Essent Biomass Conference 2009 Day 2

Mastering Biomass November 5 2009

Welcome from the Chairman

Pier Nabuurs Chairman of the Executive Board KEMA

Opening Address

Huib Morelisse Chief Technology Officer Essent

Welcome to Day 2 of the Essent Biomass Conference 2009

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Day 1: Key emerging themes

o Cooperation: Politicians/Companies

o Stability: Support mechanisms/Criteria

o Sustainability: Long term well balanced solutions

o Transparancy: Facts vs Fiction and Rational vs Emotional

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Day 2: “Deep dive” into technologies o The “making of” the wood gasifier

“goudvergasser
houtvergasser” (gold gasifier
wood gasifier)

o New promising technologies o

Torrefaction

o

Pyrolysis

o Zero emission power plant

concepts 6

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Looking forward: Right time for joint action? o

No doubt that large scale sustainable use of biomass is needed to meet targets….

o

No single party can achieve this alone…

o

Lets explore ways how to cooperate!

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Essent‘s wood gasifier project and process re-design

Wim Willeboer Manager Process Technology

Amer 9 with Wood Gasifier

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Demolition wood

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(before shreddering)

Essent Biomass Conference 2009

Wood gasifier: Starting points • Demolition wood: qualities A and B • Wood consumption: 150.000 t/a, - replacing 80.000 t/a coal - avoiding 190.000 t/a CO2

• Gas burnt in Amer 9 boiler • No negative effects on Amer 9: - availability - fly ash quality (certified)

• Low emissions • No waste water

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Essent Biomass Conference 2009

Energy balance Amer 9 with gasifier coal: 1380 MWch ∆ coal: -80 MWch •

Amer 9

•600 MWe (∆ = 0) •350 MWth (∆ = 0)

•project

•Demolition wood •84 MWch

•Gasifier

•Own consumption •0.75 MWe

•Woodgas •63 MWch •steam •15 MWth

∆ Ε -0.25 MWe (coal mills)

Equivalent E-production on demolition wood: 33 MWe

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Gasifier

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Development and commercialisation of new technology • Original gasifier concept: proven components but: the complete concept was new

• After two substantial modification actions by the supplier the plant was still not viable

• Essent then started its own process re-design (especially for starting-up and cooling-down)

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Development and commercialisation of new technology (continued) • Three project phases were necessary in stead of one: - Contracting, construction, commissioning (1998-2000) - Substantial modifications and long commissioning periods (2001 – 2003) - Re-design by Essent, construction and commissioning (2004 – 2005)

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Original gasifier process scheme (1998 – 2000) • Plaatje met het originele schema incl. filters en natte wassing

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Project phase 1: Contracting, construction, first commissioning • Contracts for demolition wood and installations: 1998 • Erection 1999 – 2000 • First commissioning 2000; results: - Gas cooler: • fouling • blocking with fly ash - Filters: • Damaged filter elements • Fire possible with O2 containing gas (at start-up and shut-down) - Wet scrubbing: • Solids in water • Extensive wear

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Project phase 2: Substantial modifications and long commissioning periods (2001 – 2003) • Gas cooler modified: outlet temperature raised to 450 °C

• Filters replaced by cyclones

• Wet scrubbing removed (by-passed)

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Gasifier process scheme after two modifications (2003)

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Ultimo 2003: goodbye to supplier Several problems remained - Unavoidable (fly ash) fire in gas cooler during start-up - Agglomeration tendency of bed material - Fast gas cooler fouling - Safeguarding system too complex and thus unreliable - Four different automation programmes - Sensitivity of the plant for metal parts in the fuel 20

Essent Biomass Conference 2009

Project phase 3: Essent’s redesign, plant modification and commissioning (2004 – 2005) • Metal catcher in fuel supply (not successful in the end) • Avoiding agglomeration: - Coarser sand - Start-up burner outside the gasifier

• Oxygen-free operation under all circumstances: - Under-stoichiometric operation of start-up burner - Fluidisation with steam in stead of air during start-up and cooling-down - Result: ignition of fly ash in the system definitely avoided!

