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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




                                                                                                                1
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                                       Temperature: 200-300 °C
                                              Torrified
 Biomass              0.3     0.1             biomass             Pressure: near atmospheric
     1                                          0.7
                     Torrefaction                                       Absence of oxygen
     1                                          0.9
                                                                         Product: solid fuel

                                             0.9                Particle size < 4 cm thickness
Energy densification (E/kg)            1             = 1.3
                                             0.7
                                                                   Residence time 10-30 min

                 mass               energy                          Heating rate: <50 °C/min



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




                                                                                                                                         2
From biomass/waste to commodity fuels
Woody biomass        Agricultural residues
                                                                           Friable and less fibrous
                                                                           19 - 22 MJ/kg (LHV, ar)                            Superior fuel properties:
                                                                                 Hydrophobic                                  • Transport, handling, feeding
                                                                                  Preserved
                                                                          Reduced contaminant level                           • Milling
                                                                                Homogeneous                                   • Combustion/gasification
                                                                                                                              • Feedstock bandwith
                                                                                                                              • Standardisation
                                  Torre
                                       fac
                                   pulve tion and
                                        risati
Mixed                                          on
waste
                                                                                                                    Pelle
       Tenacious and fibrous                                                                                             tisati
                                                                                                                                  on
                                                                                Fuel powder
      10 - 17 MJ/kg (LHV, ar)
            Hydrophilic
    Vulnerable to biodegradation
           Contaminated                                                                               Bulk density 750-850 kg/m3
          Heterogeneous                                                                             Bulk energy density 15-20 GJ/m3                      Fuel pellets


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




                                                                                Hemicellulose              Lignin            Cellulose
Decomposition regimes
                                                                                   Extensive
                                                                                                              E                    E
                                                                    300          Devolatilisation                                                            300
                                                                                      and

                                                                                 carbonisation
                                                                                      (E)
                                                                                                                                   D
                                                                                                                                          TORREFACTION




                                                                    250                                       D     D                                        250
                                                                                    Limited
                                                                                 devolatilisation
                                                 Temperature (°C)




                                                                                                                                                                   Temperature (°C)




                                                                                      and
                                                                                carbonisation (D)                                  C


                                                                    200                                                                                      200

                                                                                                              C
                                                                                depolymerisation
                                                                                      and
                                                                                 recondensation
                                                                                       (C)
                                                                    150                                                                                      150

                                                                                                       glass transition/           A
                                                                                                        softening (B)

                                                                                   drying (A)
                                                                                                              A
                                                                    100                                                                                      100
                                                                                Hemicellulose              Lignin            Cellulose




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




                                                                                                                                                                                      3
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




                                                                                                       4
5 kg/h screw
          Proof-of-concept approach                                                        reactor



                                                   Pellet press (batch)             Pellet quality
             Continuous screw
             reactor (pyromaat)
                                     Torrefied
Biomass                              biomass
                Batch reactor                            Cutting mill                Grindability


                TGA analysis
                                                   Lab-scale combustion
                                                      Simulator (LCS)
                                                                                    Combustibility
                           Torrefaction
                           gas

               Sampling methods                                                                                                   20 l batch reactor


                                                                                                                  Process
                                                                                    Torrefaction
              Analysis methods                                                                                   simulation
                                                                                     database
                                                                                                                     &
                                                                                                                design tools
      Product distribution (M & E yields)



 9 Meeting Cargill, 15 May 2006           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 ºC
                                                               Torrefaction
                                                              32 min, 260 ºC
                    Feed: Willow                                                                             Torrefied Willow
                  Size: 10 - 30 mm                                                                           Size: 10 - 30 mm
                LHV = 14.8 MJ/kg (ar)                                                                     LHV = 18.5 MJ/kg (ar)
                    MC = 14.4%                                                                                  MC = 1.9%
                                                           Mass yield: 75.3% (ar)
                Fixed carbon: 16.8 %                                                                       Fixed carbon: 22.1%
                                                          Energy yield: 94.3% (ar)



 10
  Meeting Cargill, 15 May 2006            Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                                                                       5
Grindability of (torrefied) biomass
                                               90                                                                                                               360
                                                                                       C(270,21)
                                               80                                      C(280,18)                                                                320
                                                                                       C(290,12)
                                               70                                                                                                               280
            Power consumption (kWe/MWth)




