Return to DOE Reports Table of Contents - W

Biomass Gasification Combined Cycle .  Agenda 2020.  Final Report.

 Weyerhaeuser Company

Part 1, Sections 1 - 4, 4.91 MB
Part 2, Sections 5 - 10, 5.07MB

Table of Contents

Part 1, Sections 1 - 4, 4.91 MB

1.0

Background and Introduction

1-1

1.1

Putting Gasification in Context

1-1

1.2

Brief History of Gasification Interest in the Forest Products Industry

1-1

1.3

Summary of Recent Weyerhaeuser Activities in Gasification

1-1

1.4

Opportunity at the New Bern Mill

1-2

1.5

Current DOE/Weyerhaeuser Project

1-2

1.6

The Formation and Purpose of the Forest Products Gasification initiative

1-3

1.7

The Organization of this Report

1-4

2.0

Raw Material Availability

2-1

2.1

Scope and Objectives

2-1

2.2

Approach

2-1

2.3

Findings

2-2

2.4

Supply Strategies

2-4

2.4.1

Capture Existing Volumes at Hog Fuel Values

2-4

2.4.2

Incorporate Mill Residuals Currently Going to Landfill

2-7

2.4.3

Capture Existing Residuals at Hog Fuel Prices Plus Transportation

2-8

2.4.4

Grow Biomass by Maximizing Pine Volumes

2-12

2.4.5

Grow Maximum Pine/Hardwood per Acre

2-13

2.4.6

Dedicated Short Rotation Plantation

2-14

3.0

Energy Crop Possibilities

4-1

3.1

Background

3-1

3.2

Objectives

3-2

3.3

Approach

3-2

3.3.1

Field Study

3-2

3.3.2

Treatments

3-3

3.3.3

Application Systems

3-3

3.3.4

Plot Layout

3-3

3.3.5

Monitoring

3-5

3.4

Results

3-6

3.4.1

Tree Measurements

3-6

3.4.2

Pine Foliage

3-8

3.4.3

Litter

3-8

3.4.4

Soils

3-10

3.4.5

Surface Water

3-10

3.4.6

Ground Water

3-11

3.4.7

Understory Vegetation

3-11

3.5

Discussion

3-13

3.6

Key Results

3-13

3.7

Conclusions

3-13

3.8

Literature Cited

3-14

4.0

Gasifier Island Design & Cost

4-1

4.1

Approach to Cost/Performance Analysis

4-1

4.2

New Bern Specifications & Design Basis

4-2

4.2.1

General Criteria

4-2

4.2.2

Sire-Related Conditions

4-2

4.2.3

Meteorological Data

4-2

4.2.4

Technical Data

4-3

4.2.5

Capital Cost Criteria

4-4

4.2.6

Qualifications

4-4

4.2.7

Direct Field Material Costs

4-5

4.2.8

Direct Field Labor Costs

4-5

4.2.9

Direct Subcontract Costs

4-5

4.2.10

Indirect Field and Home Office Engineering Costs

4-5

4.3

Plant Description

4-6

4.3.1

Fuel Feed and Drying System

4-6

4.3.2

Gasifier/Combustor System

4-7

4.3.3

Product Gas Clean-Up System

4-9

4.4

Significant Findings

4-14

4.4.1

Dryer Type

4-14

4.4.2

Plant Size

4-15

4.4.3

Feed Moisture

4-16

4.5

Implications to Future Designs

4-18

4.6

Areas of Significant Impact on Economics

4-19

4.6.1

Drying Technology Integration

4-19

4.6.2

Fluidizing Gas Selection

4-20

4.6.3

Dryer Product Moisture

4-20

4.6.4

Capital and Operating Cost Tradeoffs

4-20

4.7

Capital Cost Estimating Approach

4-20

4.8

Detailed Capital Costs

4-21

4.9

Capital Cost Result Summary

4-23

Part 2, Sections 5 - 10, 5.07MB

5.0

Pulp Mill Integration Design & Cost

5-1

5.1

Background

5-1

5.2

Integration Design Basis

5-1

5.3

Balance of Plant System Descriptions

5-4

5.3.1

Wood Receiving, Storage and Handling System

5-5

5.3.1.1

Equipment List

5-5

5.3.2

Ash Collection and Removal System

5-8

5.3.2.1

Equipment List

5-8

5.3.3

Product Gas System

