Results of the Technical and Economic Feasibility Analysis for a Novel Biomass Gasification-Based Power Generation System for the Forest Products Industry: Phase 1 Pre-Design Evaluation Final Report

Results of the Technical and Economic Feasibility Analysis for a Novel Biomass Gasification-Based Power Generation System for the Forest Products Industry:
Phase 1 Pre-Design Evaluation Final Report - November 2003

COOPERATIVE AGREEMENT				1
DISCLAIMER				ii
ABSTRACT				iii
TABLE OF CONTENTS				iv
LIST OF TABLES				vi
LIST OF FIGURES				vii
1.0	EXECUTIVE SUMMARY			1
	1.1	INTRODUCTION		1
	1.2	PLANT DESIGN		1
	1.3	EXPERIMENTAL		1
	1.4	RESULTS AND DISCUSSION		2
	1.5	CONCLUSIONS		2
2.0	INTRODUCTION			1
	2.1	BACKGROUND		1
	2.2	PROJECT OUTLINE AND OBJECTIVES		1
	2.3	PROJECT PARTICIPANTS		2
3.0	PLANT DESIGN STUDY & ECONOMIC ANALYSIS			3
	3.1	STUDY BASIS		3
		3.1.1	Plant Design Basis	3
		3.1.2	Site Characteristics	3
		3.1.3	Biomass Fuel Characteristics	3
		3.1.4	Emissions Standards	4
	3.2	PLANT DESCRIPTION		5
		3.2.1	Overall Plant Description	5
		3.2.2	Systems and Components of the Plant	6
		3.2.3	Implementation Steps	7
	3.3	MAJOR PLANT AREAS		15
		3.3.1	Biomass Drying System	15
		3.3.2	Gasification Plant	17
		3.3.3	Boiler Modification and Internal Air Heating	31
		3.3.4	External High Temperature High Pressure Air Heater AH-1	46
		3.3.5	Power Generation	47
		3.3.6	Heat Recovery	54
		3.3.7	Balance of Plant	55
		3.3.8	Construction Schedule	64
	3.4	PLANT OPERATION		65
	3.5	PLANT PERFORMANCE		70
		3.5.1	Feed/Product Summary	70
		3.5.2	Efficiencies	71
		3.5.3	Emissions Inventory	71
	3.6	PLANT LAYOUT		73
	3.7	PLANT PERMITTING REQUIREMENTS		74
	3.8	CAPITAL COST ESTIMATE		78
		3.8.1	Cost Estimating Approach and Basis	78
		3.8.2	Data Source for the Estimate	79
		3.8.3	Estimated Capital Cost	80
	3.9	OPERATING AND MAINTENANCE COST ESTIMATE		80
	3.10	ECONOMIC ANALYSIS		83
		3.10.1	Annual Savings	83
		3.10.2	Annual Expenses	84
		3.10.3	Payback Period	84
		3.10.4	Demonstration vs. Commercial Plant Economics	84
4.0	EXPERIMENTAL			90
	4.1	INSTITUTE OF PAPER SCIENCE AND TECHNOLOGY BARK DRYING VOC STUDY		90
	4.2	HIGH-TEMPERATURE HIGH-PRESSURE AIR HEATER MATERIALS TESTING		97
5.0	RESULTS AND DISCUSSION			100
	5.1	FINDINGS FOR THE DERIDDER MILL		100
	5.2	APPLICATION OF THE TECHNOLOGY TO OTHER MILLS		102
6.0	CONCLUSIONS			103
7.0	REFERENCES			105
8.0	LIST OF ACRONYMS AND ABBREVIATIONS			106
9.0	FIGURES			108
APPENDIX A EQUIPMENT LIST				131
APPENDIX B SOLAR TURBINES INCORPORATED Final Report				136