Black Liquor Gasification

1

• Black Liquor Gasification
• - Enabling Technology
• for the Forest Industry
• Solander Symposium
• Piteå, Sweden
• 29 March, 2007

Ingvar Landälv Chemrec AB www.chemrec.se
2
Chemrec in cooperation with and in
support by
Feedstock Supplier
End Users
Authorities
The Pulp Industry
3
Chemrec Ownership and Main Business
VantagePoint Venture Partners
Nykomb Synergetics
Volvo Technology Transfer (AB Volvo)
Chemrec AB

• Chemrec develops and Commercializes Black Liquor
  Gasification Technology which will convert Pulp
  Mills to Biorefineries
• The technology has the potential to generate near
  30 of Swedens current consumption of
  automotive fuels through black liquor
  gasification at the Swedish pulp mills. The
  potential in Finland is 50, in Canada 7 and
  in the US 3.
• Fuel generation at pulp mills becomes a second
  main product generating a cash flow on the level
  of 1/3 of the cash flow of the pulp at prices
  close to energy price of diesel and gasoline at
  crude prices of 30 USD/bbl
• Alternatively the technology has the potential to
  generate approx. 10 TWh added green power
  production or 7 of current Swedish power
  consumption.

4
Chemrecs Booster in New Bern, NC - USA

• Operates as a booster unit to the recovery boiler
  in the Weyerhaeuser pulp mill in New Bern, North
  Carolina
• Corresponds to 15 of the mills production
• Start up Dec 1996
• Capacity 330 tDS/day
• 50 MW
• Oxidant Air
• Pressure Atmospheric

5
Ceramic Lining after 2 years Operation, Oct
06(looking down)
6
Refractory Installation Oct 2006
New Back-up Material
Hot Face Fused Cast Material
Metal Foam Mtrl
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Refractory Installation Ready Oct 27
Service life Previous lining 2 years New
lining Expect 3 years
8
Reactor Ready to get back in Service
The Chemrec Booster - A Commercial Product Today
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Pressurized, O2-blown Black Liquor Gasification
- General Scheme -
DP-1 plant
Oxygen
Air separation
Steam
Power
Gasi- fication and Quench
Poly Sulph.
Sulphur Management
Black liquor
Rawgas
Gas cooling
White liquor
Weak wash
Gas Purification
LS Green liq.
Synthesis gas
Power Steam
Combined Cycle
Synthesis- and Distillation
or
or
DME/Methanol
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Chemrec DP-1 Major Equipment
White Liquor
GAS COOLER
Black Liquor
H2S- ABSORPTION
Cooling water
Oxygen
BFW
Atomising medium
LP- steam
REACTOR
Raw syngas
MP- steam

QUENCH
Purified and cooled syngas (to flare)
Green Liquor
Condensate
Weak Wash Liquor
Cooling water in DP1
11
Piteå Operating Experiences
Hours

• Last 2 runs
• gt29 bar and good quality products

Summer shut-down
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May 12 Low Content of Char, No Soot and
Excellent Settling of Dregs in Green Liquor
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Objectives with the DP-1 Operation
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Next Steps
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A DME Pilot at the Chemrec DP-1 Plant in Piteå,
SwedenPlanned start-up mid 2009
DP-1
CO2
(Guard- Bed)
ZnO Absorber
Activated Carbon
Amin Wash
- Which results? - Who should tackle?
CO2
The DME Pilot
DME or MeOH P.D.U Process Developmt Unit H2/CO
1/1
Raw MeOH or DME
HP-steam (Dp-1/mill)
Train /Truck
LP-st (Dp-1/mill)
C.W
4 ton DME / day
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Demonstration Incremental Capacity Increase at a
Pulp Mill through a small BLGMF PlantPlanned
Start-up 2010
Pulp
Typical 5-600 MW
Black liq. energy
Biomass
25 000 t DME/y
Small BLGMF Plant
DME/MeOH
17
The Users Perspective in Summary

• The pulp mill New process which can increase
  yield and bring new profit generating
  activity
• The power utility Efficient production of
  green power
• The oil company Efficient production of green
  fuels
• The chemical Efficient production of green
  synthesis company gas
• The car industry Renewable, sustainable
  production of green fuels
• The forest owner Maximize the revenue from the
  forest land

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User perspective 1The Pulp Mill
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Drivers for Technology Change
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Potential for Increased Pulp Yield, like ZAP -
Zero Effective Alkali in the Pretreatment Stage
Source STFI
21
User perspective 2The Power Industry
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Overall Energy Balance for the KAM2 Mill
45 MWe
KAM2 Pulp Mill
911 MWt
340 MWt
2000 adt/d
4100 t/dtort
SP 81 bar/ 490C
SP 81 bar/ 490C
Pulpwood
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Overall Energy Balance when the Recovery Boiler
has been changed into a BLGCC process
41 MW compared to the recovery boiler
BLGMF
86 MWe
BLGCC
0 MWt
Biomass
BL
486 MWt
GL
KAM2 Pulp Mill
911 MWt
340 MWt
2000 adt/d
4100 t/dtort
Pulpwood
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User perspective 3The Oil Industry
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Cost Data, 3Q 2005

