Torrefaction for biomass upgrading into commodity fuels

Jaap Kiel
IEA Bioenergy Task 32 workshop Fuel storage, handling and preparation and system analysis for biomass combustion technologies, Berlin, 7 May 2007

Presentation overview
ECN Torrefaction principles ECN TOP technology Economics Development status and market implementation

2 Meeting Cargill, 15 May 2006

Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Energy research Centre of the Netherlands

in the dunes of North Holland
ECN develops high-quality knowledge and technology for the transition to a sustainable energy supply and brings it to the market

Independent energy
research institute

650 staff Annual turnover:

80 million EURO

Activities:
- Biomass, Solar, Wind - Fuel Cell Technology - Clean Fossil Fuels - Energy Efficiency - Policy Studies

3 Meeting Cargill, 15 May 2006

Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Torrefaction for biomass upgrading general process description

Gas Biomass

0.3

0.1

Torrified biomass

Temperature: 200-300 C Pressure: near atmospheric Absence of oxygen Product: solid fuel

1 1

Torrefaction

0.7 0.9

Energy densification (E/kg)

0.9 0.7

= 1.3

Particle size < 4 cm thickness Residence time 10-30 min Heating rate: <50 C/min

mass

energy

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

From biomass/waste to commodity fuels

Woody biomass Agricultural residues Friable and less fibrous 19 - 22 MJ/kg (LHV, ar) Hydrophobic Preserved Reduced contaminant level Homogeneous

Mixed waste

Torre fac pulve tion and risati on

Superior fuel properties: Transport, handling, feeding Milling Combustion/gasification Feedstock bandwith Standardisation

Tenacious and fibrous 10 - 17 MJ/kg (LHV, ar) Hydrophilic Vulnerable to biodegradation Contaminated Heterogeneous

Fuel powder

Pelle tisati

on

Bulk density 750-850 kg/m3 Bulk energy density 15-20 GJ/m3

Fuel pellets

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Decomposition regimes
300

Hemicellulose
Extensive Devolatilisation and carbonisation (E)

Lignin E

Cellulose E

300

D D TORREFACTION 250 Temperature (C)

250 Temperature (C)

Limited devolatilisation and carbonisation (D)

C 200 C

200

150

depolymerisation and recondensation (C) glass transition/ softening (B) drying (A)

150 A

A 100 Lignin Cellulose

100 Hemicellulose

6 Meeting Cargill, 15 May 2006

Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Starting points ECN TOP technology development (1)

Torrefaction (combined with pelletisation) has the potential of becoming a key unit operation in biomass upgrading schemes for a wide range of applications, including: Biomass storage and (long-distance) transport biomass import Co-firing in pf boilers (Co-)firing in entrained-flow gasifiers for producing power (IGCC) or transportation fuels (e.g., Fischer-Tropsch diesel) Small-scale pellet boilers and stoves

Torrefied biomass pellets may become a biomass commodity fuel

7 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Starting points ECN TOP technology development (2)

Torrefaction principle not new, but many aspects relevant to application for upgrading biomass into biomass fuel for thermal conversion processes were not addressed, including: Scale of operation in relation to reactor technology and process layout Characterisation and quantification of product quality and how this relates to process conditions Nature and quantity of emissions Prospects of heat integration including utilisation of the energy containing torrefaction gases The economic viability of torrefaction as a biomass upgrading technique for bulk applications

2002 start ECN TOP technology development

8 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Proof-of-concept approach

5 kg/h screw reactor

Continuous screw reactor (pyromaat) Biomass Batch reactor TGA analysis

Pellet press (batch) Torrefied biomass

Pellet quality

Cutting mill

Grindability

Torrefaction gas Sampling methods

Lab-scale combustion Simulator (LCS)

Combustibility

20 l batch reactor Process simulation & design tools

Analysis methods

Torrefaction database

Product distribution (M & E yields)

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Torrefaction Typical experimental results

Gas phase composition CO 0.1 % CO2 3.3 % H2O 89.3 % acetic acid 4.8 % furfural 0.2 % methanol 1.2 % formic acid 0.1 % remainder 1.0 %

