Periodic Reporting for period 3 - SmartCHP (Smart and flexible heat and power from biomass derived liquids for small-scale CHP application)
Berichtszeitraum: 2021-12-01 bis 2023-11-30
Small scale biomass-based Combined Heat and Power (CHP) has the potential to contribute significantly to solving the challenges Europe faces while pursuing the goal to make its energy system smart, clean, flexible, secure, cost competitive and efficient. High efficiencies are achieved by combining heat and power generation, and even cooling can be integrated in such a scheme. Furthermore, CHP can play an important role in securing electricity supply by balancing a Renewable Energy Sources (RES) based grid (“dispatchable power”) to compensate for fluctuating wind and solar electricity. For small-scale biomass CHP systems, a standardized fuel, enabling optimization of the conversion units and thus creating a cost competitive value chain, is highly preferred. Moreover, to achieve high resource efficiencies at all times a highly flexible ratio between heat and power generation is desired. A smart, demand driven unit should be capable of dealing with the fluctuating energy demand and/or varying availability of wind/solar power. In such a case, it is advantageous if the CHP system is flexible enough to adjust its fuel load rapidly, and this is achievable particularly with liquid fuels. Unfortunately, most renewable biomass resources are solid materials with a low energy density, therefore a preceding liquefaction step seems attractive. The resulting liquid energy carrier is then used to fuel the CHP unit, and this is the concept under development in SmartCHP.
The overall objective of SmartCHP is the realization of a cost-effective and flexible energy system by using a liquid intermediate energy carrier in an efficient Compression-Ignition (‘diesel’) -engine based CHP system. More specifically, it concerns the development of a smart and flexible, small-scale CHP unit (100 – 1,000 kWe) fueled with fast pyrolysis bio-oil (FPBO) originating from different types of lignocellulosic biomasses and/or residues. Fast pyrolysis is a process to convert a variety of biomass resources into a uniform liquid fuel called FPBO, and the process is characterized by a high feedstock flexibility. Nowadays, FPBO is produced on a commercial scale in Europe (e.g. Finland, Sweden & the Netherlands). The SmartCHP system combines an FPBO fueled engine and flue gas boiler to produce electricity and heat at a high efficiency over the whole load range. A dedicated flue gas treatment guarantees low emissions. Furthermore, SmartCHP enables higher levels of renewables in the electricity system by providing a flexible, responsive, and intelligent solution.
The overall objective of SmartCHP is the realization of a cost-effective and flexible energy system by using a liquid intermediate energy carrier in an efficient Compression-Ignition (‘diesel’) -engine based CHP system. More specifically, it concerns the development of a smart and flexible, small-scale CHP unit (100 – 1,000 kWe) fueled with fast pyrolysis bio-oil (FPBO) originating from different types of lignocellulosic biomasses and/or residues. Fast pyrolysis is a process to convert a variety of biomass resources into a uniform liquid fuel called FPBO, and the process is characterized by a high feedstock flexibility. Nowadays, FPBO is produced on a commercial scale in Europe (e.g. Finland, Sweden & the Netherlands). The SmartCHP system combines an FPBO fueled engine and flue gas boiler to produce electricity and heat at a high efficiency over the whole load range. A dedicated flue gas treatment guarantees low emissions. Furthermore, SmartCHP enables higher levels of renewables in the electricity system by providing a flexible, responsive, and intelligent solution.
Screening of suitable biomass feedstocks was conducted for the EU countries. Multiple criteria were used like feedstock availability, suitability for pyrolysis, sustainability, support mechanisms and prices. Eventually, five countries were selected representing different European regions, scenarios, and feedstocks. Three of the biomass feedstocks were tested in the fast pyrolysis process.
The physical and chemical properties of FPBO make the direct application in conventional diesel engines very challenging. Research has started to investigate the combustion properties of FPBO in a Combustion Research Unit (CRU). The auto-ignition characteristics of FPBO are much poorer than diesel, and addition of cetane improver has been assessed. A critical element of the FPBO fueled diesel engine is the fuel supply and injection system. A dedicated, corrosion resistant unit was constructed and successfully tested. An important project milestone was 500h operation of the engine without replacing the fuel injection system, and eventually over a 1000h was achieved.
Following the successful test campaign on the 1-cylinder engine, a 4-cylinder prototype was realized, which was operated for over 100h. A flue gas treatment unit was added to ensure low emissions at all conditions and complying with European regulation. Addition of a flue gas boiler to generate additional heat was not successful as the operation was highly unstable.
To enable smart control of the SmartCHP unit, a predictive, real-time dynamic system model is developed. The model could not be demonstrated on the prototype due to the troublesome operation of the boiler.
An overview of the CHP market and its trends in the short/mid-term horizon in EU-27 has been prepared, leading to the evaluation of the potential for FPBO fueled CHP systems in the European market. The regional dimension at the EU level has been studied leading to the selection of several “focus countries” where SmartCHP technology could be effectively applied and tested. The focus countries are Croatia, Greece, the Netherlands, Romania, and Sweden. The public report can be found on the project’s website.
To foster knowledge exchange, gather feedback on R&D activities and enhance networking in the area, a stakeholder forum dedicated to biomass-based CHP – BIOCOGEN 2030 – has been established, together with sister project Blaze. So far more than 150 stakeholders have registered to the forum and three (online) dissemination events have been organised.