• Biomass 0.12 SEK / kWh 1.3 cent / kWh
• Pulp Wood 0.17 SEK / kWh 1.8 cent / kWh
• Pulp 500 EUR / ton
• El. (incl. certificate) 0.47 SEK / kWh 5.1
  cent / kWh
• Fuel price at site
• (gasoline equiv.) 3,48 SEK / l 0.37 / l
• CO2 tax, gasoline 2,16 SEK / l. 0.23 / l
• CO2 (liq.) at plant gate 200 SEK / ton 22 /
  ton

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Overall Energy Balance for the KAM2 Mill
45 MWe
KAM2 Pulp Mill
340 MWt
2000 adt/d
4100 t/dtort
SP 81 bar/ 490C
SP 81 bar/ 490C
Pulpwood
27
Overall Energy Balance when the Recovery Boiler
has been changed into a BLGMF process
El- Cond. 101MWe
45 MWe
253 MWt
414MWt
Biomass
BLGMF
BLGMF
550 t.g.e/d
161 MWt
272 MWt
BL
486 MWt
GL
KAM2 Pulp Mill
911 MWt
340 MWt
2000 adt/d
4100 t/dtort
Pulpwood
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Overall Cost and Revenue Streams for a Pulp Mill
with a BLGMF Plant (per year)
3,48 SEK/l gasoline at refinery gate
El- Cond. 101MWe
45 MWe
19 MEUR
414MWt
Biomass
BLGMF
44 MEUR
BLGMF
550 t.g.e/d
94 MEUR
BL
GL
911 MWt
KAM2 Pulp Mill
Pulpwood
2000 adt/d
4100 t/dtort
SP 81 bar/ 490C
347 MEUR
137 MEUR
29
Overall Cost and Revenue Streams for a Pulp Mill
with a BLGMF Plant (per year)
3,48 SEK/l gasoline at ref. gate CO2 tax
El- Cond. 101MWe
45 MWe
19 MEUR
414MWt
Biomass
BLGMF
44 MEUR
BLGMF
550 t.g.e/d
153 MEUR
BL
GL
911 MWt
KAM2 Pulp Mill
Pulpwood
2000 adt/d
4100 t/dtort
SP 81 bar/ 490C
347 MEUR
137 MEUR
30
Overall Cost and Revenue Streams for a Pulp Mill
with a BLGMF Plant (per year)
3,48 SEK/l gasoline at ref. gate CO2 tax CO2
export
El- Cond. 101MWe
45 MWe
19 MEUR
414MWt
Biomass
BLGMF
ca 93 t CO2/tim
44 MEUR
BLGMF
16 MEUR
550 t.g.e/d
153 MEUR
BL
GL
911 MWt
KAM2 Pulp Mill
Pulpwood
2000 adt/d
4100 t/dtort
SP 81 bar/ 490C
347 MEUR
137 MEUR
31
Swedish Fuel Consumer Price - average 2005(Net
back calculation)
CO2 tax
CO2 tax
Base price
2 USD / gallon
Base price
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Base for Economic Calculation
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Investment in new Recovery TechnologyCapacity
2000 tDS/d black liquor
130 MEUR
NEW RECOVERY BOILER
OLD RECOVERY BOILER
INCREMENTALINVESTMENT 150 MEUR
BLGMF PLANT
280 MEUR
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Pay Back Calculation Large BLGMF plants MeOH
245 000 t/y or DME 172 000 t/y
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User perspective 4The Chemical Industry
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Gas utilization together with CHEMREC s BLG
process

• Oxygen
• Ca 600 ton O2 per 1000 ADt of pulp
• Nitrogen, Argon and other rare gases
• N2 as inert gas in the BLG process
• Carbon dioxide
• Available at gt 90 purity from the BLGMF
  process. Possible to produce also from BLGCC.
• H2 and CO
• As fuel gas for combined cycle, as feedstock for
  synthesis or for other use

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BLG for Ammonia/Urea production
Nitrogen
2000 tds/d gt 260000 ton NH3/y
Oxygen
ASU
Ånga
EL
Gasifi/ cation 150MW / gasifier 3x50 1000C 30
bar
Polysulphide
Sulphur- handling
Black Liq.
Rågas
Gas cooling
White Liquor
Gas Cleaning (Rectisol) N2-wash
Weak wash
LS Green Liq.
CO2
Syngas H2
Ammonia
Urea
Urea synthesis
Ammonia Synthesis
2000 200 EUR/t 4Q, 2006 300 EUR/t
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Biomass and Black Liquor to Olefins
Ethylene is the chemical with largest production
volume, ca 75 Mton/y (PE, vinyl chloride,
styrene, ethylene oxide, ..). There are several
possible routes from renewable feed stocks, e.g.
Källa Hjertberg, Chalmers
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BLG to Methanol and further to ethylene
Eur / ton

