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Part 1, Sections 1 - 4, 4.91 MB |
| 1.0 |
Background and Introduction |
1-1 |
|
1.1 |
Putting Gasification in Context |
1-1 |
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1.2 |
Brief History of Gasification Interest in the Forest Products Industry |
1-1 |
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1.3 |
Summary of Recent Weyerhaeuser Activities in Gasification |
1-1 |
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1.4 |
Opportunity at the New Bern Mill |
1-2 |
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1.5 |
Current DOE/Weyerhaeuser Project |
1-2 |
|
1.6 |
The Formation and Purpose of the Forest Products Gasification initiative |
1-3 |
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1.7 |
The Organization of this Report |
1-4 |
|
2.0 |
Raw Material Availability |
2-1 |
|
2.1 |
Scope and Objectives |
2-1 |
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2.2 |
Approach |
2-1 |
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2.3 |
Findings |
2-2 |
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2.4 |
Supply Strategies |
2-4 |
|
2.4.1 |
Capture Existing Volumes at Hog Fuel Values |
2-4 |
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2.4.2 |
Incorporate Mill Residuals Currently Going to Landfill |
2-7 |
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2.4.3 |
Capture Existing Residuals at Hog Fuel Prices Plus Transportation |
2-8 |
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2.4.4 |
Grow Biomass by Maximizing Pine Volumes |
2-12 |
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2.4.5 |
Grow Maximum Pine/Hardwood per Acre |
2-13 |
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2.4.6 |
Dedicated Short Rotation Plantation |
2-14 |
|
3.0 |
Energy Crop Possibilities |
4-1 |
|
3.1 |
Background |
3-1 |
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3.2 |
Objectives |
3-2 |
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3.3 |
Approach |
3-2 |
|
3.3.1 |
Field Study |
3-2 |
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3.3.2 |
Treatments |
3-3 |
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3.3.3 |
Application Systems |
3-3 |
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3.3.4 |
Plot Layout |
3-3 |
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3.3.5 |
Monitoring |
3-5 |
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3.4 |
Results |
3-6 |
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3.4.1 |
Tree Measurements |
3-6 |
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3.4.2 |
Pine Foliage |
3-8 |
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3.4.3 |
Litter |
3-8 |
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3.4.4 |
Soils |
3-10 |
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3.4.5 |
Surface Water |
3-10 |
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3.4.6 |
Ground Water |
3-11 |
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3.4.7 |
Understory Vegetation |
3-11 |
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3.5 |
Discussion |
3-13 |
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3.6 |
Key Results |
3-13 |
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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 |
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4.2 |
New Bern Specifications & Design Basis |
4-2 |
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4.2.1 |
General Criteria |
4-2 |
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4.2.2 |
Sire-Related Conditions |
4-2 |
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4.2.3 |
Meteorological Data |
4-2 |
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4.2.4 |
Technical Data |
4-3 |
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4.2.5 |
Capital Cost Criteria |
4-4 |
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4.2.6 |
Qualifications |
4-4 |
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4.2.7 |
Direct Field Material Costs |
4-5 |
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4.2.8 |
Direct Field Labor Costs |
4-5 |
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4.2.9 |
Direct Subcontract Costs |
4-5 |
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4.2.10 |
Indirect Field and Home Office Engineering Costs |
4-5 |
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4.3 |
Plant Description |
4-6 |
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4.3.1 |
Fuel Feed and Drying System |
4-6 |
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4.3.2 |
Gasifier/Combustor System |
4-7 |
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4.3.3 |
Product Gas Clean-Up System |
4-9 |
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4.4 |
Significant Findings |
4-14 |
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4.4.1 |
Dryer Type |
4-14 |
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4.4.2 |
Plant Size |
4-15 |
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4.4.3 |
Feed Moisture |
4-16 |
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4.5 |
Implications to Future Designs |
4-18 |
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4.6 |
Areas of Significant Impact on Economics |
4-19 |
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4.6.1 |
Drying Technology Integration |
4-19 |
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4.6.2 |
Fluidizing Gas Selection |
4-20 |
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4.6.3 |
Dryer Product Moisture |
4-20 |
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4.6.4 |
Capital and Operating Cost Tradeoffs |
4-20 |
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4.7 |
Capital Cost Estimating Approach |
4-20 |
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4.8 |
Detailed Capital Costs |
4-21 |
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4.9 |
Capital Cost Result Summary |
4-23 |
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Part 2, Sections 5 - 10, 5.07MB |
|
5.0 |
Pulp Mill Integration Design & Cost |
5-1 |
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5.1 |
Background |
5-1 |
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5.2 |
Integration Design Basis |
5-1 |
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5.3 |
Balance of Plant System Descriptions |
5-4 |
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5.3.1 |
Wood Receiving, Storage and Handling System |
5-5 |
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5.3.1.1 |
Equipment List |
5-5 |
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5.3.2 |
Ash Collection and Removal System |
5-8 |
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5.3.2.1 |
Equipment List |
5-8 |
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5.3.3 |
Product Gas System |
5-11 |
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5.3.3.1 |
Equipment List |
5-12 |
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5.3.4 |
Condensing Steam Turbine System |
