WO2021090090A1

WO2021090090A1 - Integrated plant for the in situ production of thermal energy from biomass

Info

Publication number: WO2021090090A1
Application number: PCT/IB2020/059692
Authority: WO
Inventors: Luciano DI FELICE; Valerio MANELFI; Stefano MANELFI; Emanuele MELCHIORRI; Luigi IANNITTI
Original assignee: Reset S.R.L.
Priority date: 2019-11-05
Filing date: 2020-10-15
Publication date: 2021-05-14
Also published as: IT201900020362A1

Abstract

Integrated plant (100) for the in situ production of thermal energy from biomass, said integrated plant comprising at least a first module (1) for the formulation of said starting biomass into briquettes with predefined dimensional characteristics, said module (1) in turn comprising at least a section (10) for storing, screening, crushing, drying and briquetting said biomass; said integrated plant (100) further comprising at least a second module (2) for the controlled transport of the biomass, as formulated in said first module (1), inside at least a third module (3) which is an integral part of said plant (100) and which in turn comprises at least a gasification reactor (30) for converting said formulated biomass into syngas briquettes, said third module (3) further comprising at least a cyclone system for the recovery of possible powders, at least a system for the recovery of the condensates (300') and at least a system for the filtration (300) of the biomass, said plant (100) comprising at least an emergency torch (500) and being characterised in that it comprises at least a fifth module (5) comprising at least a boiler (50) for the production of an energy carrier.

Description

“Integrated plant for the in situ production of thennal energy from biomass”

Description Technical field

The present invention relates to the energy sector. More in detail, the present invention consists in a particular modular integrated plant suitable for the in situ production of thermal energy starting from biomass. Said plant is such as to have structural characteristics that make it, thanks to its particular variable configuration, versatile and responsive to various needs revealed by the user.

Prior art

The growing interest in reducing emissions of climate-altering gases, typically CQz and CH4, has led recent international and national policies for renewable energies to focus on the production of thermal energy, no longer from fossil fuels, but from organic and/or biological by-products, such as residual biomass from agricultural and forestry activities, digestate from anaerobic digestion plants, compost from organic waste composting plants and sludge from civil waste treatment, all by-products from primary waste treatment, aiming at obtaining two results, i.e. disposal of undesirable substances, until now transferred to landfill, and the production of thermal energy.

However, currently the technologies used for the production of thermal energy are mainly based, as far as fuels are concerned, on the use of fossil fuels (charcoal, fuel oil, gas oil, kerosene, gasoline, LPG and methane) or, in the case of biomass, “firewood”, wood chips or, in recent years, pellets. From the point of view of the “thermochemical” process, the production of thermal energy occurs through the “combustion”, i.e. the complete oxidation of the fuel components (carbon and hydrogen) at high temperature (open flame) and with direct production of heat and a gaseous effluent formed by the combustion products, mainly carbon dioxide, water vapour and nitrogen oxides.

The supply of fuels, whether of a fossil nature (methane, LPG, gas oil, fuel oil) or biomass (firewood, wood chips, pellets), occurs through a consolidated market, operating through the normal production and marketing circuits. The combustion process is carried out through a single unit operation consisting in the use of suitable boilers equipped with a suitable burner, specific for the type of fuel.

The technology is consolidated, and in recent years the only innovations have been the automation of equipment management and the reduction of emissions into the atmosphere, in particular nitrogen oxides. From this point of view, no exceptionally innovative processes are envisaged.

Obviously besides generating CO2 emissions, therefore climate-altering gases, combustion also involves a considerable production of nitrogen oxides, particularly harmful to the respiratory tracts, and partially burned fuel particles that are released into the atmosphere and constitute the “particulate”, especially the micro-particles referred to as PM10 and PM2.5 which, according to modem medicine, are among the precursors of respiratory diseases.

