Cumulative cash flow [M€]

Basis of Design

CPD 3309

Design of a life-cycle chain from biomass to syngas through large-scale of gasification

6 August 2004

• BOD

• Tools

• Evaluation

• Conclusion

Basis of Design:

Basis of Design:

Evaluation

Several unit operations differ from the winning case of SUSDAT. The Basis of Design differ in:

• Cyclone  Candle Filter

• Syngas cooler for high heat transfer

• WGS after hot gas cleaning  Sour WGS before desulphurizers • ‘Hot gas cleaning’ NH₃/HCl scrubber + active coal filter

• Low pressure (1 bar)  Moderate pressure

BOD Tools Evaluation Conclusion Recommendation

503 298 1 503 298 1 1 7 1173 206 7 1173 206 212 1180 6.4 212 212 1180 6.4 6.4 217 816 21 217 217 816 21 21 25 214 761 25 214 761 17.5 229 297 17.5 229 297 40.5 231 405 40.5 231 405 234 368 40.1 234 234 368 40.1 40.1 233 368 1 233 233 368 1 V201 R201 R202 E201 R203 R204 R205 C201 C202 S202 Wood pellets Oxygen Oxygen Syngas to SMDS Carbon dioxide S201 R206 221 773 20.5 221 221 773 20.5 20.5 204 613 7.5 204 613 7.5 7.5 283 1 201 283 1 1 201 1 504 298 1 504 298 7.5 209 640 7.5 209 640 213 474 6.3 213 213 474 6.3 6.3 219 773 21 219 219 773 21 21 E202c E202b K201 K202 K203 FC FC LC LC TC TC FT FT RC RC PC PC PC PC DPC DPC 211 211 TC TC FC FC LSLS HS HS FC FC SP=1163K PT PT TT TT CC CC Computer TC PT PT TT TT CT CT FC FC RC RC FT FT FC FC DPT DPT TC FC FC FC FC 222 773 20.5 773 222 20.5 FT LT DPT DPT DPT DPT TT TT Electricity Electricity PC PC X201 DPC DPC V202 Pulse gas 208 1173 7 208 208 1173 7 7 235 500 40 235 235 500 40 40 40.5 232 368 40.5 232 368 E203 <222> <226> RC RC 226 298 20.4 226 298 20.4 PC PC 220 1023 21 220 220 1023 21 21 15.5 223 773 15.5 223 773 21 218 773 21 218 773 237 500 40 237 237 500 40 40 Syngas to Claus plant 236 500 40 500 236 40 TC TC <222> <226> CW

Evaluation

Major Equipment Cost Review

BOD Tools Evaluation Conclusion Recommendation

Chipper Pelletiser

Circulating Fluidised Bed Candle filter

Monolith Tar Cracker

Sour Water-Gas Shift Reactor Bulk desulphuriser + regenerator Ultra desulphuriser

Ammonia/HCl Scrubber CO2-selective Membrane Compressor

Air separation plant Claus plant

Waste water treatment Steam turbine

Storage tank Syngas cooler Active coal filter bed

Evaluation

Project cash-flow diagram

BOD Tools Evaluation Conclusion Recommendation

-12000 -10000 -8000 -6000 -4000 -2000 0 2000 0 5 10 15 20 25 Time [years] Cumulative cash flow [M€]

Evaluation

Sensitivities Analysis

BOD Tools Evaluation Conclusion Recommendation

12% -5% 1% 0% 4% 8% -10% -5% 0% 5% 10% 15% -1 0 % va rian ce in pa ra met e r

% change in Cash Flow

capital charges price CFB price waste price wood price syngas

Evaluation

Proposed Cost Reduction

• A decrease in major equipment cost • An increase in syngas price

• Income from selling CO₂ allocation • A decrease in capital charges

• An increase in plant energy efficiency

• Taxes reduction and more governmental contributions

Evaluation

• Sustainable design

• Large capacity

• Less waste compared to normal refinery

• Diesel future standards

• Robust due to two separate trains of process

Achieved with:

• Sustainability tools

• Group creativity methods

• Experts and excursion

Evaluation

Conclusion

• High-quality and robust design, because the

specification from the clients is accomplished

Impurity Removal Level Achieved level

H2S + COS+ CS2 < 1 ppmV 998 ppbV

NH3 + HCN < 1 ppmV 625 ppbV

HCL + HBr + HF < 10 ppbV 9 ppbV

Alkaline Metals < 1ppbV Essentially zero

Solids (soot, dust, ash) Essentially completely Essentially zero

Organic compounds (tars including BTX) Below dew point Below dew point

Class 2 tars: phenol, pyridine, thiophene < 1ppmV ~ 0

Objectives Desired level Achieved level

Production rate 334 kg/s 340.9 kg/s H2/CO ratio Inerts 2 below 5% 2.0 3.5%

Recommendation

• Synergy with the surrounding plants in the “Tweede

Maasvlakte”

• Improving the economic feasibility by CO

sequestration and governmental contributions (taxes)

• Flexibility of the gasification towards the feedstock

• Kinetic modelling for CFB and monolith tar cracker

Basis of Design

CPD 3309

Design of a life-cycle chain from biomass to syngas through large-scale of gasification

6 August 2004