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Project phase 3: Essent’s redesign, plant modification and commissioning (2004 – 2005) (continued) • Automation concept: - Push button start-up in any condition - Avoiding false starts (avoiding damaging temperature gradients)

• Safeguarding: - Focus on O2 and temperature - O2 < x % with x only dependent on temperature - Simple and clear

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Technology development sometimes suffers from political issues 2006: Gasifier operation stopped due to new Dutch law (BVA): • Amer 9 considered as waste incinerator based upon

the input of the gasifier; Essent did not accept • European Parliament: Dutch interpretation of the EU

Waste Incineration Directive is too stringent • Essent’s wood gas is as clean as clean biomass and

it has been put on the ‘white list’ • End of 2006: gasifier restarted on demolition wood 23

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New technology needs time to grow up! • 1994 – 1996 Pre-scouting and feasibility studies • 1996 – 1998 Project preparations • 1998 Contract awarding on wood supply and installations • 2000 First commissioning phase • 2005 First commercial operation • 2007 – 2009 Commercial operation with steady improvement of availability

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Conclusion After more than ten years:

BLACK SHEEP has turned into MILK COW! (although the milk still needs stimulation!)

(“So, why don’t we build another one?”) 25

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Gasifier modifications and commissioning

Martijn Spanjers Process Engineer

Gasifier

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Process scheme gasifier

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Start up curve

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Modifications - starting points Main principle: oxygen-free operation under all circumstances

• Minimal air amount Lambda = 1

• No wood burning

• No high (flame-)temperatures • No water injection

---> Temperature [C]

• Smooth transition into gasification Lambda = 0,27 Temperature = 840 C

---> Lambda [-]

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Modifications and commissioning

(1)

Main principle: oxygen-free operation under all circumstances

• Start-up burner: - Separate burner outside gasifier (avoid agglomeration due to high (flame-)temperature) - Under-stoichiometric - Temperature control with steam-injection (instead of air)

• Fluidisation of gasifier: - Fluidisation with steam in stead of air during start-up - Fluidisation with air during gasification, however also gasification with steam fluidisation possible

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Modifications and commissioning • Gasification always with same fuel to air ratio (lambda ± 0,27): - No combustion mode on wood - No transition to gasification with water injection - Complete load range of fuel

• Automation and safeguarding concept: - Push button start-up in any condition - Transition between phases: based on temperature - Safeguarding on one criterion: O2 < x % (x = f(T))

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(2)

Modifications and commissioning • Process parameters:

(3)

Sand specifications - particle diameter distribution 100

• •

Avoid agglomeration Lower velocity

---> w%cumulative

- Bed material: quartz sand 280 µm

90

Fine (original)

80

Normal (currently in use)

70

Coarse

60 50 40 30 20 10

- Gasification temperature: 840 C

0 0

•

Avoid agglomeration

•

Tar formation (amount vs. composition)

100

200

300

400

500

600

700

800

900 1000 1100 1200 1300 1400 1500

---> diameter [um]

Conclusion: Simple and clear safeguarding and start-up procedure. 33

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Commissioning – start of learning curve (#trips/kton wood) 10,00

Apr - Jun 05

Jul - Sep 05

Oct - Dec 05

8,00 7,00 6,00 5,00 4,00 3,00 2,00 1,00

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Regular shut down

Unit 9

Measuring problems

Electric

Process control

Gascooler

Circulating fluidised bed

Gas composition

0,00

Wood logistic system

---> Number [#/kton wood]

9,00

Gas cooler • Cooling syngas from 840 to 450 °C • Production of 10 – 14 t/h steam • Pneumatic knockers • Efficiency

Example of start-up with clean gas cooler 1,20

Efficiency factor [-]

1,00 0,80 0,60 0,40 0,20 0,00 16:00

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V1B OVO V1A ECO 0:00

8:00

16:00

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0:00

8:00

16:00

Cyclone and syngas composition Syngas to unit 9

• Two parallel cyclones

• 60-80% separation of fly ash: - Separation of heavy metals - Permit for syngas as clean biomass

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Conclusion

• Successful oxygen-free operation under all circumstances • Simple and clear safeguarding • Simple and straightforward automation and process control • Steady and stable gasification without agglomeration • Syngas as clean as clean biomass: on ‘white’ list.

Successful gasification process

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Wood gasifier AC 9 Operational experience 2007-2009

Fred Hooijmaijers Asset Engineer

Operational experience 2007-2009 • Operational results • Performance killers & issues • Two examples of improvements • Maintenance strategy • Lessons learned • Prognosed operation 2009-2013

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Operational results 2001-2009 Wood gasifier; operating hours/year

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5000 hours ≈ 100.000 ton demolition wood Essent Biomass Conference 2009

Performance killers wood gasifier

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Operational issues 2007-2009 • Wood quality; reduction of metal parts due to extensive wood quality control.