Recently conceived are a type of integrated plants designed to optimise the processes of conversion of biomasses with the aim of recovering all the products of conversion, exploiting their energy potential, reducing their waste and also reducing the concentration of undesired by-products as much as possible. All this thanks to measures which, as mentioned above, aim at optimising the biogas to syngas conversion process, typically through combustion. An example of this type of plants, belonging to the more generic type of cogeneration plants, is described in document WO2018083554.

The object of the present industrial invention patent application is to provide an innovative integrated plant, similar to the one described in the aforementioned prior art document, but which, with respect to the latter, is characterised in that it comprises, “on board a machine”, a boiler for the in situ production of thermal energy, all contributing to making the integrated plant for the production of thermal energy even more effective for its installation in any context in which it is useful to have thermal energy available. Description of the invention

The integrated plant for the production of thermal energy according to the present invention is an integrated plant for the production of thermal eneigy with biomass, configurable for thermal powers comprised between 100 kWt and 1000 kWt and typically, but not limited to, with nominal thermal power of 300 kWt. Said integrated is macroscopically characterised by its consistent compactness and its high degree of modularity and assemblability, obtaining a variously configurable structure, by joining the various modules comprised therein representing structures that can be perfectly integrated with respect to each other so as to meet the various needs of the end appliance.

In greater detail, similarly to its previous version described in the aforementioned prior art document WO201808354, the integrated plant for the production of thermal energy with biomass, subject of the present industrial invention patent application, comprises integrated modules that allow the production of specific substances, in particular the synthesis gas, a mixture of fuel gas mainly containing H2, CO, CO2, CH₄, and water vapor intended for various uses including the production of thermal energy. For said modules, there is likewise the possibility of configuring them in various ways so that the resulting system is suitable particularly for the specific requirements of the user.

Even more in detail, the thermal energy production plant in question comprises basic modules such as: at least a module for the preparation of the starting biomass, suitable to form geometric elements all of the same dimensions in order to provide the biomass in a stable, non-perishable, transportable and easily storable form; at least a module for the movement and loading of the starting biomass to the gasification system; at least a gasification module suitable for the production and purification of the synthesis gas; at least a control module for the measured and recorded process variables; - at least a safety system provided with an emeigency torch for the evacuation of synthesis gas during malfunctions.

The integrated plant according to the present invention comprises, in particular:

- at least a module for the production of thermal energy supplied with synthesis gas containing one or more burners specifically designed to be supplied with synthesis gas and its specific system for adjusting and controlling the functional parameters; said system is therefore characterised in that it comprises:

- to supplement the proposed configuration, at least a boiler module for the production of an energy carrier (hot water/steam, hot diathermic oil, hot air, molten salts, etc.) as required by the thermal appliance.

Specifically, said biomass loading module comprises: a section for storage on board a machine with the optional screening and/or crushing function, drying function, briquetting function, with the optional additional storage system, and with the optional external conveyor belt per for the automatic loading of biomass. Said gasification module comprises at least a gasification unit consisting of a reactor and associated management equipment and control instrumentation, at least a synthesis gas treatment unit provided with a dedusting, cooling and filtration system.

Said gasification modules can be variously dimensioned, having various sizes depending on the overall power of the machine and the chosen configuration. Said module for the production of thermal energy is the specialised modules for the conversion of the produced synthesis gas into a stream of a fluid (water, diathermic oil, air) for the transport of thermal energy from the point of production to the point of use. Depending on the power of the plant and the needs of the end user, this module may consist of one or more burners specifically designed for the combustion of the synthesis gas, and/or of one or more boilers for the production of the energy carrier, each equipped with at least a burner specifically designed to be power-supplied by synthesis gas. Still the burner supplied with synthesis gas can be configured to obtain the reduction of the production of nitrogen oxides (LOW-NOx burner). Said control module comprises at least an electric panel, at least a plant variables management system (PLC - programmable logic controller), an interconnection panel and at least a monitoring station as provided for by the SCADA control systems.

