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Gasification Based Biomass Co-Firing
Phase I
Final Report
September 2002
(Revised January 2003)
Prepared for:
National Energy Technology Laboratory
United States Department of Energy
Pittsburgh, PA
DOE Award Number
DE-FC26-00NT40898
Prepared bv
San Francisco,
CA
Principal Investigators
Babul Patel, Nexant Inc., 101 Second Street 1Ith
Floor, San Francisco CA 94105
Kevin McQuigg, Primenergy, LLC, 3172 N. Toledo Street, Tulsa, OK 74158
Robert Toerne, WKE Corp., 145 N. Main Street, Henderson, KY 42419
John Bick, TXU Energy, 1601 Bryan Street, Dallas, TX 75201
Dr. Philip Goldberg, DOE-NETL, 626 Cochrans Mill Road, Pittsburgh, PA 15236
Gasification Based Biomass Cofiring, Phase I
DOE Proiect DE-FC26-00NT40898
DISCLA1MER
“This report was prepared as an account of work sponsored by an agency of the
United States Government. Neither the United States Government nor any
agency thereof nor any of their employees, makes any warranty, express or
implied, or assumes and legal liability or responsibility for the accuracy,
completeness, or usefulness of any information, apparatus, product, or process
disclosed, or represents that its use would not infringe privately owned rights.
References herein to any specific commercial product, process, or service by
trade name, trademark, manufacturer, or otherwise does not necessarily
constitute or imply its endorsement, recommendation, or favoring by the United
States Government or any agency thereof. The views and opinion of authors
expressed herein do not necessarily state or reflect those of the United States
government or any agency thereof.”
Prepared by
Nexant, Inc.
September
2002
I
Gasification Based Biomass Cofiring, Phase I
DOE Proiect DE-FC26-00NT40898
ABSTRACT
Biomass gasification offers a practical way to use this widespread fuel source for
co-firing traditional large utility boilers. The gasification process converts biomass
into a low Btu producer gas that can be used as a supplemental fuel in an
existing utility boiler. This strategy of co-firing is compatible with variety of
conventional boilers including natural gas and oil fired boilers, pulverized coal
fired conventional and cyclone boilers. Gasification has the potential to address
all problems associated with the other types of co-firing with minimum
modifications to the existing boiler systems. Gasification can also utilize biomass
sources that have been previously unsuitable due to size or processing
requirements, facilitating a wider selection of biomass as fuel and providing
opportunity in reduction of carbon dioxide emissions to the atmosphere through
the commercialization of this technology.
Nexant Inc., with its team member, Primenergy LLC., and utility partners Western
Kentucky Energy Corp. (WKE), and TXU Energy Services, with guidance from
Dr. Philip Goldberg of NETL, has undertaken the engineering and economic
evaluation of the biomass gasification and co-firing technology under the
Department of Energy’s Biomass Co-firing program. US DOE’S Biomass
Program within the office of Energy Efficiency and Renewable Energy sponsored
and co-funded this project under a cost share cooperative agreement DOE DE-
FC26-00NT40898. This study evaluated two plants: WKE’s Reid Plant and TXU
Energy’s Monticello Plant for technical and economical feasibility. These plants
were selected for their proximity to large supply of poultry litter in the area.
The Reid plant is located in Henderson County in southwest Kentucky, with a
large poultry processing facility nearby. Within a fifty-mile radius of the Reid
plant, there are large-scale poultry farms that generate over 75,000 tons/year of
poultry litter. The local poultry farmers are actively seeking environmentally more
benign alternatives to the current use of the litter as landfill or as a farm spread
as fertilizer.
The Monticello plant is located in Titus County, TX near the town of Pittsburg,
TX, where again a large poultry processor and poultry farmers in the area
generate over 110,000 tonslyear of poultry litter. Disposal of this litter in the area
is also concern.
This project offers a model opportunity to demonstrate the feasibility of biomass
co-firing and at the same time eliminate poultry litter disposal problems for the
area’s poultry farmers.
Prepared by
Nexant, Inc.
September
2002
II
Gasification Based Biomass Cofiring, Phase
I
DOE Project DE-FC26-00NT40898
Table of Contents
DISCLAIMER
....
...........................................................................
I
ABSTRACT
..........................................................
........................
II
EXECUTIVE SUMMARY
...............................................................
vii
1
Introduction
...........................
1
................................................
1.1
Background Information
...........................
1
.......................
1.2
2
1.3
Western Kentucky Energy Case
2
................................................
1.4
TXU Energy Case
.............................................................
4
1.5
Primenergy Gasifie
4
.........................................................................
PHASE
I
Organiza
6
1.6
asks and Schedule
.......................
2
Technology Evaluation
...........................................................
2.1
Overview of Co-firing Technologies
10
..............................................
2.1.1
Low Percentage Co-firing:
................
10
......................
2.1.2
Direct Combustion Co-firing wit
2.1.3
11
2.2
Gasification Technologies
................................................
12
2.3
14
2.4
Environmental Impact of Gasification..
....
14
.....................
2.4.1
Comparison of Coal v/s Litter Burn
............................
16
3
Project Evaluation
.................
18
.................................................
3.1
WKE Case
...............................................
18
........................
3.1.I WKE Reid Plant
18
.......................................................................
3.1.2
Reid Plant Boile
20
.................................................
3.1.3
Gasifier Material and Energy Balance
.......................
3.1.4
Gasifier Boiler Integration
..........................................
3.1.5
Overall Plant Energy Balance
...........
23
.....................
3.1.6
Solids Handling Systems
...........................................
3.1.7
Permit Issues
...........
25
..............................................
3.1.8
Fuel Contracts
..................................
28
.....................
3.1.9
Major Equipment Lis
3.1.10
Equipment Layout
31
..............................................
3.2
TXU Energy Case
............................................................
32
3.2.1
32
3.2.2
Monticello Unit 1 Boiler Data
............
33
.....................
3.2.3
Gasifier Material and Energy Balance
.......................
34
3.2.4
Gasifier Boiler Integration
36
..............................................
3.2.5
Overall Plant Energy Bala
36
.....................
3.2.6
37
3.2.7
Permit Issues
...........
41
..............................................
3.2.8
Fuel Contracts
...........................................................
3.2.9
Major Equipment List
.................................................
3.2.10
Gasification Plant Layout
...............
45
.....................
4
Economic Analysis
..................................................................
46
...
Prepared by
Nexant, Inc.
September
2002
Ill
Gasification Based Biomass Cofiring, Phase I
DOE Proiect DE-FC26-00NT40898
4.1
Reid Plant Case
46
4.1.I Capital and
46
...................................................
4.1.2
48
4.1.3
Sensitivity Analysis for Reid Plant Case
49
4.2
4.2.1
4.2.2
4.2.3
52
52
55
56
5
Results and Discussio
5.1 Infrastructure/Fuel
5.2.1
5.2.2
5.2.3
5.2.4
5.3
6
Conclusions
62
7
References
&
Bibliography
..........................................................................
65
7.1
65
Appendices
67
Prepared by
Nexant, Inc.
iv
September
2002
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