Integrated hydro-pyrolysis

Transcription

1 Integrated hydro-pyrolysis - Low sulfur waste-derived-fuels based on of mixed waste and biomass -

2 Introduction Waste-Derived-Fuels The issues Increased demand for green and low sulphur fuels Decentralized biomass processing to middle distillates

3 Introduction Waste-Derived-Fuels The answer is? Decentralized hydro-pyrolysis of solid biomass wastes and plastic residues into the following three product categories: A. Liquid MGO type fuel with very low to zero Sulphur content B. Cracking gas for green power C. Bio-fertilizer/salts and un-oxidised metal retrieval Waste Thermal Process Fuel / oil Gas Salt + metal

4 Target markets for distributed Waste-to-Fuels Where would this solution be well situated? Any industrial site or harbour where: A. Caloric waste is available and its discharge is expensive B. High / rising power and fuel cost is encountered C. Preferably with a presence of a CHP/energy generation Energy intensive industries with waste Any (remote) community where there is a: A. Local waste station B. Need for local energy generation (IPP) C. CO2 emission reduction target (2020) D. Isolated off-grid locations, where it replaces diesel gen-sets Remote sites, airports, islands and remote municipalities

5 3 Generations of sustainable fuel A comparison on cost and sustainability 1 st generation: uses food crops - rapeseed, corn etc. - Low energy efficiency, even down to zero (i.e. by fertilizer use) - Large footprint, extensive use of land - Competes with food chain Food versus Fuel issue - Only in tight integration with other crops (Brazil) Approx. 80 eurocents/liter 2 nd generation: bio-waste derived / gasification / flare gas /Fischer-Tropsch GTL and enzymatic conversions of bio-wastes - GTL: Energy efficiency losses using multiple process steps - GTL: Large scale required for economies of scale - GTL: Complex, not yet developed for the market - Enzymatic: Good potential, but cost is still a factor - Classic pyrolysis: bad fuel and char waste Approx. 50 eurocents/liter 3 rd generation: Waste-to-Fuel / Hydro-cracking XTL -Highly energy efficient, also on biomass-plastic mixtures (unlike pyrolysis) -Simple one step process, market ready -High quality middle distillate fuel ready for local use (unlike pyrolysis) -Solves both waste and energy issue at site -Decentralization of waste and energy saves on transportation and reduces CO 2 emissions -Already economical on a small scale (10,000 tons/yr) Approx. 20 eurocents/liter!

6 What types of waste are applicable? (typical waste potential not limited to list below) Non-recyclable waste with reasonable calorific value (>14 GJ/ton, the higher the better) Polymers Biomass AND AND Mixtures of polymers & biomass / municipal solid waste (MSW) comprises largest field of application Little sorting required; large metals and inerts

7 3 rd generation sustainable fuel - A highly economic one step waste-to-liquids process Shredding Hydrocracking Biomass +plastics containing waste Secondary solid fuel Waste derived green fuels

8 The process scheme - a single step closed process into drop-in fuels for local use (i.e. in power generators), unlike as in conventional pyrolysis High Calorific Waste Mixtures Inorganics and metals Input (= 100 %) Here, no emissions to the air! Syngas for power or boiler room ( %) Low Sulphur MGO type diesel fuel ( %) Shredder Self powered drier + closed reactors at approx. 400 and 800 o C Bio-fertilizer salt and metal retrieval, 0-10 %)

9 1.Polymer conversion/cracking A- Poly-olefins, i.e. PE : Thermal cracking of straight CH-chains B- Oxygenated polymers i.e. PET: Thermal cracking of CHO containing chains Oxygen is removed in hydro-pyrolysis process C- Halogenated polymers i.e. PVC: Thermal cracking of CHX containing chains Chlorine becomes chloride salt, thus no dioxins!

