Thermochemical Pathway Developments in Europe. Status and Reflections. tcbiomass2013. Chicago, September 5, 2013

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1 Thermochemical Pathway Developments in Europe Status and Reflections tcbiomass2013 Chicago, September 5, 2013 Ingvar Landälv, Luleå University of Technology, Sweden 1

2 From Prentation December 2007 Do something! 2

3 For the Prentation Today Make it Real! 3

4 Interest Indicators Consern regading GHG Climate Impact Desire to get independent of energy imports 4 Level of Engagement & Action HIGH EBTP was formed when interest was on its peek LOW Source: IL United States EU 27 Formation of EBTP Copenhagen Summit IPCC To truly globally motivate a change to renewables

5 EBTP Stakeholders Biofuels users (engine manufactorers) 3 rd June th Stakeholder Plenary Meeting Update

6 DISCLAIMER The presenter has gathered most of the information from contacts with project owners and technology suppliers. Some deviations from factual situation may be presented. The presentation does not claim to completely cover the given topic. 3 rd June th Stakeholder Plenary Meeting Update

7 Four Identified Value Chains 1. Synthetic fuels* (oxygenates or hydrocarbons) through gasification. 2. Bio-methane through gasification 3. High efficiency heat & power generation through gasification 4. Intermediate bio-energy carriers through techniques such as pyrolysis and torrefaction * Includes fuels produced via synthesis of H 2 + CO Project definition: Feedstock xx MW t / Main product / Start-up year 3 rd June th Stakeholder Plenary Meeting Update

8 1. Synthetic fuels (oxygenates or Hydrocarbons) through gasification Biomass Production System * *Could include the value chain D Pretreatment -pyrolysis - coarse prep. -drying -torrefaction -grinding -black liquor ** Co-located Initial Conversion - Feeding sys. - Gasification - CH 4 ref ng - Tar handling - Particulate handling - Shifting - Gas cleaning - Etc Final Conversion -Hydrotreatment -Co-treatment ***Final Conversion - Synthesis - reforming - Cracking - hydrotreating - Distillation - Etc Transport Biofuels Co-products ** Black Liquor is an internal, energy-rich stream within pulp mill. No pre-treatment necessary before gasification. ***certain steps of final conversion may be located elsewhere 3 rd June th Stakeholder Plenary Meeting Update

9 1. Synthetic fuels (oxygenates or Hydrocarbons) through gasification The Forest BtL Project, FI 480 MW t / FT products / Gasification technology: Carbo-V 88 million NER300 grant FEED ongoing for gas cleaning, synthesis and OSBL signed. Forest BtL flowsheet Bioliq Project, DE 2 MW t / Synthetic Gasoline / 2013 Pyrolysis and gasification in oper. Synthesis in commissioning Bioliq plant at KIT Fast pyrolysis of straw+gasification (5MW t ) + DME/gasoline synthesis 3 rd June th Stakeholder Plenary Meeting Update

10 1. Synthetic fuels (oxygenates or Hydrocarbons) through gasification Chemrec Projects, SE a. BioDME project ~3 MW t / DME / 2011 b. Domsjö and Vallvik mills Proposed Domsjö Site The BioDME Project ~200 MW t / Methanol and DME / On hold (Currently awaiting new national regulation on biofuels) UPM Project a. Pilot testing at GTI, Chicago, USA ~5 MW t / syngas production / Ongoing b. Commercial Demonstration, FR ~300MW t / FT products( t/a) / Investment decision by 2014; 170 million NER300 grant Pilot tests in Chicago at GTI Gasification Module Full sized plant Source: UPM, Andritz, Carbona 3 rd June th Stakeholder Plenary Meeting Update

11 1. Synthetic fuels (oxygenates or Hydrocarbons) through gasification The Woodspirit Project, NL Forest resid / Methanol / Dec 2016 > tpa Biometnanol Torrefied biomass into entrained flow gasif. 199 million NER300 grant Consortiun of BioMCN, Siemens, VS Hanab Site for the Woodspirit Plant Güssing Plant, AT Güssing FT production flow scheme 8 MW t / Heat and Power / 2002 H&P plant but also test site for FT, SNG, higher alcohols and H2 3 rd June th Stakeholder Plenary Meeting Update

12 1. Synthetic fuels (oxygenates or Hydrocarbons) through gasification BioTfueL Project, FR ~ 12 MW t / FT products / 2014 Fuel mix of fossil and renewable Including torrefied biomass Source: Uhde Värmlandsmetanol, SE ~ 111 MW t / Methanol / 2017 CFB Gasification Source: Uhde 3 rd June th Stakeholder Plenary Meeting Update

