Drop-in gasoline from wood in an integrated biorefinery: pilot operations under way

Transcription

1 Drop-in gasoline from wood in an integrated biorefinery: pilot operations under way > Andrew Kramer (Gas Technology Institute) Rick Knight (Gas Technology Institute) Jesper Jensen (Haldor Topsoe A/S) Jim Patel (Andritz Carbona) > Gasification Technologies Conference 2013 Colorado Springs, Colorado October 13-16, 2013

2 Disclaimer This material is based upon work supported by the Department of Energy, Golden Field Office, under Award Number DE-EE This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. Footer goes here 2

3 Why Gasoline? >Motor fuels account for 34% of CO 2 emissions >There are >250 million cars and light-duty trucks on the road >95% of them run on gasoline Biomass conversion is the only near-term option to directly replace gasoline with a renewable alternative Footer goes here 3

4 Biomass-to-tank pathway >Thermochemical gasification >Conversion of resulting synthesis gas to motor fuel Footer goes here 4

5 Biomass-to-tank pathway >Thermochemical gasification >Conversion of resulting synthesis gas to motor fuel >Woody biomass gasoline blendstock Product compatibility with existing infrastructure. Footer goes here 5

6 Biorefinery Project Team -Core financial support -Technical guidance and oversight -Project management guidance and oversight - Business: pulp and paper -Provides: gathering, handling and transporting of wood, 1 st commercial plant site -Business: catalysts & catalytic processes -Provides: TIGAS process, syngas reforming catalysts, overall project management -Business: refining & downstream -Provides: design assistance, fuel characterization, engine & fleet testing -Business: gasification & gas cleanup -Provides: fluidized-bed gasification, syngas cleanup and reforming, commercialization support -Business: R&D and process testing -Provides: design, construction, and operation of pilot plant plus modeling, data analysis, commercialization support Footer goes here 6

7 Process basics GASIFICATION BIOMASS BIOMASS GASIFIER ASH REMOVAL REFORMER HEAT RECOVERY SCRUBBER STEAM O 2 CO 2 ASH O 2 WATER WASTE WATER Footer goes here 7

8 Process basics GASIFICATION ACID GAS REMOVAL BIOMASS BIOMASS GASIFIER ASH REMOVAL REFORMER HEAT RECOVERY SCRUBBER COMPRES- SOR WASTE WATER CO 2 STEAM O 2 CO 2 ASH O 2 WATER MORPHY- SORB AGR SWEETENED Footer goes here 8

9 Process basics GASIFICATION ACID GAS REMOVAL BIOMASS BIOMASS GASIFIER ASH REMOVAL REFORMER HEAT RECOVERY SCRUBBER COMPRES- SOR CO 2 O 2 WASTE WATER CO 2 STEAM O 2 ASH WATER MORPHY- SORB AGR RECYCLE TO GASIFIER TAIL GAS TIGAS LPG BYPRODUCT PRODUCT SEPARATORS GASOLINE SYNTHESIS DME SYNTHESIS PURIFICAT- ION GASOLINE PRODUCT WASTE WATER Footer goes here 9

10 Process basics GASIFICATION CO 2 ACID GAS REMOVAL BIOMASS BIOMASS GASIFIER ASH REMOVAL REFORMER HEAT RECOVERY SCRUBBER COMPRES- SOR O 2 CO 2 STEAM OXYGEN PLANT ASH ON-SITE POWER GEN WATER TREATMENT MORPHY- SORB AGR RECYCLE TO GASIFIER TAIL GAS TIGAS LPG BYPRODUCT PRODUCT SEPARATORS GASOLINE SYNTHESIS DME SYNTHESIS PURIFICAT- ION GASOLINE PRODUCT WASTE WATER Footer goes here 10

11 Gasification (Andritz-Carbona) HOT PRODUCT GAS FEED HOPPER GASIFICATION REACTOR BIOMASS CYCLONE FLUIDIZED BED > Oxygen-blown > Bubbling bed > High thermal efficiency > Low syngas tar contamination FEEDING SCREW OXYGEN + STEAM GRID BIOMASS BIOMASS GASIFIER Gasifier (lower section) ASH REMOVAL SCREW ASH CO 2 O 2 STEAM Footer goes here 11

12 Syngas Cleanup (Andritz-Carbona & Haldor Topsoe) GAS OUTLET TUBESHEET GAS INLET PULSE PIPING > Hot particulate filter > Catalytic syngas reformer > Converts C 6+ tars and CH 4 to CO and H 2 Filter Candles ASH OUTLET ASH REMOVAL REFORMER ASH O 2 Reformer (upper section) Footer goes here 12

13 Acid Gas Removal (GTI-Uhde) > Syngas compression to 1000 psig (68 bar a ) > Removes CO 2 and H 2 S with Morphysorb physical solvent > High selectivity COMPRES- SOR CO 2 -rich acid gas ABSORBER STRIPPER Syngas Compressor N 2 AGR Pilot Plant Footer goes here 13

14 Topsoe Integrated Gasoline Synthesis (Haldor Topsoe) > Unique high-conversion once-through methanol/dme synthesis step > Tail gas recycle results in essentially powerneutral process > Syngas conversion well over 90 percent TAIL GAS LPG BYPRODUCT PRODUCT SEPARATORS GASOLINE SYNTHESIS DME SYNTHESIS PURIFICAT- ION GASOLINE PRODUCT WASTE WATER TIGAS Module in Fab Shop Footer goes here 14

15 TIGAS Chemistry 2H 2 + CO CH 3 OH H 2 O + CO H 2 + CO 2 CH 3 OH ½ CH 3 OCH 3 + ½ H 2 O Combined into a single step, which maintains low methanol concentration in the reactor nch 3 OCH 3 2(CH 2 ) n + nh 2 O Gasoline synthesis Footer goes here 15