                                                                                       W(290,24)
                                                                                       W(260,24)




                                                                                                                                      chipper capacity (kWth)
                                               60                                                                                                               240
                                                                                       Willow (MC=10-13%)
                                               50                                      Willow (dried)                                                           200
                                                                                       Cutter wood
                                               40                                      AU bituminous coal                                                       160
                                                                                       Borssele run
                                               30
                                                                                       demolition wood
                                                                                                                                                                120
                                                                                       D(300,11)
                                               20                                                                                                                   80

                                               10                                                                                                                   40

                                           -                                                                                                                    -
                                                    -                  0.5                     1.0                 1.5                                                   -        0.2      0.4     0.6      0.8         1.0
                                                           average particle size (mm, volume based)
                                                                                                                                                                             average particle size (mm, volume based)


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


      11
       Meeting Cargill, 15 May 2006                                                       Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                           Torrefaction of willow (280 oC, 17.5 min)                                                                                                               100%

                                           Product distribution                                                                                                                                                               mass
                                                                                                                                                                                                                              composition
                                                                                                                                                                Permanent gases                    75%
                                                                                                                                                                                                                              energy
           94.9
100                                                                                                                                                                                                                           composition
        87.5
90                                                                                                                                                                                                 50%
                                                                                 Mass y ield
80
                                                                                 Energy y ield
70
                                                                                                                                                                                                   25%
60
50
                                                                                                                                                                                                    0%
40
                                                                                                                                                                                                            CO      CO2       Other
30
20                                                                                                                            Organics
                                                                                        8.0
10                                              1.4 0.1      1.7 1.6     1.4 3.4                        70%
 0                                                                                                      60%                                                                                                                     mass composition
         Solid                                 Permanent    Organics         Lipids    Reaction         50%                                                                                                                     energy composition
                                                    Gas                                  Water
                                                                                                        40%

       Main product groups (dry basis)                                                                  30%
                                                                                                        20%
                                                                                                        10%
                                                                                                         0%
                                                                                                                               ol




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      12
       Meeting Cargill, 15 May 2006                                                       Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                                                                                                                                                                     6
Combustion reactivity of torrefied wood
                                      Lab-scale Combustion Simulator
                                      experiments
                                           high-volatile coal                        low-volatile coal                           torr. (300° demolition wood
                                                                                                                                            C)
                                           HVC (LOI)                                 LVC (LOI)                                   torr. (300° demolition wood (LOI)
                                                                                                                                            C)
                                           torr. (280° prune wood
                                                      C)                             torr. (280° prune wood (LOI)
                                                                                                C)                               torr. (280° demolition wood
                                                                                                                                            C)
                                           torr. (280° demolition wood (LOI)
                                                      C)                             prune wood (fresh)                          prune wood (fresh, LOI)

                                 100

                                 90
conversion [%] or LOI [% d.b.]




                                 80

                                 70

                                 60

                                 50

                                 40

                                 30                                                            High reactivity for
                                 20                                                             torrefied wood
                                 10

                                  0
                                       0                     500                     1000                      1500                     2000                   2500
                                                                                               time [ms]


                                 13
                                  Meeting Cargill, 15 May 2006                 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


                                 14
                                  Meeting Cargill, 15 May 2006                 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




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


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




          ECN directly heated torrefaction technology
                                                            Air
Features:
                                                            Utillity fuel
• High energy efficiency (> 90%)
• Heat integration                                                                                                                  Flue gas

• Conventional drying and
  pelletisation
                                                                                                      Combustion
• Compact moving bed
                                                          Torrefaction
  technology                                                 gas
                                                                                       Gas
• Cost effective                                                                      recycle

                        Biomass                                                                                                                                 TOP pellets
                                         Drying                    Torrefaction                                      Cooling                   Pelletisation



                                                                                            ∆P


                                  Flue gas
               15-20%                                             Heat exchange
                                                                                                         Flue gas
               moisture




  16
   Meeting Cargill, 15 May 2006              Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                                                                                              8
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



