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This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
New results of the SECTOR Project: Solid Sustainable
Energy Carriers from Biomass by Means of Torrefaction
A European R&D Project funded within the Seventh Programme for
research, technological development and demonstration by the
European Union
1
Helsinki, 16.09.2014
D. Thrän, K. Bienert, M. Carbo, J. Kiel, U. Wolfesberger-Schwabl
Bionergy from Forest Topic 3: Processes for Solid Fuels from Forest Biomass
© 1,5,6: ECN; 2-4 Jasper Lensselink
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
The SECTOR project
Collaborative project: SECTOR
Project start: 01.01.2012
Duration: 42 months
Total budget: 10 Mio. Euro
Participants: 21 from 9 EU-countries
Coordinator: DBFZ
2
Helsinki, 16.09.2014
© DBFZ
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
SECTOR objectives
Support the market introduction of torrefaction-based bioenergy carriers as a commodity renewable solid fuel
Further development of torrefaction-based technologies (up to pilot-plant scale and beyond)
Development of specific production recipes, validated through extensive lab-to-industrial-scale logistics and end-use performance testing
Development and standardisation of dedicated analysis and testing methods for assessment of transport, storage, handling logistics and end-use performance
Assessment of the role of torrefaction-based solid bioenergy carriers in the bioenergy value chains and their contribution to the development of the bioenergy market in Europe
Full sustainability assessment of the major torrefaction-based biomass-to-end-use value chains
Dissemination of project results to industry and into international forums (e.g. EIBI, EERA, CEN/ISO, IEA and sustainability round tables)
3
Helsinki, 16.09.2014
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
project structure
Helsinki, 16.09.2014
4
© DBFZ
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Torrefied biomass properties in perspective
Wood chips Wood pellets Torrefied wood
pellets
Charcoal Coal
Moisture content (wt%) 30 – 55 7 – 10 1 – 5 1 – 5 10 – 15
Calorific value (LHV, MJ/kg) As received
7 – 12 15 – 17 18 – 22 30 – 32 23 – 28
Volatile matter (wt% db) 70 – 84 75 – 84 55 – 80 10 – 12 15 – 30
Fixed carbon (wt% db) 16 – 25 16 – 25 22 – 35 85 – 87 50 – 55
Bulk density (kg/l) 0.20 – 0.3 0.55 – 0.65 0.65 – 0.80 0.18 – 0.24 0.80 – 0.85
Vol. energy density (GJ/m3) 1.4 – 3.6 8 – 11 12 – 19 5.4 – 7.7 18 – 24
Hygroscopic properties Hydrophilic Hydrophilic (Moderately)
Hydrophobic
Hydrophobic Hydrophobic
Biological degradation Fast Fast Slow None None
Milling requirements Special Special Standard Standard Standard
Product consistency Limited High High High High
Transport cost High Medium Low Medium Low
Abbreviations: db = dry basis LHV = Lower Heating Value wt% = weight percentage
Helsinki, 16.09.2014
5
© ECN
© OFI © 1 and 3: ECN; 2: Thomas Siepmann/ PIXELIO; 4: ofi; 5: Gabi Schönemann/PIXELIO
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
© DBFZ
TORREFACTION
6
Helsinki, 16.09.2014
Torrefaction (WP3)
Activities: Execute series of lab/batch and pilot tests in different torrefaction facilities in order to:
• Further optimise torrefaction technologies (ECN, Umea Univ, CENER, Topell) • Broaden the feedstock range • Produce solid sustainable bioenergy carriers with properties that meet
requirements set by subsequent densification, logistics and end use
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Torrefaction technologies
Helsinki, 16.09.2014
7
Production with available demo plant Continuous operation
Production of 100-200 tons Specific feedstock
Production with available pilot scale facilities Typical test runs 50-100 hours
Typical production per test few tons 3-6 different feedstocks
Moving bed* (ECN) pilot
Rotary drum (Umeå University)
pilot
Rotary drum (CENER)
pilot
Toroidal (Topell) demo
Different technologies
* And the resulting Andritz/ECN technology, successfully demonstrated in Denmark at a scale of 1 ton/h
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
© DBFZ
DENSIFICATION
8
Helsinki, 16.09.2014
Densification Process (WP4)
Activities: Lab-scale densification
• Testing of torrefied biomass provided by SECTOR partners
• Parametric study
