Biomass-to-Liquids (B2L) Technologies

Transcription

Biomass-to-Liquids (B2L) Technologies
Experiences in Development of
Gasification for Power
Lars Waldheim
Alsätravägen 130
12736 SKÄRHOLMEN
lars.waldheim @waldheim-consulting.se
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Synopsis
 Brief technology overview
 Process development
 Process applications
 Sugar mill applications
 Some final words
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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TPS Termiska Processer AB
Roots in the national energy
laboratory Studsvik,
Nyköping:
Formed in 1992 by staff buy-out
Part of TallOil in 2004
Part of ACAB Invest 2007
Ceased operation in 2010
Energy-related Product
and Services with
Emphasis on:
Stockholm
Nyköping
Biomass and waste
Combustion and gasification
Heat and electricity generation
Environment
Products/ Engineering:
TKC for boiler systems < 30 MW
CFB and FB bed boiler technology
CFB gasification system
Wood pellet and PF burners
Special flow measurement devices
Licensing, technical know-how transfer
Engineering consultancy and services
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Pressurised Gasification
CFB know-how in-house
Proprietary CFB boiler design licensing
Peat
Wood residues
Bark
High Tem perature
Fly ash Filter
Chipping
Secondary Reform er
with Cataly st
Oxy gen
Dry ing
950°C
Boiler
Feedwater
30 atm .
800°C
Feeder
Fly ash
Lock
Hopper
Steam
Steam &
Oxy gen
Ash
Lock
Hopper
Final Treatm ent
Raw
Sy nthesis
Gas
Fuel
Gas
Am monia
Methanol
Oxo Chem icals
Iron pre-reduction
Local Distribution
Combined Cy cle
MINO process 1978-1986
• pressurised 28 bar, oxygen blown, hot gas cleaning
• 2 MWth pilot plant at Studsvik national laboratory
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Gasification Flexibility in Products
CONVERSION
TECHNOLOGY
PRIMARY
PRODUCTS
PROCESSING
TECHNOLOGY
FINAL PRODUCTS
ALCOHOLS
DME
SYNTHESIS
GASIFICATION
HYDROGEN
HYDOROCARBONS
MEDIUM HEATING
VALUE (MCV) GAS
TURBINE
LOW HEATING
VALUE (LCV) GAS
ENGINE
ELECTRICITY
BOILER/ FURNACE
PROCESS STEAM
PROCESS ENERGY
COMBUSTION
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
FLUE GAS
BOILER
STEAM & ELECTRICITY
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Gasification Power Potential
Adapted from: VTT PowerBiGPower –project no. 019761 2009
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Biomass Gasifier Technologies
Repotec
Ortner
FERCO
Taylor
Bioneer
B&W Völund
Nexterra
Fluidyne
Xylowatt
PPC
Pyroforce
TERI
(TPS)
Foster Wheeler
UHDE
Foster Wheeler
Carbona
Chemrec
Metso
UHDE
(CHOREN)
Carbona
Enerkem
Gas
Host
Fuel
Air
INDIRECT
DOUBLE BED
CFB
DOWNDRAFT
FIXED BED
10 kW
UPDRAFT
FIXED BED
1000 kW
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
10 MW
Ash
CFB or FB P>1 MPa
,
100 MW
ENTRAINED FLOW
FUEL THERMAL CAPACITY
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Gasifiers and Prime Movers
PRESSURISED FLUIDISED BED
ATM. CIRC. FLUIDISED BED
ATMOSPHERIC FLUIDISED BED
UPDRAFT FIXED BED
DOWNDRAFT FIXED BED
5
10
15
20
60
25
70
90
80
100 MWe
IGCC (Integrated Gasification Combined-Cycle)
DUAL FUEL + STEAM
CYCLE
DUAL FUEL (INJECTION IGNITED
DIESEL ENGINE)
GAS ENGINE
5
10
15
20
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30
70
75
80
85
90
95 100 MWe
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Gasifier, Post-treatment & Applications
GASIFICATION
CYCLONE GAS CLEANING
FIRING IN
BOILER
· Lime kilns
· Bioneer
·
CO-FIRING
IN BOILER
· Lahti
· Ruien
· Amercentrale
EXTENSIVE GAS CLEANING
FIRING IN
BOILER
· Lahti II
CO-FIRING
IN BOILER
· (Amercentrale)
ENGINE
·
·
·
·
Harboøre
Güssing
Skive
Móra d’Elbe
GAS
TURBINE
· Värnamo
· ARBRE
SYNTHESIS
·
·
·
·
(CHOREN)
GoBiGas
Bio2G
Enerkem
The technical aspects of gas cleaning, relative to the quality
requirements of boilers, engines gas turbines, and last but not
least, chemical syntheses are among the main technical hurdles
IPT Biomass Gasification Symposium
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Fuel Contaminants
Fuel component
CHO
Nitrogen
Sulfur
Chloride
Fluoride
Heavy metalls
Alkalis
Ash
POPs
IPT Biomass Gasification Symposium
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Gasifier gas
emission pre-cursors
Tar, CxHy, CO
NH3, HCN
H2S, COS, org. S
HCl, org. Cl, KCl
HF
Hg, Cd, Zn etc.
