2005 OBP Bi-Annual Peer Review Thermochemical Processing Effort

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2005 OBP Bi-Annual Peer Review Thermochemical
Processing Effort

• Dr. Don J. Stevens, PNNL
• Thermochemical Platform
• November 14, 2005

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Overview
Work Objective Promote efficient conversion
of lignin-rich biomass to useful intermediates
including syngas
Relevant Pathways Agricultural Residues, Energy
Crops, Forest Products, Pulp and Paper
Partners
NREL PNNL Bioengineering Resources Antares Eastman
Chemical Weyerhaeuser University of Utah
Budget (K)
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Technical Barrier Areas

• Addressing technical barriers
• Handling varying biorefinery residues,
  lignin-rich feedstocks, and off-specification
  biomass
• Efficiently converting biomass with low tar
  production
• Achieving desired syngas composition
• Handling/recovering inorganic material

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Strategy and Pathways Intermediate to Long Term
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Impact of Thermochemical Platform RDon A and B
Milestones in the Agricultural Residues and
Perennial Crops Pathways
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Impact of Thermochemical Platform RDon A and B
Milestones in the Pulp and Paper and Forest
Products Pathway
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Thermochemical Platform
3.0 Thermochemical Platform RD
3.1 Feed Processing and Handling
3.2 TC Processing
3.3 Cleanup and Conditioning
3.5 TC Platform Analysis
3.3.1. Cleanup and Conditioning Core RD
3.1.1.2. Feed Improvement
3.2.1. Biomass Gasification
3.5.1. TC Platform Analysis
3.2.2. Pyrolysis
3.3.2. Cleanup and Conditioning Partnerships
3.5.2. BLG for Fuels/ Chemical in at Kraft Mills
3.2.3 Black Liquor Gasification
3.2.4 Innovative Gasification
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Thermochemical Platform
3.2. TC Processing
3.2.1. Biomass Gasification
3.2.3. Black Liquor Gasification
3.2.4. Innovative Gasification
3.2.1.2. Gasification of Corn Stover
and Biorefinery Residues
3.2.3.1.3. Adv. High Temp BLG Tech.
3.2.4.2. TC Conversion of Corn Stover
3.2.1.3. Wet Gasification of Biorefinery Residues
3.2.4.3. Catalytic Hydrothermal Conversion
3.2.4.4. Innovative Membranes/Gasification
Technologies
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Thermochemical Processing
Current Program Includes

• Thermal gasification using oxygen-blown or
  indirectly heated gasifiers for medium-energy
  syngas
• Hydrothermal gasification for medium-energy
  syngas
• Current focus is on producing syngas, suitable
  with conditioning, for liquid fuels production

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TC Processing Technical Areas
Project Areas Description
Biomass Gasification (NREL, PNNL) Core RD to better understand gasification processes and guide process improvements, with particular emphasis on agricultural biorefinery residues
Black Liquor Gasification (Weyerhaeuser) Process RD to assist with integrated gasification of black liquor to syngas in a forest biorefinery
Innovative Gasification (Antares/Eastman, Bioengineering Resources, PNNL/NREL) RD on innovative, higher risk thermal conversion approaches that will, if successful, provide advantages for biorefineries.
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TC Processing Biomass Gasification

• Task 3.2.1. Biomass Gasification of Biorefinery
  Residues
• Objective Obtain basic data on thermochemical
  gasification of selected feedstocks to facilitate
  production of liquid fuels
• Technical Approach
• Conduct benchmark studies using NREL and PNNL
  gasification systems
• Focus specifically on corn stover and biorefinery
  residues
• Collect detailed data on solids conversion, tar
  and char yields, gas compositions, N and S
  release, and other parameters
• Needs Basic data on gasification of corn stover
  and biorefinery residues is not available.
  Reliable data is needed to ensure compatibility
  with industry goals for liquid fuels
• Milestones Relevance Data assists meeting
  programmatic milestones on TC conversion to
  syngas
• Projects and Participants
• NREL Basic studies of gasifying corn stover and
  biorefinery residues
• PNNL Parametric studies of wet gasification of
  biorefinery residues

NREL TCPDU Gasifier System
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TC Processing Biomass Gasification

• Task 3.2.1. Biomass Gasification of Biorefinery
  Residues (Continued)
• Accomplishments Plans
• NREL Basic Gasification Studies
• Work conducted in NREL TCPDU gasification system
• 20 corn stover gasification conditions studied
  to provide data for crucial for development of
  technical validation model
• Work proceeding as scheduled, milestones met
• FY06 work to focus on fermentation based
  lignin-rich biorefinery residues
• PNNL Parametric Wet Gasification Study
• Work conducted in PNNL wet gasification reactor
  system
• Hydrothermal catalytic process at 350C, 200 atm
• Produces methane-rich gas
• Data collection on gasification of biorefinery
  residues underway as scheduled
• All work complete in early FY06, project will end
  as planned

PNNL Wet Gasification System
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TC Processing Black Liquor Gasification

• Task 3.2.2. Gasification for fuels/chemicals in
  a pulp mill
• Objective Conduct process RD to assist with
  integrated gasification of black liquor to syngas
  in a paper mill
• Technical Approach
• Conduct research on q high temperature
  gasification concept
• Focus on black liquor feedstock
• Recognize BL gasification must be integrated with
  heat and chemical recovery
• Collect process data to assist industry
• Needs Black Liquor is a difficult feedstock to
  handle with high sulfur content. Process must
  also provide integration of heat use and chemical
  recovery.
• Milestones Prior analysis shows BL Gasification
  has the potential to be more cost effective than
  current combustion systems. Project technical
  milestones support the syngas cost goal.
• Projects and Participants
• Weyerhaueser High temperature BL gasification