10 2. Biopolymer conversion (biomass) Issue: oxygen needs to be removed for good fuel A- Polysaccharides : Mainly contains C 5 and C 6 sugars, i.e. (C 5 H 10 O 5 )n, (C 6 H 12 O 6 )n,... (ligno-)cellulose etc. B- Polypeptides: Contains CHNO(S,P) Oxygen is removed in a hydro-cracking process C- Mean biomass: Contains C 5 H 7 O 2 N

11 Typical target product fuels 1- Middle distillates (low Sulphur MGO diesel) production: C 9 C 27 : olefins: CH 3 (CH 2 ) n CH 3 2- Aviation fuel production requires a next isomerisation step: C 9 C 19 : isomers: CH 3 (CH 2 ) n CH 3

12 Typical gaseous product fuels 3- Process gas : H 2 CO C 2 /C 3 (minor amounts) N 2 (inert) Typical current calorific value of the gas: 4-5 MJ/m 3 (@ air blown gasifier)

13 Integrated Green Modem hydro-pyrolysis technology yielding good de-oxygenated fuel from mixed biomass/heavy oils/caloric wastes Emergency flare Controls Hydrocracker Self powered steam dryer

14 Example Fuel Analyses - GCMS - General fuel analysis, SGS

15 Red = sample Black = alkane injection alkanes are present in large quantity. No or little oxygen is present, according to FTIR data.

16 > Maximum caloric value > Low Sulphur MGO

17 First Order Business Cases Examples

18 First order Business Case- Example 1: Moderate caloric value Generic Mixed Waste (MSW with 20% non-recyclable plastic waste) Investment Annual income Capacity ton waste / year Liquid Fuel (3.7 m liter) 1.8 million Euro Fuel installation 5.3 million Euro Gas (0.7 MW power) 0.4 million Euro Generator Separator shredder 1.1 million Euro 0.3 million Euro Avoided gate fee (3,6 Euro/ton) Subsidies + carbon credits 0.04 million Euro Assumed zero Total Investment 6.7 million Euro Total Annual Income 2.2 million Euro Operational Costs Annual costs Summary Labor (3 shifts) 300 keuro Investment 6.8 million Euro Maintenance 400 keuro Annual Operational Costs 1.1 million Euro Ash Disposal p.m.(input related) Annual Income 2.2 million Euro Interest 440 keuro Annual Margin 1.1 million Euro Total Operational Costs 1.1 million Euro Earn Back Period ~ 6 years * Depends on oil price, NPW sourcing cost, waste composition etc.

19 First order Business Case- Example 2: Highest caloric value Non-recyclable plastic waste (NPW) / waste or heavy oils Investment Annual income Capacity ton waste / year Liquid Fuel (9 m liter) 4.4 million Euro Fuel installation 5.3 million Euro Gas (0 MW power) Assumed zero Generator Separator shredder Not used/minor 0.1 million Euro Gate fee & transportation cost (0 Euro/ton) Subsidies + carbon credits Assumed zero Assumed zero Total Investment 5.4 million Euro Total Annual Income 4.4 million Euro Operational Costs Annual costs Summary Labor (3 shifts) 300 keuro Investment 5.4 million Euro Maintenance 400 keuro Annual Operational Costs 1.0 million Euro Ash Disposal p.m.(input related) Annual Income 4.4 million Euro Interest 320 keuro Annual Margin 3.4 million Euro Total Operational Costs 1.0 million Euro Earn Back Period ~ 2 years * Depends on oil price, NPW sourcing cost, waste composition etc.

20 Waste-Derived-Fuels System design in a local supply chain Added value: Know-how concerning: Legislation Thermodynamics Subsidies Ecological impact Technical integration Economic value for all parties concerned Experience with design of sustainable systems Clean Fuel Gas Heat CO 2 Network of players

21 Project References Diederik Jaspers A selection of Waste-Derived-Fuel references Industry: Obtain 100% waste recycling Forbo, Flooring Industry Bio-CHP power generation Energy security for greenhouses Essent, Dutch Utility Airplane catering waste conversion KLM Catering Services Bio-CHP for KLM-KCS at Amsterdam Int. Airport Government: Municipal solid waste and industrial bio-waste Accra ATMF-Ghana Rotterdam Municipality waste collection Roteb - transportation fuel for own waste trucks Rijssenhout 120 ha greenhouse development SGN/BNG, Dutch Govt. Bank Bio-CHP power generation Bio-CHP Clusters

22 Sustainable Solutions ir. Diederik Jaspers MBA Senior Consultant Waste-Derived-Fuels Disclaimer: statements and values in this presentation are indicative and may vary per feed composition, do not represent any claims, and are for information only.