17
 Meeting Cargill, 15 May 2006               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

                              5
                TCI (MEuro)




                                                                                                   Drying
                              4
                                                                                                   Torrefaction

                              3                                                                    Size Reduction and Pelletisation
                                                                                                   Storage
                              2                                                                    Indirect Cost
                                                                                                   Working Capital
                              1

                              0
                                    TOP Process             Conventional Pelletisation




18
 Meeting Cargill, 15 May 2006               Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                                                      9
Total production cost (TOP pellets vs. wood pellets)
                                                                 4,0


                                                                 3,5

                  Production Cost Indication (Euro/GJ product)
                                                                 3,0


                                                                 2,5


                                                                 2,0


                                                                 1,5


                                                                 1,0


                                                                 0,5


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

                                                                       Total Cost                          Other                                 Power
                                                                       Support Fuel                        Personnel                             Maintenance
                                                                       Depreciation and Financing          Feedstock (=0 Euro/tonne)




 19
  Meeting Cargill, 15 May 2006                                                      Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




         Chain study (TOP pellets vs. wood pellets)

                                                                                     TOP process
    Sawdust                                                                                                                                      Logistics
                                                                                     (South Africa)
0.7 EUR/GJ                                                                                                                           <2.0 EUR/GJ
                                                                                2.0 EUR/GJ
                                                                                                                                                                          <4.7 EUR/GJ

            Favourable                                                                                                                                                    (Co-)firing
                                                                                                                                                                  coal-fired power stations
            economics!                                                                                              Higher co-firing capacity
                                                                                                                                                                 or entrained-flow gasifiers
                                                                                                                    Lower capital investment
                                                                                                                    Higher co-firing flexibility                     North-West Europe
                                                                                                                        and availability

                                                                               2.3 EUR/GJ                                                                                 5.9 EUR/GJ
0.7 EUR/GJ                                                                           Conventional                                   2.9 EUR/GJ
    Sawdust                                                                           Pelletisation                                              Logistics
                                                                                     (South Africa)


 20
  Meeting Cargill, 15 May 2006                                                      Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                                                                                                               10
Road map ECN TOP technology development


     capacity                                                               5-10 kg/h                     100 kg/h             20 kton/a            60-100 kton/a

      Green                          Proof-of-                                                           Prototype             Technical             Commercial
                                                                        Proof-of-concept
     biomass                         principle                                                          (pilot-scale)        demonstration          demonstration

       Time                        2002             2003           2004           2005           2006           2007         2008            2009          2010

                                    Proof-of-                                                                              Prototype             Technical
      Waste                                                                        Proof-of-concept
                                    principle                                                                             (pilot-scale)        demonstration




Proof-of-concept                                       Prototype (pilot-scale evaluation)                          Technical demonstration
•Experimentally based process design                   •Pilot plant / prototype technology                         •Demonstration plant (semi-commercial)
•Technology identification                             •Demonstration technical feasibility                        •Technical feasibility (refined design)
•Knowledge base torrefaction                           •Process and product characterisation (design data)         •Product applications (large scale)
•Experimental infrastructure torrefaction              •Economic evaluation full-scale                             •Economic evaluation full-scale
•Economic evaluation full-scale                         (preliminary estimate 20%)                                  (definite estimate <10%)
 (study estimate 30%)                                  •Business plan(s)                                           •Business plan(s)
•Set-up pilot phase of development                      (technical demo, semi-commercial)                           (commercial operation)



 21
  Meeting Cargill, 15 May 2006                   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


 22
  Meeting Cargill, 15 May 2006                   Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                                                                                    11
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



23
 Meeting Cargill, 15 May 2006       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




24
 Meeting Cargill, 15 May 2006       Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel




                                                                                                          12

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Torrefaction technology by ECN

