Modelling and Process

Integration of Black Liquor

Gasification with Fischer-
Tropsch Synthesis

Niklas Berglin (STFI-Packforsk)

Black liquor colloquium

Jyvskyl 2006-08-02

Picture source: NSD

2006-07-28/ 1 turning science into reality

Chemical pulping process

Bleached Pulp yield:
softwood 43-44%
kraft pulp,
typical

Losses:
1-2%

Black Liquor: 55%

Source: Aker Kvaerner

2006-07-28/ 2 turning science into reality

1
 Chemical pulping process
Pulp
Bleached Value, ~500 EUR per
softwood tonne pulp
kraft pulp,
typical

Black Liquor
Value, ~100 EUR per
tonne pulp

Source: Aker Kvaerner

2006-07-28/ 3 turning science into reality

Chemical pulping process

Pulp
Bleached Value, ~500 EUR per
softwood tonne pulp
kraft pulp,
typical

Black Liquor
Future Value,
200-400? EUR per
tonne pulp
Source: Aker Kvaerner

2006-07-28/ 4 turning science into reality

2
 Projects
z BLGMF, Black Liquor Gasification with Motor
Fuels Production
Methanol/DME
z STFI-PF Biorefinery Cluster
Modelling of BLGFT
z BLGMF II
Synthetic diesel (Fischer-Tropsch)
z RENEW
DME in demo scale
z BLG program
Activities tied to DP-1 in Pite

2006-07-28/ 5 turning science into reality

Work method
Models (WinGEMS,
Reference mills
Aspen, HYSYS)
ST MIX

1 49
Stmi x14
Steam
Condensate
143 SPL IT
Excess steam Spl i t115
11 5

Terpentine condensor MT -steam

Lab data
For hot water production

P DRO P Steam
d r156
op 15
Smelt dissolver condensor
88 For hot water production
CNCG

1 44
SPL IT
Continous Digester

Spl i t33
di ssolving tank
vapour fr om

21 Flash Steam
33
24
To chi p bin Evaporators
Temp 147 C SPL IT
Recovery
Spl i t 150
15 0 boil er
Air
A CT I
Chemicals
23
31 Hot water ti in vapour
production Smelt dissol ver
M IX Green li quor
Mi x15 3 40 42 tank
1 53
4
cl ari fi er Ai r Fl ue gas
White Liquor Temp 151 C 36
M IX SPLIT MIX
Mi x 44 Sp l i t11 M i x1 20
6 TTA 147 g /l EA CT IO
M IX 44 113 120 11 6
Fl ash steam M i x5 0
3 eac46
ti o n
Whi te liquor to digester

50
M IX Fuel
M i x15 1 SPLIT Green liq uor 11 SP LIT Mud
151 Bypass Spl i t5
dr eg s
Spl i t14
washer
Soap 5
digester wash SPL IT
Slaker 13
Spl i t53
Condensate
53 Na2SO4 White li quor CaO make up uppdelat i pfg och CaO Lime kiln 14
Precipitants CNCG From mud wash
T A LL OI
Terpentin make up filter
10
35
Talloi l AL102
LO IL Lime mud To SDT
B N DSU LF
B nd sul f 118 From Cl O2 16 MIX SPLI T SPL IT MIX SPLI T 15 12
60
M 93
i x93 M 124
i x1 2
Producti on 92 32 20

118 1 H2SO4
Sulf 0.35 Lost l ime dust
MI X SP LIT SPLI T
Mi x 146 Spl i t3 0 125
NaOH Lime 0.9
ST OR E 14 6 30
EA 115.5
Temp 81 C

Sto r e1 32
EA 107.255 make up

WL Losses NaOH to
132
Whi te l iquor to chip and r est NCG scrubber
ST OR E Hot water
SP LI T
Sto r e 45 41
production Sur pl us Condensate: Sp l i t5 1
M IX
M i x2 To wash press
45 SPL IT Bypass digester wash 51
Spl i t13
13 0
2
Wet dryer vent
Fresh water
(If needed) Warm water
Temp 92 C

Broke
Steam i nto
Di ffuse gaseous emi ssions
Bl stank Steam box
W ASH
Wa sh10 0 Bl eached/ Unbleached MIX
M i x7 3

Cons: 2 Kraftpulp 1 40

DIL UT E SPL IT SP LIT

SPLI T pH:10 73
Spl i t 52
D i l u te11 1 Spl i t96 Sp l i t3 4 M IX M IX
76 81 70 SP LIT
1 05
Mi x85 Mi x 131
Spl i t211 Paper
1 11 96 34
52
136 Liner machine 1 04 Dryer 14 1

Hot stock refiner Final 85 1 31

75 2 11
1 00
Screening
InLine refi ner Diffuser Reject
Knots and final screeni ng
Leakag es (seal ing water etc)
screen rejects SPL IT
Spl i t1 01

