2005 obp bi-annual peer review tc platform analysis overview richard bain thermochemical platform...
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2005 OBP Bi-Annual Peer Review
TC Platform Analysis Overview
Richard Bain
Thermochemical Platform
November 14-16
Overview
Budget• Nexant – Sulfur Removal
• PNNL – Alcohols Separations
• Princeton – Black Liquor Gasification for fuels
• UOP – Refinery Analysis
Partners
• Provide performance and cost data to Integrated Biorefinery models
• Provide research direction and focus through technoeconomic and environmental evaluation addressing technical barriers
• Set goals/targets
• Measure progress.
Analysis Objective
0
100
200
300
400
500
600
700
800
TC
An
alys
is B
ud
get
(K
$)
FY2004 FY2005 FY2006
Thermo ChemicalR&D
FeedstockR&D
BiochemicalR&D
ProductsR&D
IntegratedBiorefinery
Corn Wet Mill Improvements
Corn Dry Mill Improvements
Agricultural Residue
Processing
Energy Crops
Pulp & Paper Mill
Improvements
Forest Products Mill
Improvements
Corn
Other Grains
Corn StoverWheat StrawRice Straw
Perennial GrassesWoody Crops
Mill WastesWood
Mill WastesWood
Fiber Conversion
DDG Conversion
Biomass & Lignin Gasification
Systems- level demonstration & validation of technologies to
improve corn wet milling facilities using corn grain feedstock by
2008
Systems- level demonstration & validation of technologies to
improve corn dry milling facilities using corn grain feedstock by
2008
Systems- level demonstration & validation of technologies to
utilize agricultural residue feedstocks in existing or new
facilities by 2009
Systems- level demonstration & validation of technologies to
utilize perennial crops in existing or new facilities by 2012
Systems- level demonstration & validation of technologies to improve pulp & paper mill facilities and/ or produce
additional products from wood by 2012
Systems- level demonstration & validation of technologies to improve forest products mill facilities and/ or produce
additional products by 2012
Biomass & Lignin Gasification
Biomass & Lignin Gasification
Biomass & Lignin Gasification
Biomass Pyrolysis
Strategic fit with Pathways
The (Fully) Integrated Biorefinery
An effective integrated biorefinery must include biological and thermochemical conversion
Maximize efficiency of biomass (and land) utilization by producing fuels thermochemically and biologically
Potential Biorefinery Products
Biorefinery Product Target Product Market Comment
Mixed Alcohols Ethanol, existing alcohols marketsEthanol is largest component of mixed alcohol and can enter U.S. ethanol market. Higher alcohols are high-value byproducts.
FT Liquids - Naphtha Motor Gasoline FT naphtha is upgradeable to gasoline blendstock. Co-produced with FT distillate.
FT Liquids – Distillate Distillate Fuel High cetane, sulfur-free diesel blendstock. Co-produced with FT naphtha.
FT Liquids – Waxes WaxesPotential high-value co-product, but wax production in the US is declining. Can crack wax to make more distillate and naphtha.
Renewable Diesel Distillate Fuel Produced by hydrotreating of fatty acids. Also called Green Diesel
Dimethyl Ether (DME) Distillate or LPGBlendable with LPG to 20-25%. Diesel engine use requires fueling infrastructure changes – centrally fueled fleet vehicles are potential near-term market.
Pyrolysis Oil – Naphtha Motor Gasoline Upgrading of lignin fraction
Pyrolysis Oil - Distillate Distillate Upgrading of lignin fraction. Co-produced with naphtha fraction
Methanol MethanolMethanol as chemical intermediate (e.g., for olefins) is most promising market, since fuel use (MTBE) is in decline in U.S.