Ash particles
Flue gas
Stack emissions
CO
VOC, PAH
NOx, SOx, HCl, HF
Org. Cl
(incl. Dioxine)
Heavy metalls
Particulates
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Tar Yield for Different Fuels
Source: VTT
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CFB Gasification
CFBG developed for lime kilns with ABB Fläkt in 2 MW pilot
Proprietary TPS technology dolomite tar cracker developed
Target market CHP 5- 20 MW heat demand (eq. 4-18 MWe)
Vattenfall power
Hedemora Diesel
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TPS 2 MW CFBG Pilot Plant
(even with oxidation catalyst)
G A S I F IE R
D O LO M IT E
and S A N D
FURNACE
FLARE
Tests with 500 kWe dual fuel diesel engine > 700 hrs op.
Lessons learned
+Tar cracker validation.
Economy of scale!
Engine emissions!
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SCRUBBER
GAS
CO O LER
D O LO M IT E
6
10
16
15
31
14
30
1
2
FUEL
9
22
3
4
32
8
5
21
24
F ILT E R
11
33
13
25
A IR 7
18
27
12
26
TA R C R A C K E R
FLY-ASH SILO
20
A IR
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Tar in Pilot Plant Tests, Wood Fuels
TAR CONTENT
3
(mg/Nm gas)
10000
8000
6000
PILOT PLANT DATA WITH SAND 1988
LABORATORY DATA WITH DOLOMITE
4000
PILOT PLANT DATA WITH DOLOMITE, SHORT PERIODS
IINITIAL PILOT PLANT CONTINUOUS OPERATION
OPTIMIZED PILOT PLANT TESTS, CONTINUOUS OPERATION
2000
0
780
800
820
840
860
880
900
920
TEMPERATURE (°C)
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Grève-in-Chianti WtE
Technical characteristics
• 2 Gasifiers, 15 MWth each
• Gas Boiler and Flue Gas Cleaning
• 6.7 MWe Condensing Turbine
• Fuel Gas to Cement Factory
• Licensee: Ansaldo Aerimpianti
History
• Start-up of Gasifier # 1: Nov. 1991
• Turned over to Client: Aug. 1992
• Start-up of Gasifier # 2: Sep. 1992
• Turned over to Client: March 1993
• 4000 and 5000 ton RDF processed
in 1999 and 2000, resp.
