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158 Evaluation of Opportunities for Converting Indigenous UK Wastes to Wastes and Energy AEA/ED45551/Issue 1 Figure 20 Gasifier used at Lahti Bioflow, Värnamo, Sweden Bioflow Ltd (a joint venture of Foster Wheeler and Sydkraft) has operated a demonstration plant producing approx. 6 MWe and 9 MWth for district heating. This plant has been operated using a variety of fuels, including RDF, but it is likely that the system will be targeted at biomass fuels. It is included here as an example of the concept of integrating gasification with combined cycle power generation to achieve higher electrical conversion efficiencies. The operating temperature of the gasifier is 950-1000°C at an approximate pressure of 20-22 bar. The gasifier system is based on the CFB principle (see Figure 20) with integrated cyclone and cyclone return leg. The three parts (gasifier, cyclone, cyclone return leg) are totally refractory lined. Following the cyclone, the fuel-gas produced is led to a cooler and a hot gas filter. The gas cooler is of a fire tube design and cools the gas to a temperature of approximately 350°C prior to entering the filter. Following the filter the fuel-gas is burned in the combustion chambers of a single shaft industrial turbine (Alstom Typhoon). The hot flue gas from the gas turbine is ducted to the heat recovery steam generator. This process has the potential to deliver the highest electrical efficiency of all the options described here (40%). To do this however would require a suitable waste treatment plant to remove and recycle plastics and metals and supply a consistent fibrous fuel. SVZ Swartzepompe, Saxony, Germany This large chemical complex was built originally to convert brown coal into a range of chemicals and fuels as part of the energy system of the former DDR (East Germany). With reunification the plant was successfully modified to accept industrial and domestic waste. In its current configuration it comprises seven fixed bed, steam/oxygen blown gasifiers operating at 25 bar and fed by a mixture of waste and coal. The complex also includes two oxygen-blown, entrained flow gasifiers that accept liquid and slurry
Evaluation of Opportunities for Converting Indigenous UK Wastes to Wastes and Energy AEA/ED45551/Issue 1 wastes. The company has plans to complete the installation of a larger fixed bed British Gas/Lurgi slagging gasifier. The medium CV product gas is cleaned and used to generate electricity, through a combined cycle using a 44 MWe Alstom Turbine and a 30 MWe steam turbine. There are plans to synthesise methanol to enhance the degree of recycling that can be achieved in the installation. Current capacities are • Plastics 5 tonnes/hr • Wood 6 tonnes/hr • Liquid waste 200 tonnes/day • Domestic waste 20 tonnes/ hr All residues leave the site as inert slag This project represents a technically viable waste disposal and energy complex on a very large scale. It is an engineering success that combines a high degree of material recovery with a high electrical efficiency. It did however make substantial use of the existing brown coal processing plant so replication may prove difficult. Choren, Freiberg, Germany CHOREN Gmbh have been developing a process to produce a renewable fuel compatible with the diesel fuel infrastructure that uses lignocellulose materials. The concept is to gasify biomass and use the resultant gas as a feedstock to synthesise alkanes using the Fischer Tropsch reaction. The process for the gasification of wood and similar materials is based on an entrained flow gasifier used for brown coal in the 1980’s in the former DDR. The gasification process comprises two steps, slow pyrolysis of chipped material followed by the oxygen gasification of the tar vapours and char produced. The oxygen gasifier is interesting in that it is arranged in two stages; the first gasifies the pyrolysis vapours in oxygen and the second gasifies the char by reaction with the product gases from the first stage, having first been finely ground. A consequence of the second reaction is that the gasses are cooled by the endothermic reaction of char with CO2. The synthesis gas from the gasifier is essentially free from tar contamination and can be cleaned by filtration before the CO/H2 ratio is adjusted using the CO shift reaction. CO2 is then removed by scrubbing and the gas passed further into the Fischer Tropsch reactor to form a product mixture of diesel oil and naphtha. The first installation was a pilot, or alpha, plant which operated from the mid 90’s to 2005 and had a fuel input of 1MW. The second, or beta, installation is a demonstration with a fuel input of 45MW and is just undergoing commissioning and testing near Freiberg in Saxony. The third installation, or sigma, is a full scale commercial unit of 640 MW which is in the design phase and should enter service in 2015. The overall energy balance of the beta demonstration unit is predicted to convert 100% fuel energy value to 39% diesel, 13% naphtha, and 6% export electricity giving an overall efficiency of 58% fuel to energy product. This is expected to improve with scale up. The development of the process is being supported by a consortium of Daimler Chrysler, Shell, Volkswagen, and others with assistance from local German authorities and the EU. 292 292 Start-up of the first commercial BTL production facility. Lecture by Dr. Christoph Kiener, Project Development Manager at the 16th European Biomass Conference & Exhibition, 3. June 2008, Valencia. www.choren.com 159
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