Advances in the techno-economic assessment to identify the ideal plant configuration of a new biomass-to-liquid process - Comsyn
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COMSYN project has received funding from
the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
Advances in the techno-economic assessment to
identify the ideal plant configuration of a new
biomass-to-liquid process
Simon Maier1, Ralph-Uwe Dietrich1, Sanna Tuomi2, Esa Kurkela2, Johanna Kihlman2,
Pekka Simell2, Tim Böltken3
1 German Aerospace Center (DLR)
2 VTT Technical Research Centre of Finland
3 INERATEC GmbH
27th of April 2021
COMSYN project has received funding
DLR.de • Chart 2 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
COMSYN – Compact Gasification and Synthesis process for Transport Fuels
www.comsynproject.eu – EU No. 727476
New BtL production concept with biofuel production cost reduction up to 35 % compared to alternative routes
(Project goal: < 1.05 €/kg production cost for diesel)
PRIMARY CONVERSION PRODUCT
Decentralized FT wax UPGRADING
production at small-to- Centralized FT
medium scale units product refining to
located close to biomass high quality drop-in
resources liquid fuels* at
(50-150 MWth input) existing oil refineries
+ locally utilized excess
heat for
80+ % overall efficiency
COMSYN project has received funding
DLR.de • Folie 3 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
Techno-economic and ecological evaluation at DLR
1. Step
Simulation & Process evaluation
Literature
2. Step Variation of process 3. Step 4. Step
survey parameters
Detailed Techno-economic Identifying
process and ecological crucial process
simulation Aspen-TEPET- evaluation parameters
Brightway2-Link
[1]
Exchange with [2]
Material and energy
project balance data
• Upscaling
partners • Technical optimization
• Economic calculation
• Sensitivity analysis
• Cases studies
• Heat integration
• Exergy analysis
• LCA
[1] Albrecht et al. (2016) - A standardized methodology for the techno-economic evaluation of alternative fuels – A case study, Fuel, 194: 511-526
[2] Mutel (2017) - Brightway: An open source framework for Life Cycle Assessment, Journal of Open Source Software, 2(12): 236
COMSYN project has received funding
DLR.de • Chart 4 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
COMSYN – Compact Gasification and Synthesis process for Transport Fuels
Process concepts
Steam
Gas ultra-cleaning
Case 1 Case 2 Case 3
• Base case • Autothermal reforming with air • Allothermal steam reforming
• Autothermal reforming with air • CO2 removal after guard bed ➢ Required heat is provided by
➢ Operating at 6 bar an additional burner
➢ 80 % CO2 is removed ➢ Steam is led into the reformer
COMSYN project has received funding
DLR.de • Chart 5 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
Process flowsheet model
Feedstock Gasi- Reforming and gas cleaning
fication
HRSG
FT
synthesisCOMSYN project has received funding
DLR.de • Chart 6 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
TEPET Results
Techno-economic assessment of process concepts
100 MW biomass input Case 1 Case 2 Case 3
Electricity demand MW 11.4 12.3 9.1 Case 1 Case 2 Case 3
Steam + Distr. heating MW 39.7 38.7 47.7 1.8
Product output MW 51.4 50.6 38.1
1.7
BtL efficiency % 46.1 45.1 35.0
Energetic efficiency % 81.7 79.3 78.7 1.6
NPC / €/kg
1.5
Boundary conditions
Base year 2019 1.4
Full load hours h/a 8260
1.3
Interest rate % 10
Electricity costs €/MWh 60 1.2
Biomass costs €/GJ 11.3
District heating revenue €/MWh 30 1.1
30 % 35 % 40 % 45 % 50 %
Process steam revenue €/MWh 36.2 ηBiomass-to-liquid / %
Labor costs €/h 28.94COMSYN project has received funding
DLR.de • Chart 7 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
TEPET Results
Techno-economic assessment of process concepts
2.0
100 MW biomass input Case 1 Case 2 Case 3 Biomass pretreatment
Electricity demand MW 11.4 12.3 9.1 Reformer Case 1 Case 2 Case 3
Steam + Distr. heating MW 39.7 38.7 47.7 1.8
Gas cleaning
1.5
Product output MW 51.4 50.6 38.1 Gas compression
1.7
CO2-removal
BtL efficiency % 46.1 45.1 35.0
FT-Reactor
NPC / €/kgFT-syncrude
Energetic efficiency % 81.7 79.3 78.7 1.6
Steam turbine 1.0
HRSG
NPC / €/kg
1.5
Boundary conditions Remaining CAPEX
District heating 0.5
Base year 2019 1.4
Steam generation
Full load hours h/a 8260
Biomass
1.3
Interest rate % 10
Electricity
Electricity costs €/MWh 60 0.0
Remaining
1.2 direct OPEX
Biomass costs €/GJ 11.3 Maintenance etc.
