Torrefaction for biomass upgrading into commodity fuels

Jaap Kiel
IEA Bioenergy Task 32 workshop “Fuel storage, handling and preparation and system analysis for
biomass combustion technologies”, Berlin, 7 May 2007

Presentation overview

• ECN
• Torrefaction principles
• ECN TOP technology
• Economics
• Development status and market implementation

2 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 Energy research Centre of the Netherlands
in the dunes of North Holland

ECN develops high-quality knowledge and technology

for the transition to a sustainable energy supply and
brings it to the market

• Independent energy
research institute
• 650 staff
• Annual turnover:
80 million EURO
• Activities:
- Biomass, Solar, Wind
- Fuel Cell Technology
- Clean Fossil Fuels
- Energy Efficiency
- Policy Studies

3 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Torrefaction for biomass upgrading

general process description

Gas Temperature: 200-300 °C

Torrified
Biomass 0.3 0.1 biomass Pressure: near atmospheric
1 0.7
Torrefaction Absence of oxygen
1 0.9
Product: solid fuel

0.9 Particle size < 4 cm thickness

Energy densification (E/kg) 1 = 1.3
0.7
Residence time 10-30 min

mass energy Heating rate: <50 °C/min

4 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 From biomass/waste to commodity fuels
Woody biomass Agricultural residues
Friable and less fibrous
19 - 22 MJ/kg (LHV, ar) Superior fuel properties:
Hydrophobic • Transport, handling, feeding
Preserved
Reduced contaminant level • Milling
Homogeneous • Combustion/gasification
• Feedstock bandwith
• Standardisation
Torre
fac
pulve tion and
risati
Mixed on
waste
Pelle
Tenacious and fibrous tisati
on
Fuel powder
10 - 17 MJ/kg (LHV, ar)
Hydrophilic
Vulnerable to biodegradation
Contaminated Bulk density 750-850 kg/m3
Heterogeneous Bulk energy density 15-20 GJ/m3 Fuel pellets

5 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Hemicellulose Lignin Cellulose

Decomposition regimes
Extensive
E E
300 Devolatilisation 300
and

carbonisation
(E)
D
TORREFACTION

250 D D 250
Limited
devolatilisation
Temperature (°C)

Temperature (°C)

and
carbonisation (D) C

200 200

C
depolymerisation
and
recondensation
(C)
150 150

glass transition/ A
softening (B)

drying (A)
A
100 100
Hemicellulose Lignin Cellulose

6 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 Starting points ECN TOP technology development (1)

• Torrefaction (combined with pelletisation) has the potential of becoming

a key unit operation in biomass upgrading schemes for a wide range of
applications, including:
− Biomass storage and (long-distance) transport – biomass import
− Co-firing in pf boilers
− (Co-)firing in entrained-flow gasifiers for producing power (IGCC) or
transportation fuels (e.g., Fischer-Tropsch diesel)
− Small-scale pellet boilers and stoves

⇒ Torrefied biomass pellets may become a biomass commodity fuel

7 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Starting points ECN TOP technology development (2)

• Torrefaction principle not new, but many aspects relevant to application

for upgrading biomass into biomass fuel for thermal conversion
processes were not addressed, including:
− Scale of operation in relation to reactor technology and process
layout
− Characterisation and quantification of product quality and how this
relates to process conditions
− Nature and quantity of emissions
− Prospects of heat integration including utilisation of the energy
containing torrefaction gases
− The economic viability of torrefaction as a biomass upgrading
technique for bulk applications

⇒ 2002 start ECN TOP technology development

8 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 5 kg/h screw
Proof-of-concept approach reactor

Pellet press (batch) Pellet quality

Continuous screw
reactor (pyromaat)
Torrefied
Biomass biomass
Batch reactor Cutting mill Grindability

TGA analysis
Lab-scale combustion
Simulator (LCS)
Combustibility
Torrefaction
gas

Sampling methods 20 l batch reactor

Process
Torrefaction
Analysis methods simulation
database
&
design tools
Product distribution (M & E yields)

9 Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Torrefaction
Typical experimental results

Gas phase composition

CO 0.1 %
CO2 3.3 %
H2O 89.3 %
acetic acid 4.8 %
furfural 0.2 %
methanol 1.2 %
formic acid 0.1 %
remainder 1.0 %