13 2. Bio-methane through gasification Biomass Production System *Could include the value chain D * Pre- Treatment -pyrolysis -coarse prep. -drying -torrefaction -grinding Initial Conversion - Feeding sys. - Gasification -Tar handling -Particulate handling - Shifting - Gas cleaning - Etc Final Conversion - Methanation Methane CNG energy carrier Co-located 3 rd June th Stakeholder Plenary Meeting Update

14 2. Bio-methane through gasification ECN / HVC Project, NL 12 MW t / Fuel Gas + SNG(10%) / 2014 Illustration of the ECN / HVC Plant MILENA and OLGA technology Güssing, AT 8 MWt / Heat & Power / 2002 Test (=>2009): Side stream converted to SNG SNG (1 MW t ) now restarted BioSNG PDU Plant at Güssing Technikum Fuelling Station Three other plants (AT, DE) producing H&P in operation. One planned also for SNG production GAYA Project, FR 0.6 MW t / SNG / 2013 Decentralized SNG for transportation application 3 rd June th Stakeholder Plenary Meeting Update

15 2. Bio-methane through gasification GobiGas Gothenburg Energy, SE a. Phase 1 Wood pellets / 20 MW t of SNG / 2013 Güssing type technology b. Phase 2 Biomass / MW t of SNG / 2016 Illustration of GoBiGas Project, Phase 1 59 million NER300 grant E.On Bio2G Project, SE a. Pilot testing at GTI, Chicago, USA ~5 MW th / syngas production / Ongoing b. 1 st Commercial plant, Landskrona or Malmö ~200 MW SNG / SNG / 2018 PreFEED performed - 4 years to plant completion after decision. Ccurrently awaiting new national regulation on biofuels. Illustration of E.On. Bio2G Project 3 rd June th Stakeholder Plenary Meeting Update

16 Summary of gasification technologies in Value Chain 1 and 2 Product Pretreatment Type of gasifier Number of FT, Methanol, DME, synth. gasoline SNG (BioSNG) Drying, 2 Torrefaction, 2 Pyrolysis w dry feeding, 1 Pyrolysis, 1 Other *, 1 Drying, 4(5) (Pellets, 1) ** black liquor from pulp mills - Entrained Flow with dry feed -CFB with dry feed All HP Entrained Flow with wet feed All HP CFB (direct or indirect heating) LP or HP rd June th Stakeholder Plenary Meeting Update

17 3. High efficiency heat & power generation through gasification Biomass Production System * *Could include the value chain D Pre- Treatment -coarse prep. -drying -torrefaction -grinding -pyrolysis Initial Conversion - Feeding sys. - Gasification - Tar handling - Particulate handling - Gas cleaning - Etc Final Conversion - Electricity generation Electricity for vehicles As energy carrier Co-located 3 rd June th Stakeholder Plenary Meeting Update

18 3. High efficiency heat & power generation through gasification Güssing Plant, AT Güssing heat&power plant 8 MW t / Heat & Power / 2002 (3 more plant in operation and 2 in EPC phase, MW t ) Atmospheric indirect gasification and gas engines Skive Plant, DK From the Skive Plant Skive heat&power plant 19.5 MW t / 11.5 MW Heat & 6 MW Power / 2011 Max input: 28 MW t Atmospheric direct gasification and gas engines 3 rd June th Stakeholder Plenary Meeting Update

19 4. Intermediate bio-energy carriers Biomass Production System Conversion Steps -coarse prep. -drying -torrefaction -grinding -pyrolysis+ stabilization Distributed 1. Bioenergy carrier for further processing to fuels (2. As energy carrier) 3 rd June th Stakeholder Plenary Meeting Update

20 4. Intermediate bio-energy carriers PYROLYSIS Fortum Joensuu Plant, FI Forest residue / t/y pyrolysis oil / end Will replace HFO in districting heating and industrial plants. Technology development in an alliance with VTT/Metso/Fortum/UPM KIT (former FZK), DE Part of Bioliq project (see Value Chain 1) Illustration of Fortum demonstration plant, Joensuu, Finland Pyrogrot Project, SE Forrest residue / large PO plant / end Milj. NER300 grant Feedstock secured GWh PO / year Pre FEED Phase 3 rd June th Stakeholder Plenary Meeting Update