5-14 |
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5.3.4.1 |
Equipment List |
5-14 |
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5.3.5 |
Cooling Water System |
5-16 |
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5.3.5.1 |
Equipment List |
5-16 |
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5.3.6 |
Other Utility/Infrastructure Requirements |
5-18 |
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5.3.6.1 |
Nitrogen System |
5-18 |
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5.3.6.2 |
Instrument Air |
5-18 |
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5.3.6.3 |
Process Water Make-up to Gasification Plant & New Cooling Tower |
5-18 |
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5.3.6.4 |
Boiler Feedwater Make-up to Gasification Plant |
5-18 |
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5.3.6.5 |
HP Superheated Steam Connection |
5-19 |
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5.3.6.6 |
Condensate Return from Gasification Plant to Mill Deaerator |
5-19 |
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5.3.6.7 |
Blowdown from HRSG Drums |
5-19 |
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5.3.6.8 |
Wastewater |
5-19 |
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5.3.6.9 |
Vent VOC Collection |
5-19 |
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5.3.6.10 |
Start Up Fuel |
5-10 |
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5.3.6.11 |
Fire Protection |
5-10 |
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5.3.6.12 |
Electrical Interconnections |
5-20 |
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5.3.6.13 |
Control System |
5-21 |
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5.4 |
Capital Cost Estimates |
5-34 |
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5.4.1 |
Estimating Approach |
5-23 |
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5.4.2 |
Estimating Basis and Assumptions |
5-23 |
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5.4.3 |
Estimate Components |
5-24 |
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5.4.3.1 |
Direct Field Material Costs |
5-24 |
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5.4.3.2 |
Direct Field Labor Costs |
5-24 |
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5.4.3.3 |
Direct Subcontract Costs |
5-24 |
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5.4.3.4 |
Indirect Field and Home Office Engineering Costs |
5-25 |
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5.4.3.5 |
Process Contingency |
5-25 |
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5.4.3.6 |
Project Contingency |
5-26 |
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5.4.4 |
Nth Plant Design at New Bern Cost Estimate |
5-26 |
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5.4.5 |
Next Plant Design at New Bern Cost Estimate |
5-26 |
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5.4.6 |
Generic Nth Plant Gasification Plant Cost Estimate |
5-27 |
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5.5 |
Operating & Maintenance Costs |
5-27 |
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5.5.1 |
Staffing Requirements |
5-27 |
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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 |
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7.2 |
Design Basis |
7-2 |
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7.3 |
System Descriptions |
7-5 |
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7.3.1 |
Boiler/Flue Gas System Modifications |
7-5 |
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7.3.1.1 |
Equipment List |
7-5 |
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7.3.2 |
Condensing Steam Turbine System |
7-8 |
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7.3.2.1 |
Equipment List |
7-8 |
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7.3.3 |
Wood Handling System |
7-10 |
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7.3.3.1 |
Equipment List |
7-10 |
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7.3.4 |
Ash Handling System |
7-12 |
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7.3.4.1 |
Equipment List |
7-12 |
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7.3.5 |
Cooling Water System |
7-15 |
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7.3.5.1 |
Equipment List |
7-15 |
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7.3.6 |
Other Utility/Infrastructure Requirements |
7-17 |
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7.4 |
Capital Cost Estimate |
7-17 |
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7.4.1 |
Estimate Approach |
7-17 |
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7.4.2 |
Estimating Basis and Assumptions |
7-18 |
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7.4.3 |
Estimate Components |
7-19 |
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7.4.3.1 |
Direct Field Material Costs |
7-19 |
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7.4.3.2 |
Direct Field Labor Costs |
7-19 |
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7.4.3.3 |
Direct Subcontract Costs |
7-19 |
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7.4.3.4 |
Indirect Field and Home Office Engineering Costs |
7-19 |
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7.4.3.5 |
Contingency |
7-20 |
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7.5 |
Boiler Relifting Project Cost Estimate |
7-20 |
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7.6 |
Operating & Maintenance Costs |
7-20 |
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7.6.1 |
Staffing Requirements |
7-20 |
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8.0 |
Economics of New Bern Alternatives |
8-1 |
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8.1 |
Approach |
8-1 |
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8.2 |
Overview of Alternatives |
8-1 |
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8.3 |
Results and Discussion |
8-4 |
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8.4 |
Results and Discussion |
8-4 |
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8.4.1 |
Results |
8-4 |
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8.4.2 |
Discussion – Comparison to BGCC Technology |
8-18 |
|
8.5 |
Conclusions: New Bern Gasification Project Economic Analysis |
8-21 |
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9.0 |
Public Policy & Sustainable Economic Considerations |
9-1 |
|
9.1 |
Approach |
9-1 |
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9.2 |
Overview of Alternatives |
9-2 |
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9.3 |
Analytical Method, Assumptions and Key Inputs |
9-3 |
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9.4 |
Results and Discussion: Generic LIVG Process Economics |
9-4 |
|
9.4.1 |
Economic Assumptions |
9-4 |
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9.5 |
Conclusions |
9-15 |
|
10.0 |
Overall Conclusions |
10-1 |