Tad = 1045 ºC
Torrefaction
32 min, 260 ºC
Feed: Willow Torrefied Willow
Size: 10 - 30 mm Size: 10 - 30 mm
LHV = 14.8 MJ/kg (ar) LHV = 18.5 MJ/kg (ar)
MC = 14.4% MC = 1.9%
Mass yield: 75.3% (ar)
Fixed carbon: 16.8 % Fixed carbon: 22.1%
Energy yield: 94.3% (ar)

10Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 Grindability of (torrefied) biomass
90 360
C(270,21)
80 C(280,18) 320
C(290,12)
70 280
Power consumption (kWe/MWth)

W(290,24)
W(260,24)

chipper capacity (kWth)

60 240
Willow (MC=10-13%)
50 Willow (dried) 200
Cutter wood
40 AU bituminous coal 160
Borssele run
30
demolition wood
120
D(300,11)
20 80

10 40

- -
- 0.5 1.0 1.5 - 0.2 0.4 0.6 0.8 1.0
average particle size (mm, volume based)
average particle size (mm, volume based)

Torrefaction leads to a dramatic decrease in required milling power

and increase in milling capacity

11Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Torrefaction of willow (280 oC, 17.5 min) 100%

Product distribution mass

composition
Permanent gases 75%
energy
94.9
100 composition
87.5
90 50%
Mass y ield
80
Energy y ield
70
25%
60
50
0%
40
CO CO2 Other
30
20 Organics
8.0
10 1.4 0.1 1.7 1.6 1.4 3.4 70%
0 60% mass composition
Solid Permanent Organics Lipids Reaction 50% energy composition
Gas Water
40%

Main product groups (dry basis) 30%

20%
10%
0%
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12Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 Combustion reactivity of torrefied wood
Lab-scale Combustion Simulator
experiments
high-volatile coal low-volatile coal torr. (300°C) demolition wood
HVC (LOI) LVC (LOI) torr. (300°C) demolition wood (LOI)
torr. (280°C) prune wood torr. (280°C) prune wood (LOI) torr. (280°C) demolition wood
torr. (280°C) demolition wood (LOI) prune wood (fresh) prune wood (fresh, LOI)

100

90
conversion [%] or LOI [% d.b.]

80

70

60

50

40

30 High reactivity for

20 torrefied wood
10

0
0 500 1000 1500 2000 2500
time [ms]

13Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Semi-industrial pelletisation tests

Features:
• 10 kg/h
• No automatic moisture supply

• Preliminary findings:
− Easy pelletisation
− Low energy input required
− Pellet quality strongly dependent on
pelletisation conditions

14Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 TOP pellets vs. wood pellets
Properties unit Wood Torrefied biomass Wood pellets TOP pellets
low high low high
Moisture content % wt. 35 3 7 10 1 5
Calorific value (LHV)
dry MJ/kg 17.7 20.4 17.7 17.7 20.4 22.7
as received MJ/kg 10.5 19.9 15.6 16.2 19.9 21.6
Mass density (bulk) kg/m3 550 230 500 650 750 850
Energy density (bulk) GJ/m3 5.8 4.6 7.8 10.5 14.9 18.4
Pellet strength - - Good Very good
Dust formation Moderate High Limited Limited
Swelling / Water Limited swelling /
Hygroscopic nature Water uptake Hydrophobic
uptake Hydrophobic
Biological degradation Possible Impossible Possible Impossible
Seasonal influences
High Poor Moderate Poor
(noticable for end-user)
Handling properties Normal Normal Good Good

15Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

ECN directly heated torrefaction technology

Air
Features:
Utillity fuel
• High energy efficiency (> 90%)
• Heat integration Flue gas

• Conventional drying and

pelletisation
Combustion
• Compact moving bed
Torrefaction
technology gas
Gas
• Cost effective recycle

Biomass TOP pellets

Drying Torrefaction Cooling Pelletisation

∆P

Flue gas
15-20% Heat exchange
Flue gas
moisture

16Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 ECN torrefaction technology
Innovative moving bed reactor

• Compact reactor
• Small footprint
• High heat transfer rates
• Accurate T-control
• Uniform product quality
• Feedstock flexibility
• Low capital investment

Pilot-scale torrefaction reactor at ECN

17Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Total capital investment – study estimate (TOP pellets vs. wood pellets)

