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Industrial Gasification Implementation for Biomass

Industrial Gasification Implementation for Biomass. Presentation to Mosaic Company 22 May 2006. Presentation Objectives. Industrial Gasification – Wellman Galusha (commercial industrial gasifier reference ) HMI Background MIFGA Project Capital Steam Plant Study (USDOE)

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Industrial Gasification Implementation for Biomass

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  1. Industrial GasificationImplementation for Biomass Presentation to Mosaic Company 22 May 2006

  2. Presentation Objectives • Industrial Gasification – Wellman Galusha (commercial industrial gasifier reference ) • HMI Background • MIFGA Project Capital Steam Plant Study (USDOE) • HMI/ARI Collaboration • MIFGA Project HMI/ARI Heads of Agreement, 1998 • Coal gasification to MN Peat & Faggio wood gasification • Vision 21 Proposal Recap • HMI/ARI/CPM/Coen/EPRI

  3. Desired Outcome • Mosaic commit to Industrial Biomass Gasification for drying processes (displacing high cost natural gas) • Define Objectives and begin Site specific Feasibility Study – June 2006 • Develop Hot-Raw Wood Gasification plant to be on-line in early 2007 fueling Mosaic’s dryers

  4. Industrial Gasification • Wellman Galusha gasifier reference • HMI personnel have 50+ years of industrial operational experience with W-G gasifier • W-G gasifier operated worldwide commercially from 1930’s to 1960’s (principally gasifying coals) • MIFGA project (1981-85) quantified gasifier performance, efficiency & gas cleaning

  5. Justification for Small Industrial Gasifiers • Cost and availability of waste wood in Florida • Cost of HMI wood Gasification system applied to industrial dryers & other thermal processes • Clean utilization of industrial waste (will further enhance the economics)

  6. MIFGA Project1981-1984 • Scope Driven by the energy economics and gas curtailments in the mid 70’s and early 80’s, industry and the US DOE needed to demonstrate the gasification performance of US coals in a proven industrial gasifier (single-stage fixed bed gasifier)

  7. MIFGA ProjectProcess Flow Schematic

  8. MIFGA ProjectCoals Gasified

  9. MIFGA ProjectOperations • Continuous 10-day runs (minimum) for each fuel gasified • Continuous process monitoring and raw fuel gas sampling • Process operations limits quantified throughout each test • 203 days of continuous gasifier operation on 15 different coals/fuels

  10. MIFGA ProjectContinuous Gas Sampling

  11. MIFGA ProjectTarDroplet Size Distribution

  12. MIFGA ProjectTar/Oil Yield Correlation

  13. MIFGA ProjectTar/Oil Quality (HHV)

  14. MIFGA ProjectBarrel Quantities of Tar • Enlarged tar removal and collection system was designed and operated to recover gallon-quantities of tar and oil • Tar/oil collection efficiency greater than 99.99% • Established foundation for complete gas cleanup system with 99.99% removal efficiency

  15. MIFGA ProjectSingle Stage Gasifier Schematic

  16. MIFGA ProjectImpact on Capital Steam Plant Study • KY coal gasification performance quantified • Product gas quality known • Coal liquids quantified • System performance & economics quantified • Environmental impact known • O&M known

  17. Capital Steam PlantHMIGasification Economics Gasifier Island $18.8 million Net Power 40.3 MWe Gasifier Island installed @ $466/KW

  18. MIFGA ProjectARI selected HMI Gasifier • Gasifier design and performance demonstrated (fuel flexible) • High gasification conversion efficiency (80-85%, gas+liquids) • Simple and reliable gasifier operation • Flexible fuel experience and knowledge • HMI O&M capabilities desired by ARI • HMI gas cleaning technology & experience

  19. Ansaldo RicercheContracts/Collaboration • Early 1998 ARI began evaluating mild gasification technologies worldwide • Late 1998 ARI selected HMI, Inc. as technical partner • December 1998 Signed HEADS of the AGREEMENT

  20. Ansaldo RicercheContracts/Collaboration • Q1 2000 HMI, Inc. Biomass Gasifier design completed • Q2 2001 HMI/ARI gasifier fabrication and installation completed • July/August 2001 HMI commissioned 1.3m HMI/ARI gasifier • Started on coke • Initial biomass faggio (beech wood) chips • Commissioning complete success