• Data collection and analysis Feedback and process optimisation
Bench-scale/industrial-scale densification
• Production in pilot plants of CENER, UMU, ECN and Topell
• Data collection and analysis Process improvement
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Densification - Example: Single Pellet Tests – Torrefied Spruce
(DTI)
with increasing torrefaction temperature:
• Friction and max. force are increasing
• Unit density is decreasing
Helsinki, 16.09.2014
9
Energy to push pellet 1 cm in pellet die
Maximum force to initiate pellet movement
© DTI
© DTI © DTI © DTI
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Densification: Pilot-scale tests (CENER)
Optimisation of densification process
Helsinki, 16.09.2014
10
Image © Andritz © Image from Andritz
Parameters optimized: - Particle size of feedstock - Moisture content of feedstock - Torrefaction degree of feedstock - Die: diameter/length - Die rotation speed
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Densification: Pilot scale densification (DTI)
Helsinki, 16.09.2014
11
Briquetting tests:
Material torrefied at ECN: Spruce and Bamboo
Briquetting tests DTI in cooperation with CF Nielsen
Briquetting gets more challenging with increasing torrefaction degree
Keeping the briquette hot and under pressure for extended time improves quality
Good quality: Smooth surface, high density, stability but still optimization potential
Materials tested
Spruce
240 °C
260 °C
280 °C
Bamboo
245°C
255°C
265°C
300 kg each
material
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
© DBFZ
DEMONSTRATION TESTS (WP5)
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Helsinki, 16.09.2014
Demonstration Tests (WP5)
Proof of concept of Topell torrefaction system in 2013 at commercial scale for forest residues
Demonstrated continuous production of torrefied pellets with the product quality required by end users (biomass co-firing biomass)
Achieved and demonstrated full heat integration within the plant use of torgas to supply most of the heat demand of the plant, including drying and torrefaction
Production for successful co-firing trial (2300 tonnes, 5-25 wt% co-milling and co-firing in RWE/Essent Amer 9 power station) (conducted outside SECTOR)
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
© DBFZ
LOGISTICS
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Helsinki, 16.09.2014
Logistics (WP6)
Activities:
Characterise logistics performance:
• First by small-scale tests, later followed by larger-scale outdoor
storage and handling tests
• Assess various logistic aspects and produce optimised torrefaction-
based bioenergy carriers
• Test optimised pellets under real case conditions, e.g. in existing coal-
handling lines
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Logistics - Outdoor storage and handling tests (EON)
Two outdoor storage piles were built in June 2013:
Helsinki, 16.09.2014
14
Flat-topped pellets Model the formation of pellets after com-
paction (though no compaction has occurred)
3 tonnes
2.34 x 2.36 x 1.5 m
Peaked-topped pellets
Model the formation of pellets after it
has been delivered.
4 tonnes
2.34 x 2.36 x 1.5 m
© EON © EON
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Logistics - Outdoor storage and handling tests (EON)
In-situ measurements
• Temperatures in piles
• Weather data (ambient temp, humidity, wind speed, wind direction, rainfall)
Sampling
• Surface and middle of each pile
Physical parameter tests
• Pellet durability
• Diameter
• Particulate size
• Particle distribution
Proximate Analysis
• Moisture
• Ash
• Volatiles
• Calorific Value
Helsinki, 16.09.2014
15
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Logistics - Outdoor storage and handling tests (EON)
Pellet durability as function of time
Helsinki, 16.09.2014
16
60
65
70
75
80
85
90
95
100
105
0 10 20 30 40 50 60 70 80
Du
rab
ility
(%
)
Time (Days) Peak Middle Flat Middle Peak Surface Flat Surface
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Logistics - Achieved results
Outdoor storage and handling tests (EON)
• Temperature profile in piles follows ambient temperature closely (few degrees C higher in piles)
• Continuously increasing moisture content of pellets observed on a monthly basis. Inside as well as close to the surface of the piles.