  • 1. 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 1
  • 2. 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 Temperature: 200-300 °C Torrified Biomass 0.3 0.1 biomass Pressure: near atmospheric 1 0.7 Torrefaction Absence of oxygen 1 0.9 Product: solid fuel 0.9 Particle size < 4 cm thickness Energy densification (E/kg) 1 = 1.3 0.7 Residence time 10-30 min mass energy Heating rate: <50 °C/min 4 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 2
  • 3. From biomass/waste to commodity fuels Woody biomass Agricultural residues Friable and less fibrous 19 - 22 MJ/kg (LHV, ar) Superior fuel properties: Hydrophobic • Transport, handling, feeding Preserved Reduced contaminant level • Milling Homogeneous • Combustion/gasification • Feedstock bandwith • Standardisation Torre fac pulve tion and risati Mixed on waste Pelle Tenacious and fibrous tisati on Fuel powder 10 - 17 MJ/kg (LHV, ar) Hydrophilic Vulnerable to biodegradation Contaminated Bulk density 750-850 kg/m3 Heterogeneous Bulk energy density 15-20 GJ/m3 Fuel pellets 5 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel Hemicellulose Lignin Cellulose Decomposition regimes Extensive E E 300 Devolatilisation 300 and carbonisation (E) D TORREFACTION 250 D D 250 Limited devolatilisation Temperature (°C) Temperature (°C) and carbonisation (D) C 200 200 C depolymerisation and recondensation (C) 150 150 glass transition/ A softening (B) drying (A) A 100 100 Hemicellulose Lignin Cellulose 6 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 3
  • 4. 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 4
  • 5. 5 kg/h screw Proof-of-concept approach reactor Pellet press (batch) Pellet quality Continuous screw reactor (pyromaat) Torrefied Biomass biomass Batch reactor Cutting mill Grindability TGA analysis Lab-scale combustion Simulator (LCS) Combustibility Torrefaction gas Sampling methods 20 l batch reactor Process Torrefaction Analysis methods simulation database & design tools Product distribution (M & E yields) 9 Meeting Cargill, 15 May 2006 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 ºC Torrefaction 32 min, 260 ºC Feed: Willow Torrefied Willow Size: 10 - 30 mm Size: 10 - 30 mm LHV = 14.8 MJ/kg (ar) LHV = 18.5 MJ/kg (ar) MC = 14.4% MC = 1.9% Mass yield: 75.3% (ar) Fixed carbon: 16.8 % Fixed carbon: 22.1% Energy yield: 94.3% (ar) 10 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 5
  • 6. Grindability of (torrefied) biomass 90 360 C(270,21) 80 C(280,18) 320 C(290,12) 70 280 Power consumption (kWe/MWth) W(290,24) W(260,24) chipper capacity (kWth) 60 240 Willow (MC=10-13%) 50 Willow (dried) 200 Cutter wood 40 AU bituminous coal 160 Borssele run 30 demolition wood 120 D(300,11) 20 80 10 40 - - - 0.5 1.0 1.5 - 0.2 0.4 0.6 0.8 1.0 average particle size (mm, volume based) average particle size (mm, volume based) Torrefaction leads to a dramatic decrease in required milling power and increase in milling capacity 11 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel Torrefaction of willow (280 oC, 17.5 min) 100% Product distribution mass composition Permanent gases 75% energy 94.9 100 composition 87.5 90 50% Mass y ield 80 Energy y ield 70 25% 60 50 0% 40 CO CO2 Other 30 20 Organics 8.0 10 1.4 0.1 1.7 1.6 1.4 3.4 70% 0 60% mass composition Solid Permanent Organics Lipids Reaction 50% energy composition Gas Water 40% Main product groups (dry basis) 30% 20% 10% 0% ol r ol te ol de id de id e n he ton an en yd no an eta ac Ac hy hy Ot ce eth Ph eh ta th ic lac lde lde c me ya bu eti ion ald M thy ra eta ox 2- Ac 2- fur op Fu y- Me dr n- Ac Pr 2- ox 2- Hy ra yl - dr Fu eth Hy 1- M 5- 12 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 6
  • 7. Combustion reactivity of torrefied wood Lab-scale Combustion Simulator experiments high-volatile coal low-volatile coal torr. (300° demolition wood C) HVC (LOI) LVC (LOI) torr. (300° demolition wood (LOI) C) torr. (280° prune wood C) torr. (280° prune wood (LOI) C) torr. (280° demolition wood C) torr. (280° demolition wood (LOI) C) prune wood (fresh) prune wood (fresh, LOI) 100 90 conversion [%] or LOI [% d.b.] 80 70 60 50 40 30 High reactivity for 20 torrefied wood 10 0 0 500 1000 1500 2000 2500 time [ms] 13 Meeting Cargill, 15 May 2006 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 14 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 7