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TC Processing Black Liquor Gasification

• Task 3.2.2. Gasification for fuels/chemicals in
  a pulp mill (continued)
• Accomplishments Plans
• Weyerhaeuser Advanced High Temperature
  Gasification
• Project began in 2005
• Utilizing CHEMREC New Bern gasifier as a test-bed
  facility
• Conducting long-term continuous trials under real
  process conditions
• Combining fundamental chemistry and modeling to
  address issues
• FY06 work will continue tests and modeling
• Project has clear milestones and go/no-go
  decision points

New Bern Gasifier
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TC Processing Innovative Gasification

• Task 3.2.3. Innovative Gasification
• Objective Conduct research on innovative
  thermal conversion approaches that will, if
  successful, provide advantages for biorefineries
• Technical Approaches
• Industry-led RD on the hydrothermal gasification
  of wet biomass (Antares/Eastman Chemical/PNNL)
• Industry-led RD to determine the feasibility of
  gasification systems followed by fermentation of
  syngas (Bioengineering Rseources)
• Assess the feasibility of ceramic membranes
  inside or close-coupled to biomass gasifiers for
  producing improved syngas for producing liquid
  transportation fuels (NREL/PNNL)
• Needs The innovative nature of these projects
  entail higher technical and economic risks, but
  they offer potential for significant improvement
  if successful. In most cases, Industry is
  providing cost-sharing.
• Milestones Projects have clear technical
  milestones, and industry projects are reviewed
  regularly against go/no-go decisions.
• Projects and Participants
• Antares/Eastman Chemical/PNNL Catalytic
  hydrothermal gasification of biosludge
• Bioengineering Resources Thermochemical
  conversion of corn stover
• NREL/PNNL Evaluation of membrane systems for
  biomass gasification

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TC Processing Innovative Gasification

• Task 3.2.3. Innovative Gasification (continued)
• Accomplishments Plans Competitive, industry
  cost-shared projects
• Antares/Eastman Chemical/PNNL Catalytic
  Hydrothermal Gasification
• Low temperature catalytic wet gasification of
  biosludge, 350 C, 200 atm
• FY05 Feedstock characterization and conversion
  studies in bench-scale units
• FY06 Go/no-go decision on conducting larger
  scale gasification tests at the Eastman Chemical
  site. Critical success factor catalyst
  lifetimes
• Bioengineering Resources Thermochemical
  Conversion of Corn Stover
• Pilot scale gasification/fermentation process to
  convert corn stover to ethanol
• Utilizes oxygen-enriched gasification in a
  Consutech gasifier
• Syngas converted to ethanol by anaerobic
  fermentation
• Gasifier constructed and operated in 2005
• FY06 will include studies to convert syngas to
  ethanol. Critical success factor 50 g/l-day
  must be achieved

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TC Processing Innovative Gasification

• Task 3.2.3. Innovative Gasification (continued)
• Accomplishments Plans
• NREL/PNNL Evaluation of Membrane Systems for
  Biomass Gasification
• Evaluation of high-temperature membranes located
  in or closely coupled to a biomass gasifier
• Focus on systems producing liquid transportation
  fuels
• Includes technical and economic feasibility
• One-time study to be completed in FY06

From Julbe, et al, Catalysis Today, 2005
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Stage Placement Portfolio Alignment Review

• DOE Office of the Biomass Program
• FY05 Thermochemical Portfolio Alignment Review
• June 7-8, 2005
• Stage placement of all new and existing
  projects (16) in the Thermochemical Platform.
• Evaluations based on Program Relevance,
  Approach, Progress, Success Factors, and Future
  Plans
• 7 core RD projects (NREL, PNNL) primarily
  focused on developing biomass gasification and
  gas clean-up technology that can applied many
  different biomass feedstocks.
• 9 subcontracted industrial/cost-shared RD
  projects selected by competitive solicitations or
  directed by Congress to develop/commercialize gas
  cleanup technology, black liquor gasification,
  and other thermochemical processes.
• Reviewers
• Professor Robert Brown, Iowa State University
• Professor Esteban Chornet, Université de
  Sherbrooke
• Viorel Duma, Abengoa Bioenergy RD, Inc.
• John Scahill, DOE Golden Field Office
• David Turpin, MeadWestvaco Research

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Stage Placement Portfolio Alignment Review

• General Comments on Thermochemical Program
• Thermochemical Program has clear goals which
  support the overall program
• Technical barriers are clearly identified
• RD is good fit with the program and there is
  good balance
• Funding may be inadequate to meet program goals
• Specific Reviewer Comments on TC Processing
• Reviewers offered many detailed technical
  suggestions
• Response DOE provided technical feedback to
  PIs
• High level BL Gasification milestones may not be
  met at current budget levels
• Response Current funding availability is
  limited
• Several projects have high risk enforce stage
  gate
• Response DOE agrees, reviews will be held as
  scheduled
• Pyrolysis should be supported in the TC
  Processing Area
• Response Given current budget levels and
  priorities, DOE is currently unable to fund
  pyrolysis to bio-oil RD

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Summary and Future Work

• TC Processing Work In FY06
• Biomass Gasification
• Core RD on gasification of stover and
  biorefinery residues will continue at the NREL
  TCPDU gasifier
• Other projects will end as scheduled
• Pyrolysis
• Future projects on biocrude as a refinery
  feedstock will depend on industry interest and
  OBP funding availability
• Black Liquor Gasification
• RD work will continue in the larger-scale
  facility with industry cost-sharing
• Progress will be tracked and reviewed
• Innovative Gasification
• Two industry-led projects will continue
• Go/no-go decision in FY06 for Antares/Eastman
  project
• Ongoing reviews for Bioengineering Resources
  syngas fermentation