• Heating value of pellets (LHV, as received) has decreased due to the increased moisture content. On dry basis no difference observed indicating very minor losses due to biological activity or losses through leachate.
• Mechanical integrity of pellets close to surface has decreased; pellets close to the surface are porous and disintegrate easily. Updated mechanical durability tests to be carried out on final samples.
• Note: storage tests were conducted during 9-10 month period; strategic reserve at power plant is typically 2-3 weeks
Helsinki, 16.09.2014
17
Image © Andritz © Image from Andritz
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
© DBFZ
END USE
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Helsinki, 16.09.2014
End use (WP7)
Activities:
End-use applications of torrefied biomass:
• Milling and feeding tests
• Medium-to-large scale firing and co-firing in pulverized-fuel boilers
• Medium-to-large-scale gasification and co-gasification in entrained-
flow gasifiers
• Small-scale combustion in commercial pellet boilers
• As feedstock or co-product for the production of bio-chemicals or bio-
materials
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
End Use - Milling & feeding
Milling tests performed at USTUTT in a hammer mill (200 kg/h):
Torrefied pellets from Topell (woodmix), ECN (Spruce), CENER (Beech and
Pine), and reference white wood pellets.
Preliminary results show significantly lower energy consumption for
torrefied pellets with finer and more spherical material output.
Preliminary results of feeding tests for both 20 kW and 500 kW PF
burners at USTUTT show no bridging and agglomeration problems.
Helsinki, 16.09.2014
19
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
End use: Milling and feeding (ECN)
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Helsinki, 16.09.2014
Glass beads Coal
Raw Spruce Torrefied spruce chips Torrefied spruce pellets
Importance of particle morphology
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
End use: (Co-)gasification in EF gasifiers (Vattenfall)
21
NUON/Vattenfall Buggenum IGCC Plant:
• 253 MWe power plant, entered service in 1993
as a coal gasification demonstration plant,
closed in 2013
• Hard coal as main fuel with continuous co-
gasification of saw dust up to 15 wt%
• Trial (outside SECTOR, but results brought in): • 1200 tonnes of torrefied fuel co-gasified with
hard coal in a 24 hours trial • Mixing rate ~70% on energy basis
Helsinki, 16.09.2014
Main observations during tests in 2012:
• No big technical challenges during conveying, sluicing and milling of torrefied
pellets/coal blend
• Estimated to be possible to achieve 90% of the plant nominal capacity without
major modifications in the fuel feeding system
• Higher heating value in the pellets connected to better milling properties but less
advantageous dust formation behaviour
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
End use: Commercial pellet boilers (TFZ, BIOS, BE2020)
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Helsinki, 16.09.2014
Torrefied pellets can be applied in commercial small-scale wood
pellet boilers and may provide the same or even higher combustion
efficiency as obtained with wood pellets, given the following
considerations:
• Slightly higher fixed carbon content in torrefied pellets vs. need for
burnout time (adaptations of grate and burnout zone possibly required)
• Air ratio and air-staging may require some adaptations
• Pollutant emissions (CO, VOC, NOx and PM) depend on wood resources
used, similar as for wood pellets. Higher expected fuel bed
temperatures may lead to higher fine particle emissions
• Ash and slag related problems may occur earlier due to higher ash
content
Experimental work is supported by CFD modelling
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
FUEL SPECIFICATION AND ANALYSIS
23
Helsinki, 16.09.2014
© DBFZ
Fuel specification and analysis (WP8)
Activities:
Round Robin test 1 concluded: Validation of “standard” test methods for torrefied pellets:
• 43 participants, 18 countries, 11 parameters
• Ash, moisture content, chlorine and sulfur content, CHN analysis – comparable to solid biofuels performance in BIONORM II Round Robin test
• Net calorific value – reproducibility limit is higher than for solid biofuels
• Ash melting behaviour – reproducibility of deformation temperature is high; subjective method
Proposal for product standard for torrefied materials (thermally treated biomass):
• ISO 17225-1 publication date: April 2014
• ISO 17225-8 work item accepted Jan. 2014 – developed until 2016
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
© DBFZ
VALUE CHAINS AND
SUSTAINABILITY
24
Helsinki, 16.09.2014
Value chains and sustainability (WP9)
Activities: assessment of the environmental and socio-economic impacts of torrefied
solid biomass in different value chains
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
WP9: Achieved results - Task 9.3 LCA
Helsinki, 16.09.2014
1.5 – 10.311.3 – 28.2 14.4 – 22.6
86.1 – 130.0
208.14
423.3 – 694.2
749.9
818.9
0
100
200
300
400
500
600
700
800
900
hydropower1
wind power
onshore1
wind power
offshore1
photovoltaics1
torrefied
pellets2
pellets2 biogas
2
(renewable
resources,
liquid manure)
natural gas1 hard coal
(ZA)2
Renewable energies Fossil fuels
co-firing
of tor. pellets2
GH
G e
mis
sio
ns in
g C
O2-e
q./kW
h
Range
99.0 – 286.0
175.8
685.7 – 752.3
co-firing
of pellets2
1 ecoinvent 2.1, gemis (profiles in annex A2)
2 DBFZ in-house calculations (profiles in annex A2)
93.8
wood-fired
CHP1
25
Exemplary results: comparison of GHG mitigation potentials against reference options
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
CONCLUSION & OUTLOOK
26
Helsinki, 16.09.2014
© DBFZ
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Conclusion
EU-FP7 project SECTOR well underway (successful mid-term review)
Wealth of experimental lab-to-demo scale data generated on torrefaction,
densification, and product properties and performance in view of logistics and
end-use (co-firing, entrained-flow gasification and small-scale combustion),
and a lot more to come
Within SECTOR, over 100 tonnes of torrefied material produced and densified
This has allowed:
• Improved fundamental understanding of torrefaction and densification
• Improved performance of the torrefaction and densification technologies involved (e.g. in terms
of energy efficiency and availability)
• Gradual improvement of torrefied pellet properties and a better understanding of how to
optimise logistics and end-use
No show stoppers for torrefaction identified yet (but be realistic and do not
support the hype)
Product standardisation started
27
Helsinki, 16.09.2014
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
Outlook
Expected future SECTOR results include:
• Full sustainability assessments (environmental, economic and social)
• Development of new “non standard” analysis methods for complete description of
torrefied material and proposals for standardisation
• Material Safety Data Sheets (MSDS)
• Data incorporation into ECN Phyllis/BIODAT biomass properties database
Torrefaction is ready for commercial market introduction, but:
• This appears more difficult (take more time) than initially anticipated
• Co-firing in European coal-fired power plants may not be the primary market
opportunity
• Other markets (e.g., gasification-based biochemicals and biofuels production,
distributed/industrial heat generation) and/or other regions (e.g. South-East Asia)
may be more attractive
28
Helsinki, 16.09.2014
This project has received funding from the European Union’s Seventh Programme for research, technological development and demonstration
under grant agreement n° 282826
thank you very much for your attention
29
Coordination & Speaker: Prof. Dr.-Ing. Daniela Thrän DBFZ gGmbH Torgauer Str. 116 04347 Leipzig Germany www.dbfz.de
SECTOR contact: Marlen Ristola t: +49 (0) 341 2434 588 e: [email protected] w: www.sector-project.eu
© Karl-Heinz Liebisch/PIXELIO
Helsinki, 16.09.2014