Pickup water Broke

Leakag es wash. and dig dept. SP D N
101
74 NI
P D

Water in spillsystem Sump wi th conductivity

m easurement
SPLIT
Sp l i t5 6
Spil l
56
Sludge
To exter nal tr eatment Reject
ST M IX
St mi x 17 2
SP LI T Steam
Sp l i t1 60
17 2
M IX
160
Coarse screeni ng Fracti onation Short fibre Mi x13 4
RCF M IX SPL IT M IX
10 6

SP LI T 1 34
Recovered M i x9 5 Spl i t 90 Mi x 10 3
Sp l i t9 4
3% Di sperser
paper 95 18% 90 1 03
94
ST MI X M IX
Drum pul per 1 10 Stmi x 123 Mi x13 3

Long fibre 135

121 123 1 33

DAF
MI X
M i x 126 Refiner
12 6
Whi te water
D ILU T E
84
T SPD NIN from Liner
D i l ute 83
T SP D NIN G m aschine
86
83 55

White water
tank RCF
T o external treatment

Economic assessment Material and energy balances

(EUR/ADt)
15
Unbleached Bleached AIR SEPARATION METHANOL SYNTHESIS
10

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GASIFICATION SULFUR
turningRECOVERY
In

2004-09-21 / 6 science into reality

2006-07-28/ 6 turning science into reality

3
 BLGFT Concept
Raw Syngas Clean Syngas

Air Air S Removal Sulfur

FT Reactor
Separation & Recovery

Oxygen
Black
Liquor Steam
Gas Gas/Liquid
Gasification CO Shift
Cooling Sep

Smelt C5+
Weak
Wash CO2 Hydrogen
Smelt CO2 Hydro-
Dissolver Removal cracking

Green Off-Gas
Liquor
Pressure Auto- C1-C4 Naphtha
Swing thermal Distillation
Adsorption Reforming Diesel

Hydrogen Purge
Steam Oxygen Gas Wax

2006-07-28/ 7 turning science into reality

Process models

COMBINED
CYCLE

AIR MeOH/DME MILL STEAM

SEPARATION GAS CLEAN-UP
SYSTEM
AND
CONDITIONING
GASIFICATION/
GAS AND GREEN
LIQUOR COOLING
FISCHER-
TROPSCH

2006-07-28/ 8 turning science into reality

4
 Product composition FT

10%
Hydrocracker feed
9%
Shell data
8% Hydrocracker product

7%
Mass Fraction

6%

5%

4%

3%

2%

1%

0%
0 10 20 30 40 50
Carbon Number

2006-07-28/ 9 turning science into reality

Distillation curve for FT products

Calculated Distillation Curve for Hydrocracker Product

450
ASTM D86 C
400

350
Boiling Point (C)

300

250
360C
200
320C
150
295C
100
285C
50 180C

0
0 10 20 30 40 50 60 70 80 90 100
Mass Percent

2006-07-28/ 10 turning science into reality

5
 FT fuels from a 2000 ADt/d mill

FT-diesel
320 t/d
FT-
Black liquor naphtha
3400 tDS/d 160 t/d

2006-07-28/ 11 turning science into reality

Energy Balances

Fuel options Methanol DME FTD

Biomass consumption 414 MW 408 MW 378 MW
Black liquor consumption 487 MW 487 MW 487 MW
Fuel production, total 273 MW 275 MW 244 MW
Fuel production, total 410,600 t/year 286,000 t/year 109,700 t/year
(+56,200 t/year)
Energy efficiency (LHV): 33% diesel +
56% 56%
Black liquor to fuel 17% naphtha
43% diesel +
Biomass to fuel 66% 67%
22% naphtha

(Ekbom, Berglin, Lgdberg, 2005)

2006-07-28/ 12 turning science into reality

6
 Production Costs
Capital investment and BLGMF BLGMF BLGMF
Production costs Methanol DME FTD
Equipment and assembly M EUR 290 304 317
Total investment cost M EUR 345 361 375
Additional investment cost M EUR 174 190 205
Total additional capital cost M EUR/year 19.3 21.1 22.7
Total incremental operating cost M EUR/year 66.3 66.1 68.2
Total incremental cost M EUR/year 85.6 87.1 90.9
Production cost EUR /kWh 3.8 3.8 4.5b
Production cost EUR/GJ 10.5 10.6 12.4b
Production cost EUR/tonne 209 305 549b
Production cost, EUR /equivalent litre 32.8 36.4 42.8b
petrol/diesel equivalent litrea
Production cost, SEK/equivalent litre 3.1 3.5 4.1b
petrol/diesel equivalent litrea

(Ekbom, Berglin, Lgdberg, 2005)

2006-07-28/ 13 turning science into reality

Sasol, South Africa

97 gasifiers, 150 000 bpd, 200 products

2006-07-28/ 14 turning science into reality