Process Design Methodology for Thermochemical Production of ...

5 downloads 20083 Views 8MB Size Report
performance of fuel production from biomass and stresses the importance of ... à l 'exemple de la production de Gaz Naturel de Synthèse (GNS) par gazéi ..... process design methodology (Douglas, ½ ), the block flow diagram of the conversion ...
Process Design Methodology for Thermochemical Production of Fuels from Biomass. Application to the Production of Synthetic Natural Gas from Lignocellulosic Resources

THÈSE NO 4693 (2010) PRÉSENTÉE LE 25 JUIN 2010 À LA FACULTÉ SCIENCES ET TECHNIQUES DE L'INGÉNIEUR LABORATOIRE D'ÉNERGÉTIQUE INDUSTRIELLE PROGRAMME DOCTORAL EN ENERGIE

ÉCOLE POLYTECHNIQUE FÉDÉRALE DE LAUSANNE POUR L'OBTENTION DU GRADE DE DOCTEUR ÈS SCIENCES

PAR

Martin Gassner

acceptée sur proposition du jury: Prof. D. Bonvin, président du jury Dr F. Maréchal, directeur de thèse Prof. R. Gani, rapporteur Prof. W. Marquardt, rapporteur Prof. A. Wokaun, rapporteur

Suisse 2010

                                                                                  !       "    #    "              $                $ % #           $    $    &     $'                                   $   $                       "  (                                                          

                     $ % 



                      ) ( * +                )        ) )   ,     )    )  )#        ))    )  - .+      /    * !  /)# "         )    /)"    )   0   ) )#  )   *    )   ))     ) . )  ))  .  $ %     ) "  ) )       "   )        )    *  .)       %    1 )    ) )     * )   . )  )) %  2   )       ))   )  ,         )) #     .)   ) )   .  "  )) 3    )    )         ))  )  "        * )   * (  )    * )      #           -        .      )    ))

  

       )) )   ))  ) ) )  )  ))  ) )   $ %



       4   4    5 6 7)                     "       8  "                                             % .    .      (  (   ,    7   ((,7$(8!       4   4     %  4                5  %      9   7 7//      5 :                            8   4        "                      ;          , 94    ;                    ; +   



 < 5  < 5  =

 =

  

−1 dry −1 dry

;     2   =

9   =

  =

3   =

Δh0  /   + (     

   +

0   '+        '   '  + +  



 7         



 $        "     5                                                     $    



#     

                       ,      %    "#   !     +!      ( #                         "   5     "                     ;       +           (?2  $#                          /          !   '     #                                    #               8                   #                9 >      !                                                        ---

"$  

"               4         +   + #        ;        "   

   "    "         $         ;       #            +       (             3     !       +  "                  "#   ,   & "                    "        "  3    #   "+         7        

 .  * ,      T "       T ,      "       9           = 4.  7         !      :      1       9          = 3 1    =# = 1      9     Δh  4             7                       ?        !  -       =      7    2 1     ?  #  2 829

 ?       7    

  7> >       7      2  29    =#     @      2     9    2 1          #   1 2 829  2 82 2 83    1 9 829   !&  #   5   A >     9       

  6  -     = '   6    $          #             4      5      10   air,out

H2O,sat

2

0 wood

−3 gas

−1

2

2

2

4

4

2

2

2

2

2

4

2

2

4





2

−1

,     

 Up           Δplm   #   $ '     J Δplm =

Δp1 − Δp2 ln(Δp1 /Δp2 )

!

   Δp1   '            Δp2      Up   "           5%    !       11.16 · 10−3 −1     (                     .                  ;           UT                 J Δhvap m ˙ H2O,vap = UT ΔT lm ! m ˙ steam

UT   "      $       9 # >  !        B 4−1 @−1                       th,d    "       e+d   #   "                          , !    #      4          ,  !J th,d = e+ d =

Δhvap m ˙ H2O,vap ˙ Q+ d E˙ + d m ˙ H2O,vap

!  !

5                       &            th,d               H         +             H    5    "                    4B 4−1 H2O, vap  -- -

"$  

      4    +        4    $   $    

     &    )*+    &            

80

400 Air drying Steam drying Thermal drying efficiency Specific energy consumption

300

60

200

εth,d [%]

e+d [kJ/kgH2O,vap]

70

50 160

180

200

220

100 240

Inlet temperature [°C]

 '     -    .      /

        





;    +  0   9 / !          "                               '             #     &                  "+       #   ;         !!              "+   &  "             #      7        1    ! 0      ?  B !   0>   8  !  "+       I                          #  B    3  8    9  !    /  !          # "      0     !           ! @  !    !       #                  '  ΔT eq     J ˆ p = Kp (T g + ΔT eq ) K

!

