9th international freiberg conference · 2018 9th international freiberg conference introduction...

2018 9th International Freiberg Conference

9th International Freiberg Conference

Techno-Economic Analysis of Syngas and Electric Power Production in FOAK Industrial Gasification Plant fed by Biomass and Agro-industrial Residues

G. Calì1, P. Deiana2, E. Maggio1, C. Bassano2, S. Meloni1

Sotacarbo S.p.A.1

c/o Grande Miniera di Serbariu , 09013 Carbonia, ITALY

ENEA2

Italian National Agency for New Technologies, Energy and Sustainable Economic Development Via Anguillarese 301, 00123 Rome, ITALY

Berlin - 6 June 2018


Summary

• Introduction

• Description of Demonstration Plant

• Experimental Activities

• Economic Analysis

• Conclusions


Low Carbon Advanced Technology Company

Sotacarbo S.p.A.

Sustainable Energy Research Center Company structure: 50% ENEA e 50% RAS

Plants, Laboratories and Study Activities for Gasification, CO2 Capture, Utilization and Storage

SW Sardinia

Into the area of

Sulcis Coal Basin


Introduction

The Energy Roadmap 2050 (EU)

Shows that energy from renewable sources should reach the objective of 20% in 2020 (Renewable Energy Directive, 2009/28/EC).

This requires R&I to reduce technology and non-technology cost, improve performance and promote

technology deployment to market.

ITALY

National Energy Strategy

defines objectives, key policies and priority measures in the energy sector. In particular it is expected that renewables will become the primary source in the Italian electricity sector together with gas, accounting for 34-38% at 2020 of consumption. Italian government has outlined an incentive scheme (Green Certificates) to support the production of energy from Renewables (e.g. biomass). Typically one certificate represents the generation of 1 MegaWatthour of electricity and it’s a tradable commodity that producers and importers of electricity generated from non-renewable sources must annually purchase covering 2% of their total production.


Description Demostration plant



NORTH SOUTH



• Fixed bed with rotative grate

• Wellman-Galusha based technology

• Up-Draft Reactor

• Design Pressure 3 bar

• Operating Pressure 0.2-0.1 bar g

• Syngas Outlet Temperature 200-300°C

• Fuel Feed Biomass/Coal

• Water Jacket and Stirrer

• Start up Ceramic Irradiators

• Dry Ash Discharging

• On line Syngas Analisys

The gasifier



Sampling and analysis system

Continuous monitoring of syngas composition:

1. Multi module industrial gas analysis system: H2, CO, CO2, CH4, H2S and O2

2. Portable Micro GC dedicated to: H2, CO, CO2, CH4, H2S, O2 N2, COS, C2H6 e C3H8

3. Sampling line for Tar and Dust


Sperimental Activities and Results

Several sperimental test are performed

Gasification of only wood chips

Gasification of blend of coal and Wood

Chips

Gasification of only coal

Characterization of tested fuels

Fuel fed

Colombian

coal

Wood chips

Wood chips

Mix

10% coal and 90% Wood chips

Classification Sub-bituminous Eucalyptus Pinus Pinea Sub-bituminous - Pinus Pinea

Origin Colombia Siurgus Donigala (Sardinia - Italy)

Ortacesus (Sardinia – Italy)

Bulk density (kg/dm3)

Density 0,85 0,28 0,36

Proximate analysis (% wt)

Fixed Carbon 60,33 19,25 21,87 25,60

Moisture 1,96 7,84 9,56 8,86

Volatiles 36,37 63,03 67,25 64,26

Ash 1,34 0,92 1,33 1,29

Ultimate analysis (% wt)

Total Carbon 76,30 39,4 57,27 61,48

Hydrogen 5,54 4,94 6,148 6,09

Nitrogen 1,42 0,18 0,40 0,48

Sulphur 0,59 0,01 0,09 0,13

Oxygen n.d.