Tad = 1045 C

Torrefaction 32 min, 260 C

Feed: Willow Size: 10 - 30 mm LHV = 14.8 MJ/kg (ar) MC = 14.4% Fixed carbon: 16.8 % Torrefied Willow Size: 10 - 30 mm LHV = 18.5 MJ/kg (ar) MC = 1.9% Fixed carbon: 22.1%

Mass yield: 75.3% (ar) Energy yield: 94.3% (ar)

10 Meeting Cargill, 15 May 2006

Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Grindability of (torrefied) biomass

90 C(270,21) 80 70 60 50 40 30 20 10 0.5 1.0 1.5 average particle size (mm, volume based) C(280,18) C(290,12) Power consumption (kWe/MWth) W(290,24)

360 320 280 chipper capacity (kWth) 240 200 160 120 80 40 0.2 0.4 0.6 0.8 1.0 average particle size (mm, volume based)

W(260,24) Willow (MC=10-13%) Willow (dried) Cutter wood AU bituminous coal Borssele run demolition wood D(300,11)

Torrefaction leads to a dramatic decrease in required milling power and increase in milling capacity

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Torrefaction of willow (280 oC, 17.5 min) Product distribution

Permanent gases
100 90 80 70 60 50 40 30 20 10 0 Solid Permanent Gas Organics Lipids Reaction Water 1.4 0.1 1.7 1.6 1.4 3.4 8.0
70% 60% 50% 40% 30% 20% 10% 0%

100% mass composition energy composition 50%

75%

94.9 87.5 Mass y ield Energy y ield

25%

0% CO CO2 Other

Organics
mass composition energy composition

Main product groups (dry basis)

M eth an ol

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Ph en ol Pr op ion ic ac Fu id ra n2me 5M th eth an yl ol 2fur ald eh yd e Ac eta lde hy de Me thy lac eta te

2Fu ra lde hy de Hy dr ox ya 1ce Hy ton dr ox y2bu ta no n

Ac eti c

Ot he r

Ac

id

Combustion reactivity of torrefied wood Lab-scale Combustion Simulator experiments

high-volatile coal HVC (LOI) torr. (280 prune wood C) torr. (280 demolition wood (LOI) C) low-volatile coal LVC (LOI) torr. (280 prune wood (LOI) C) prune wood (fresh) torr. (300 demolition wood C) torr. (300 demolition wood (LOI) C) torr. (280 demolition wood C) prune wood (fresh, LOI)

100

conversion [%] or LOI [% d.b.]

90 80 70 60 50 40 30 20 10 0 0 500 1000 1500 2000 2500

High reactivity for torrefied wood

time [ms]

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Semi-industrial pelletisation tests

Features: 10 kg/h No automatic moisture supply

Preliminary findings:
Easy pelletisation Low energy input required Pellet quality strongly dependent on pelletisation conditions

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

TOP pellets vs. wood pellets

Properties Moisture content Calorific value (LHV) dry as received Mass density (bulk) Energy density (bulk) Pellet strength Dust formation Hygroscopic nature Biological degradation Seasonal influences (noticable for end-user) Handling properties MJ/kg MJ/kg kg/m3 GJ/m3 17.7 10.5 550 5.8 Moderate Water uptake Possible High Normal 20.4 19.9 230 4.6 High Hydrophobic Impossible Poor Normal 17.7 15.6 500 7.8 17.7 16.2 650 10.5 Good Limited Swelling / Water uptake Possible Moderate Good 20.4 19.9 750 14.9 22.7 21.6 850 18.4 Very good Limited Limited swelling / Hydrophobic Impossible Poor Good unit % wt. Wood Torrefied biomass 35 3 Wood pellets low 7 high 10 TOP pellets low 1 high 5

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

ECN directly heated torrefaction technology

Features: High energy efficiency (> 90%) Heat integration Conventional drying and pelletisation Compact moving bed technology Cost effective
Biomass Drying Torrefaction Cooling Pelletisation Air Utillity fuel Flue gas

Combustion Torrefaction gas Gas recycle TOP pellets

P Flue gas

15-20% moisture

Heat exchange Flue gas

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

ECN torrefaction technology Innovative moving bed reactor

Compact reactor Small footprint High heat transfer rates Accurate T-control Uniform product quality Feedstock flexibility Low capital investment

