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Techno‐Economic Analysis and Life Cycle Assessment of Biofuel and Electricity
derived from Wastewater Algae
Jeffery Moody1Ashik Sathish2, Terence Smith2, Ronald Sims2,
Jason C. Quinn1
1Mechanical &Aerospace Engineering2Biological Engineering
Utah State University, Logan, Utah
1
Acknowledgements
• Financial Support from:– Utah Science Technology and Research (USTAR)– State of Utah
• Special Thanks:– Conference Organizers
2
BioEnergyCenter
Systems Level Assessment
Techno‐economic Analysis
Modular Systems Engineering Model
Multi Pathway Flexibility
Experimentally Validated
Large‐scale Representative
Life Cycle Analysis
Methods ResultsIntroduction to Algae TEA & LCA
Experimental Systems
RABR Wet Lipid ExtractionAnaerobic Digestion
Outline
Data Feedback For Process Optimization
Life Cycle Assessment (LCA)
• Fundamental Tool for understanding environmental impact
• Global warming potential– CO2, CH4, and N2O emissions
4
Materials
Energy
Life Cycle Inventory
System BoundaryAtmospheric Emissions
Techno‐economic Assessment
• Economic Feasibility of non‐commercial technologies 5
Experimental Systems
Large‐Scale Systems
Challenge area
LCA of Algae Systems
• LCA results are process dependent
• Large uncertainty in results
• NER defined as Energy in/Energy out
6
TEA of Algae Systems
• Large uncertainty in the literature7
Study Result
Davis et al. (NREL) $8.52 gal‐1
Lundquist et al. (Biofuel) $5.71 gal‐1
Lundquist et al. (Biofuel & Elec) $7.90 gal‐1 and $0.72 kWhr‐1
NMSU $25.22 gal‐1
Beneman et al. $3.57
Pienkos and Darzins $25.00 gal‐1
Benemann & Ozwald $1.64 gal‐1
Van Harmelen & Oonk $4.00 gal‐1
Chisti $6.83 gal‐1
Systems Level Assessment
Techno‐economic Analysis
Modular Systems Engineering Model
Multi Pathway Flexibility
Experimentally Validated
Large‐scale Representative
Life Cycle Analysis
Methods ResultsIntroduction to Algae TEA & LCA
Experimental Systems
RABR Wet Lipid ExtractionAnaerobic Digestion
Outline
Data Feedback For Process Optimization
Systems Level Assessment
Techno‐economic Analysis
Modular Systems Engineering Model
Multi Pathway Flexibility
Experimentally Validated
Large‐scale Representative
Life Cycle Analysis
Methods ResultsIntroduction to Algae TEA & LCA
Experimental Systems
RABR Wet Lipid ExtractionAnaerobic Digestion
Outline
Data Feedback For Process Optimization
Multi‐Pathway Assessment
• Primary Product is Electricity 10
Electricity Based Biorefinery
Model is constructed modularly which enables evaluation of other pathways and technologies
Multi‐Pathway Assessment
• Primary Product is Biodiesel11
Biofuel Based Biorefinery via WLEP
Multi‐Pathway Assessment
• Primary Product is Biodiesel12
Biofuel Based Biorefinery via HTL
Rotating Algal Biofilm Reactor (RABR)
13
• Biofilm based growth system
• Integrated with wastewater for nutrients
• Experimentally demonstrated – 29 g m‐2 d‐1
0
5
10
15
20
25
30
35
40Growth (g
m‐2d‐
1 )
Global Modeling
14
• EnergyPlus Weather Files• DOE• ASHRAE• Hourly data• Light intensity• 4,388 global locations
• Global Map• Biomass yield• Optimum growth locations
Dynamic Map
15
Biomass G
rowth
g∙m‐2∙day
‐1
Biofuel Based Inputs WLEP
16
Input Value Units
Harvested Biomass 28.98 g/m2 day
Motor Size 0.08 hp/RABR
Motor Duty Cycle 24 hrs/day
Amount of Rope 4000 ft/RABR
Lipid Content 10 %
Methane Production 0.43 L CH4/g VS
Temperature for WLEP 90 °C
Sulfuric Acid, 1M 10 L/g
Sulfuric Acid, 0.5M 30 L/g
Sodium Hydroxide, 5M 10 L/g
Hexanes 50 L/g
Centrifuge Cost 58,108 $/acre
Conversion 90 %
Growth
AD
WLEP
Conv.