21 4. Intermediate bio-energy carriers PYROLYSIS Btg, NL a. Pilot ~1 MW t / Pyrolysis oil / 1998 b. Demonstration, NL ~25 MW t / Pyrolysis oil, tpy / 2014 Illustration of Btg s planned demo in Hengelo, NL 3 rd June th Stakeholder Plenary Meeting Update

22 4. Intermediate bio-energy carriers TORREFACTION ECN Project, NL Runs a pilot (50 kg/h) 1t/h demo started up 2012, DK BioTfueL, FR 3 t/h / energy carrier / 2014 Other Projects There are a great number of actors in the field of torrefaction technology utilizing different technologies. Some demonstrations are in commercial scale such as: Topell, NL: 60 kton/y in operation Rotary drum reactor Screw conveyor reactor Multiple hearth furnace Moving bed reactor 3 rd June th Stakeholder Plenary Meeting Update

23 How can we describe the European (EU) way forward? EU agrees on directives which sets directions and also mandatory roles and goals So called EII:s are formed, among them EIBI, the European Industrial Bioenergy Initiative EU has arranged one powerful financing scheme through NER 300 program Deployment is no straight road and industry together with academia and other parties form groups sharing same/similar visions Some projects move but few. 23

24 European Industry Initiatives (EII) in brief Public private partnerships (PPPs) in sectors where barriers can best be tackled collectively Risk sharing, pooling resources, co-ordinated work Generate the critical mass to accelerate technology development and deployment Demonstration activities & support actions One of 7 Initiatives launched is European Industrial Bioenergy Initiative (EIBI) focusing on advanced biofuels. It is governed by e.g. EU Renewable Energy Directive (2009/28/EC) EU Fuel Quality Directive (2009/30/EC) of April 2009 which stems out of the SET Plan (2008) 24

25 NER300 Financing Scheme by the European Commission, European Investment Bank and Member States December 2012: EC awarded over 1.2 b to 23 highly innovative, renewable energy demonstration projects ~ 629 M to Bioenergy ~ 82 M (13%) to Biochemical Processes ~ 547 M (87%) to Thermochemical Processes Out of 8 projects, 5 to Advanced Biofuels 3 Thermochemical, ~457 M (88, 170, 199 M ) 2 Biochemical, ~59 M (28, 31 M ) The other projects on Bioenergy are targeting pyrolysis oil, SNG (Thermochem) and Straw-to-Biomethane (Biochem), total 112 M ( M ) 25

26 The European Biofuels FlightPath A Cross Industry & government collaboration and consensus Involved Parties: DG Energy By 2015: Set-up financial mechanisms Secure sustainable feedstock production to feed 3 refineries Construct 3 new refineries and launch Biofuel production Manage communication strategy Objective 3 Refineries Cost M By 2018: Regular commercial flights using bio-jet fuel blends Construct 4 additional refineries Construct 2 additional refineries producing algal & microbial oil based aviation Biofuels Objective 6 Refineries Cost M By 2020: Full deployment of at least 2 million tons of biofuels per annum for EU aviation 9 Refineries and M total Cost 26 Source: EU Commission 2 6

27 Leaders of Sustainable Biofuels Quote (From May 13, 2013): Now is the time to bring advanced second-generation biofuels to the market, the chairman of LSB said. The industry is committed to delivering on its promise but we need the stable long-term investment conditions which encourage investment while at the same time promoting true advanced biofuels. This will have a positive economic as well as ecological impact on the EU 27

28 Price Levels of some Key Energy Commodities Commodity / MWh (approx.) Crude at 110 USD/bbl 47 Gasoline at refinery gate, NW Europe (0.5 /lit / 0.6 /lit) 56 / 67 Diesel at refinery gate, NW Europe (0.5 /lit / 0.6 /lit) 51 / 61 Nat. Gas at 2-4 USD/MMBtu 5-11 LNG, NW Europe at LNG hub (based on 4 USD / MMBtu) Methanol, NW Europe (200 /t) 36 DME (based on methanol price + 5%) Cost of biomass, typical Europe / US 20/10 Advanced biofuels

29 ...but we need the stable long-term investment conditions / MWh 100 /MWh = ~4.4 USD/g.g.e. Today s cost for advanced biofuels In Europe Long term stable legislation is required to cope with the difference LOW

30 If we do not Make it Real If the above (i.e. long term stable legislation) does not materialize the risk is big that developers and their financers leave the green fuels business for an indefinite time period. This has major consequences like Built up knowledge disappears Key individuals change work focus IPR portfolios loose value Time to get up and running again will be long Etc This scenario is a not unlikely and a real threat to continued R&D efforts. 30

