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Gasification 2010
Swedish Gas Centre (SGC)
28-29 October, Scandic Crown, Gothenburg, Sweden
Carbona Inc.Kari Salo
Carbona Gasification Technologies
Biomass Gasification Plant in Skive
2 SGC October 13, 2010
Carbona is a biomass gasification technology based company supplying plants for
various applications
Andritz Oy (Finnish subsidiary of Austrian based Andritz Group) acquired
ownership in Carbona Inc. gradually from 2006
Andritz is one of the leading suppliers in P&P industry and has also biomass CFB
gasification background from 1980’s as Ahlstrom Machinery Oy, Pyroflow
Carbona has developed BFB biomass gasification technology since 1996
ANDRITZ Carbona now offers plants on combined ANDRITZ Carbona technology,
for both BFB and CFB gasification technologies
ANDRITZ Carbona
3 SGC October 13, 2010
Biomass Gasifier Applications
IGCC(gas turbine)
Syngasproduction
Fuel gasfor kilns
(Co-)firing(boiler)
Co-generation(gas engine)
30-150MWth.
Pressurized BFB(air blown)
Power bygas/steam turbines
150 MWth/unit
Pressurized BFB(oxygen blown)
Developmentphase
10-100 MWth.
Atmospheric CFB(circulatingfluidized bed)
Fossil fuelreplacement
BTL producers(P&P & others)and utilities
Bio liquids
10-150 MWth.
Atmospheric CFB
Power by steamcycle
Utilities and allindustries with largefossil fuel firedboilers
Green power
10-50 MWth.
Low pressure BFB(bubbling fluidizedbed)
Power by gasengine units
Fuel gas
Pulp and paper andcement industries
Municipal utilities
Green power
New mid-size powerplants with maxpower
Green power
4 SGC October 13, 2010
Feasible Fuels
Bark, wood residues
Forest residue
Wood chips, pellets
Saw dust
ANDRITZ Carbona offers gasificationplants for mainly wood based fuels today.
New fuels like waste, rejects, sludge, etc.
may require further development work ongasification and especiallyon gas cleanup.
5 SGC October 13, 2010
Two Gasifier Product Lines
Atmospheric 20-150 MWth Atmospheric 10-50 MWth
Pressurized 30-150 MWth
Circulating fluidized bedBubbling fluidized bed
BFB CFB
6 SGC October 13, 2010
CFB Gasification Technology Basis
Location Year Size/Fuel
Wisaforest 1983 35 MW/ bark/saw dustFinland
Norrsundet Bruk 1985 25 MW/bark/saw dustSweden
ASSI 1986 27 MW/bark/saw dustKarlsborg Bruk, Sweden
Portucell 1986 17 MW/barkRodao Mill, Portugal
Norrsundet
Wisaforest
Cumulative operational experience exceeds 70 years
7 SGC October 13, 2010
ANDRITZ Carbona CFB Gasifier with Boiler
CFB Gasifier for Biomass
CFB Gasifier producing fuel gas from Renewablesto replacefossile boiler fuels
Gasifier/Boiler application with gas cleanup
Renewable fuel
Air
Fuel Gas
OilCoalNatural Gas
OilCoal
Natural Gas
Gas cooler
Filter
8 SGC October 13, 2010
Dryer
CFB Gasifier
Fuel receiving
Fuel screening/crushing
Lime Kiln
Gas for Kilns
Typical Plant Arrangement
9 SGC October 13, 2010
BFB Gasification Technology BasisOriginally Licensed from the Gas Technology Institute, GTI
GTI Old Pilot Plant Facility,ChicagoHigh Pressure, Oxygen
GTI New Pilot Plant, ChicagoHigh Pressure, Oxygen
GTI Pilot Plant, HawaiiHigh Pressure,Air
Old Pilot Plant, FinlandHigh Pressure, Air
Carbona GasificationPlant, DenmarkMedium Pressure, Air
10 SGC October 13, 2010
Skive Gasifier/Engine Plant in Denmark
Gasification
Engines and boilers
Fuel storage
Hot water
accumulator
11 SGC October 13, 2010
