Periodic Reporting for period 2 - FlexSNG (Flexible Production of Synthetic Natural Gas and Biochar via Gasification of Biomass and Waste Feedstocks)
Période du rapport: 2022-12-01 au 2024-12-31
The FlexSNG project was an EU-Canada jointly funded action that aimed at developing a cost-effective gasification-based process for flexible production of pipeline-quality biomethane (also known as bio-based synthetic natural gas), high-value biochar and renewable heat from low-quality biomass residues and biogenic waste feedstocks. The overall objective was to accelerate the deployment of sustainable advanced biofuels and bioenergy and replace the use of fossil fuels in the transport, power and heating sectors. The produced biomethane could be readily injected into the existing gas infrastructure for distribution to various end-consumers in the transport sector, heat and power production, industries, and households. The biochar product, on the other hand, could be used to displace fossil feedstocks in energy production but also has high potential in other applications, such as carbon sequestration. The by-product heat recovered from the process could be sold as steam to industrial customers or used for district heating. The gasification process was designed as flexible, being able to switch between two different operation modes according to market signals: 1) co-production of biomethane, biochar and heat, and 2) maximised production of biomethane and heat.
During the project, the key enabling technologies of the FlexSNG process were developed and validated to TRL5 through pilot test campaigns. The new cost-cutting features of the process combined with optimisation of the feedstock supply chain resulted in up to 29% reduction in biomethane production costs in comparison to the state-of-the-art reference, making FlexSNG an attractive option for industrial deployment of biomethane production in large scale.
During the project, the key enabling technologies of the FlexSNG process were developed and validated to TRL5 through pilot test campaigns. The new cost-cutting features of the process combined with optimisation of the feedstock supply chain resulted in up to 29% reduction in biomethane production costs in comparison to the state-of-the-art reference, making FlexSNG an attractive option for industrial deployment of biomethane production in large scale.
The project activities were divided into the following categories: (1) technical development and validation of the key enabling technologies, (2) feedstock supply chain optimization, (3) evaluation of utilization options for biomethane and biochar, (4) techno-economic and environmental assessments and case studies, and (5) exploitation, dissemination and communication.
The technical development activities focused on the four key enabling technologies - low-cost oxygen supply with oxygen transport membranes, flexible gasification, filtration and catalytic reforming - that form the backbone of the FlexSNG concept. During the first half of the project, preliminary pilot runs were carried out to optimize the process conditions in the gasifier, the filter and the catalytic reformer for both operation modes: (1) co-production of biomethane, biochar and heat, and (2) maximised production of biomethane and heat. In parallel, lab-scale testing and screening of reformer catalysts and sulphur removal sorbents were performed to support the pilot activities. Development of oxygen transport membranes suitable for gasification started with lab-scale tests in simulated gasification conditions. Based on the experiences gained in the lab tests, a proof-of-concept oxygen production module was designed and constructed.
The experimental work culminated to three pilot test campaigns where the operation of the gasifier, the filter and the catalytic reformer were successfully validated to TRL5. The process was operated under gasification conditions for over 190 hours using different types of woody residues, waste wood and waste-derived feedstock mixed with wood and/or biochar. The proof-of-concept oxygen production module was also coupled with the gasification pilot. The oxygen production unit was operated successfully for over 150 hours in real gasification conditions, demonstrating more than 50% reduction in energy consumption compared to state-of-the-art oxygen production technologies.
Feedstock supply chain optimization activities started with mapping of the feedstock potential and gathering of relevant feedstock quality and cost data. The most eligible feedstocks were selected for FlexSNG based on the collected data and the assessment of their suitability for the gasification process. The pre-processing requirements, storage and collection methods were then determined for the selected feedstocks and the potential benefits of co-handling forest/agro/waste feedstocks were evaluated. This data was ultimately implemented into optimization models that could demonstrate up to 30% reduction in feedstock supply costs through optimized operational planning and better coordination of logistics operations.
The different end-use options for biomethane and biochar were assessed by experimental characterization of biochar samples produced in the pilot tests and studying the current and future markets for both products. The most potential applications for FlexSNG biochar were considered to be energetic use and carbon sequestration. The most promising markets for biomethane, on the other hand, were the hard-to-electrify sectors for long-distance transport (heavy trucks and maritime) as well as industries with demand for high temperature heat, e.g. cement production, when considering the longer-term perspective.
Techno-economic assessments, including designing and cost estimation of a commercial-scale FlexSNG process and benchmarking it against the state-of-the-art reference, were carried out towards the end of the project. The FlexSNG process was estimated to achieve up to 29% lower biomethane production costs compared to the state-of-the-art biomass-to-biomethane reference case. Case studies were also carried out to evaluate the implementation potential of the FlexSNG process in selected regions in Canada and Europe. The case study assessments showcased the significance of economies of scale and the need for public funding especially for demonstration and first-of-a-kind plants. A pathway for the follow-on demonstration stages was also prepared.
