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Novel Design of an Integrated Pulp Mill Biorefinery for the Production of Biofuels for Transportation

An integrated gasification process was developed for an Ohio-based kraft pulp mill to produce liquid transportation fuels from biomass and coal. Black liquor byproduct from the pulp mill is co-gasified with coal to generate high quality syngas for further synthesis to dimethyl ether (DME) and/or Fischer-Tropsch fuels. A Texaco gasifier was chosen as the focal point for this design. Whenever possible, energy is recovered throughout to generate heat, steam, and power. Mass and energy balances were performed for individual process components and the entire design. An overall process efficiency of 49% and 53% was achieved for DME and FT-fuels, respectively | Novel Design of an Integrated Pulp Mill Biorefinery for the Production of Biofuels for Transportation EGEE 580 May 4 2007 By Jamie Clark Qixiu Li Greg Lilik Nicole Reed Chunmei Wang Abstract An integrated gasification process was developed for an Ohio-based kraft pulp mill to produce liquid transportation fuels from biomass and coal. Black liquor byproduct from the pulp mill is co-gasified with coal to generate high quality syngas for further synthesis to dimethyl ether DME and or Fischer-Tropsch fuels. A Texaco gasifier was chosen as the focal point for this design. Whenever possible energy is recovered throughout to generate heat steam and power. Mass and energy balances were performed for individual process components and the entire design. An overall process efficiency of 49 and 53 was achieved for DME and FT-fuels respectively. 2 Table of Contents List of Figures.5 List of Tables.6 1 Introduction.7 2 Background.9 2.1 Pulp Mill Background.9 2.1.1 Harvesting and Chipping.9 2.1.2 Pulping . 10 2.1.3 Chemical Recovery.12 2.1.4 Extending the Delignification Process.13 2.1.5 Bleaching.13 2.1.6 Causticizing and Lime Kiln.14 2.1.7 Air Separation Unit.15 2.1.8 Pulp Drying.15 2.2 Black Liquor Gasification to Syngas.16 2.2.1 Low-Temperature Black Liquor Gasification.17 2.2.2 High-Temperature Black Liquor Gasification.18 2.2.3 Black Liquor Gasifier Recommendation.20 2.2.3 Coal Gasification Technology.20 2.3 Background of DME Synthesis.21 2.3.1 Properties of DME.21 2.3.2 Features of DME Synthesis Technologies.22 2.3.3. DME separation and purification.28 2.3.4 DME Utilization. .29 2.4 Fischer-Tropsch synthesis.30 2.4.1. Fischer-Tropsch Reactors.31 2.4.2. Fischer-Tropsch Catalyst.32 2.4.3. Fischer-Tropsch Mechanism.34 2.4.4. Fischer-Tropsch Product Selection.35 2.4.5. Fischer-Tropsch Product Upgrading.37 2.5 Heat and Power Generation.38 3 Process Design.39 3.1 Pulp Mill.39 3.1.1 Reference Plant.39 3.1.2 Group Design Modifications.42 3.2 Black Liquor and Coal Gasification to .