• Operator experience; start up and shut down procedures. Automation optimization.

• Trips due to instrumentation; O2-measurements. • Refractory damage; due to frequent flushing with cold N2. • Bottom ash blockages; agglomerates and metal parts from the wood.

• Partial blockage of gas cooler; due to fouling with a mixture of fly ash and tar.

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Example: O2-instrumentation

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(1)

Example: O2-instrumentation

(2)

• Principle: 2 out of 3 O2-optical cross duct sensors. • Problems: - Gasifier trips due to wrong detection (fouling and dust clouds). - Maintenance intensive; daily cleaning, outlining problems. - Refractory damage due to frequent flushing with cold nitrogen.

• Solutions: - Downstream repositioning of O2-sensors, less blocking due to dust and tar. - Mechanical fixation to solve outlining problems. - Reduced path length and reduced tube diameter.

• Result: - Reduction of false O2-trips > 50%

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- Substantial reduction of maintenance effort. Essent Biomass Conference 2009

Example: gas cooler cleaning

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(1)

Example: gas cooler cleaning

Significant increase of cleaning interval

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(2)

Example: gas cooler cleaning

(3)

Partial blockage of gas cooler; due to fouling with a mixture of fly ash and tar.

• Significant increase of cleaning interval from 2 to 4 months, due to; - Reduction of trips. - Fluidization with steam instead of air on the siphon bottom of the gasifier. - Slight reduction of gasification temperature to 840 ºC.

• Side effect is increase of tube leakages due to local erosion. 47

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Maintenance strategy From breakdown maintenance to preventive maintenance.

• As is: - Many unplanned outages due to breakdown of non redundant components. - Opportunity based cleaning and repair of gas cooler.

• To be: - 3 to 4 planned outages per year, mainly driven by cleaning interval of gas cooler. - Combine this activity with preventive maintenance actions and inspections. Scope is based on operational experience over the last years.

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Lessons learned • Commitment of operations and maintenance is a critical success factor.

• At the background ongoing technical support and trouble shooting necessary.

• No standard technology for traditional power plants; link with other industries, like petro-chemical and wood industry is needed.

• Lack of redundancy, asks for a strong preventive maintenance program.

• Over 1,3 Mio Euro improvement program in 2009-2010 to increase availability > 5000 EOH/year.

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Prognosed 2009-2013 Wood gasifier; operating hours/year

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Thank you for your interest

Have a nice site visit! 51

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Innovative Technologies: Torrefaction and Pyrolysis Biomass pre-treatment options for source-to-power chain optimization and for broadening feedstock options

Jan de Jong Innovation Manager

Content 1. Introduction

2. Technology assessment -

Some basics

-

Torrefaction

-

Pyrolysis

3. Chain analysis

4. Conclusions

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Why considering torrefaction and pyrolysis? Biomass (raw material) is a rather difficult fuel:

     

availability nearby energy-density hydrophilic Handling at power plant (co-) combustion Increasing competition (e.g. oil-industry)

Note: “Biomass”: fulfils the accepted sustainability criteria,

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Torrefaction offers the solution for most of these difficulties? And what about pyrolysis? Investigation:

 Focus on 

Upstream application



Downstream (co-)combustion (-gasification)



Wood pellets: reference

 Performed by Jacobs Consultancy  Reviewed by experts from Twente University  Led by Innovation (BU New Energy)  Steered by experts from relevant BU’s

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Basically rather similar processes with mainly two output streams Torrefaction 250-400 oC Dry Biomass

slow

Hot Hot pyrolysis pyrolysis gases gases

Bio-coal (Char)

Pelletizer briquetizer

Process: heat

virtually oxygen free

Combustion

endotherm Main parameters: - Particle size - Temperature - Residence time -Gas velocities

Hot Hot pyrolysis pyrolysis gases gases

Pyrolysis 400 – 600 oC Dry Biomass

fast

Hot Hot pyrolysis pyrolysis gases gases Bio-Coal Bio-Coal (Char) (Char) heat Combustion

char char Non Noncondensible condensiblegases gases

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Bio-coal: Pellets Briquettes

Essent Biomass Conference 2009

Cooler/ Condenser

Bio-oil: Emulsion

Pyrolysis has some basic advantages over torrefaction for some biomass types • Opens up the agro-residues market for (co-)combustion • Valuable minerals stay upstream / fertilizer

But: in (co-)gasification low melting components can be very welcome

Biomass type

Origin

Ash-content

(typical age)