Hydrogen Hydrogen Market is growing, mainly for use in refineries (captive market)
Ammonia Ammonia Among the largest commodity chemicals
Targets – End Products
Ethanol from Thermochemical Mixed Alcohols
Year
2005 2010 2015 2020
Min
imu
m E
tha
no
l o
r M
A S
ell
ing
Pri
ce
($
/ga
l)
0.00
0.50
1.00
1.50
2.00
2.50
3.00Ethanol w MA at Market - Conversion CostEthanol w MA at Market - Feed CostMixed Alcohols - Conversion CostMixed Alcohols - Feed Cost
Mixed Alcohol (MA) 3% Methanol 73% Ethanol 15% n-propanol 6% n-butanol 3% C5+
Stateof Technology
CostTarget
CostTarget
CostTarget
Eth
ano
l
Mix
ed A
lco
ho
ls
Feed = wood @ $30/BDTValues in 2002$
Feed Processing & Handling
Thermochemical Processing
Clean-Up & Conditioning
Fuels & Chemicals
Heat & Power
Biomass ResiduesDedicated Crops
BiorefineryResidues
Fuels Production
Sensors & Control
Targets – Syngas Intermediate
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
Today SOT - Currentdesign
Gas clean up &conditioning - Goal
design
Feed handling &drying
Gasification Process integration
Inte
rmed
iate
cle
an,
refo
rmed
syn
gas
pri
ce (
$/M
MB
tu)
Research in this area results in the largest syngas cost reduction
$4.75 $5.25 $7.25 $3.93 $4.05
Plant size = 2,000 BD tonne/day
• DOE program targets based on intermediate syngas price to track progress toward reducing technical barriers
Decrease in syngas price due to increased yields, decreased capital costs, & efficiency gains
(2025)(2010)
Fractional Conversion at 875oCModel N1D1
Time, Hours
0 1 2 3 4 5
Fra
cti
on
al C
on
ve
rsio
n
0.0
0.2
0.4
0.6
0.8
1.0
Benzene
Ethane
Methane
Naphthalene
Total Tar & Toluene
Targets – Tied with Research
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
Current Design Goal Design
Inte
rmed
iate
cle
an,
refo
rmed
syn
gas
pri
ce (
$/M
MB
tu)
Current
Goal
Results from NREL’s PDU tar reformer
• Goal case yield is increased & capital cost is less
Potential Impact of Reformer Efficiency on Syngas Price
Attaining research goals = reduction in syngas price
Ethanol via bioconversion
Corn Stover 2,000 dMT/day
Ethanol198,400 gpd
Lignin-rich Residue
600 dMT/day
Steam & Power
Gas-FiredCHP Plant
SyngasProduction
Synthesis
Chemical Alcohols 11,800 gpd n-Propanol
9,100 gpd n-Butanol11,800 gpd Amyl/Hex Alcohols
Biomass Residues/Pyrolysis Oils1,205 dMT/day
SyngasEthanol
98,000 gpd
Ethanol296,400 gpd
Products from sugars will be made in both the stand-alone sugars biorefinery and in this Advanced Ethanol Biorefinery.
Sugars Based Biorefinery
FY05 Tasks
• State of syngas technology/update
• Equipment design and costs – design & cost detail for gas clean up, air separation unit, and modular systems (work with Nexant)
• Potential of ethanol from mixed alcohols (gasification of biomass and subsequent conversion to ethanol from mixed alcohols)
• Effect of oxygen purity on direct gasification (examine different oxygen purities then compare indirectly-heated LP gasification to directly heated HP gasification)
• Energy densification of distributed biomass (energy requirements and cost of delivering pyrolysis oil and biomass in various forms)
• Cost-benefit assessment of biorefineries making fuels from black liquor – Princeton University/Navigant/IPST-Georgia Tech/ Politecnico di Milano
• Opportunities for Bio-renewables in petroleum refineries – UOP/NREL/PNNL
Equipment Design & Costs Task
Gas Cleanup Design and Cost Estimates• Detailed design and costs for low pressure & high pressure gas
clean up & conditioning designs
cyclonessyngas
ScrubberTar reformer
Syngas cooling
Water
To treatment
LO-CATSulfur
Amine
CO2
Syngas compression
ZnO bed
For LP case
O2 Purity & Direct versus Indirect Gasification Task
Parameter Indirect BCL Direct GTI
Pressure Low pressure (25 psia) High pressure (350-450 psia)
Feeding system Feed screw conveyor Pressurized lock hoppers with feed screw conveyor
Syngas compression Additional compression needed No additional compression
Heat supply -two vessels (gasifier/combustor) with a circulating medium-air for combustion
-one vessel-oxygen blown thus ASU is needed
Raw syngas quality/properties
-more tar-more char-more CO-lower H2:CO ratio-higher heating value
-more CO2
-higher H2:CO ratio-lower heating value but higher gasifier efficiency because mass flow of dry gas is higher
Operating cost - lower - same
Capital cost - lower - 25% higher
Biofuel product yield - same - 3% higher
Energy Densification Task
• total delivered cost on an energy equivalent basis ($/GJ) for transport distances of 0 – 200 miles for:- wood chip delivery with drying at end use site - delivery of dried wood chips- delivery of pelletized wood- delivery of corn stover cubes- delivery of pyrolysis oil
Small Distributed Systems100 ton per day
Wood Chips
Truck Delivery
Pyrolysis Unit
Truck Delivery
Pelletizing Plant
Truck Delivery
Wood Chipping
Truck Delivery
Dryer Facility
At Forest/Field Harvesting Site
At End-Use Facility
On Delivery Truck
Wood Chips
Wood Pellets
Pyrolysis Oil
Raw Biomass
Dryer Facility
Dryer Facility
Corn Stover Cubing
Truck Delivery
Corn Stover CubesField-Dried
Corn Stover Bales
Wood Chips
Truck Delivery
Pyrolysis Unit
Truck Delivery
Pelletizing Plant
Truck Delivery
Wood Chipping
Truck Delivery
Dryer Facility
At Forest/Field Harvesting Site
At End-Use Facility
On Delivery Truck
Wood Chips
Wood Pellets
Pyrolysis Oil
Raw Biomass
Dryer Facility
Dryer Facility
Corn Stover Cubing
Truck Delivery
Corn Stover CubesField-Dried
Corn Stover Bales
LargePyrolysis
Plant
$0.00
$2.00
$4.00
$6.00
$8.00
$10.00
$12.00
$14.00
0 50 100 150 200 250
Delivery Distance (mi)
Del
iver
y C
ost
($/
GJ(
LH
V),
dry
)
Wood Chip Delivery, Drying at Pad Pellet Delivery
Pyrolysis Oil Delivery Wood Chip Delivery, Drying at Conversion Facility
Central Pyrolysis: Dry Chips Central Pyrolysis: Wet Chips
Pyrolysis Oil
Dry Wood
Forest Biorefinery Analysis
ObjectiveComplete a detailed design and cost-benefit assessment of biorefineries making synthetic fuels from
black liquor (BL) and wood residues at U.S. Kraft pulp mills; reference mill case-study approach; assess potential energy and environmental impacts for the industry and the country.
