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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 September 2001 to August 2003

Bruce Bryan
Joseph Rabovitserm
Sunil Ghose
Jim Patel

Gas Technology Institute

In this pdf format, this document has 183 pages and is 4.85MB.

Table of Contents

COOPERATIVE AGREEMENT

i
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 Charactertistics 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 Capitol 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
 
LIST OF TABLES
Table 3.1.2-1 Site Characteristics 3
Table 3.1.3-1 Biomass Fuel Characteristics 4
Table 3.1.4-1 Permit Levels of Recent Utility Boilers 5
Table 3.2.3-1 Heat and Material Balance for Implementation Step 1 9
Table 3.2.3-2 Heat and Material Balance for Implementation Step 2 11
Table 3.2.3-3 Heat and Material Balance for Implementation Step 3 13
Table 3.3.1-1 Fuel Dryer Design Basis 16
Table 3.3.1-2 Fuel Dryer Process Parameters 16
Table 3.3.2-1 Fuel Specification 18
Table 3.3.2-2 Limestone Feed Properties 19
Table 3.3.2-3 Gasifier System Design Basis 22
Table 3.3.2-4 Ash Properties 23
Table 3.3.2-5 Process Air Compressor Design Parameters 24
Table 3.3.2-6 Product Gas Composition 25
Table 3.3.2-7 Product Gas Properties After Partial Combustion 26
Table 3.3.2-8 Gas Turbine Air Heater Heat Exchanger AH-1 26
Table 3.3.2-9 Design Parameters of Emergency Spraying Nozzle 27
Table 3.3.2-10 Product Gas Properties 28
Table 3.3.2-11 Flare Design Parameters 29
Table 3.3.2-12 Nitrogen Generation System Process Design Parameters 31
Table 3.3.3-1 Boiler Performance - Original Design and 2001 Upgrade 34
Table 3.3.3-2 Boiler #2 Heat and Mass Balance 36
Table 3.3.3-3 Circulation Study Results 42
Table 3.3.3-4 FD Fan and ID Fan Performance 45
Table 3.3.6-1 HRSG Performance 54
Table 3.5.1-1 Baseline and Modified Plant Performance Comparison 70
Table 3.5.3-1 #2 Bark Boiler Data 72
Table 3.8-1 Estimated Capitol Cost - Direct Cost 81
Table 3.10-1 Input Parameters for Economic Analysis 83
Table 3.10-2a Economic Analysis - Energy Consumption and Saving 86
Table 3.10-2b Economic Analysis - Cost Savings and Payback Period 87
Table 3.10-3a Economic Analysis - Alternative - Energy Consumption and Saving 88
Table 3.10-3b Economic Analysis - Alternative - Cost Savings and Payback Period 89
 
LIST OF FIGURES
Figure 3.1.1-1 Step 1 Process Flow Diagram 109
Figure 3.1.1-2 Step 2 Process Flow Diagram 110
Figure 3.1.1-3 Step 3 and Overall Plant Process Flow Diagram 111
Figure 3.3.1-1 Biomass Dryer Process Flow Diagram 112
Figure 3.3.2-1 Gasification Process Flwo Diagram - Step 3 113
Figure 3.3.3-1 Internal High Temperature High Pressure Air Heater 114
Figure 3.3.3-2 Internal HTHP Air Heater - Selected View 1 115
Figure 3.3.3-3 Internal HtHP Air Heater - Selected View 2 116
Figure 3.3.3-4 Metal Study for Internal HTHP Air Heater - No Air Imbalance 117
Figure 3.3.3-5 Metal Study for Internal HTHP Air Heater - With Air Imbalance 118
Figure 3.3.4-1 External High Temperature High Pressure Air Heater-Design 1 119
Figure 3.3.6-1 HRSG Arrangement and Performance 120
Figure 3.3.7-1 Cooling Water System 121
Figure 3.3.7-2 Compressed Air System 122
Figure 3.3.7-3 Electrical Single Line Diagram 123
Figure 3.3.7-4 Bark Conveying and Delivery System 124
Figure 3.3.8-1 Plant Construction Schedule 125
Figure 3.6-1 Integrated Plant Layout - Sheet 1 126
Figure 3.6-1 Integrated Plant Layout - Sheet 2 127
Figure 3.6-1 Integrated Plant Layout - Sheet 3 128
Figure 4.2-1 Locations of Tube Samples in No. 2 Bark Boiler at Boise DeRidder 129
Figure 4.2-2 Test Assemblies for Tube Testing in No. 2 Bark Boiler DeRidder 129
Figure 4.2-3 Typical Temperature Profile for Test Tube Coupons with air temperature control (800 H) and skin temperature control (353 MA) 130