It should be observed that the exhaust gases flowing from the burner or from the boiler can, in some embodiments of the plant, provide for a particulate holding station and catalytic conversion sections as a function of any use of fumes and any regulations to be applied at the plant installation site.

It should also be observed that, irrespective of the final configuration chosen for the plant, it is linked to the same software (SCADA) which enables full remote control thereof. More clearly, the various parts included in the aforementioned modules, as well as the very modules, can be enabled or disabled in the software depending on whether installation is provided or not provided for in the final configuration of the plant.

Furthermore, the integrated plant according to the present invention is such to allow delivery thereof fully assembled, wired and tested, ready for connection to the power mains and with the terminals (flanges) of the customer’s systems for the use of heat in “PLUG & PLAY” mode.

Before getting into details as concerns the detailed description of the components of the plant subject of the present industrial invention patent application, it should be observed that the advantages offered by said plant are such to meet the types/needs of the appliance that are extremely different from each other. By way of non-limiting example, said plant, in the various possible configurations, is suitable to meet the needs of users with high thermal consumption, such as in the case of remote heating or of energy process plants, but who, at the same time, have considerable amounts of waste biomass that can be used for supplying the plant; of users interested in intensive farming carried out both by the use of heated greenhouses and by the introduction of air enriched with CO2 (carbon fertilisation - negative CO2 cycle) into said greenhouses and for many other needs required of all possible configurations of the plant that can be derived from its easy and particular modularity. Advantageously, the integrated plant according to the present invention does not generate waste required to be gotten rid of through disposal in landfills or through other systems; Advantageously, the power supply thereof is of the “polyfuel” type this implying that the biomass that fuels it upstream can be represented either by virgin wood chips and/or by biomass of various origin, by way of non-limiting example by sludge obtained from purification of human or industrial waste water, by digestate from anaerobic digestion processes, by compost from the stabilisation treatment of the organic fraction of municipal solid waste (OFMSW), by screening the chips or by pruning even more fine crushed, enabling the use of waste material produced physiologically by the screening operation. Advantageously, its versatility, which can be derived from its degree of modularity as well as from the consequent variable configurability, allow to obtain, starting from the biomass, thermal energy in various forms, transferred by means of a flow of hot water, hot air, hot diathermic oil or molten salts.

Advantageously, and as previously mentioned, its variable configurability enables adapting the plant diagram as a function of the use needs. Advantageously, the integrated plant in question allows to obtain a negative CO2 balance thanks to the possibility of reusing part of the CO2 produced and thanks to the fact that the unused portion of the biomass sent to the gasification process is transformed into a vegetable charcoal usable in agriculture and known globally as Biochar. The Biochar produced by the plants with the technology of the integrated plant in question is suitable to be approved by the regulations in force, as a soil improvers that can be used both in agriculture and in floriculture.

Description of the figures

The invention will be described in detail hereinafter with reference to the attached figure and precisely to:

FIGURE 1 which shows the simplified process flow chart. More in detail, the figure shows that said integrated plant 100 comprises the first module 1 for the preparation of the biomass suitable to form briquettes with the same characteristics so as to always have reproducible results, and in particular performance; the second module 2 for the movement of said suitably formulated biomass; the third module 3 for the gasification of said biomass so as to produce and transfer the syngas to other modules of the plant; the fourth module 4 for controlling the measured and recorded process variables and at least a fifth boiler module 5 for producing an energy carrier according to the appliance requirements.

The figure in question also shows the presence of the storage section 10 with optional function of screening and/or crushing, drying, briquetting and transporting the biomass. The gasification reactor 30 with the relative devices for managing the syngas produced and the boiler 50 can also be observed. FIGURE 2 shows a further perspective view of the integrated plant 100 according to the present invention. The figure in question shows the presence and the allocation of the boiler 50, of the burner 50’, of the torch 500, of the control panel 40, of the filtration system 300. FIGURE 3 shows a front view of the cross-section of the integrated plant 100 according to the present invention. Indicated therein is the boiler 50, the burner 50’, the torch 500 and the filtration system 300.