GAS ENGINES
BFB GASIFIER
Bubbling Fluidized Bed Gasification Plant for Engines
Gasification Plant Process:
Carbona air blown, low pressure bubbling fluidized bed gasifier
Limestone based bed material
Catalytic tar reforming
Gas cooling and filtration
Gas scrubbing
System pressure 0.5 – 2 barg
Power Plant Process:
3 Gas Engines with heat recovery and 2 Gas Boilers
(Also demonstration for IGCC and BTL)
DISTRICTHEATING
11.5MWth
POWER
3x2 MWe
GAS FILTER
3 GAS ENGINES
BIOMASS, 28 MWth
2 BOILERS
TO S TACK
GASSCRUBBER
GAS BUFFERTANK
2x10 MWth
AIR/STEAM
TAR REFORMER
GAS COOLERS
Danish Skive CHP-plant flow sheet
12 SGC October 13, 2010
Gasification Plant Process:
Carbona air blown, low pressure bubbling fluidized bed gasifier
Limestone based bed material
Catalytic tar reforming
Gas cooling and filtration
Gas scrubbing
System pressure 0.5 – 2 barg
Typical dry gas composition after reformer:
CO %-vol 20
CO2 %-vol 12
H2 %-vol 16
CH4 %-vol 4
N2 balance
LHV MJ/m3n 4.8 – 5.2
Gasification Plant
13 SGC October 13, 2010
CHP Plant
Plant Capacity:
Nominal biomass feed 19.5 MWth, max. 28 MWth
Power generation 6.0 MW (3x2MW GEJ620 gas engines)
11.5 MW district heat in CHP-mode
Optional gas consumers 2x10 MWth gas boilers
Plant Operation:
Fully automated
All combinations of gas consumers
Load range 50-130%
Fuel:
Wood pellets
Plant design for wood chips
14 SGC October 13, 2010
Gas Parameters from Plant Control System
Gasifier temperature 850 C˚
CO ~20%
H2 ~16%
CO2 ~12%
LHV 4,8- 5,0 MJ/kg
p ~ 0,7 barg
p ~1,2 barg
CH4 ~ 5%
15 SGC October 13, 2010
General Operation Experience
Gasifier (pressurized, bubbling fluidized bed, bed material dolomite,
operated @ 850 °C)
Fuel feed is simple due to wood pellets, wood chips not used yet
Gasifier generates stable gas with constant composition and LHV
Tar content of the gas is low
Tar Reformer (monolith catalysts, operated @ 930-850 ºC, steam/nitrogen
pulse cleaning)
Reformer temperature auto control functions properly
Reformer pressure drop stable (pulse cleaning)
Reformer performance is under optimization (different catalysts)
Gas Filter (bag house filter operated @ 200 ºC, nitrogen pulse cleaning)
Filtration performance is good
16 SGC October 13, 2010
Operation Experiences
Gas Boilers (2x10 MJ/s)
Utilizing gas from filter (200 ºC) and gas from scrubber (40 ºC)
Clean heating surfaces (4000 h inspection)
Gas Engines (3x2MW GEJ620)
Gas engines “like” the stable quality gas
Gas ramp filters and valves are clean 3000 h inspection)
Full load (2 MW) operation of the engines
Gas engine emissions under guarantee limits
17 SGC October 13, 2010
Tar Reforming Experience after 7500 Operation Hours
Tar Reformer (monolith catalysts, operated @ >900ºC, steam/nitrogen
pulse cleaning)
Reformer temperature control accurate
Reformer pressure drop stable
No soot formation
Reformer performance is under optimization
no tar (heavy) found after the reformer
light hydrocarbon conversion satisfactory
– activated carbon filter needed in waste water stream ammonia conversion low in the beginning
– improved from 20% to 60% due to new catalyst Mechanical improvements during last summer break and new catalyst
Reformer outsourced to Haldor Topsoe
18 SGC October 13, 2010
Future Plans
Research & Development
Tar catalyst development for dust containing gas
Tar reforming to at least 95%
Ammonia reforming at least 70%