Plant stopped in 2004 from fuel supply restrictions and the
building of a large scale WtE plant in the Florence region
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Grève-in-Chianti
FLUE GAS
TREATMENT SECTION
FUEL
POWER
PROCESS GAS
PRODUCTION
SECTION
GASIFICATION
SECTION
ELECTRIC POWER
(public use)
ASHES
HEAT RECOVERY
(MULTI-USE)
CEMENT INDUSTRY
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Scale-up experiencerom Pilot Plant
• A pilot unit is essential to have real life experience
• A number of design issues must be addressed scaling up
• Preferred equipment for industrial size identified/selected
• Models and other procedures developed part of know-how
Gas heating value vs. scale
Scale
Pilot
Industrial
Vol (%)
H2
N2
CO
CH4
CO2
C2H4
11
55
14
3
16
1
17
43
25
4
10
1
LCV (MJ/Nm3)
4.6
6.9
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Atmospheric BIG-GT Flowsheet
Target output range 20-60 MWe
Filter and scrubber ensures gas quality
Multi-stage
compressor
Feeding simplified, ”difficult ”fuels
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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SIGAME Project, Brazil
Objective:
A 30 MWe BIG-GT plant
based on eucalyptus at
Mucuri, Bahia
Grant support from
WB/UNDP (GEF), EU
1st. phase 1992 -1996
Development involved GE,
TPS and Bioflow competing.
2nd. Phase 1996-1999
EU-BR-IDGE 2000-2003
TPS selected as gasifier
supplier. Engineering and
commericial development
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General Electric LM 2500 Gas Turbine
Aeroderivative gas turbine with nominal 24 MWe output
TPS development activities included:
• Several tests in the modernized pilot plant on eucalytus wood
• Develop Gasifier-GT interface and performance data with GE
• Plant definition and integration, performance estimation
• Plant basic engineering and costing together with JPE
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Sao Paulo, Brazil, 2012-09-17
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ARBRE –
ARable Biomass Renewable Energy
Eggborough
Selby
North Yorkshire
• Owner: Kelda (FRL) 89%, from 2002 EPRL 89%, TPS 11%
•Supplier: Schelde Engineering Contractrs BV, NL (TPS)
• TIC:
30 M£~ 45 M$ 1997, EC grant: 35 %
• PPA: 105 £/MWh ~ 150 $/MWh (2001
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Arbre Plant Technology
Gas turbine (SGT 100)
Steam turbine
Gross output
4.7
6.0
10.7 MW
Gas compressor
Misc. usage on site
Net output
- 1.5
- 1.2
8 MW
Wood feed: 7 to 8 tonne/hr wet
> 30% el. efficiency LHV
IPT Biomass Gasification Symposium
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Suppl. firing in HRSG
Steam 60 bar, 485°C
Atmospheric gasification
Suppl. firing from Thermie
Band, 8 to 12 MW, size of
GT and plant, as well as
conservative design
reduce efficiency
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Project ARBRE History
1994
financial support from EC THERMIE program
1994
15 year UK NFFO power purchase contract signed
1995
Arbre Energy Ltd (AEL) formed, Kelda main owner
1997
planning permission granted
1998
turnkey contract awarded to SEC (NL)
1999
turnkey contractor mother company insolvent
2001
AEL completes construction, hot commissioning
started
gas
turbine operates on wood fuel gas
2002
April 2002
Kelda management turn-over, sells plant to EPRL
July 2002
plant operation suspended, AEL in liquidation
2003
DAS Green Energy UK Ltd. buys assets,
no activity on site.
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Sao Paulo, Brazil, 2012-09-17
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Project ARBRE
Flare, September 2001
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Geração de energia por biomassa
Bagaço e palha de cana
Integração: BIG/GT - Usina
IPT Biomass Gasification Symposium
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Francisco A. B. Linero
linero@ctc.com.br
Helcio M. Lamonica
lamonica@ctc.com.br
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Bagasse and Trash as Gasifier Fuels
Objectives:
 Characterisation of bagasse and trash gasification
properties in laboratory and bench scale
 Pilot plant tests to demonstrate technical feasibility
 Initial test pelletised bagasse
 Tests with trash (loose & pelletised)
 Tests go-feeding pelletised bagasse and loose trash
 Gas cleaning data and contaminant data
 Empirical test data for modelling and scale-up studies
 Model data as input to sugar mill integration studies
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Bagasse and Cane Trash
as Gasifier Fuels
Sharp edges
Trash + sand
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Bagasse and Cane Trash
as Gasifier Fuels
Incipient
droplet
shape
bagasse+sand
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Sao Paulo, Brazil, 2012-09-17
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Bagasse and Cane
Trash as Gasifier Fuels
Small
agglomerate
Trash + sand
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Conclusion of Pilot Plant Tests
Pelletised bagasse tests (3 x 1 weeks) 1998-1999
Loose trash tests (4 x 1 weeks)
2000-2001
 feeding properties
 availability in tests
 gas heating value, rel. wood
 carbon conversion
 tar content in gas, rel wood
 agglomeration
 carbon content in bed ash
 fouling of gas cooler
 ammonia content, rel. wood
 mixed trash bagasse fuel op.