FIGURE 4 is a further perspective view of the integrated plant 100, in which specific components present therein are indicated. In particular, the boiler 50, the burner 50’, the emergency torch 500, the gasification reactor 30, the condensate recovery system 300’, the section 10 for the storage, screening, crushing, briquetting and drying of said starting biomass are highlighted.

Detailed description of the invention

In the preferred embodiment thereof, the integrated plant 100 subject of the present description comprises at least a first module 1 for the preparation of the starting biomass where said biomass is purposely converted into briquettes with predefined dimensional characteristics and such to be easily processed for the conversion thereof into syngas. To this end, said module 1 comprises at least a section 10 for storing, screening, crushing, briquetting and drying said starting biomass. Said integrated plant 100 also comprises at least a second module 2 for the controlled transport of the biomass previously treated in said first module 1 and converted into briquettes, inside the gasification module. Said plant 100 further comprises at least a third gasification module 3. To this end, said third gasification module 3 comprises at least a gasification reactor 30 for the production of the syngas obtained by gasifying the starting biomass converted into H2 and CO and all the systems useful for the purification of said gaseous mixture such as at least a cyclone system for the recovery of possible powders, at least a system for the recovery of the condensates and at least a system for the filtration of the biomass.

Said plant is characterised by the in situ presence of at least a fifth module 5 comprising at least a boiler 50 for the production of an energy carrier such as hot water, hot diathermic oil, molten salts, Hot air, etc. said boiler 50 comprises at least a burner 50’ specifically designed for the combustion of the syngas and it may comprise at least a system for reducing any NOx produced.

In all its embodiments, the integrated plant 100 in question comprises at least a fourth module 4 for controlling the measured and recorded process variables, and in particular for controlling air quality; Said control module comprises at least a control panel 40, at least a system for managing the plant variables, at least an interconnection panel and at least a supervision station as provided by the SCADA control systems.

As previously mentioned, all the embodiments of the integrated plant according to the present invention provide for that the modules thereof be variously dimensionable and modulable, making the plant highly versatile as a whole, thus meeting the needs of the appliance for a particular installation thereof.

As indicated in the attached claims, the subject of the present description is also a method for the particular production of thermal energy, characterised in that it uses the integrated plant 100 described above.

Said method therefore provides for that the starting biomass be inserted into at least a first module 1 in turn comprising at least a section 10 for the storage, screening, crushing, drying and briquetting of said biomass and that the latter, suitably formulated into briquettes, be transferred to at least a second module 2 for the controlled transport of the biomass, as formulated in said first module 1, before being transferred to the at least a third module 3 which is an integral part of said plant 100 and which in turn comprises at least a gasification reactor 30 for converting said formulated biomass into syngas briquettes, and at least a cyclone system for the recovery of possible powders, at least a system for the recovery of the condensates and at least a system for the filtration of the biomass. Said method is characterised in that said biomass as obtained at the output of said third module 3 is transferred to at least a fifth module 5 comprising at least a boiler 50 for the production of an energy carrier selected from hot water, hot diathermic oil, hot air, molten salts and wherein each boiler 50 comprises at least a burner 50 for the combustion of syngas, comprising H₂, CO, CO2, CH4 and water vapour.

As stated several times in the course of the present description, the starting biomass can be selected, by way of non-limiting example, from: virgin wood chips, sludge from human or industrial waste water, digestate from anaerobic digestion processes, compost from the stabilisation treatment of the organic fraction of municipal solid waste, under-screening of the wood chips or from pruning, also chopped, and combinations thereof.