  • 8. TOP pellets vs. wood pellets Properties unit Wood Torrefied biomass Wood pellets TOP pellets low high low high Moisture content % wt. 35 3 7 10 1 5 Calorific value (LHV) dry MJ/kg 17.7 20.4 17.7 17.7 20.4 22.7 as received MJ/kg 10.5 19.9 15.6 16.2 19.9 21.6 Mass density (bulk) kg/m3 550 230 500 650 750 850 Energy density (bulk) GJ/m3 5.8 4.6 7.8 10.5 14.9 18.4 Pellet strength - - Good Very good Dust formation Moderate High Limited Limited Swelling / Water Limited swelling / Hygroscopic nature Water uptake Hydrophobic uptake Hydrophobic Biological degradation Possible Impossible Possible Impossible Seasonal influences High Poor Moderate Poor (noticable for end-user) Handling properties Normal Normal Good Good 15 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel ECN directly heated torrefaction technology Air Features: Utillity fuel • High energy efficiency (> 90%) • Heat integration Flue gas • Conventional drying and pelletisation Combustion • Compact moving bed Torrefaction technology gas Gas • Cost effective recycle Biomass TOP pellets Drying Torrefaction Cooling Pelletisation ∆P Flue gas 15-20% Heat exchange Flue gas moisture 16 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 8
  • 9. 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 17 Meeting Cargill, 15 May 2006 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 5 TCI (MEuro) Drying 4 Torrefaction 3 Size Reduction and Pelletisation Storage 2 Indirect Cost Working Capital 1 0 TOP Process Conventional Pelletisation 18 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 9
  • 10. Total production cost (TOP pellets vs. wood pellets) 4,0 3,5 Production Cost Indication (Euro/GJ product) 3,0 2,5 2,0 1,5 1,0 0,5 0,0 Green Wood Saw Dust 47 MW / 47 MW / 47 MW / 47 MW / 47 MW / Pellets Pellets 75 kton/a 75 kton/a 75 kton/a 36 kton/a 112 kton/a MC = 50% MC = 35% MC = 25% MC = 35% MC = 35% BASE CASE Total Cost Other Power Support Fuel Personnel Maintenance Depreciation and Financing Feedstock (=0 Euro/tonne) 19 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel Chain study (TOP pellets vs. wood pellets) TOP process Sawdust Logistics (South Africa) 0.7 EUR/GJ <2.0 EUR/GJ 2.0 EUR/GJ <4.7 EUR/GJ Favourable (Co-)firing coal-fired power stations economics! Higher co-firing capacity or entrained-flow gasifiers Lower capital investment Higher co-firing flexibility North-West Europe and availability 2.3 EUR/GJ 5.9 EUR/GJ 0.7 EUR/GJ Conventional 2.9 EUR/GJ Sawdust Pelletisation Logistics (South Africa) 20 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 10
  • 11. Road map ECN TOP technology development capacity 5-10 kg/h 100 kg/h 20 kton/a 60-100 kton/a Green Proof-of- Prototype Technical Commercial Proof-of-concept biomass principle (pilot-scale) demonstration demonstration Time 2002 2003 2004 2005 2006 2007 2008 2009 2010 Proof-of- Prototype Technical Waste Proof-of-concept principle (pilot-scale) demonstration Proof-of-concept Prototype (pilot-scale evaluation) Technical demonstration •Experimentally based process design •Pilot plant / prototype technology •Demonstration plant (semi-commercial) •Technology identification •Demonstration technical feasibility •Technical feasibility (refined design) •Knowledge base torrefaction •Process and product characterisation (design data) •Product applications (large scale) •Experimental infrastructure torrefaction •Economic evaluation full-scale •Economic evaluation full-scale •Economic evaluation full-scale (preliminary estimate 20%) (definite estimate <10%) (study estimate 30%) •Business plan(s) •Business plan(s) •Set-up pilot phase of development (technical demo, semi-commercial) (commercial operation) 21 Meeting Cargill, 15 May 2006 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 22 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 11
  • 12. 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 23 Meeting Cargill, 15 May 2006 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 24 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel 12