Low temperature melting components / chlorides

“old”

Wood (> 10 y)

low

low

“young”

Agro-residues ( 50%

Expectations (expressed by potential technology providers) need still to be proved! Tests will start after first delivery from “Stramproy” 58

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Under investigation

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Attention: biocoal is pyrophobic

Ash composition will hardly differ from woodpellets

Torrefaction: many demo-initiatives/still a lot to prove  

 

No commercially operating installations yet Different process types under development e.g.: developed from  Slow scratch /scientifically based (e.g. ECN)  Slow existing process equipment (e.g. Stramproy)  Fast existing process equipment (e.g. Topell)  … Different process conditions and product properties Room for optimization / Optimization through cooperation !?

Lightly torrefied (brown)

Intensively torrefied (black)

…. optimization .... Energy loss •Energy density •Hydrofobicity •HSE •Milling •Combustion •…. • costs

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Commercially operating pyrolysis installations available But bio-oil is not an “ideal” fuel     

Emulsion: mixture of oils, water and fines High oxygen content Corrosive: pH ~ 2.5: stainless steel required Pungent odour Not stable: ”ages” with time HSE aspects

Suitable for co-combustion in a: Coal fired PP ?

R&D going on in upgrading pyrolysis oil Combined Cycle ?

Remark on downstream application:  hot gas combustion: “nasty” condensation step can be avoided (e.g. RWE Conthermplant in Hamm (D))  Can be attractive alternative for locally available biomass / waste streams

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LCA-analysis: the CO2-footprint Internal research

LCA-stages included by JC

HARVESTING

TRANSPORT

(Grading, planting, fertilization, pesticide usage, machinery)

Only applicable in case of energy-crops, not for by-products

Input data for this specific case calculation: • biomass source: saw-dust (= residue) with 60% dm from eastern Canada (BC) • Mean (truck) distance raw material: 110 km to lumber mill + 28 km to production plant • Distance to Vancouver Sea Port: 780 km (by train) • sea transport distance to EU (via Panama Canal): 15.500 km

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Power Plant conversion

Pyrolysis Pyrolysis plant plant

COMBUSTION

Gate delivery PP

Torrefaction Torrefaction plant plant

Ship Transport

Wood Wood pellet pellet plant plant

Train to seaport

Truck-2 transport Truck-2 transport transport Truck-2

Lumber mill mill Lumber

Truck-1 transport transport Truck-1

Tree harvesting harvesting Tree

Re-forestation Re-forestation

PRODUCTION

Conclusions

(1/2)

1. Torrefaction and pyrolysis technologies offer potential chain advantages 2. Torrefaction: o still in the development phase / several (pre-)commercial initiatives o Bio-coal properties far from uniform; therefore … o optimization potential in process development (through cooperation !?) o Essent starts testing bio-coal as delivery from “Stramproy” begins o Bio-coal from agro-residues not suitable for significant cocombustion rates 3. Pyrolysis: o development clearly ahead of torrefaction; o Technology commercial available although poor in number o opens up the (large) market of agro-residues for co-combustion

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Conclusions

(2/2)

4. CO2-footprint: o o o

Bio-coal and bio-oil: very good score compared to (dutch) hurdle rate Bio-coal: better than wood pellets Bio-oil: hardly any difference with wood pellets

5. Essent will further assess torrefaction and pyrolysis as these technologies provide significantly potential: o o

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In optimizing the chain from biomass source to green power and therefore .. In reaching sustainability targets more efficiently

Essent Biomass Conference 2009

Low carbon IGCC

Jan Eurlings Manager Conceptual Design

Introduction • Increasing emphasis on Carbon Capture & Storage (CCS)

• Pre-combustion capture closest to maturity

• (Un)availability coherent performance data

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CCS: CO2 Capture and Storage

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IGCC: Integrated Gasification Combined Cycle IGCC CCS

Air Nitrogen

Gasification Island

ASU

Steam, BFW El. Power Syngas

Coal

Coal Milling and Drying

Gasification

Gas cleaning

CO2 capture

Hydrogen

Power Island

CO2 Auxiliaries

PSA

Waste Disposal e.g. Slag, Filter Cake Waste Water

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Utility Supply

H2 networks

Sulfur

CO2Transport & -Storage

Essent Biomass Conference 2009

Refinery

Power

Design study

(launched 2009)

Deliverables:

• Process design IGCC+CCS • Plant performances • Insight key performance drivers (technologies) • Lowest integral power price (€/MWh), at a • carbon emission