• Calculation 2Q, 2005
• Process
• Gas phase hydrogenation of MeOH over a zeolite
  catalyst
• Yield
• Ca 3 ton methanol per ton ethylene
• Economy
• Methanol at 200 /ton plus capital and other
  operation costs at 150 /ton of ethylene gives
  ethylene at 750 /ton
• Dec 2006 Ethylene price at approx. 900 /t

900
800
700
600
500
400
2000
2004
2002
2006
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User perspective 5The Car Industry
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Well to Wheel Analysis (heavy duty vehicles)
Source AB Volvo
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Honored Best New Achievement by Best of What's
New Science Magazine, Nov 2005
Even higher figures can be expected when
optimized for methanol
20 on power when optimized for E100
16 on torque when optimized for E100
SAAB (GM Europe) has also done initial
testing) on M85 / M100
) exhaust emission testing
43
User perspective 6The Forest Owner
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Biomass to Automotive Fuels Replacement
Potential within EU-25 in 2040
Potential added to 2040
Used today
Potential today
Energy in transports 2002
Total biomass potentials 2040
Transport share
Source EU project Renew within FP6 and
EUCAR/Concawe/JRC (2005)
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Major Biomass Flow Today and Tomorrow
TODAY
Forest
Logs
Pulp
Wood
Saw
-
mill
Pulp
Recovery
Boiler
Wood
Mill
Products
Pulp
Mill
Pulp
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The Pulp Mill Biorefinery
The Pulp Mill Biorefinery
TOMORROW
Forest
Logs
Pulp
Wood
Saw
-
mill
Pulp
Recovery
Boiler
Wood
Mill
Products
Pulp
Mill
Pulp
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Pay Back Calculation Large BLGMF plants MeOH
245 000 t/y or DME 172 000 t/y
Biomass 67 to 78 /ton gt 2.8 MEUR in oper.
cost
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Key PerspectiveConversion Efficiency and
Life Cycle Assessment
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Watch the whole chain From use of land to
useful energy e.g. on an engine shaft
Finally utilized energy

• Example
• ethanol
• RME
• DME/methanol

• Conversion
• to
• useful energy
• in the vehicle
• Diesel cycle
• Otto cycle

• Example
• wheat
• raps
• biomass

Conversion to fuel - fermentation -
gasification - etc
Use of land
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Driving range per hectare of land for heavy duty
vehicles
FTD
MeOH
DME
Source AB Volvo
Diesel engine efficiency assumed for all fuels
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Definition of Concepts
BIOMASS TO FUELS
BIOMASS TO FUELS AT A PULP MILL (utilizing the
BLGMF concept)
Gasification- based Fuel Production
Bl. Liquor
BLGMF
Pulp Mill
HeatPower Plant
Biomass
Fuel Product
Steam
Power
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Definition of a Stand Alone Concept
BIOMASS TO FUELS
BIOMASS TO FUELS AT A PULP MILL (utilizing the
BLGMF concept)
Gasification- based Fuel Production
Bl. Liquor
BLGMF
Pulp Mill
HeatPower Plant
0 MW
Biomass
Fuel Product
0 MW
Steam
(compared to Pulp Mill without BLGMF)
Power
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Definition of Biomass to Fuel Efficiency for
Stand Alone Concepts
BIOMASS TO FUELS
BIOMASS TO FUELS AT A PULP MILL (utilizing the
BLGMF concept)
?
Gasification- based Fuel Production
Bl. Liquor
BLGMF
?
Pulp Mill
HeatPower Plant
0 MW
Biomass
Energy in Fuel Energy in Biomass
Fuel Product
?
0 MW
Steam
(compared to Pulp Mill without BLGMF)
Power
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The BLGMF Report, 2003
Report Partners
Process engineering consultant
Gasification technology
Research centre for
supplier
pulp and papermaking
Worlds largest methanol
National gasoline and
producer and distributor
oil distributor
Automotive fuel and
World
-
known automotive
engine consultant
and engine developer
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The Princeton Biorefinery Report, 2006
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The BLGMF Study vs. the Princeton StudyDME case
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Definition of a Stand Alone Concept
BIOMASS TO FUELS
BIOMASS TO FUELS AT A PULP MILL (utilizing the
BLGMF concept)
Gasification- based Fuel Production
Bl. Liquor
BLGMF
Pulp Mill
IGCC technology
HeatPower Plant
0 MW
Biomass
Fuel Product
0 MW
Steam
(compared to Pulp Mill without BLGMF)
Power
58
The BLGMF Study vs. the Princeton Study (DME
case)Focus on Energy efficiency
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Questions?
Why dont you try DME?