Activities to date• Screened and prioritized biorefinery products for detailed analysis. • Developed modeling tools for process design/simulation, mill-integration analysis, financial analysis,
and cost-benefit evaluation.• Heat and mass balances developed for two fuel products (F-T liquids and DME), ongoing for third
product (mixed alcohols), and planned (pending additional funding) for fourth product (methanol as a chemical intermediate).
• Scoping analysis ongoing for low-temperature BLG to identify most promising mill integration and biorefinery products.
• Financial/environmental cost-benefit spreadsheet model under development.• Initial discussions with engineering company for capital cost estimates.
Analytical Team Eric Larson – Princeton University Ryan Katofsky – Navigant Consulting Stefano Consonni – Politecnico di Milano Kristiina Lisa – IPST/Georgia Tech Jim Frederick – IPST/Georgia Tech
Opportunities for Bio-renewables in Petroleum Refineries
• Evaluate the economics for use of Biorenewables in Oil Refineries ( Based on $40/bbl crude)
• Uncover attractive near and long term Opportunities for Biorenewables in Oil Refineries
- Proof of Principle Experiments to Confirm Ideas
Goal
Activities
• Production of Renewable (green) Diesel• Upgrading of Pyrolysis Oils
•Separation into Lignin and Aqueous Fractions•Upgrading of Lignin Fraction
Team
UOP/NREL/PNNL
Renewable Diesel
Stand Alone Skid Mounted Unit
Oil or grease
DHTDiesel
H2
Green Diesel
Diesel
12-16% water,C02
80-100Cetane Number
Feed
<10
83-89
2-5
1.5-3.8
100
ppm S
% diesel
% Lt HC
Products
% H2
% Oil or Grease
12-16% water,C02
80-100Cetane Number
Feed
<10
83-89
2-5
1.5-3.8
100
ppm S
% diesel
% Lt HC
Products
% H2
% Oil or Grease
.78.883Density g/ml
0 to -10+10 % change in NOx emission
265-320340-355Distillation 10-90% pt
<10ppm<10ppmSulfur content
4438Heating Value (lower) MJ/kg
011%O
-5 to -30-5 Cloud Point C
80-9050Cetane
Green dieselBiodiesel (FAME)
.78.883Density g/ml
0 to -10+10 % change in NOx emission
265-320340-355Distillation 10-90% pt
<10ppm<10ppmSulfur content
4438Heating Value (lower) MJ/kg
011%O
-5 to -30-5 Cloud Point C
80-9050Cetane
Green dieselBiodiesel (FAME)
H2
FY05 Milestones
Milestone type
Task / Milestone DescriptionCompletion
Date
D Biomass syngas to product design report 1/31/05
D Energy densification of distributed biomass 4/15/05
DEffect of oxygen purity on direct-fired gasification & comparison to indirect gasification
9/30/05
EPotential of thermochemical ethanol from mixed alcohols
10/31/05
J
Complete a technical and economic evaluation to validate the cost of syngas from biomass suitable for producing a fuel product.
3/31/056/30/059/30/05
Future Work - FY06
• State of syngas technology/update
• Dry or CO2 reforming versus steam reforming – potential economic & environmental benefits
• Sugars/Thermochemical Integrated Biorefinery (cost shared with strategic analysis)
• Cost-benefit assessment of biorefineries making fuels from black liquor
Lignocellulosic Biomass
Fermentation
Catalysis
Syngas Production
Sugar Production
Ethanol
Products:propanol, butanol
other alcohols
Lignin-rich Residues
Low Quality Residues
CHP DistillationCO2