Moisture 1,96 0,84 9,56 8,86

Ash 1,34 0,92 1,33 1,29

Calorimetric analysis (MJ/kg)

Lower Heating Value 32,47 13,25 17,09 18,97


Sperimental Activities and Results

Gasification parameters and performans for different experimental test

Fuel fed

Colombian coal

Wood chips Pinus Pinea

Wood chips Pinus Pinea

Mix 10% coal and 90%

Wood chips

Flow fuel fed (kg/h)

130-140 600-650 500-800 300-400

Flow air (kg/h) 630-640 590-600 700-850 650-700

Steam (kg/h)

20 - - -

Syngas composition (molar fraction on a dry basis)

CO 0,170 0,295 0,297 0,271

CO2 0,097 0,060 0,062 0,038

H2 0,106 0,084 0,120 0,099

CH4 0,02 0,018 0,210 0,016

H2S 0,008 - - 0,0007

N2 0,597 0,542 0,497 0,544

O2 0,0008 0,001 0,003 0,003

Raw syngas properties (molar fraction on a dry basis)

Lower Heating Value (MJ/kg)

3,41 5,05 5,6 5,03

Flow syngas (kg/h)

650

600 950 820

Cold gas efficiency

0,68 0,8 0,8 0,79

Gasification process parameters Operating procedures include the following main phases:

1. Testing and start-up of the auxiliary systems

2. Start-up of the plant

3. Operational phase

4. Shut-down of the plant


Sperimental activities and results

Syngas composition trend


Economic Analysis

Method: COE and cash flow analysis

Estimation BEC (Bare Erected Cost)

Estimation TPC (Total Plant Cost)

Includes: Engineering, Procurement and Construction Cost

Estimation COE (Cost of Electricity)

Estimation NPV (Net Present Value)


COE Calculation and Assumptions

e

costcostcostCoste

kWh

Tax Personnel M&O Variable M&O FixedCapital)kWh/(€COE

Capital Cost= CRF*TPC Assumptions BEC 1.8 M€ Contingency (5% BEC) 0.1 M€ TPC 2.08 M€ Capital Recovery Factor (CRF) 7.1 % Load factor 80% (7000 h) Annual electric energy 3731000 kWhe

Fixed O&M cost 1 % TPC Variable O&M cost 2 % TPC Personnel 0.19 M€ TAX 30 %


BEC results

0%

20%

40%

60%

80%

100%

BEC

water treatment

BOP

Civil work

clean up

MCI

gasifier

ICE


COE results

0.00

0.02

0.04

0.06

0.08

0.10

0.12

0.14

0.16

0.18

0.20

COE €/kWhe

Fuel cost

Variable O&M

Fixed O&M

Personell

Capital cost

Tax


COE analysis and sensitivity

Sensitivity analysis to investigate the most influencing factors

+/-15% input variables has been changed

COE variation

Sensitivity analysis results

load factor

capital cost

biomass costBiomass Cost is the parameter that most influence the COE


NPV Calculation and Assumptions

Parameter / Assumption Value

Construction Period 3 years Incurred capital in: year 1 10% year 2 60% year 3 30% Debt Equity Ratio 50:50 Capacity factor 80% (7000 h) Plant lifetime 25 years Electricity price 0.20 €/kWhe


NPV results

Biomass Cost

50 €/t

Biomass Cost

30 €/t NPV (25 y) 1.73 M€ 2.62 M€

IRR (%) 13.5 17 pay back period 9 y 7 y


Ongoing activities

The work of the ENEA/Sotacarbo task force is progressing:

New experimental tests on different types of biomass and agricultural residues, and their mixtures with a strong effort focused on the characterization of the syngas production process

Design and implementation of a Mild Combustion System to burn and enhance the tar contained in the syngas and eliminate the costs related to its disposal.

Design and implementation of automatic feedstocks loading system.

Improve plant automation to reduce personnel costs for plant management.

Future developments include:

The optimization and the complete automation of the process.

The declared objective is to demonstrate a full concept 1MWe sized gasification plant, fed by coal and biomass, connected to the grid for power generation. This complete plant would be the FOAK running facility, which could be happily replicated by patenting and commercial activity, but also open to future research projects and programs in the field of coal and biomass gasification.


Conclusions

A task force dedicated to the start up and management of the gasification demonstration plant was set up with the participation of ENEA and Sotacarbo Staff.

The purpose of this work is to evaluate the financial and economic parameters

Economic results can be improved by new technical developments in order to reduce the capital cost (economically sustainable project) and operation cost.

The cost of fuel has an important influence on the COE costs of the plant, for this reason tests will be carried out with agricultural residues and other products (screws, rice husk, digestate)

The ultimate objective is to bring the process of R&D on a new level and to demonstrate the technical, operational and, definitely, economic feasibility of a complete 1 MWe Unit for energy generation based on biomass gasification


Thank you for your attention

[email protected]

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