Total Capital Investment TOP and Pelletisation

(Feedstock: 180 kton/a woodchips @ 50%mc)
8

5
TCI (MEuro)

Drying
4
Torrefaction

3 Size Reduction and Pelletisation

Storage
2 Indirect Cost
Working Capital
1

0
TOP Process Conventional Pelletisation

18Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 Total production cost (TOP pellets vs. wood pellets)
4,0

3,5

Production Cost Indication (Euro/GJ product)

3,0

2,5

2,0

1,5

1,0

0,5

0,0
Green Wood Saw Dust 47 MW / 47 MW / 47 MW / 47 MW / 47 MW /
Pellets Pellets 75 kton/a 75 kton/a 75 kton/a 36 kton/a 112 kton/a
MC = 50% MC = 35% MC = 25% MC = 35% MC = 35%
BASE CASE

Total Cost Other Power

Support Fuel Personnel Maintenance
Depreciation and Financing Feedstock (=0 Euro/tonne)

19Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

Chain study (TOP pellets vs. wood pellets)

TOP process
Sawdust Logistics
(South Africa)
0.7 EUR/GJ <2.0 EUR/GJ
2.0 EUR/GJ
<4.7 EUR/GJ

Favourable (Co-)firing
coal-fired power stations
economics! Higher co-firing capacity
or entrained-flow gasifiers
Lower capital investment
Higher co-firing flexibility North-West Europe
and availability

2.3 EUR/GJ 5.9 EUR/GJ

0.7 EUR/GJ Conventional 2.9 EUR/GJ
Sawdust Pelletisation Logistics
(South Africa)

20Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 Road map ECN TOP technology development

capacity 5-10 kg/h 100 kg/h 20 kton/a 60-100 kton/a

Green Proof-of- Prototype Technical Commercial

Proof-of-concept
biomass principle (pilot-scale) demonstration demonstration

Time 2002 2003 2004 2005 2006 2007 2008 2009 2010

Proof-of- Prototype Technical

Waste Proof-of-concept
principle (pilot-scale) demonstration

Proof-of-concept Prototype (pilot-scale evaluation) Technical demonstration

•Experimentally based process design
•Technology identification
•Knowledge base torrefaction
•Experimental infrastructure torrefaction
•Economic evaluation full-scale
(study estimate 30%)
•Set-up pilot phase of development
•Pilot plant / prototype technology
•Demonstration technical feasibility
•Process and product characterisation (design data)
•Economic evaluation full-scale
(preliminary estimate 20%)
•Business plan(s)
(technical demo, semi-commercial)
•Demonstration plant (semi-commercial)
•Technical feasibility (refined design)
•Product applications (large scale)
•Economic evaluation full-scale
(definite estimate <10%)
•Business plan(s)
(commercial operation)

21Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

ECN TOP technology development – 2007 activities

• Pilot-scale testing
− Validation of reactor and process concept
− Optimisation of process conditions for a broad feedstock
range
− Industrial pelletisation tests
− Extensive quality evaluation TOP pellets
(e.g., hygroscopic nature, biodegradation, strength, milling
characteristics, combustion/gasification reactivity)

• Demonstration plant basic design

• Business plan for technical demonstration(s) through BO2
Energy Concepts
• Continued basic R&D (co-operation with TU Eindhoven)
− Contaminated biomass (residues) and waste

40-100 kg/h torrefaction

pilot-plant at ECN

22Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

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 In conclusion
• ECN TOP technology allows cost effective production of commodity fuels from a
wide range of biomass/waste feedstocks with a high energy efficiency (>90%)
• ECN TOP fuels show:
− High energy density
− High water resistance
− No/Limited biological degradation
− Excellent grindability
− Good combustion properties

• Fields of application:
− Long distance biomass transport
− Co-firing in pf boilers
− (Co-)firing in entrained-flow gasifiers
− Small-scale pellet boilers/stoves

• In 2007 pilot-plant testing and

initiation of demo-projects

23Meeting Cargill, 15 May 2006 Torrefaction for biomass upgrading into commodity fuels – Jaap Kiel

For further information please contact:

Dr.ir. Jaap Kiel

e: kiel@ecn.nl
t: +31 224 56 4590
w: www.ecn.nl

ECN
P.O. Box 1
NL 1755 ZG Petten
the Netherlands

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