5-11

5.3.3.1

Equipment List

5-12

5.3.4

Condensing Steam Turbine System

5-14

5.3.4.1

Equipment List

5-14

5.3.5

Cooling Water System

5-16

5.3.5.1

Equipment List

5-16

5.3.6

Other Utility/Infrastructure Requirements

5-18

5.3.6.1

Nitrogen System

5-18

5.3.6.2

Instrument Air

5-18

5.3.6.3

Process Water Make-up to Gasification Plant & New Cooling Tower

5-18

5.3.6.4

Boiler Feedwater Make-up to Gasification Plant

5-18

5.3.6.5

HP Superheated Steam Connection

5-19

5.3.6.6

Condensate Return from Gasification Plant to Mill Deaerator

5-19

5.3.6.7

Blowdown from HRSG Drums

5-19

5.3.6.8

Wastewater

5-19

5.3.6.9

Vent VOC Collection

5-19

5.3.6.10

Start Up Fuel

5-10

5.3.6.11

Fire Protection

5-10

5.3.6.12

Electrical Interconnections

5-20

5.3.6.13

Control System

5-21

5.4

Capital Cost Estimates

5-34

5.4.1

Estimating Approach

5-23

5.4.2

Estimating Basis and Assumptions

5-23

5.4.3

Estimate Components

5-24

5.4.3.1

Direct Field Material Costs

5-24

5.4.3.2

Direct Field Labor Costs

5-24

5.4.3.3

Direct Subcontract Costs

5-24

5.4.3.4

Indirect Field and Home Office Engineering Costs

5-25

5.4.3.5

Process Contingency

5-25

5.4.3.6

Project Contingency

5-26

5.4.4

Nth Plant Design at New Bern Cost Estimate

5-26

5.4.5

Next Plant Design at New Bern Cost Estimate

5-26

5.4.6

Generic Nth Plant Gasification Plant Cost Estimate

5-27

5.5

Operating & Maintenance Costs

5-27

5.5.1

Staffing Requirements

5-27

6.0

Syngas Utilization Considerations

6-1

6.1

Process Impacts of MCVG

6-1

7.0

Power Boiler Relifting as a Conventional Alternative

7-1

7.1

Background

7-1

7.2

Design Basis

7-2

7.3

System Descriptions

7-5

7.3.1

Boiler/Flue Gas System Modifications

7-5

7.3.1.1

Equipment List

7-5

7.3.2

Condensing Steam Turbine System

7-8

7.3.2.1

Equipment List

7-8

7.3.3

Wood Handling System

7-10

7.3.3.1

Equipment List

7-10

7.3.4

Ash Handling System

7-12

7.3.4.1

Equipment List

7-12

7.3.5

Cooling Water System

7-15

7.3.5.1

Equipment List

7-15

7.3.6

Other Utility/Infrastructure Requirements

7-17

7.4

Capital Cost Estimate

7-17

7.4.1

Estimate Approach

7-17

7.4.2

Estimating Basis and Assumptions

7-18

7.4.3

Estimate Components

7-19

7.4.3.1

Direct Field Material Costs

7-19

7.4.3.2

Direct Field Labor Costs

7-19

7.4.3.3

Direct Subcontract Costs

7-19

7.4.3.4

Indirect Field and Home Office Engineering Costs

7-19

7.4.3.5

Contingency

7-20

7.5

Boiler Relifting Project Cost Estimate

7-20

7.6

Operating & Maintenance Costs

7-20

7.6.1

Staffing Requirements

7-20

8.0

Economics of New Bern Alternatives

8-1

8.1

Approach

8-1

8.2

Overview of Alternatives

8-1

8.3

Results and Discussion

8-4

8.4

Results and Discussion

8-4

8.4.1

Results

8-4

8.4.2

Discussion Comparison to BGCC Technology

8-18

8.5

Conclusions:  New Bern Gasification Project Economic Analysis

8-21

9.0

Public Policy & Sustainable Economic Considerations

9-1

9.1

Approach

9-1

9.2

Overview of Alternatives

9-2

9.3

Analytical Method, Assumptions and Key Inputs

9-3

9.4

Results and Discussion:  Generic LIVG Process Economics

9-4

9.4.1

Economic Assumptions

9-4

9.5

Conclusions

9-15

10.0

Overall Conclusions

10-1