District heating revenue €/MWh 30 1.1
Distribution & selling costs
30 %
Labor costs 35 % -0.5 40 % 45 % 50 %
Process steam revenue €/MWh 36.2 Case€/kg 1 /%
ηBiomass-to-liquid Case€/kg
2 Case 3
1.23 1.38 1.42 €/kg
Labor costs €/h 28.94 1.23 €/kg
Case 1 1.38 €/kg
Case 2 1.42 €/kg
Case 3COMSYN project has received funding
DLR.de • Chart 8 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
Process flowsheet model
Various heating and cooling units require heat integration
Feedstock Gasi- Reforming and gas cleaning
fication
HRSG
FT
synthesisCOMSYN project has received funding
DLR.de • Chart 9 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
TEPET – Heat integration
The process concept yields in a high Hot Streams Cold Streams
1200
amout of excess heat 16.1 MW
High amount of
→ Heat integration options have to be 1000 excess heat
evaluated technically and economically > 400°C
800
Electricity Process steam &
T/C
generation District heating 600
SC0 0.0 MW 42.2 MWth cooling
SC1 2.8 MW 37.8 MWth 400 demand
(< 65 °C)
SC2 9.7 MW 30.2 MWth
200
SC3 12.7 MW 0.0 MWth
22.1 MW
0
0 10 20 30 40 50 60 70 80 90 100
E / MWCOMSYN project has received funding
DLR.de • Chart 10 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
TEPET – Results
Techno-economic comparison of different steam cycle modes
Selection of heat utilisation method
strongly dependent on revenue for Case 1 Case 2 Case 3
1.8
process steam & district heating
1.7
1.6
Electricity Process steam &
NPC / €/kg
1.5
generation District heating SC3
SC0 0.0 MW 42.2 MWth 1.4
SC1 2.8 MW 37.8 MWth 1.3
SC2
SC1
SC2 9.7 MW 30.2 MWth 1.2
SC0
SC3 12.7 MW 0.0 MWth 1.1
30 % 35 % 40 % 45 % 50 %
ηBiomass-to-liquid / %COMSYN project has received funding
DLR.de • Chart 11 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
TEPET – Results
Techno-economic comparison of different steam cycle modes
2.0
Selection of heat utilisation method Biomass pretreatment
strongly dependent on revenue for Reformer Case 1 Case 2 Case 3
1.8
Gas cleaning
process steam & district heating Gas compression
1.5
1.7
CO2-removal
FT-Reactor
NPC / €/kgFT-syncrude
1.6
Steam turbine 1.0
Electricity Process steam & HRSG
NPC / €/kg
1.5
generation District heating Remaining CAPEX SC3
District heating 0.5
SC0 0.0 MW 42.2 MWth 1.4
Steam generation
Biomass
SC1 2.8 MW 37.8 MWth 1.3
SC2
Electricity
0.0 SC1
SC2 9.7 MW 30.2 MWth Remaining
1.2 direct OPEX
SC0
Maintenance etc.
SC3 12.7 MW 0.0 MWth 1.1
Distribution & selling costs
30 %
Labor costs 35 % -0.5 40 % 45 % 50 %
ηBiomass-to-liquid
1.23 €/kg / %1.27 €/kg 1.31 €/kg 1.48 €/kg
SC0 SC1 SC2 SC3COMSYN project has received funding
DLR.de • Chart 12 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
TEPET – Results
Identification of potential sweet spots and their most feasible process configuration
• Assumptions:
• Bark as biomass feedstock
• 200 MW max. plant scale (84 t/h)
• 20 years of plant lifetime
• 8260 h/a operation
• 10 persons per shift
• 10% interest rate
• Heat market for district heating available
• Product refining at Litvinov ORLEN
UniPetrol refinery (14 wt.% losses)
Data based on: Ruiz (2019), ENSPRESO - an open, EU-28 wide, transparent and coherent database of wind, solar and biomass energy potentials [3]COMSYN project has received funding
DLR.de • Chart 13 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
Summary & Outlook
• Advances in techno-economic methodology allow …
• to screen potential regions while including all site-specific boundary conditions
• Technical parameter variations while tracking economic impacts
• Apply methodology for any other process conept on biomass feedstock
• Ecologcial assessment has to be taken into account (4CO.14 – Julia Weyand, DLR)
Data based on: Camia (2018), Biomass production, supply, uses and flows in the European UnionCOMSYN project has received funding
DLR.de • Chart 14 EUBCE 2021 • Simon Maier • Advances in the techno-economic assessment • April 27, 2021 from the European Union’s Horizon 2020
research and innovation programme under
grant agreement No. 727476
References
1) Albrecht et al. (2016), A standardized methodology for the techno-economic evaluation of alternative fuels.
2)Mutel et al. (2017) - Brightway: An open source framework for Life Cycle Assessment, Journal of Open Source
Software, 2(12): 236
3) Ruiz et al. (2019), ENSPRESO - an open, EU-28 wide, transparent and coherent database of wind, solar and
biomass energy potentials [3]COMSYN project has received funding from the
European Union’s Horizon 2020 research and innovation
programme under grant agreement No. 727476
Project partners
Thank you!
German Aerospace Center (DLR)
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