Pilot-scale torrefaction reactor at ECN

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Total capital investment study estimate (TOP pellets vs. wood pellets)
Total Capital Investment TOP and Pelletisation (Feedstock: 180 kton/a woodchips @ 50%mc) 8 7 6 TCI (MEuro) 5 4 3 2 1 0 TOP Process Conventional Pelletisation
Drying Torrefaction Size Reduction and Pelletisation Storage Indirect Cost Working Capital

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Total production cost (TOP pellets vs. wood pellets)

4,0

Production Cost Indication (Euro/GJ product)

3,5

3,0

2,5

2,0

1,5

1,0

0,5

0,0 Green Wood Pellets Saw Dust Pellets 47 MW / 75 kton/a MC = 50% 47 MW / 75 kton/a MC = 35% BASE CASE 47 MW / 75 kton/a MC = 25% 47 MW / 36 kton/a MC = 35% 47 MW / 112 kton/a MC = 35%

Total Cost Support Fuel Depreciation and Financing

Other Personnel Feedstock (=0 Euro/tonne)

Power Maintenance

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

Chain study (TOP pellets vs. wood pellets) Sawdust

0.7 EUR/GJ
TOP process (South Africa) Logistics

2.0 EUR/GJ

<2.0 EUR/GJ

<4.7 EUR/GJ
(Co-)firing coal-fired power stations or entrained-flow gasifiers North-West Europe

Favourable economics!

Higher co-firing capacity Lower capital investment Higher co-firing flexibility and availability

2.3 EUR/GJ 0.7 EUR/GJ

5.9 EUR/GJ
2.9 EUR/GJ
Logistics

Sawdust

Conventional Pelletisation (South Africa)

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

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Road map ECN TOP technology development

capacity Green biomass Time Waste Proof-ofprinciple 2002 Proof-ofprinciple 2003

5-10 kg/h Proof-of-concept 2004 2005 2006

100 kg/h Prototype (pilot-scale) 2007

20 kton/a Technical demonstration 2008 Prototype (pilot-scale) 2009

60-100 kton/a Commercial demonstration 2010

Proof-of-concept

Technical demonstration

Proof-of-concept Experimentally based process design Technology identification Knowledge base torrefaction Experimental infrastructure torrefaction Economic evaluation full-scale (study estimate 30%) Set-up pilot phase of development

Prototype (pilot-scale evaluation) Pilot plant / prototype technology Demonstration technical feasibility Process and product characterisation (design data) Economic evaluation full-scale (preliminary estimate 20%) Business plan(s) (technical demo, semi-commercial)

Technical demonstration Demonstration plant (semi-commercial) Technical feasibility (refined design) Product applications (large scale) Economic evaluation full-scale (definite estimate <10%) Business plan(s) (commercial operation)

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

ECN TOP technology development 2007 activities

Pilot-scale testing Validation of reactor and process concept Optimisation of process conditions for a broad feedstock range Industrial pelletisation tests Extensive quality evaluation TOP pellets
(e.g., hygroscopic nature, biodegradation, strength, milling characteristics, combustion/gasification reactivity)

Demonstration plant basic design Business plan for technical demonstration(s) through BO2 Energy Concepts Continued basic R&D (co-operation with TU Eindhoven) Contaminated biomass (residues) and waste
40-100 kg/h torrefaction pilot-plant at ECN

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In conclusion

ECN TOP technology allows cost effective production of commodity fuels from a wide range of biomass/waste feedstocks with a high energy efficiency (>90%) ECN TOP fuels show:
High energy density High water resistance No/Limited biological degradation Excellent grindability Good combustion properties

Fields of application:
Long distance biomass transport Co-firing in pf boilers (Co-)firing in entrained-flow gasifiers Small-scale pellet boilers/stoves

In 2007 pilot-plant testing and initiation of demo-projects

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

For further information please contact:

Dr.ir. Jaap Kiel e: kiel@ecn.nl t: +31 224 56 4590 w: www.ecn.nl ECN P.O. Box 1 NL 1755 ZG Petten the Netherlands

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Torrefaction for biomass upgrading into commodity fuels Jaap Kiel

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