 Kp            Kˆ p      #      +        " 

,     

 T g     J  j

Kp (T ) = exp 

nj g˜0j (T ) − ˜ RT

n

pj j ˆ  Kp = ni i pi

i

ni g˜0i (T )



!  !

j

 n          i    ˜    j p    g˜         R    ;              82 (? (?2 (84 (2 84 82? 2        ( !                            ;   '         "  !  !       !   $   !                   ;             "        82   (?   (?2 (84 (284   =          = ( !              "  82 (84 (2 84   ( !   +    &  "      1     9 -    !      "           "  (?   (?2 9 -    !     "  +  #   (?2    (?          !  '      +        +   

                          (?2  ;     '                            &      4                                  "   +  ,  !     (84$                                               '          -        f (i, t ) = a + a t + a t + a t + a t   !$      



r

0

1 r

2 2 r

3 3 r

4 4 r

    J m ˙ i,out = f (i, tr1 )m ˙ i,in  m ˙ i,rec = f (i, tr2 )m ˙ i,in − m ˙ i,out

 tr2 = (1 − tr1 )tr2 + tr1

 !  !

 f (i, tr )          i        tr       ;             0 /4   8   !                      f (i, tr )       th        5   5               $"      0   1 !                  ;  +                            (  ;     0;          "        ;!    $+    7B 4−1       ! H2O   $   ,+                 2        Φ + =   T +  '   '    1  1 1 1 4.  '         62       2              4.  

9 9 8             +       4    4       

1       1 1 1  1 1 1 7> 1 2 1 # > 2  # 1 1 1 = 1      7          '      341 "   0  E '> 0  2 1 # 7> 1     7    1   29 1 #  = = 9 1        p             4  .       = 29   5 7    #    T +           ;    #                  2    #       7           #     ,    -      

     &    )*+    &            

                          "          7    -             /



   +           "      H 3                           # "               "  

         7,9      4 E 7    7> 7   



2





T d,in T d,in pd Φd,wood T t,in T t,out Tg pg Tg pg rS/B T g,ph T m,in T m,out pm Ws,n rCO2,rem rCH4 pP SA psel Asel

 5, 3 = =   1



−3



C C

B C B  C B C B C  B C B C

B B



8

  pm  pm                 

  1



 =



* 8?  B  C B  C B C B  C B  C

; 

 7  .           #      

2

        >             7  9       6          '    7  '    7          8       6          7  , 6  > 2  #    #  >     2   >   

       +   )   /'    012  )        012  ) (      

4   

'   >         1   '      '   4.  6    62  "   2  1        6    

   "  

    

















Ws,n θ1 θ2 pf 1 pf 2 pf 3 sin,2 ps,p T s,s N s,u T s,u3 T s,c

; 

5, 3 1 1    1  1 −3

* 8?  B  C B C B C B C B C B C B C B C B  C B C B C B C

7  .           #      





        , 6                                       7      7           ;      3       #  '         #  2    #    

'     

)           , 

  '/              !    )

  5

   4   

# 1       

    



    

;   (             #      "                             ?               &    %                       #   "             ;                        "        #       $    5           $                %             $ % $    +          %    #                 #   '    1//  1//   '         ! ;       %                                           5                 chem    $         "   ,  !        %   #   ;    %  "     cGR             ,  !       J cGR =

C GR 0 Δhbiomass m ˙+ biomass

!

         %   7)     !             7 #              62 





                     "     (                        "      "          $         #    $    0   400°C)

Combustion

air

1 bar, >900°C +

Q (180°C)

H2O(v) 0.42 kg/s 300°C

Wood Steam drying

Q+ (900°C) 4.2 MW

char: 1.8 MW 0.05 kg/s

Gasification

20 MWth 5 bar, 180°C, 10%wt 1.19 kg/s 100°C 2.15 kg/s H2O(l) Φ=50% 0.96 kg/s

1 bar, 850°C

3.1 MW 0.21 kg/s

19.6 MW 1.56 kg/s 850°C

-

Q (800-150°C)

Gas cooling and cold cleaning

400°C H2O(v) 0.44 kg/s 399°C

Q (400°C) air 320°C +

Q (181°C)

Wood Steam drying

H2O(v) 0.42 kg/s 300°C

H2O(v) 0.20 kg/s 344°C

-

Q (800-344°C)

Gasification

20 MWth 5 bar, 181°C, 10%wt 1.19 kg/s 30 bar, 800°C 100°C 2.15 kg/s H2O(l) Φ=50% O2 0.96 kg/s 0.26 kg/s (278 kWel)

17.4 MW 1.87 kg/s 800°C

Hot gas cleaning

Q (900°C

fumes/CO2 1.23 kgCO2/s

depleted stream 1.18 kg/s

-

Methanation 17.4 MW 1.87 kg/s 344°C

Combustion

15.7 MW 1.49 kg/s 25°C

3+1 membranes SNG & compressions 13.6 MW hydrogen 0.01 kg/s recycling

0.30 kg/s 25°C, 50 bar

( *   '    





,





 

th,biomass

   0        

          .  