16 Conversion (CO+CO 2 ) Combined Synthesis Drives Yield MeOH / DME MeOH Key Reactions: 4H 2 + 2CO 2CH 3 OH 2CH 3 OH CH 3 OCH 3 + H 2 O CO + H 2 O CO 2 + H H 2 + 3CO CH 3 OCH 3 + CO :33: Pressure (bar) Then in the gasoline reactor: CH 3 OCH 3 2(CH 2 ) + H 2 O H 2 + 3CO 2(CH 2 ) + H 2 O + CO 2 Footer goes here 16

17 Gasoline Blendstock Properties >Octane (R+M)/2 > 87 >Zero Sulfur >Aromatics < 35 vol%, but benzene < 0.3 vol% >Low RVP (~9 psi) >Durene <2% Footer goes here 17

18 Biomass-to-tank pathway >Thermochemical gasification >Conversion of resulting synthesis gas to motor fuel >Woody biomass gasoline blendstock Product compatibility with existing infrastructure. >Pilot plant 21 ton/day (19 MT/day) BD feedstock 23 bbl/day (3700 L/day) product Commissioning and shakedown: November 2012 Integrated long-term testing: March 2013 April 2014 Footer goes here 18

19 Pilot Plant Block Flow Diagram BIOMASS BIOMASS STORAGE SILO BED MEDIA MAKEUP O 2 WATER RECYCLE TO GASIFIER SOUR GAS TO FLARE TAIL GAS TO FLARE WEIGH HOPPER SCRUBBER COMPRES- SOR ACID GAS REMOVAL N 2 LOCK HOPPER REFORMER PURIFICAT- ION FEED HOPPER GASIFIER FILTER DME SYNTHESIS GASOLINE SYNTHESIS PRODUCT SEPARAT- ORS CO 2 STEAM O 2 GASOLINE TANK WASTE WATER TANK BED SOLIDS FILTER SOLIDS WASTE WATER GASOLINE PRODUCT WASTE WATER Footer goes here 19

20 Biorefinery Facility Gasoline synthesis Syngas Conditioning Gasoline & Waste Water Tanks Cooling Tower Gasoline synthesis Syngas conditioning Feed Storage Silo Stack Acid Gas Removal Feed System, Gasification, Filtration Syngas Compressor Chiller Feedstock Unloading Oxygen, Nitrogen, and CO 2 Supply Footer goes here 20

21 Feedstock >Wood pellets provided by UPM Blandin Mill in Grand Rapids, MN >Source: bark-on aspen logs >Pelletized at Indeck mill in Ladysmith, WI Represents mix of mill residue, logging residue, & roundwood Shipped to GTI in 22-ton (20-MT) pneumatic trucks Footer goes here 21

22 Pilot Project Status > Project started Feb 2010 > Engineering completed Jun 2011 > Existing equipment upgrades & new construction completed Oct 2012 > Commissioning & shakedown completed Jan 2013 > Long-term testing (3 campaigns) Test #1 (completed) Mar 2013 Test #2 (under way) Oct 2013 Test #3 (future) Feb-Mar 2014 > Engine emissions tests & moderate fleet testing Nov 2013-Oct 2014 > Technology evaluation, readiness, & commercialization plan Oct-Dec 2014 Footer goes here 22

23 Construction: TIGAS Bay FLOOR EXCAVATED ROOF REMOVED NEW GRADE BEAMS & FLOOR LOOKING UP FROM BAY 3 FLOOR Footer goes here 23

24 Construction: TIGAS Lower Module LIFTING ABOVE ROOF LIFTING FROM STAGING AREA UPRIGHTING MODULE LOWERING INTO BAY Footer goes here 24

25 Construction: TIGAS Upper Module LIFTING ABOVE ROOF LIFTING FROM STAGING AREA UPRIGHTING MODULE LOWERING INTO BAY Footer goes here 25

26 Construction: Tank Farm EXCAVATION FOR PAD TANK DELIVERY & SETTING PAD, SUPPORTS, & CONTAINMENT POURED & CURED INSTALLATION COMPLETED Footer goes here 26

27 Commercial Outlook >Pilot plant will establish design basis for a commercial plant 85 million gal (322 million L) per year of drop-in renewable gasoline 4 gasifiers convert 4000 MT/day of 20%-moisture biomass to syngas for one AGR train + one TIGAS train 100 plants of this size would meet 24% of the EISA goal for % reduction in GHG life-cycle emissions compared to conventional gasoline Preferred co-location with existing pulp & paper mill Footer goes here 27

28 Commercial Outlook: California 2020 example $4.11 $4.11 $0.67 $0.04 $1.83 $0.04 $2.99 $0.93 Source: AEO Report Number DOE/EIA-0383(2013) Footer goes here 28

29 Acknowledgment > U.S. Department of Energy - EERE > National Renewable Energy Laboratory > With valuable contributions from: Gas Technology Institute: Bruce Bryan, Jim Aderhold, Andy Kramer, Stan Wohadlo, Pat Bishop, Mark Stevens, Rachid Slimane, Mike Mensinger, and many others Haldor Topsoe: Arne Knudsen, Samy Diab, Tommy Hansen, Nanna Topsoe, Martin Sorensen, Finn Joensen, Rasmus Nielsen, and others Andritz-Carbona: Heikki Virta, Vellu Pietarinen, Andras Horvath, Mika Ketomaki UPM: Pekka Jokela, Jim Marshall Phillips 66: Kip Walston SAIC: Herb Kosstrin, Clare Behrens Footer goes here 29