Claims

1. Integrated plant (100) for the in situ production of thermal energy from biomass, said integrated plant comprising at least a first module (1) for the formulation of said starting biomass in briquettes with predefined dimensional characteristics, said module (1) in turn comprising at least a section (10) for the storage, sieving, crushing, drying and briquetting of said biomass; said integrated plant (100) further comprising at least a second module (2) for the controlled transport of the biomass, as formulated in said first module (1), inside at least a third module (3) which is an integral part of said plant (100) and which in turn comprises at least a gasification reactor (30) for the conversion of said biomass formulated in briquettes into syngas, said third module (3) also comprising at least a cyclone system for the recovery of any powders, at least a system for the recovery of condensate (300’) and at least a system for filtering (300) the biomass, said plant (100) comprising at least an emergency torch (500) and being characterised in that it comprises at least a fifth module (5) comprising at least a boiler (50) for the production of an energy carrier selected from hot water, hot diathermic oil, molten salts, hot air, each boiler (50) also comprising at least a burner (50’) for the combustion of the syngas, said syngas comprising H2, CO, CO, CH4 and water vapour.

2. Integrated plant (100) for the in situ production of thermal energy from biomass, according to the preceding claim wherein at least a fourth module (4) is further comprised for controlling the measured and recorded process variables and in particular for controlling the air quality; said control module comprises at least an electrical panel; at least a plant variables management system, at least an interconnection framework and at least a supervision station.

3. Integrated plant (100) for the in situ production of thermal energy from biomass, according to the preceding claim wherein each boiler (50) comprised in the fifth module (5) comprises at least a system for the containment of any NOx produced.

4. Integrated plant (100) for the in situ production of thermal energy from biomass, according to the preceding claim wherein the starting biomass that can be used is selected from: chips from virgin wood, sewage sludge of water from human or industrial use, digestate resulting from anaerobic digestion processes, compost resulting from the stabilisation treatment of the organic fraction of organic solid waste, subsieving of wood chips or pruning, also chopped, and combinations thereof.

5. Integrated plant (100) for the in situ production of thermal energy configurable for thermal powers comprised between 100 kWt and 1000 kWt.

6. Integrated plant (100) for the in situ production of thermal energy according to the preceding claim with a nominal thermal capacity of 300 kWt.

7. Integrated plant (100) for the in situ production of thermal energy according to any one of the preceding claims, wherein the modules of said plant are variously scalable, assemblable and spatially configurable depending on user needs.

8. A method for the in situ production of thermal energy from biomass using the integrated plant (100) as defined in any one of the preceding claims, said process providing that the starting biomass is inserted in at least a first module (1) in turn comprising at least a section (10) for the storage, sieving, crushing, briquetting and drying of said biomass and that the latter, suitably formulated in briquettes, is transferred to at least a second module (2) for the controlled transport of the biomass, as formulated in said first module (1), to then be transferred inside at least a third module (3) that is an integral part of said plant (100) and which in turn comprises at least a gasification reactor (30) for the conversion of said biomass formulated in briquettes into syngas, said third module (3) also comprising at least a cyclone system for the recovery of any powders, at least a system for the recovery of condensate and at least a system for filtering the biomass, said process being characterised in that said biomass as obtained at the output of the third module (3) is transferred to at least a fifth module (5) comprising at least a boiler (50) for the production of an energy carrier selected from hot water, hot diathermic oil, molten salts, hot air, and wherein each boiler (50) comprises at least a burner (50’) for the combustion of the syngas, said syngas comprising ¾, CO, CO, CH4 and water vapour.

9. The method according to the preceding claim wherein the thermal energy is produced starting from a biomass selected from: chips from virgin wood, sewage sludge of water from human or industrial use, digestate resulting from anaerobic digestion processes, compost resulting from the stabilisation treatment of the organic fraction of organic solid waste, sub-sieving of wood chips or pruning, also chopped, and combinations thereof.

10. The method according to any one of claims 8 and 9 wherein each boiler (50) is associated with at least a system for the recovery of any NOx produced.