks in customer operation • Demonstrate and verify DME technology in commercial operation • Planned yearly distance 100 000 km per truck (avg)
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Final construction - Late Autumn/winter 2010 • Severe winter conditions on site stressed the importance of winterization of the plant
• By at the10th of January all critical construction work was finalized.
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Pre-commissioning during winter condition
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BioBME Plant Start-Up 2011 June 6th: Start of gasifier. July 18th: Start of Bio-meOH production August 1st: 7m3 of Bio-meOH produced
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First Bio-methanol produced Methanol sample from intermediate methanol production step
Host mill outage in August – mid September Minor modifications in the BioDME plant. Restart October 17
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BioDME during 2011 (..cont´d) • • •
November 10: First production of BioDME
December 1: First transfer of on-spec BioDME to Storage tank December 21: First delivery of BioDME to PREEM, Gothenburg
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Energy to Succeed
Stockolm BioDME filling Station
Investment 180 000€ CHEMREC 18
Energy to Succeed
BioDME Truck 10
Customer: BDX Företagen AB Truck supplying SmurfitKappa paper plant with timber
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Energy to Succeed
BioDME Truck 9
Customer: Burlink Transport AB, in cooperation with Smurfit Kappa. Truck transporting paper from SmurfitKappa paper plant to Haraholmen harbour
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Energy to Succeed
DME technology for HD trucks
400 bar pump
Piping and filters
Two pumps increase the pressure with ~8bar
Source: Volvo
CHEMREC Energy to Succeed
THE PULP MILLS One Powerful
way to green chemistry CHEMREC 22
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Energy to Succeed
Conventional Paper Pulp Production of Today Fresh Wood for Pulping
Flue gas
Pulp MIll
Electric Power
Waste Heat/ Cooling water
Paper Pulp
2012-01-11
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CHEMREC Energy to Succeed
A typical Pul Mill One feedstock – one product
Paper Pulp
Typically 5-600 MW
Black Liquor Energy
Biomass (bark) 2012-01-11
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CHEMREC Energy to Succeed
The Chemrec Biorefinery Concept: Turn the Pulp Mills of Today into Modern Biorefineries
Today
Tomorrow Fresh Wood for Pulping
Fresh Wood for Pulping
Biomass Fuel
Massafabrik
Paper Pulp
Paper Pulp 2012-01-11
Automotive Fuels
Bioraffinaderi
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CHEMREC Energy to Succeed
The Chemrec Pulp Mill based Biorefinery has outstanding Product efficiency
Wood for pulping
New technology for recovery of chemicals and energy HP-steam
Biofuel boiler
~
Power
Cellulose /Pulp mill
Biomass Fuels
Steam
Green liquor+ H2S
cellulose/ paper pulp
Product efficiency =
Black liquor
BLGMF plant
Biomethanol/ BioDME Added Biomass fuels
Biomethanol or BioDME
= 66-67 %
CHEMREC Energy to Succeed
Domsjö BioFuels plant (BFP)
• >300 Million Euro investment at Domsjö Aditya Birla mill • 120/170 kton BioDME/methanol per year from Chemrec gasification of thick liquor • Eliminates 220 000 ton/yr fossil CO2 • Production of BioDME corresponds to 2400 heavy vehicles . CHEMREC 2/6/2012
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Energy to Succeed
Recovery boilers in Sweden Nr
Mill owner, name
Nominal capacity
1
Billerud, Karlsborg
2
SCA, Munksund
3
Smurfit Kappa, Lövholmen
1450
4
SCA, Obbola
1000
5
Husum, M-Real
750
1100
1965
6
Husum, M-Real
700
2000
1978
7
Husum, M-Real
1100
1300
1988
8
Domsjö, Domsjö
375
1958
9
Domsjö, Domsjö
375
1964
10
Dynäs, Mondi
915
1978
11
Östrand, SCA
3300
2006
4
12
Iggesund, Holmen
520
900
1966
13
Iggesund, Holmen
520
900
1967
14
Vallvik, Rottneros
760/1000
1200
1974/1999
5 6 7 8 9 10 11
15
Korsnäs, Korsnäs
865
1330
1968
16
Korsnäs, Korsnäs
1550
1550
1987
17
Skutskär, StoraEnso
585
650
1967
18
Skutskär, StoraEnso
1900
2800
1976
19
Frövi, Korsnäs
520
1260
1970
20
Skoghall, Stora Enso
2200/(3350)
2005
21
Gruvön, Billerud
2500/(3300)
2000
22
Billingsfors, Munksjö
230
330
1976
23
Bäckhammar, Wermland Paper
570
750
1976
24
Aspa, Munksjö
510
1200
1973
25
Skärblacka, Billerud
1250
1850
1976
26
Värö, Södra
2500
2002
27
Mönsterås, Södra
4000
1996
28
Mörrum, Södra
2000
1250
Current capacity 1500
600
Year of start-up
Approx: 5000 MW Black Liquor
1980 1965
1950
1972 2007
2260
1
”Domsjö x 25”
1213
14 15 16 17 18 20 23 21 22 24
19
25
27
26 28
1995
28
2 3
2/6/2012
CHEMREC Energy to Succeed
Chemrec Unit Design Package well under way Steam Drum
Reactor
Quench
CCC
CHEMREC Energy to Succeed
Gasification unit including low structure Steam Drum
Green liquor Flash system
Green liquor tanks
Pipe Bridge with all connections to unit
Black liquor tanks
CHEMREC Energy to Succeed
Kort om Chemrecs teknik Drivmedelsproduktion baserad på Chemrecs teknik vid samtliga svenska massabruk skulle ge: 1. Miljövinster Reduktion om ca. 10% av Sveriges fossila CO 2 utsläpp (6 miljoner ton CO2 per år) motsvarar hälften av alla tyngre
fordonstransporter i Sverige
2. Ekonomi och energibalans Ersätter import av fossilt fordonsbränsle med biodrivmedel till ett värde av ca 10 miljarder SEK per år.
3. Gynnsamt för svensk industri o sysselsättning -Fordonsindustrin tar fram nya miljövänliga fordon -Massa o pappersindustrin får ökad lönsamhet -Arbetstillfällen skapas under byggtid och drift
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