2005 OBP Biennial Peer Review Thermochemical Platform Presentation

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2005 OBP Biennial Peer Review Thermochemical
Platform Presentation

• Paul Grabowski
• Technology Manager
• Department of Energy
• Biomass Program
• October 25, 2005

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Thermochemical Platform Overview

• Technology Development
• Thermochemical Conversion of biomass
• Definition
• Thermal decomposition of biomass
• Why
• yield chemical intermediates and then fuels
  chemicals

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Thermochemical Platform Overview
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
3.4 Sensors and Controls
3.3.1. 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. Industry 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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Strategic fit with Pathways
Feedstock
Biochemical
Products
Integrated
Thermo Chemical RD
R

D
R

D
R

D
Biorefinery
Systems
-
level demonstration

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

validation of technologies to
Corn Dry Mill
DDG Conversion Off Spec Lignin
Other Grains
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

Biomass, Lignin, Pulping Liquor Gasification
validation of technologies to
Pulp

Paper
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
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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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Relevance to Pathways the Biorefinery
Products from syngas and bio-oils 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 cracwax 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 Blendablewith 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, 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

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TC Platform Approach

• Develop and Validate Technology
• Utilize Partnerships with Labs, Industry,
  Universities
• Thermochemical Technologies
• Any Biomass
• Produce Fungible Intermediates
• Synthesize value-added products
• Fuels, Chemicals

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Current Partnerships

• Lab and University Partners
• NREL
• PNNL
• University of Utah
• Princeton Univ.

• Industry Partners
• Weyerhaeuser
• GTI
• Antares/Eastman
• Bioengineering Resources
• Southern Research Institute
• Research Triangle Institute

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TC Platform Goals

• Strategic
• The TC Element has one Strategic Goal that
  supports EEREs Goals of reducing imported
  petroleum and developing the biobased industry.
• That TC strategic goal is to develop technology
  for producing, clean, low-cost syngas or bio-oils
  (intermediates) from biomass and biorefinery
  residues.
• Working in concert with the other OBP platforms
  these technologies will be integrated into a
  biorefinery producing fuels, chemicals, heat and
  power.
• Cost
• For biomass-derived syngas, the goals of the
  program are
• Production of clean syngas at 5.25 / million Btu
  by 2010 and for 4.05 by 20203.
• Production of stable bio-oil for 6.88 / million
  Btu by 2010 and for 6.21 by 20204.

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TC Cost Targets
Costs are in 2002, Feed cost - 30/dry ton,
Plant size - 2000 dry tonne/day
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FY05 Key Accomplishments

• Feed Processing and Handling
• The Program has assessed the need for a
  capability to handle slurries and other residue
  streams that might come from a biorefinery.
• Thermochemical Processing
• Gasification technology applicable for spent
  pulping liquors has been developed, are under
  demonstration, and are readying for application
  as biorefineries.
• Industrial partners are evaluating innovative
  gasification technology for several different
  biomass feedstocks.
• Cleanup and Conditioning
• Industrial partners and national laboratories are
  developing and demonstrating technology for
  cleanup (removal of tars and other impurities) of
  biomass derived syngas.
• Options for removal of sulfur from syngas to
  levels suitable for production of liquid fuels
  have been identified.

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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
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Stage Placement Portfolio 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
• Robert Brown, Iowa State University
• 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 Review

• DOE Office of the Biomass Program
• FY05 Thermochemical Portfolio Alignment Review
• June 7-8, 2005
• General Comments on TC Program
• TC 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 Comments on TC Processing
• Included in report
• Each succeeding presentations will discuss for
  each technical barrier area

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TC Platform Future Work

• The Thermochemical Platform RD effort will
  initially focus on utilizing process residues of
  sugar-based biorefineries (off-spec feedstock,
  low quality biomass, lignin-rich residues) to
  provide clean syngas or bio-oils.
• Expand to produce syngas from energy crops and
  forest-based biorefineries.
• Expand to produce bio-oils from resources
  available within various platforms.
• Fold in efforts to convert intermediates to
  marketable fuels and chemicals.

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TC Targets and Milestones
FY2005 FY2006 FY2007 FY2008
Complete a technical and economic evaluation of integrated biomass to fuels systems to validate a syngas cost of 6.13 per million Btu. Develop a fluidizable tar- reforming catalyst for synthesis gas production. Demonstrate conversion of 50 of non-methane hydrocarbons resulting in a syngas cost of 6.84/MMBtu in 2007. Demonstrate (at pilot scale) technology capable of economically converting biomass residues, pulping liquors or waste fats and greases to synthesis gas or bio-oils that are suitable for fuels and chemicals production.
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TC Targets and Milestones
FY2009 FY2010 FY2011
Validate technology capable of economically converting biomass residues, pulping liquors or waste fats and greases to synthesis gas or bio-oils that are suitable for fuels and chemicals production. The target is 5.76/MBtu in 2009 Validate and demonstrate technology for the cost-effective clean-up of biomass synthesis gas leading to syngas costs of 5.25/MBtu in 2010 Demonstrate (at industrial scale) the conversion of synthesis gas or bio-oils, derived from biomass residues, pulping liquors or waste fats and greases, to chemicals or transportation fuels. The target is 5.15/MBtu in 2011
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TC Platform Budget
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Presentation Agenda