Within the project three internal Exploitation workshops were held to identify the key exploitable results., The industrial partners -following the successful demonstration of the SmartCHP prototype- are aiming at scaling-up and market implementation of the SmartCHP unit, whereas the academic partners can exploit their knowledge in future activities. The core will be the modified engine combined with the flue gas treatment, but the boiler might be replaced by an electrical heating system to achieve higher reliability, robustness and flexibility.
The physical and chemical properties of FPBO make the direct application in conventional diesel engines very challenging. Research has started to investigate the combustion properties of FPBO in a Combustion Research Unit (CRU). The auto-ignition characteristics of FPBO are much poorer than diesel, and addition of cetane improver has been assessed. A critical element of the FPBO fueled diesel engine is the fuel supply and injection system. A dedicated, corrosion resistant unit was constructed and successfully tested. An important project milestone was 500h operation of the engine without replacing the fuel injection system, and eventually over a 1000h was achieved.
Following the successful test campaign on the 1-cylinder engine, a 4-cylinder prototype was realized, which was operated for over 100h. A flue gas treatment unit was added to ensure low emissions at all conditions and complying with European regulation. Addition of a flue gas boiler to generate additional heat was not successful as the operation was highly unstable.
To enable smart control of the SmartCHP unit, a predictive, real-time dynamic system model is developed. The model could not be demonstrated on the prototype due to the troublesome operation of the boiler.
An overview of the CHP market and its trends in the short/mid-term horizon in EU-27 has been prepared, leading to the evaluation of the potential for FPBO fueled CHP systems in the European market. The regional dimension at the EU level has been studied leading to the selection of several “focus countries” where SmartCHP technology could be effectively applied and tested. The focus countries are Croatia, Greece, the Netherlands, Romania, and Sweden. The public report can be found on the project’s website.
To foster knowledge exchange, gather feedback on R&D activities and enhance networking in the area, a stakeholder forum dedicated to biomass-based CHP – BIOCOGEN 2030 – has been established, together with sister project Blaze. So far more than 150 stakeholders have registered to the forum and three (online) dissemination events have been organised.
Within the project three internal Exploitation workshops were held to identify the key exploitable results., The industrial partners -following the successful demonstration of the SmartCHP prototype- are aiming at scaling-up and market implementation of the SmartCHP unit, whereas the academic partners can exploit their knowledge in future activities. The core will be the modified engine combined with the flue gas treatment, but the boiler might be replaced by an electrical heating system to achieve higher reliability, robustness and flexibility.
The SmartCHP™ concept is a new concept with some specific features:
o Using fast pyrolysis oil –a 2nd generation, sustainable biofuel- as primary fuel;
o A flexible heat to power ratio (from 1:1 to 10:1) with high efficiency over the entire range;
o Demand driven, without having to rely on external heat/power grids for balancing purposes.
Higher heat to power ratios is specifically suitable for integration in a RES net, increasing the uptake capacity of solar/wind power systems.
The development of the SmartCHP technology will contribute to the fulfilment of two out of the three RED 2030 targets (i.e. at least 40% cuts in GHG emissions -from 1990 levels- and at least 27% share for RES). In the longer term, the SmartCHP technology will also support the new electricity market providing local energy markets with a flexibility solution delivering a wide range of heat to electricity ratios at high efficiency.
The final result of SmartCHP is a validated, integrated system consisting of an engine, boiler and flue gas treatment system adapted and optimized to run on FPBO (TRL 5-6). Alternative SmartCHP configurations have been evaluated to replace the boiler with electrical heating systems, and these alternatives appear to be more cost-effective and reliable. A real-time, predictive, dynamic model will be developed to find the optimal operation point for all energy demands. Techno-economic, socio-economic and environmental assessments will be performed to identify real market opportunities. The SmartCHP unit will be based on standard diesel engines, and specific investment costs are expected to be around 1,400 Eur/kWe; an electricity price below 0.10 Eur/kWh is achievable depending on actual costs of pyrolysis oil and sales of heat. Several case studies have been developed to illustrate the opportunities throughout Europe.
o Using fast pyrolysis oil –a 2nd generation, sustainable biofuel- as primary fuel;
o A flexible heat to power ratio (from 1:1 to 10:1) with high efficiency over the entire range;
o Demand driven, without having to rely on external heat/power grids for balancing purposes.
Higher heat to power ratios is specifically suitable for integration in a RES net, increasing the uptake capacity of solar/wind power systems.
The development of the SmartCHP technology will contribute to the fulfilment of two out of the three RED 2030 targets (i.e. at least 40% cuts in GHG emissions -from 1990 levels- and at least 27% share for RES). In the longer term, the SmartCHP technology will also support the new electricity market providing local energy markets with a flexibility solution delivering a wide range of heat to electricity ratios at high efficiency.
The final result of SmartCHP is a validated, integrated system consisting of an engine, boiler and flue gas treatment system adapted and optimized to run on FPBO (TRL 5-6). Alternative SmartCHP configurations have been evaluated to replace the boiler with electrical heating systems, and these alternatives appear to be more cost-effective and reliable. A real-time, predictive, dynamic model will be developed to find the optimal operation point for all energy demands. Techno-economic, socio-economic and environmental assessments will be performed to identify real market opportunities. The SmartCHP unit will be based on standard diesel engines, and specific investment costs are expected to be around 1,400 Eur/kWe; an electricity price below 0.10 Eur/kWh is achievable depending on actual costs of pyrolysis oil and sales of heat. Several case studies have been developed to illustrate the opportunities throughout Europe.