 other contaminants
Bagasse Trash
excellent
excellent
similar
>95 %
low
> limit temp
low
not observed
similar
yes
no
good
fair-good
slightly less
> 95 %
low to medium
none
low
not observed
higher
yes
some S, Cl
Both fuels, alone and as mixtures, acceptable for TPS process
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Sao Paulo, Brazil, 2012-09-17
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Integration of a BIG-GT in a Sugar Mill
Objective:

determine the energy generation and the fuel and energy
consumption patterns of the mill
 evaluate the plant integration in economic terms
Assumptions:
Average mill data representing state-of-the-art in 1998
General Electric LM 2500 gas turbine (data Braz. BIG-GT project)
Trash available as to supplement bagasse as fuel
Work split:
CTC lead partner- Fuel availability and cost, mill aspects
TPS input was BIG-GT cycle calculations and costs
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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PFD and Mill Data- Sugar and Ethanol
Fibre 13.8%=
Bagasse 350 000 ton/y
Trash pot. 120 000 ton/y
Cane: 300 000 ton/season Pol 14.8%
Milling cap.300 ton/hr Juice treatment
Juice extraction
Cane
Steam/cane
0.5 ton/ton
Evaporators
Crystallisation
Centrifugation
Product drying
8 800 bags/d
Sugar
Fermentation
Distillation
Dehydration
Ethanol
Ethanol:
177 m3/d hydrated
177 m3/d hydrated
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Starting point-Typical Mill 1998
Excess bagasse 7%
Mill is self-sufficient
in electrical power
22 bar – 300 ºC
Turbogenerator
Multi-stage
Cane prep.
Single-stage
Milling
Single-stage
Auxiliaries
Single-stage
2,5 bar
Process ~ 0.5 steam/cane (330 kWh/t)
Export power ~ 0-10 kWh/tc
0-3 MW only in season
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How to Achieve Energy Export
Export of energy = less energy available for mill
 Reduce energy consumption
– Improve steam economy
• Improve evaporator train to save primary steam
• Improve heat recovery from evaporated steam
– Integration of drives to increase efficiency and reduce steam
consumption
• Change from direct turbine drives to mechanical drives
• Change from single to multi stage turbines where possible
• Install extraction-condensing turbine to allow off-season operation
• Result: Steam/cane 0.5 → Stage I 0.34 → Stage II 0.28 t/t
• Increase bagasse recovery, trash as supplementary fuel
 Restrictions
– The least impact possible on the mill for demonstration project
– Use no more than the trash realistically recoverable
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Sao Paulo, Brazil, 2012-09-17
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Integration Flowchart
22 bar- 300 ºC
or 82 bar- 400 ºC
Bagasse
Extract.-cond.
