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열적변환의 플랫폼 경제 분석
Economics of Thermal Conversion
Examining economics of syngas in an integrated process & biorefinery design
Examples of specific thermochemical products for which detailed designs exist:
• Biomass syngas to hydrogen (complete)
• Biomass syngas to mixed alcohols with separation of ethanol (on-going)
Performing A Detailed Design
Discounted Cash Flow Economic Spreadsheet
Product Selling Price
Process Flow Diagrams
Literature InformationCommercial Technology
DOE SponsoredResearch Results
(gasification/ gas clean up & conditioning)
Rigorous Material & Energy Balance
ASPEN Plus Software
Capital & Project Cost Estimation
Capital Costs from Other Studies
ICARUS Software Cost Estimation
Operating Costs Fixed & Variable
Intermediate Syngas Price –Targets & Barriers
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
Today SOT - Currentdesign
Gas clean up &conditioning - Goal
design
Feed handling &drying
Gasification Process integration
Inte
rmed
iate
cle
an, r
efor
med
syn
gas
pric
e ($
/MM
Btu
)
Research in this area results in the largest syngas cost reduction
$4.75 $5.25 $7.25 $3.93 $4.05
Plant size = 2,000 BD tonne/day
• DOE program targets based on intermediate syngas price to track progress toward reducing technical barriers
Decrease in syngas price due to increased yields, decreased capital costs, & efficiency gains
(2025)
(2010)
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
Current Design Goal Design
Inte
rmed
iate
cle
an, r
efor
med
syn
gas
pric
e ($
/MM
Btu
)
Fractional Conversion at 875oC
Model N1D1
Time, Hours
0 1 2 3 4 5
Fra
ctional C
onvers
ion
0.0
0.2
0.4
0.6
0.8
1.0
Methane
Benzene
Naphthalene
EthaneTar & Toluene
Current
Goal
Results from NREL’s PDU tar reformer
Tie in With Research
• Goal case yield is increased & capital cost is less
Potential Impact of Reformer Efficiency on Syngas Price
Attaining research goals = reduction in syngas price
Progression of Analysis
Progression of analysis toward integrated biochemical/thermochemical biorefinery design
Syngas ProductionBiomass Hydrogen
Mixedalcohols
Syngas ProductionBiomass
Biomass Sugar Production Ethanol
(integration)
Mixedalcohols
Syngas ProductionBiomass
• Using results of biomass to H2 detailed design to move forward for mixed alcohol detailed design
• Begin by building stand-alone mixed alcohol design
• Build off of stand-alone mixed alcohol analysis and stand-alone ethanol analysis to create a biochemical/thermochemical integrated biorefinery design
Biomass Gasification – Syngas to Products
• FY 2003 NREL’s preliminary screening study showed H2 to be technically and economically feasible product from biomass gasification
• H2 was picked as a model product to show effect of process integration & economics of a final product from biomass gasification
• Performed detailed process design and modeling using Battelle Columbus Laboratory (BCL) low pressure, indirectly-heated gasifier
Gas composition mol% (dry) H2 23.85
CO2 12.79 CO 42.18 CH4 15.36 C2H2 0.41 C2H4 4.35 C2H6 0.29 C6H6 0.13
tar (C10H8) 0.23 NH3 0.32 H2S 0.07
H2:CO molar ratio 0.57 Gasifier efficiency 72.1% HHV basis
71.8% LHV basis
Two designs examined based on catalytic tar destruction and heteroatom removal work at NREL:
• current design – defines today’s state of the technology
• goal design – shows the effect of overcoming R&D technical barrier
Compound Current GoalMethane (CH4) 20% 80%
Ethane (C2H6) 90% 99%
Ethylene (C2H4) 50% 90%
Tars (C10+) 95% 99.9%
Benzene (C6H6) 70% 99%
Ammonia (NH3) 70% 90%
Tar reformer conversion #’s
Syngas Clean Up & Gas Conditioning
Higher conversions for goal case; notably methane.
Both designs broadly consist of:
• feed handling, drying, gasification, gas clean up and conditioning, shift conversion, and purification integrated with a steam and power generation cycle
Current Goal
Tar reformer Bubbling fluidized bed with 1% per day catalyst replacement
Reactor vessel & catalyst regeneration
vessel operating isothermally
Steam methane reformer (SMR)
SMR downstream of sulfur removal
None (SMR eliminated)
Main design differences:
Biomass Gasification - Detailed Design
areas with significant heat recovery
• FT & mixed alcohols will have large amount of heat available in synthesis step due to exothermic reactions
Integration is Important
Syngas Production is Large Contribution to Product Price
• This is true of other products, not just H2
• An estimation of the syngas cost can be made and used as a benchmark……………however, it doesn’t make sense to look at just stand-alone syngas production because integration is important and a key to economical process designs
Case 2 - Direct: GTI, HGCU, ATR, shift, conv MeOH, stm turbine
Case 1 - Indirect: BCL, scrubbing, stmreformer, shift, conv MeOH, stm turbine
Clean, reformed syngas generation = 60-64% of total capital in thermochmeical conversion
feed prepgasificationO2 plant (Case 2 only)clean up & cooling
syngas compression (Case 1 only)reformingCO2 removalMeOH synthesis & compressionpower generation
7%
14%
15%
9%15%
9%
22%
9%8%
6%
19%
9%
22%
5%
27%
4%
From FY 2003 preliminary screening study
($/MMBtu, LHV)Current Goal
Intermediate syngas price 7.25 5.25
Stand-alone syngas price 8.67(20% higher)
7.10(35% higher)
Syngas Price – Integration Results & Lower Price
• More economical to build entire syngas generation to fuels production plant than to purchase syngas due to process integration advantages
• Completed analysis; NREL technical report available at www.nrel.gov/docs/fy05psti/37408.pdf
• Intermediate – Price of clean, reformed syngas in an integrated process.
