Biomass to Green Gasoline by the TIGAS Technology Finn Joensen, Haldor Topsøe A/S fj@topsoe.dk DTU International Energy Conference 2012
Haldor Topsøe committed to catalysis for more than 70 years Anchored in fundamental research Headquarters in Denmark Engineering offices in Denmark, USA, India and Russia Catalyst Manufacture in Denmark and USA Copenhagen Edmonton Moscow Los Angeles Houston Catalysts, technology & services for Kuala Lumpur Fertilizer industry Rio de Janeiro Heavy chemical/petrochemical industry Buenos Aires Refineries Environmental & power sector Renewables Beijing Bahrain New Delhi Cape Town
Introduction Easy oil is fading out Exploitation & upgrading is becoming more difficult Continuing increase in demand Synfuels and catalysis are part of the equation TIGAS offers a variety of options for adapting gasoline production to existing fuel and energy infrastructure Natural gas/associated gas coal biomass waste Direct (syngas) indirect(methanol) stand alone cogeneration Blendstock diluent regular/premium gasoline 1,000 50,000 bbl/d
Topsoe Improved Gasoline Synthesis from natural gas, coal, biomass or waste to clean transportation fuels
Methanol to Gasoline Syn Gas MeOH Gasoline CO/H 2 CH 3 OH CH 3 OH Gasoline + H 2 O
Syngas to Gasoline Syn Gas MeOH /DME Gasoline CO/H 2 DME DME Gasoline + H 2 O
Combined MeOH and DME Synthesis H (kj/mol) 2H 2 + CO = CH 3 OH 91 2CH 3 OH = CH 3 OCH 3 + H 2 O 24 CO + H 2 O = CO 2 + H 2 41 3H 2 + 3CO = CH 3 OCH 3 + CO 2 246
Syngas to MeOH/DME Equilibrium 100 80 MeOH / DME Maximum conversion is obtained at H 2 :CO 1 Conversion (H 2 +CO) 60 40 20 T = 250 C H 2 = 51 CO = 48 CO 2 = 1 MeOH Equilibrium, mol% 100% 80% 60% 40% 20% CO DME CO 2 MeOH H 2 O 0 0 20 40 60 80 100 Pressure (bar g) H 2 0% 0.5 1 1.5 2 2.5 H 2 /CO
TIGAS - Historical Perspective 1983-1986: 8 bpd Demonstration Facility Houston, TX lb/h Test Facility Denmark 2011: Current MTG Test Facility Denmark
Wood-to-Gasoline Demonstration 20-25 bbl/d, Des Plaines, IL, 2010-2014 DOE Award No. DE-EE0002874
Syngas to gasoline once-through Syn Gas MeOH /DME Gasoline 100
Biogasoline Demonstration Plant Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes BIOMASS BIOMASS GASIFIER TAR REFORMER TAR REFORMER GASIFIER ASH OXYGEN OXYGEN Gas Cleaning MeOH /DME MeOH/DME Gasoline http://www.energy.gov/news2009/releases.htm Entire value chain: biomass in gasoline out
Project objectives Demonstrate a technology for thermochemical conversion of woody biomass to gasoline Pilot plant data will support the design of commercial plants based on gasification of woody biomass Conduct single engine emission test and fleet testing in preparation of EPA registration of green gasoline
Pilot plant location GTI Energy & Environmental Technology Campus Des Plaines, Illinois 4 2 1 3 5 6 1. Flex-Fuel Test Facility Carbona gasifier 2. Gas conditioning Tar reformer Scrubber 3. Morphysorb CO 2 & H 2 S removal 4. TIGAS syngas to gasoline Guard reactor MeOH/DME reactor Gasoline reactor 5. SulfaTreat Sulfur scavenger 6. High-pressure oxygen and nitrogen supply
Syngas compressor and tank farm
Biorefinery facility Gasification & Tar reforming (existing) Morphysorb AGR unit (existing) Utility units & control system (existing) Syngas compression (new) TIGAS synthesis unit (new) Gasoline & waste water tanks (new)
TIGAS module A2 & MeOH/DME reactor lift UPRIGHTING A2 MODULE DME REACTOR LIFT LIFTING ABOVE ROOF LOWERING INTO BAY
Biogasoline Project Schedule DOE grant Project started Engineering completed Existing equipment upgrades completed TIGAS construction completed Comissioning & shakedown completed Test run completed Long term testing campaigns Engine fleet testing Technology evaluation & commercialization plan
Process Flow Sheet Gasifier Scrubber Morphysorb TIGAS Off-gas Wood chips Oxygen steam Gasoline Water Tar reformer Syngas compressor Guard bed Separator
Test #1 technical data Integrated TIGAS operation periods Hours of operation TIGAS unit 56 hours Gasoline production Period 1 (03/12-13) 9 hours Gasoline production Period 2 (03/18) 15 hours Gasoline production Period 3 (03/21-22) 23 hours Total gasoline production time 47 hours Gasoline produced 14 bbl Syngas (H 2 +CO) conversion 86% Methanol in process condensate < 10 ppm Octane number (R+M)/2 > 96
First TIGAS gasoline product
Gasoline Yield & Properties High selectivity - 80-90 % Gasoline - remainder essentially LPG Octane (R+M)/2 > 87 Major component: i-paraffins Aromatics < 30 % Benzene < 0.5 % Olefins 5-10% No sulfur C n
Syngas to MeOH/DME Equilibrium 100 80 MeOH / DME MeOH / DME T = 250 C Feed Gas (mol%): Conversion (H 2 +CO) 60 40 Enabling Air-Blown Gasification MeOH MeOH H 2 = 51 CO = 48 CO 2 = 1 20 40 % N 2 0 0 20 40 60 80 100 Pressure (bar g)
STG Air Blown (once-through) Gasoline/power co-generation Syn Gas/N 2 MeOH /DME Gasoline
Skive District Heating/Power Plant 16 MW th
Gedankenexperiment 2 atm (Air) N 2 7 MW th 16 MW th ~ 100 bbl/d
Economics 4000 t/d 5700 bpd gasoline 4760 bpd gasoline Green Gasoline * Gasoline $2.9/gal ~ $120/bbl gasoline Crude oil br even $90/bbl *No carbon credits assumed (94% carbon footprint reduction) Wood consumption (TPD) Gasoline production (bpd) Power generation (MW e ) Oxygen Air 4000 4000 5700 4760 0 +125
Summary Easy oil is fading out Exploitation & upgrading is becoming more difficult Continuing increase in demand Synfuels and catalysis are part of the equation TIGAS offers a variety of options for adapting gasoline production to existing fuel and energy infrastructure Natural gas/associated gas coal biomass waste Direct (syngas) indirect(methanol) stand alone cogeneration 1,000 50,000 bbl/d Blendstock diluent regular/premium gasoline
Acknowledgement Financial support by U.S. Department of Energy Energy Efficiency & Renewable Energy is gratefully acknowledged
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