  21. HMI/ARI Gasifier • Performance: • 1.3 Meter Diameter • Coal throughput: • 0.7-1.0 T/hr • Clean gas: • 14-16 MM/BTU/hr • Electrical output: • 0.7-1.0 MWe

  22. HMI/ARI Gasifier • R&D Activities: • Flexible fuel pellet development • Automatic bed level and fuel feed • Automate grate drive and ash management • Process control via continuous gas analysis • Gas cleaning for both fuel cell & gas engine implementation

  23. HMI/ARI GasifierFaggio Woodchip Feed

  24. MN Peat pellets (MIFGA) • Excellent gasification performance • Hot-raw gas yields 92% conversion efficiency ( 60 MMBtu/hr/10-ft dia unit) • Mosaic/HMI will establish integration and utilization of Hot-raw gases in dryers • Degree of gasifier automation will be jointly defined by HMI & Mosaic

  25. MN Peat Pellets Proximate & Ultimate Analyses Proximate Analysis (%)Ultimate Analysis (%) Volatile Matter 42.20 Carbon 34.30 Fixed Carbon 16.10 Hydrogen 3.50 Ash 7.30 Nitrogen 1.60 Moisture 34.40 Sulfur 0.20 Sulfur 0.20 Oxygen 18.70 Ash 7.30 Moisture 34.40

  26. MN Peat Pellets Proximate & Ultimate Analyses Heating Value: 6,092 BTU/lb Ash Fusion Temperatures (Deg F) OxidizingReducing Initial deformation 2135 2050 Softening 2155 2085 Hemispherical 2205 2100 Fluid 2220 2135 Free Swelling Index (FSI): 0

  27. MIFGA ProjectMN Peat pellets Product Gas Dry Gas Composition (Mol %) Hydrogen 17.20 Carbon Monoxide 28.40 Methane 1.46 Ethane 0.10 Ethylene 0.087 Propane 0.024 Propylene 0.04 Carbon Dioxide 7.97 Nitrogen & Argon 44.3 Dry Gas HHV 168 Dry Gas LHV 158

  28. MIFGA ProjectMN Peat pellets Design Performance MN Peat gasification throughput (120 lb/hr/sq-ft grate) Air/Peat 1.29 lb/lb Steam/Peat 0.19 lb/lb Saturation Temperature 139 ºF Gas Offtake Temp 251 ºF Gas Dewpoint 153 ºF Tar Yield 7.9 lb/100 lb-peat Tar HHV (dry) 15,552 Btu/lb Tar Pour point 110 ºF Tar Specific gravity (60/60 ºF) 1.0491

  29. Vision 21 Overall US DOE Goal: Effectively eliminate, at competitive costs, environmental concerns associated with the use of fossil fuels.

  30. Vision 21 Goals • Efficiency – Electrical generation 60% for coal-based systems • Environmental – <0.01 lb/MMBtu sulfur & NOx <0.005 lb/MMBtu particulate <50% emission rates organic compounds <1 lb/trillion Btu, Hg 50% reduction in CO2 via efficiency gains • Costs – Must be cost competitive • Timing – Major improvements by 2007

  31. Vision 21 Proposal Objectives • Demonstrate fuel flexibility (coal & biomass) • Demonstrate nominal $0.00 cost for industrial fuel pellets • Utilize air blown fixed-bed industrial gasifier • Clean gas for fuel cell or gas engine operation • Gas used for various power generation systems (0.5 – 10MWe) • Demonstrate 50+% efficiency using fuel cells for power generation

  32. Vision 21 ProposalIndustrial Gasification Economic Objectives • Coal/Biomass pellets cost < $0.00 • Industrial gasifier island installed for < $500/KW • Operational costs at industrial site < $50/Kwyr • Clean fuel gas cost < $3.00/MMBTU

  33. Vision 21 ProposalThree Phase Project • Phase I Coal/Biomass pellet development • Phase II Demonstrate gasification performance of best commercial pellets • Phase III Demonstrate gas cleaning & fuel cell performance/efficiency

  34. Vision 21 ProposalHMI/CPM Pellet Development • Car fluff and coal pellet development

  35. Action Plan(HMI & Mosaic) • Scope & Begin Feasibility Study for waste wood by 12 June 2006 and complete by mid August 2006 (8 weeks) • Begin Permitting Process by First of September 2006 • Deliver Hot-raw Gas to Mosaic’s dryer by end of August 2007

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