• Stand-alone – Price of syngas with synthesis steps downstream of gas clean up & conditioning removed, natural gas used as fuel, and heat balance is reconfigured.
-$2.00 -$1.50 -$1.00 -$0.50 $0.00 $0.50 $1.00 $1.50 $2.00 $2.50
Cooling Water and OtherUtilities
Steam System and PowerGeneration
Steam Methane Reforming &BOP
Compression
Tar Reforming, & Quench &sulfur removal
Gasification
Feed Handling and Drying
Feedstock
Capital Recovery Charge Raw Materials Process ElectricityElectricity Generated Fixed Costs
syngas = $7.25/MMBtu
$2.45 $0.81
$1.15
$0.54
$1.47
$0.69
$0.67 -$0.69
$0.17
(34%)(11%)
(16%)
(7%)
(20%)
(10%)
(0%) Net
(2%)
-$2.00 -$1.50 -$1.00 -$0.50 $0.00 $0.50 $1.00 $1.50 $2.00 $2.50
Cooling Water and Other Utilities
Steam System and Pow erGeneration
BOP
Compression
Tar Reforming, & Quench & sulfurremoval
Gasif ication
Feed Handling and Drying
Feedstock
Capital Recovery Charge Raw Materials Process ElectricityElectricity Generated Fixed Costs
syngas = $5.25/MMBtu
$2.18 (42%)$0.72 (14%)
$0.60 (11%)
$1.02 (19%)
$1.49 (28%)
$0.04 (1%)
$0.70 -$1.77
(-20%) Net
$0.27 (5%)
Reforming cost is reduced and shifted to a different plant section
($0.64 vs $1.23/MMBtu contribution to syngas price)
Intermediate Syngas Cost Contribution –Current & Goal Design
Current Design
Goal Design
• Dec 2004 refocused thermochemical conversion to examine synergies & integration into a sugars biorefinery
• Mixed alcohols detailed design is a follow on to the biomass to H2study and validates initial December spreadsheet material balance & cost calculations
Mixed Alcohols Analysis
Ethanol via bioconversion
Corn Stover 2,000 dMT/day
Ethanol198,400 gpd
Lignin-rich Residue 600 dMT/day
Steam &Power
Gas-FiredCHP Plant
SyngasProduction Synthesis
Chemical Alcohols
11,800 gpd n-Propanol9,100 gpd n-Butanol
11,800 gpd Amyl/Hex Alcohols
Biomass Residues1,205 dMT/day
SyngasEthanol
98,000 gpd
Ethanol296,400 gpd
Any products from sugars will be made in both the sugars biorefinery and the Integrated Biorefinery.
Ethanol via bioconversion
Corn Stover 2,000 dMT/day
Ethanol198,400 gpd
Lignin-rich Residue 600 dMT/day
Steam &Power
Gas-FiredCHP Plant
SyngasProduction Synthesis
Chemical Alcohols
11,800 gpd n-Propanol9,100 gpd n-Butanol
11,800 gpd Amyl/Hex Alcohols
Biomass Residues1,205 dMT/day
SyngasEthanol
98,000 gpd
Ethanol296,400 gpd
Any products from sugars will be made in both the sugars biorefinery and the Integrated Biorefinery.
Stand Alone Mixed Alcohols
Feed Handling andConditioning Gasification
PreliminarySeparation
DriedBiomass
Ethanol
Biomass CrudeSyngas
Mixed AlcoholSynthesis
SyngasCompression
Tar ReformingAnd Scrubbing
Crude
ProductsH
igh PSyngas
ScrubbedSyngas
C3 +Alcohols
Mixed
Alcohols
Methanol
H2, CO, CO2, CH4
• First step, stand alone system
• Conducted literature search - gathered information including types of catalysts, yields, operating conditions, and syngas requirements
• H2:CO ratio is crucial; desired value of about 1
Stand Alone Mixed Alcohols
• Maximum hydrocarbon conversion in conjunction with optimal/most economical gas clean up and conditioning steps is challenging
• Selected modified FT catalyst (MoS2-variation) based on its ability to produce linear alcohols & higher sulfur tolerance
• Working on modifying biomass to H2 model for mixed alcohols production using BCL gasifier
• Milestone report due 7/18/05
Feed PrepBiomass
Dryer
Gasification (BCL, & cyclones)
Scrubber Syngas Compression
Char & Sand
Char combustor & cyclonesAir
SteamFlue gas
Tar reformer
Sand
Ash
Water
Totreatment SteamSteam
Reformer
LO-CAT
Sulfur
Amine System
CO2
Gas Compression
Mixed Alcoholssynthesis
Liquids
Mol sieve Separation EtOH
C3+ alcohols
Gas
MeOH
Steam to reformer
Steam to gasifier
DeaeratorIP LP VP
Cooling water
Process integration heat exchange
• Preliminary block flow diagram
• 20% single pass CO conversion
• 80% alcohol selectivity
• Recycle MeOH to extinction
purge to fuel
Stand Alone Mixed Alcohols -Simulation
Separation
Integrated Sugars/Thermochemical Biorefinery
LignocellulosicBiomass
Fermentation
Catalysis
Syngas Production
Sugar Production
Ethanol
Products:propanol, butanol
other alcohols
Lignin-rich Residues
Low QualityResidues
CHP Distillation
• Next step, in FY 2006 will combine mixed alcohols and ethanol stand alone systems to create an optimized biochemical/thermochemical biorefinery
Acknowledgements
Additional analysts:
Andy Aden
Tim Eggeman
Matt Ringer
Bob Wallace
John Jechura
Kelly Ibsen