Carbona/Andritz and Skive Fjernvarme cooperate in catalyst testing and
development
Skive reformer is equipped with new type of HT catalyst since summer 2009
Testing of different gasifier bed materials
to avoid dolomite re-carbonization during upsets
to reduce dust amount from pellet fuel
Testing of different fuels, mainly wood chips
Optimization of process parameters “also BTL in mind”
19 SGC October 13, 2010
Carbona Gasification Development
Skive: R&D Platform for Clean Gas – Power & BTL/SNG
Skive Plant
BiodieselGTI PilotSkive Gasifier GTI Gasifier
150 MWfuel
Air
2 bar
Oxygen
10 bar
30 MWfuel
Power
Heat
20 SGC October 13, 2010
Pilot Plant Demonstration Site
GTI Energy &EnvironmentalTechnology CampusDes Plaines, Illinois
1(Bay 3)
2
3 4 5
1(Bay 2)
1(Bay 1)
1. Advanced Gasification
Test Facility• Bay 1: Carbona
syngasconditioning system
• Bay 2: PWR, CoalGasification System
• Bay 3: open 5-storytest bay (available for
TIGAS)
2. Flex-Fuel Test Facility• Carbona biomass
gasification system3. Morphysorb®
• Absorption/strippingfor CO2 & H2S
removal4. SulfaTreat®
• Sorbent-based sulfurscavenger
5. High-pressure oxygenand nitrogen supply
Testing for BTL and Skive-processes
21 SGC October 13, 2010
Testing for Skive and BTL/SNG
Testing Program at GTI
Catalyst Test Facility- to evaluate different catalyst types
Bench Scale Unit- testing of fuels,
bed materials,additives
Pilot Plant
- pellets, wood chips, bark, logging residue andstumpfuel and their mixtures
- testing of different operation conditions forrelated equipment and sub-processes
- testing of different reformer setups andcatalysts
- several test campaigns and set points alreadyconducted during the program
- long duration testing ongoing
22 SGC October 13, 2010
BFB Gasifier for Synthesis Gas Applications
Ash
Gasifier
(cooling, filtering,reforming, etc. )
Biomass
Oxygen
(shift, scrubbing, etc.)
AirOxygenPlant
SyntheticNaturalGas
Synthesis
Gas
Biodiesel
Steam
Gasoline
Ethanol
Fischer-Tropsch
Tigas
Bio-Fermentation
Methanation
GasProcessing
GasConditioning
Pipeline, Gas turbine, etc.
High Pressure Oxygen Gasification
Typical plant size 150 – 450 MWfuel
23 SGC October 13, 2010
General Conclusion
Good cooperation with plant owner and crew is essential
The commitment and skill of the Skive Fjernvarme staff has been of special
importance in plant implementation, operation and development
Continuation on process development at site
Cooperation concerning commissioning new plants has been agreed
ANDRITZ Carbona sincerely thanks Skive Fjernvarme for cooperation
24 SGC October 13, 2010
Legal Disclaimer
All data, information, statements, photographs, and graphic illustrations contained in this presentation are
without any obligation to the publisher and raise no liabilities to ANDRITZ AG or any affiliated companies,
nor shall the contents in this presentation form part of any sales contracts, which may be concluded
between ANDRITZ GROUP companies and purchasers of equipment and/or systems referred to herein.
© ANDRITZ AG 2010. All rights reserved. No part of this copyrighted work may be reproduced, modified or
distributed in any form or by any means, or stored in any database or retrieval system, without the prior
written permission of ANDRITZ AG or its affiliates. Any such unauthorized use for any purpose is a violation
of the relevant copyright laws.
