The biocrack Process a refinery integrated biomass-to-liquid concept

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1 The biocrack Process a refinery integrated biomass-to-liquid concept Peter Pucher, IEA Bioenergy Conferce, BDI - BioEnergy International AG

2 BDI at a glance Austrian based, highly professional plant engineering and construction company Tailor-made turn-key solutions Own biodiesel & biogas technologies from waste to value More than 40 reference plants on 4 continents, since 1991 Strong in-house r & d (5 10% of annual revenue) Key figures 2013: Staff: 113 employees Turnover: 36 Mio Equity ratio: 67% Stock market listed in Frankfurt 2

3 Pilot Plant biocrack Vienna Austria Capacity: 2,4 tons biomass / Day Scope of performance: R&D, complete engineering, construction, commissioning and trial operation Scope of delivery: Delivery of entire plant Raw material/substrate: wood/straw + heavy ends Project start: April 2010 Construction start: October 2011 Commissioning + trial operation start: summer

4 biocrack - Concept In liquid phase pyrolysis (LPP) a hot liquid is used as heat carrier Pro: Moderate process conditions (ambient pressure, temperature <400 C) Compared to other technologies simple concept Heat recovery possible Usage of standard industrial equipment Time to market short Direct conversion from solid biomass to liquid hydrocarbon Contra: Limitation in maximum temperature Limited conversion from solid to fuel Challenging separation task solid/liquid Utilisation of by-products necessary Cracking of the heat carrier oil Chance for integrated process in standard refinery To succeed with LPP one need to use a heat carrier oil where cracking is desired! 4

5 biocrack - Process Scheme Gas Biomass Carrier oil liquid phase pyrolysis (LPP) Raw fuel with renewable content Pyrolysis oil Biochar 5

6 biocrack - Refinery Integration Crude oil processing utilities LF/MD heavy oil fraction biomass steam power cooling water nitrogen refinery biocrack biocrack process gas biocrack refinery heavy oil fraction reaction water raw fuel pyrolysis oil biochar CHP FCC WWT Hydrogenation steam, power gasoline, lower HC diesel 6

7 biocrack - Feedstock Ideal biomass for biocrack is renewable lignocelluloses + Low water content + Low nitrogen, chlorine, toxics + Fine particle size (<5mm) possible Examples: o Wood chips (soft and hard wood) o Forestry residues o Chopped straw/agricultural residue o.. Biomass contains up to 50% oxygen in complex molecular structure. Oxygen is unwanted element in liquid fuels and has to be removed to reach requested fuel quality! 7

8 biocrack - C14 Balance Bio-carbon transfer vs. temperature 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Results from biocrack pilot plant Schwechat Feedstock: spruce 20% 11% 18% 50% 19% 28% 21% 15% 38% 24% 14% 30% 350 C 375 C 390 C Reactor Temperature Gas Pyrolysis oil Mixed oil Carrier oil (after treatment) Carrier oil (contained in biochar) Biochar extracted 8

9 biocrack - Diesel Fuel Upgrading of raw diesel to EN590 quality is possible Parameter Untreated raw diesel After hydro treatment EN 590 Density (15 C) 868 kg/m³ 833 kg/m³ kg/m³ Viscosity (40 C) 2,53 mm²/s n.a. 2-4,5 mm²/s Cetan > 51 C/H/O 85/13/2 wt.% 86/14/0 wt.% n.a. Volatile <350 C 83 wt.% 86 wt.% > 85 % (v/v) Sulfur 177 mg/kg 3 mg/kg < 10 mg/kg Results from biocrack pilot plant and hydrogenation at OMV/Schwechat Feedstock: spruce 9

10 biocrack - Biochar Analysis of biomass (spruce) and biochar Biomass (spruce) Biochar Carbon [wt.%] Hydrogen [wt.%] Nitrogen [wt.%] Rest (Oxygen + Ash) [wt.%] Utilisation: Renewable solid fuel for combustion Additive in steel industry, construction material,... Fertilizer and carbon sink Further upgrading to transportation fuel 10

11 biocrack - Pyrolysis Oil Dehydration of biocrack pyrolysis oil is possible Pyrolysis Oil Water Content [wt.%] 50 Lower Calorific Value [kj/kg] 8700 Pyrolysis Oil dehydrated Crude Oil Carbon [wt.%] 22 Hydrogen [wt.%] 10 Oxygen [wt.%] 68 Nitrogen [wt.%] <1 Utilisation: Renewable liquid fuel for combustion Source for chemicals Further upgrading to transportation fuel <1 <1 <1 1 Mortensen et al., Applied Catalysis A: General, 407 (2011) 11

12 biocrack - Research & Development bioboost Hydro-Deoxygenation of biocrack pyrolysis oil Diesel Fuel 20-30% wt bio Carbon 12

13 biocrack - Industrial Scale - Layout - Capacity: to/y BM to/y biofuels III II I Total Area: m 2 - Area I: Multi-Feedstock biomass feedstock preparation, - Area II: biocrack Refining 1-4, Product treatment (BCO, FCO, PYO), TOL Conditioning - Area III: Energy central station, biochar treatment 13

14 biocrack Partners BDI BioEnergy International AG OMV Refining and Marketing GmbH Institute of Chemical Engineering and Environmental Technology Institute of Chemical Engineering JOANNEUM RESEARCH - Resources Austrian Climate & Energy Fund New Energies

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