"  

      $       #              "      (        $ %#          0$ &                               "       #                             "  +            "           # "        0   5(5 $                     

    

                    "   ;                                ;                                  #     ?                      H   "      "  $      5                 "             ;                       $    #              5      5(5 "                     3        (5# $? "               "                                                                     3                 "   '     "    "



 

#               0   #    # 

  #        !"     #            $                                  %                #                     1                 #             #       #        *   



  

8 "                        "#                4              4      #                             "                          7     ! @  ! ,  !   0    !                          ,+ # 

1             )*+    

  T T #  !       H  >  > ?   6  ( <     3 7     # 9   #        /           1:  #  1    /

  6 @ 7       6          -            #         !2   ? 7  O   9  !   3 5 9!3             1      6 @   !   /   2  > 7  !    !2>7!  %           4 ?  2      )O#  O $  O O '   7 2



2

  

2 ( 

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

  

9  5 2 3 : > 7 2 ; 9    9   7    '        T                 #    '    !23 7

 3    9  5 2 3 : > 7 2 ; 9    9  7    '        T                 #    !    H

 9  5 2 3 # 9:  5 4 : > 7  !      /  @ '  1        1   1   1        H  9 5  ; >     K ( 5  2   4     >  7                             #     7          H  

  

9  9 ?        .     /  $  >         H 9  1' (   (           *  ' /

$       ,  3  K5        .          / .      H  (  >  9     .              -     ' 6      2  !   %   7   , !   36' 2   , 5 36'             %    7  , * : , 7  * "     !

 " 2 3    4 4 (  > >      >    3 7 > :  2  9  "   /      -        1         

 1            2    2  ! /

  '     H  7    %  #   1   $      6    !    2         H 7 

   > *   %   ? 7 L   >   > *   7 *   '    *   7 *   '   /  4N             2 '   9 * /   ( ( ? %   ?    .     297  4   H            6 @  , 2     '   !     !   6    2 7 /

  ?  ?  ? " ,  '                 2  !     7      H  ?    ?                  6 @      !22   ?    ?  4  4      @ 4               5 6 @ ;

)           

 !    , 1*29 ?$  917 %    7  "5  H>         

     4, H48!   H    ?  2   9  )           /             #      #     1  # 8    9   1:  #     #        5       > !     H  

  

 

     4  L (       " "    .     '  ?  "!1 213' ; "    !      7 2 9  5 2 3 # 9 #    ?   !              ' $     #  .         H  '  "  ?    9  %

 >  !#       1:  # /                 !    H  '  , 7     4      /          7  9 3  K5 ; 41"  >              ,  3  K5 ; 4 " * #  7 '  2           >      !    7    3  9  ;7 %%2  # 8 8  8   ;  , 4  ( %

 9  '    (  /       !      !   !    5     1 '      16    N ;  1    1  ! /  5 *   ?#   4                 

     7     H  ,O  2 ?   >   9              @       '   

H ,  4   *1$ $ J6 >               2      H  ,  6   # 8    K5 (  ?E" ?    " #         /       !   H  I ? L  9 4  9  ? % 

  ,M  7    5/   # !   5 @  5      #    &  '      %      '     ?   !7>     I   O  4   7O 1% #  I W , ?  I K  K #  "  7                             !       H  I   K  K % ' ?  I  ;    $            '    H I  ? , ?    9  9 -  1       3  4 34   1'  '         !       H  

 

   $   

     #      '                  !"     -      .  +  +             '            2       

       $    +   -            *         )3      



.         

heat recovery from humid air air Td,in

humid air wet wood (chipped)

dried wood Φd,wood

rotary air dryer

 $ + ' heat recovery from excess steam

wet wood (chipped & pressurised)

dried wood Φd,wood fixed bed steam dryer, pd superheated steam, Td,in

(  + ' torrefaction gas & steam

torrefaction gas, to combustion

dried wood Φd,wood waste water, to treatment torrefied wood

torrefaction unit Tt,in

     



> '         



producer gas, to gas cooling & cleaning

flue gas

cyclone

hot bed material

dried (& opt. torrefied) wood

additional fuel, chosen by MILP

fluidised bed gasification char, to combustion

air preheating fluidised bed combustion

steam generation

ash

 2   +   '/    " : $       0    ( 

 '/              '+4!   2             '   +  '/ ?            '+

'     (+ 2% 34       



%             #            3       #                -  +     $   .  %  %  $                   3    '               *              /           '                      /    #        4  

        4         4 .