The project has been very active in disseminating the project results throughout the project. Several project events, including workshops and a webinar series, were organized to engage with key stakeholders. Already now six academic papers have been published, two manuscripts submitted for review in scientific journals and several papers are in the pipeline.
The technical development activities focused on the four key enabling technologies - low-cost oxygen supply with oxygen transport membranes, flexible gasification, filtration and catalytic reforming - that form the backbone of the FlexSNG concept. During the first half of the project, preliminary pilot runs were carried out to optimize the process conditions in the gasifier, the filter and the catalytic reformer for both operation modes: (1) co-production of biomethane, biochar and heat, and (2) maximised production of biomethane and heat. In parallel, lab-scale testing and screening of reformer catalysts and sulphur removal sorbents were performed to support the pilot activities. Development of oxygen transport membranes suitable for gasification started with lab-scale tests in simulated gasification conditions. Based on the experiences gained in the lab tests, a proof-of-concept oxygen production module was designed and constructed.
The experimental work culminated to three pilot test campaigns where the operation of the gasifier, the filter and the catalytic reformer were successfully validated to TRL5. The process was operated under gasification conditions for over 190 hours using different types of woody residues, waste wood and waste-derived feedstock mixed with wood and/or biochar. The proof-of-concept oxygen production module was also coupled with the gasification pilot. The oxygen production unit was operated successfully for over 150 hours in real gasification conditions, demonstrating more than 50% reduction in energy consumption compared to state-of-the-art oxygen production technologies.
Feedstock supply chain optimization activities started with mapping of the feedstock potential and gathering of relevant feedstock quality and cost data. The most eligible feedstocks were selected for FlexSNG based on the collected data and the assessment of their suitability for the gasification process. The pre-processing requirements, storage and collection methods were then determined for the selected feedstocks and the potential benefits of co-handling forest/agro/waste feedstocks were evaluated. This data was ultimately implemented into optimization models that could demonstrate up to 30% reduction in feedstock supply costs through optimized operational planning and better coordination of logistics operations.
The different end-use options for biomethane and biochar were assessed by experimental characterization of biochar samples produced in the pilot tests and studying the current and future markets for both products. The most potential applications for FlexSNG biochar were considered to be energetic use and carbon sequestration. The most promising markets for biomethane, on the other hand, were the hard-to-electrify sectors for long-distance transport (heavy trucks and maritime) as well as industries with demand for high temperature heat, e.g. cement production, when considering the longer-term perspective.
Techno-economic assessments, including designing and cost estimation of a commercial-scale FlexSNG process and benchmarking it against the state-of-the-art reference, were carried out towards the end of the project. The FlexSNG process was estimated to achieve up to 29% lower biomethane production costs compared to the state-of-the-art biomass-to-biomethane reference case. Case studies were also carried out to evaluate the implementation potential of the FlexSNG process in selected regions in Canada and Europe. The case study assessments showcased the significance of economies of scale and the need for public funding especially for demonstration and first-of-a-kind plants. A pathway for the follow-on demonstration stages was also prepared.
The project has been very active in disseminating the project results throughout the project. Several project events, including workshops and a webinar series, were organized to engage with key stakeholders. Already now six academic papers have been published, two manuscripts submitted for review in scientific journals and several papers are in the pipeline.
The FlexSNG process is founded on the project partners’ advanced technologies and latest innovations in the field of oxygen production, gasification and gas clean-up, and methanation. Combining the technology innovations with feedstock supply chain optimization activities carried out during the project, the FlexSNG process was found to achieve up to 29% lower biomethane production costs compared to the state-of-the-art biomethane production technologies that are based on gasification.
The FlexSNG concept is foreseen to have a significant impact in supporting the decarbonization of the transport and energy production sectors and the overall transition towards low-carbon economy both in Europe and in Canada. The FlexSNG project will boost Europe’s global leadership as a provider of sustainable biofuels/bioenergy technologies for domestic and export markets. The production of renewable methane from domestic biomass and waste resources will also reduce the dependency on natural gas imports, thus improving the security of energy supply in European countries. The commercialization of the FlexSNG technology will also bring new growth and jobs throughout the entire value chain from feedstock sourcing up to the distribution and end-use of biomethane and biochar.
The FlexSNG concept is foreseen to have a significant impact in supporting the decarbonization of the transport and energy production sectors and the overall transition towards low-carbon economy both in Europe and in Canada. The FlexSNG project will boost Europe’s global leadership as a provider of sustainable biofuels/bioenergy technologies for domestic and export markets. The production of renewable methane from domestic biomass and waste resources will also reduce the dependency on natural gas imports, thus improving the security of energy supply in European countries. The commercialization of the FlexSNG technology will also bring new growth and jobs throughout the entire value chain from feedstock sourcing up to the distribution and end-use of biomethane and biochar.