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D APPENDIX D: TECHNOLOGY SOLUTIONS FOR ENERGY RECOVERY is normally burned in a large recovery boiler, named that because the black liquor combustion is used to recover the chemicals used in the delignification process. Because of the relatively high water content of the black liquor fuel (usually combusted at a solids content of 65-75 percent), the efficiency of existing recovery boilers is limited. Electricity production capacity is also reduced since recovery boilers produce steam at lower pressures for safety reasons. Black liquor gasification is used to produce gas from spent pulping liquor. This gas can be used in a traditional boiler, or may in the future be used in conjunction with gas turbines. There are two major types of black liquor gasification: low temperature/solid phase and high temperature/smelt phase. Today, black liquor gasifiers are used as an incremental addition in chemical recovery capacity in situations where the recovery boiler is a process bottleneck. In the future, gasifiers may be able to provide fuel for gas turbines and lime kilns by means of a standard combined cycle power generation system (made up of a gas turbine, heat recovery system, steam turbine, and electricity generators). The success of turbine-based technology depends on making a turbine that can use low energy gas (produced by an air blown gasifier) or the creation of more efficient oxygen blown gasifier. Gasification produces a fuel gas that needs to be cleaned to remove unwanted impurities for the power system and to recover pulping chemicals. Low-temperature gasification is based on a fluidized bed at atmospheric pressure and a temperature of approximately 700oC or lower, below the melt point of inorganic salts that comprise most of the char from black liquor. Sodium carbonate is used as the bed material and is precipitated out and reused. High-temperature gasification occurs at 2.5 MPa and above the melt point of the inorganic salts (950oC) or higher, and the chemicals are recovered in a smelt. Higher temperatures lead to higher carbon conversion rates but also may lead to more corrosion in the reactor vessel. The synthesis gas is water quenched to produce steam and cleaned before being fired in the turbine. Energy savings estimates for this technology vary, but are potentially significant. Existing recovery boilers consume roughly 27 MBtu of black liquor and other biomass per air dried ton of chemical pulp with power production efficiencies using steam turbine systems of 10%. While increased fuel inputs are required for gasification systems, and increased electricity inputs are required, power efficiencies are much higher thereby allowing for significant primary energy savings. Based on an electricity production capacity of 2,000 kWh/ton, which represents an average of the range of outputs from the various systems, a primary energy savings potential of 6 MBtu/ton pulp is expected. Currently, there are no full-scale gasifier/combined cycle plants operating—although the opportunities for this technology are quite large. A majority of the recovery furnaces and conventional power boilers in existing pulp and paper plants are 20 to 30 years old and more than half of them will need to be replaced or upgraded in the near future. The gasification systems also are expected to improve environmental performance, with fewer particulates and nitrogen oxides than in conventional systems. However, additional research and demonstration are needed before gaining market acceptance. Some key 125PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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