31 An example where an international agreement results in a fundamental rethink: IMO, International Maritime Organization, legislation regarding new sulphur levels in bunker fuels coming into force 1 January

32 Upcoming regulations for Marine Fuels Sulphur level in bunker fuels must be <0.1 % by 2015 gnox/kwh IMO NOx Technical code NOx Tier II (Global) 12 NOx Tier III (NOx emission control areas) rpm 32 Source: ScandiNAOSAB

33 Stena Germaica will run on Methanol from January 2015 (project received 11 Milj in EU support) Fuel: tons of MeOH / year 33 Source: Stena

34 Stena s Global Methanol Project (Initial time plan for converting Stena s SECA fleet) Methanol consumption will approach 1 million tons by 2018 Source: STENA and Effship 34

35 has led to: Vision for a Methanol based Energy System Natural gas Various renewable Wastes Biomass Pyrolysis Biomass Biomass Methanol plants Fossil MeOH Liquefact. Gasification Nutrients MeOH Gasification Pulp mill MeOH Renewable MeOH Gasification of biomass MeOH Via Ports Ports 1 2 n nn Energy usage DME DME M e t a n o l Distribution Chemical industry Marine sector Heavy transports 35

36 In Summary There are a number of very interesting advanced biofuels projects under development in Europe. Before final plant investment decision long term stable legislation is required to secure sufficient cash floe to raise funding. There are technology challenges but with the aforementioned legislation in place securing cash flow the technology risks can be managed. Before concluding: The following leads over to today s theme, pyrolysis oil: It reveals a technology which has the potential to utilize pyrolysis oil in a very efficient way 36

37 LTU Biosyngas Centre is currently under formation. It will be a unique infrastructure open for international collaboration. Powder Torrefied Mtrl ETC EF gasifier 4 ton product per 24h Others Pyrolysis oil LOW Cleaning BioMeOH Black Liquor Membranes bar > 100 bar BioDME DP-1 Plant Active C Abs WG Shift Amine Wash MeOH Synth. DME Synth. Distillation O 2 H 2 CO Catalytic Process Development Existing facilities Electrolysis CO 2 Future development Fuel Cells 37 The Renewable Syngas Highway

38 Turning Alkali to an Advantage BL/PO co-gasification - why can it work? BL: Black Liquor PO: Pyrolysis Oil Black liquor gasifies at 1000 C with full carbon conversion due to catalytic activity of alkali (20% Na) Use catalytic activity of BL alkali also for PO, so that mixture can be gasified at 1000 C PO gasification alone requires much higher temperature, gives lower efficiency and soot problems 38

39 Key physical properties of PO/BL mixtures are promicing based on lab tests Viscosity Surface tension 1 000,00 100, Hanging droplet 100 C Shear viscosity(pa s) 10,00 1,00 0,10 0% 10% 20% 30% Surface tension (mn/m) Black liquor 10% pyrolysis oil 20% pyrolysis oil 30% pyrolysis oil 0,01 0, Shear rate(s-¹) Time (s) 39

40 Drop tube furnace experiments shows carbon conversion of PO/BL mixtures to be at least as good as BL alone (PO(20) /BL(80) = 20% PO in BL, dry by weight) Gasification ash microscopy (same magnification) Ash recovery - cyclone and filter Ash recovery, comapred to theoretical 140% 120% 100% BL at 1000 C BL at 1200 C 80% 60% 40% 20% BL BL rep PO/BL at 20/80 0% 800 C 1000 C 1200 C PO(20) /BL(80) at 1000 C Quantification of residual carbon in progress 40

41 Co-gasification of BL and PO offers many potential advantages All calculations thus assume that BL/PO can be gasified at same temperature as BL is today. 400% Capacity can be increased up to 100% by adding about 25% PO to the BL (by weight) Energy efficiency for gasification of added PO is 80-85% 100% 350% 95% Production (syngas energy) 300% 250% 200% 150% 100% CGE 90% 85% 80% 75% 70% 65% 60% SF-LHV total H2CO total SF-LHV incr PO H2+CO incr PO 50% 55% 0% 0% 10% 20% 30% 40% 50% PO mix (part of total feed) 50% 0% 10% 20% 30% 40% 50% PO mix (part of total feed) Figure shows simulated increased production of final liquid biofuel product at fixed BL feed (i.e. for specific mill) Figure shows simulated gasifier energy efficiency of total mixed feed (solid) and for added PO (dashed) 41

42 Finally, we do not want to hear.. You did not Make it Real! Thank you! 42