2005 OBP Bi-Annual Peer Review

1
2005 OBP Bi-Annual Peer Review

• TC Platform Analysis Overview
• Richard Bain
• Thermochemical Platform
• November 14-16

2
Overview
Analysis Objective

• 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.

Partners
Budget

• Nexant Sulfur Removal
• PNNL Alcohols Separations
• Princeton Black Liquor Gasification for fuels
• UOP Refinery Analysis

3
Strategic fit with Pathways
Feedstock
Biochemical
Products
Integrated
Thermo Chemical RD
R

D
R

D
R

D
Biorefinery
Systems
-
level demonstration

validation of technologies to
Corn Wet Mill
Corn
Fiber Conversion
improve corn wet milling facilities
Improvements
using corn grain feedstock by
2008
Systems
-
level demonstration

validation of technologies to
Corn Dry Mill
Other Grains
DDG Conversion
improve corn dry milling facilities
Improvements
using corn grain feedstock by
2008
Systems
-
level demonstration

Agricultural
Corn Stover
validation of technologies to
Biomass Lignin Gasification
Residue
Wheat Straw
utilize agricultural residue
Processing
Rice Straw
feedstocks in existing or new
facilities by
2009
Systems
-
level demonstration

Biomass Lignin Gasification
Perennial Grasses
validation of technologies to
Energy Crops
Woody Crops
utilize perennial crops in existing
or new facilities by
2012
Systems
-
level demonstration

validation of technologies to
Pulp

Paper
Biomass Lignin Gasification
Mill Wastes
improve pulp

paper mill
Mill
Wood
facilities and
/
or produce
Improvements
additional products from wood by
2012
Systems
-
level demonstration

Forest
validation of technologies to
Biomass Lignin Gasification Biomass Pyrolysis
Mill Wastes
Products Mill
improve forest products mill
Wood
facilities and
/
or produce
Improvements
additional products by
2012
4
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
5
Potential Biorefinery Products
Biorefinery Product Target Product Market Comment
Mixed Alcohols Ethanol, existing alcohols markets Ethanol 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 Waxes Potential 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 LPG Blendable 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 Methanol Methanol 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
6
Targets End Products
Ethanol from Thermochemical Mixed Alcohols
7
Targets Syngas Intermediate

• 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)
8
Targets Tied with Research
Results from NRELs PDU tar reformer
Potential Impact of Reformer Efficiency on Syngas
Price
Attaining research goals reduction in syngas
price
Goal
Current

• Goal case yield is increased capital cost is
  less

9
Sugars Based Biorefinery
Ethanol 198,400 gpd
Products from sugars will be made in both the
stand-alone sugars biorefinery and in this
Advanced Ethanol Biorefinery.
Ethanol via bioconversion
Corn Stover 2,000 dMT/day
Ethanol 296,400 gpd
Steam Power
Lignin-rich Residue 600 dMT/day
Gas-Fired CHP Plant
Syngas Production
Synthesis
Syngas
Ethanol 98,000 gpd
Biomass Residues/ Pyrolysis Oils 1,205 dMT/day
Chemical Alcohols
11,800 gpd n-Propanol 9,100 gpd
n-Butanol 11,800 gpd Amyl/Hex Alcohols
10
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

11
Equipment Design Costs Task

• Gas Cleanup Design and Cost Estimates
• Detailed design and costs for low pressure high
  pressure gas clean up conditioning designs

12
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 H2CO ratio higher heating value more CO2 higher H2CO 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
13
Energy Densification Task
Small Distributed Systems 100 ton per day

• 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

14
Forest Biorefinery Analysis

• Objective
• Complete 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

15
Opportunities for Bio-renewables in Petroleum
Refineries
Goal

• 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

• Activities
• Production of Renewable (green) Diesel
• Upgrading of Pyrolysis Oils
• Separation into Lignin and Aqueous Fractions
• Upgrading of Lignin Fraction
• Team
• UOP/NREL/PNNL

16
Renewable Diesel
H2

17
FY05 Milestones
Milestone type Task / Milestone Description Completion Date
D Biomass syngas to product design report 1/31/05
D Energy densification of distributed biomass 4/15/05
D Effect of oxygen purity on direct-fired gasification comparison to indirect gasification 9/30/05
E Potential 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. 3/31/05 6/30/05 9/30/05
18
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

CO2