Biofuel Based Inputs HTL
17
Input Value Units
Harvested Biomass 28.98 g/m2 day
Motor Size 0.08 hp/RABR
Motor Duty Cycle 24 hrs/day
Amount of Rope 4000 ft/RABR
Centrifuge Cost 58,108 $/acre
Bio‐Oil Percentage 45 %
Hydro Processing Efficiency 80 %
Growth
HTL
Refining
Systems Level Assessment
Techno‐economic Analysis
Modular Systems Engineering Model
Multi Pathway Flexibility
Experimentally Validated
Large‐scale Representative
Life Cycle Analysis
Methods ResultsIntroduction to Algae TEA & LCA
Experimental Systems
RABR Wet Lipid ExtractionAnaerobic Digestion
Outline
Data Feedback For Process Optimization
LCA Assumptions
• Life cycle inventory data– ANL GREET model– NREL LCI database
• Environmental Impact– Global warming potential based on CO2‐equvalance
• Includes CH4 and N2O based on IPCC 100 year impact– Net Energy Ratio (NER)
• NER of less than 1 is desirable
19
TEA AssumptionsInput Value Units
Equity 40 %
ROI Equity 15 %
Bank 60 %
ROI Bank 8 %
Facility Lifetime 20 years
Operational Days 365 days
20
• Includes Capital and Operation Costs• Results presented on annualized basis• Results are based on 2013 Dollars• Economic data from commercial enterprises
Systems Level Assessment
Techno‐economic Analysis
Modular Systems Engineering Model
Multi Pathway Flexibility
Experimentally Validated
Large‐scale Representative
Life Cycle Analysis
Methods ResultsIntroduction to Algae TEA & LCA
Experimental Systems
RABR Wet Lipid ExtractionAnaerobic Digestion
Outline
Data Feedback For Process Optimization
LCA Sensitivity
22
Improvements Value Units
Conversion 95 %
Motor Size 1/16 horsepower
Biomass 58 g∙m‐2∙day‐1
Duty Cycle 12 hours
Lipid % 20 %
Improvements Value Units
Duty Cycle 12 hours
Motor Size 1/16 horsepower
Biomass 58 g∙m‐2∙day‐1
Electricity Source 294 g CO2∙kWh‐1
Commercial Scale NER
2391% decrease
Experimental
Commercial
Commercial Scale GHG
24200% decrease
Experimental
Commercial
25
TEA Sensitivity
Improvements Value Units
Sodium Hydroxide 7.5 L∙g‐1
Conversion 95 %
Amount of Rope 2000 feet
Duty cycle 12 hours
Motor Size 1/16 horsepower
Biomass 58 g∙m‐2∙day‐1
Lipid 20 %
Cost Breakdown (WLEP)
26
$‐
$20,000
$40,000
$60,000
$80,000
$100,000
$120,000
$140,000
$160,000
RABR WLEP Seperation AD & CHP Conversion
$/acre year
Annualized Cost
68%
24%
6%
2%
RABR WLEP Seperation AD & CHP
Cost Breakdown
27
$‐
$10,000
$20,000
$30,000
$40,000
$50,000
$60,000
$70,000
Motor Cost Rope RABR Wheel Shaft Angle Bars Flotation Device
$/acre year
Annualized RABR Cost
53%
23%
14%
4% 3%
3%Motor Cost Rope RABR Wheel Shaft Angle Bars Flotation Device
Cost Breakdown
28
$‐
$5,000.00
$10,000.00
$15,000.00
$20,000.00
$25,000.00
$30,000.00
$35,000.00
$40,000.00
$45,000.00
Solution Cost Centrifuge Natural Gas Cost Electricity Cost Plate and Frame HEX
$/acre year
Annualized WLEP Cost
81%
10%7%
1% 1%
Solution Cost Centrifuge Natural Gas Cost Electricity Cost Plate and Frame HEX
Cost Breakdown (HTL)
29
$‐
$10,000
$20,000
$30,000
$40,000
$50,000
$60,000
$70,000
$80,000
RABR HTL Seperation Hydro Processing
$/acre year
55%35%
9%
1%
RABR HTL Seperation Hydro Processing
Results Summary
• Commercial Large‐scale system
• Comparison to commercial technologies
30
Scenario NER GHG (g CO2‐eq MJ‐1) Cost
Baseline 2.04 ‐70 $ 1.72 kWhr‐1
Biofuel via WLEP 2.87 ‐63 $126 gal‐1
Biofuel via HTL 1.38 ‐37 $27 gal‐1
Scenario NER GHG (g CO2‐eq MJ‐1) Cost
Coal Electricity ‐ 311 $0.04 kWhr‐1
Natural Gas Elec. ‐ 173 $0.08 kWhr‐1
Conventional Diesel 0.2 98 $3.85 gal‐1
Systems Level Assessment
Techno‐economic Analysis
Modular Systems Engineering Model
Multi Pathway Flexibility
Experimentally Validated
Large‐scale Representative
Life Cycle Analysis
Methods ResultsIntroduction to Algae TEA & LCA
Experimental Systems
RABR Wet Lipid ExtractionAnaerobic Digestion
Outline
Data Feedback For Process Optimization
General Impact
32
• Direct Research & Development for commercialization
• Pathway optimization
• Feasibility assessments
• Large‐scale resource assessment
Model
Evaluate
Refine
R&D