Steam Turbine
and trash
Exhaust flue
Back-pressure
Steam Turbine
gas
Gasification and
Gas Cleaning
Bagasse
Dryer
Boiler
Clean LCV
gas
2.5 bar
Process
Gas Turbine
One or two units
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
Cooling tower
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New HP Boiler– Optimisation Ia
New mill boiler
82 bar 480
ºC
22 bar – 300 ºC
Turbogenerator
Turbogenerator
Multi-stage
Auxiliaries – E-motor
Preparation
Single stage
Milling
Single stage
Condenser
Para caldeiras
2,5 bar
Process~ 0.34 steam/cane (220 kWh/t)
Export power ~ 90 kWh/tc
10 MW season and 20 MW off-season
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Partial Integration – Optimisation
1 module
BIG-GT
22 bar
300 ºC
Mill boiler
Consumption 100% of bagasse
~ 40% of trash potential
22 bar – 300 ºC
Turbogenerator
Auxiliaries – E-motor
Preparation
Single stage
Milling
Single stage
Condenser
2,5 bar
Para caldeiras
Process~ 0.34 steam/cane (220 kWh/t)
Export power ~ 170 kWh/tc
28 MW season and 29 MW off-season
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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New HP Boiler Optimisation II
82 bar – 400 ºC
21 bar – 300 ºC
Auxiliaries – E-motor
Cane prep. – E-Motor
Turbogenerator
Milling
Multi-stage
Single-stage
Condenser
2,5 bar
Return to
boilers
Process ~ 0.28 steam/cane (185 kWh/t)
Export power ~ 180 kWh/tc
20 MW in season, 40 MW in off-season
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Total Integration-Optimisation II
1 module
BIG-GT
1 module
BIG-GT
80 bar – 480 ºC
Consumption: 100% of bagasse available
~ 70 % of trash potential
21 bar – 300 ºC
Auxiliaries – E-motor
Cane prep. – E-Motor
Turbogenerator
Milling
Multi-stage
Single-stage
Condenser
2,5 bar
Return to
boilers
Process ~ 0.28 steam/cane (185 kWh/t)
Export power ~ 290 kWh/tc
43 MW season and 60 MW off-season
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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Integration of a BIG-GT in a Sugar Mill
- Without steam savings 500 kg/tc, low export potential
- Old boiler system 0-10 kWh/tc
- new boiler, 10-20 kWh/tc
- With moderate optimization and steam saving 340 kg/tc
- With new HP boiler 90 kWh/tc
- With BIG-GT partial integration 170 kWh/tc
- With moderate optimization and steam saving 280 kg/tc
- With new HP boiler 170 kWh/tc
- With BIG-GT full integration 290 kWh/tc
Conclusion for first BIG-GT demonstration plant:
- partial integration preferred due to increased reliability
- Cost 73 M$, op cost 5 M$,
- Required PPA 73 $/MWhe w/o any grant
- Formation of a PPP to realize project failed
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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The ”Mountain of Death”
BIG-GT Developments stranded on the west slope
However, the potential for high efficiency remains
Source EPRI, USA
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Sao Paulo, Brazil, 2012-09-17
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SYDKRAFT BIG-GT Plant at Värnamo
Mothballed in 2000 as revenues • Supplier: Bioflow (Foster
Were too low to cover op. costs Wheeler, Sydkraft (EON))
VVBGC IGCC Plant
• Tests 1995-2000, 2007
• Fuel 18 MW
• Power 4,2+1,8= 6 MW
• Heat
9 MW
• Typhoon GT (Siemens SGT 100)
•18 bar pressure.
• >8000 hours of gasifier and
3 600 hours of GT operation
• Good emission data
IPT Biomass Gasification Symposium
Sao Paulo, Brazil, 2012-09-17
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LCV Gas Turbines
Gas turbine supplier
Model
Development status on LCV
gas
Power
MW
GE 10
Developed for one project
10
GE LM2500
Developed for one project
24
GE Frame 6B
Developed for projects
43
Siemens SGT 100
3 installations
5
Typhoon
Siemens SGT 400
Initial developments
13
Tornado
Siemens SGT 600
Initial developments
25
GT 10B
Siemens SGT 1000F
5 non-biomass LCV installations
68
V64.3
Mitsibushi MW261
Initial developments
32
Rolls Royce RB211
Initial developments
25
Volvo Aero VT 4400
Developed for one project
4.4
GT older name
Nuovo Pignone GT10
Dresser Rand 4400
Most larger gas turbine are available for heavy residue, coal gasification LCV gas
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Sao Paulo, Brazil, 2012-09-17
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It Takes a Bit of Time
Vintage 1904 Coal Gasifier Integrated with a
200 hp (very nominal) Gas Turbine
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Acknowledgement
For further gasification information
IEA Biomas Agreeement
Task 33 Thermal Gasification
www.ieatask33.org
Work presented was sponsored by
 Global Environmental Facility (GEF),
through UNDP
 European Commission (EU)
FP5 ENERGIE program
(EU-BR-IDGE Project NNE5-0489)
 Swedish National Energy Agency
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