   $             '    #         $      

           

           $         #          *    #      



!       

2000

2200 5 MW, optimised 20 MW, optimised 100 MW, optimised 5 MW, downscaled from 20 MW 100 MW, upscaled from 20 MW

Specific investment cost [EUR/kW]

Specific investment cost [EUR/kW]

2200

1800

1600

1400

1200

1000

800 56

58

60

62

64

66

68

70

72

2000

5 MW, optimised 20 MW, optimised 100 MW, optimised 5 MW, downscaled from 20 MW 100 MW, upscaled from 20 MW

1800

1600

1400

1200

1000

800 66

74

68

SNG efficiency equivalent [%]

70

72

74

76

SNG efficiency equivalent [%]

 < $ 2200

Specific investment cost [EUR/kW]

Specific investment cost [EUR/kW]

2200

2000

1800

1600

1400

5 MW, optimised 20 MW, optimised 100 MW, optimised 5 MW, downscaled from 20 MW 100 MW, upscaled from 20 MW

1200

1000

800 62

64

66

68

70

72

2000

1800

1600

1400

1200

1000

800 64

74

5 MW, optimised 20 MW, optimised 100 MW, optimised 5 MW, downscaled from 20 MW 100 MW, upscaled from 20 MW

66

SNG efficiency equivalent [%]

68

70

72

74

76

74

76

SNG efficiency equivalent [%]

( 7       34       '> '         # * ,9* ,    #  

, 

  α 2 #  #       -

α    # δ '5       Δh %      # ˜ Δh          Δh 9   #  Δk !  # Δp 7   ΔT '    &    $ ΔT       ΔT ?         !  -   2  -  ε  -  ε 2  #  -  η !  -  0 0 r

vap 0

eq

min ref

cg

cc



5,8 ( 1 A 5 #              62                            >#             &  .  /

         1             

 7 1    @ 2   2 1 #       .                     ?                   .                      1      62  .              0          ,         .                1      2 1 .       

     0          ,           .             

 5 0          .      

                       

                       /

                                     

 2         2  29                                            

2

2

th,biomass

th,biomass

2



4

   

                 

                              

     $             #        #           /                                 

 7   #        #          $    =  -         

    -          #  

    #                       

 4  #     -    .           #    5       

     1    1&             ,                            

    1    1&              ,                             

         1    1&   ,  

 !#       .    7    /            ,                                          > '                                > 4.                                 > 4                                    >                 :   

> 34                                 62  .                             62  .                           2 1 .                            2 1 .                         2 7  hT 1.                      2 6 0              2 829 1                



th,biomass

th,biomass

th

th

2

4



&  !               /                                        *   α   &      α  ΔT  b      7                     4.                            4      5      10     ?                         ?   .                       >                                                       7           #             ;      -     #         

  "     . #                                              ?         $            ,                                                        ?                              4.                                5                                 !                                

  !     -                       

  !             .    62  .                                    "      34                  

  2   0  #       34       2         34              j

ref

th,wood



ref

HE

   

     



    





    



 













'                            4     $                         7                           "  #                       "  #  :  #         5 /                -          

"  #  :  #         5 /                             "  #  :  #         5 /          22        /                                        -    &    #/

                           

7  .           #    /                                      ?            .      !                               "  #            

 .    62  .             "  #            

 .      2 1 .                                        4     .           #/                                  '              34     '       -       0       #                          "  #              ./

                                 "  #             ./

    ,        51 #         #       #                                   "  #             ./

    ,        51 #         #       #                                  "  #             ./

    ,        51 #         #       #                                    

2

chem

th,biomass





th,biomass





th,biomass



   

 "  #             ./        51 #   

    ,      #       #    /                               

  ?            .     

 7           5                 2 ?  #             2 129                                



th,biomass

2



4





  

        3   (/  ( 

7 ;,9    1    R&

%' ) 

=

 



=



  

= =

!

03   1     ,   ,  0   5))   1  ,051!  /   9  A4  1  4    #   B  9  J 0          9   1     ,   ,051 ,+           #         $       4 





7        ,051  /   ,+    (  C        



         ,(?     M# $                 M M, M$      :  7   ,051