• The following presentations will cover the
  Thermochemical Platform Analysis and Barriers
• Richard Bain, NREL Analysis
• John Jechura, NREL - Barriers
• Don Stevens, PNL Barriers
• David Dayton, NREL Barriers

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• BACK UP SLIDES

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TC Program Pathways
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Strategic Direction
Biomass Thermochemical Conversion For Fuels and
Chemicals
PRODUCTS

• Hydrogen
• Alcohols
• FT Gasoline
• FT Diesel
• Olefins
• Oxochemicals
• Ammonia
• SNG

Gasification
Cleanup
Synthesis
Biomass

• Gasoline
• Hydrogen
• Olefins
• Oils
• Specialty Chem

Conversion or Collection
Purification
Pyrolysis

• Hydrogen
• Methane
• Oils
• Other

Separation
Purification
Other Conversion
Examples Hydrothermal Processing,
Liquefaction, Wet Gasification
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Technical Barrier Areas

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Technical Barrier Areas
Heat Power
Biomass Residues Dedicated Crops
Feed Processing Handling
Thermochemical Processing
Clean-up Conditioning
Fuels Chemicals

Biorefinery Residues
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Milestones

• 1 Investigate alternate sources for dry mill heat
  and power (B) (2.7)
• 2 Demonstrate and validate combined heat and
  power from lignin intermediates/residue (B)
  (4.10)
• 3 Demonstrate combined heat and power production
  from lignin (C) (4.10.1)
• 4 Validate integrated production of heat and
  power from lignin at pilot scale (C) (4.10.2)
• 5 Demonstrate and validate lignin gasification to
  produce syngas for 0.xx/MM Btu by 20xx (B)
  (4.11)
• 6 Validate feeder system performance (C) (4.11.1)
• 7 Validate gasification performance (C) (4.11.2)
• 8 Validate gas cleanup performance (C) (4.11.3)
• 9 Validate capital costs - ROI hurdle rate versus
  cost magnitude hurdle amount (C) (4.11.4)
• 10 Validate integrated gasification and gas
  cleanup at pilot scale (C) (4.11.5)
• 11 Demonstrate and validate combined heat and
  power from lignin intermediates/residue (B)
  (5.10)
• 12 Demonstrate combined heat and power production
  from lignin (C) (5.10.1)
• 13 Validate integrated production of heat and
  power from lignin at pilot scale (C) (5.10.2)
• 14 Demonstrate and validate lignin gasification
  to produce syngas for 0.xx/MM Btu by 20xx (B)
  (5.11)

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Milestones

• 15 Validate feeder system performance (C)
  (5.11.1)
• 16 Validate gasification performance (C) (5.11.2)
• 17 Validate gas cleanup performance (C) (5.11.3)
• 18 Validate capital costs - ROI hurdle rate
  versus cost magnitude hurdle amount (C) (5.11.4)
• 19 Validate integrated gasification and gas
  cleanup at pilot scale (C) (5.11.5)
• 20 Demonstrate and validate reliable and economic
  gasification of spent pulping liquor and recycle
  liquor causticization in a pulp mill (B) (6.1)
• 21 Validate reliable and economic performance of
  gasification of spent pulping liquor (C) (6.1.1)
• 22 Validate advantages of co-gasification of
  spent pulping liquors and other forms of biomass
  (woody, recycle paper streams, and bio-oil) (C)
  (6.1.3)
• 23 Validate integrated black liquor gasification
  and causticization process at pilot scale (C)
  (6.1.4)
• 24 Demonstrate and validate gas cleanup and
  process chemical recovery and recycle from spent
  pulping liquor syngas (B) (6.2)
• 25 Validate process chemical recovery from spent
  pulping liquor syngas (C) (6.2.1)
• 26 Validate gas cleanup technologies on spent
  pulping liquor syngas (C) (6.2.2)
• 27 Validate integrated chemical recovery and gas
  cleanup process at pilot scale (C) (6.2.3)
• 28 Validate integrated chemical recovery and gas
  cleanup process in pulp and paper mill (C)
  (6.2.4)
• 29 Demonstrate and validate cost-effective
  biomass gasification of wood residues and other
  process residues and synthesis gas cleanup in a
  pulp and paper mill environment (B) (6.3)

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Future Challenges

• Thermochemically-derived FUELS from Biomass