Biorefineries Workshop - 2010 Renewable feedstock co-processing in oil refining / petrochemical units Luiz Fernando Leite UFRJ Firjan Convention Center Rio de Janeiro November 10-12, 2010
Biofuels & Bioproducts are driven by three fundamental policy considerations: rural development; energy independence; and reduction of carbon footprint.
Primary Energy Production in Brazil (2008) Source: Mines & Energy Ministry, BEN (National Energy Balance) Non-renewable % Renewable % Petroleum 39.7 Hydraulic 13.4 Natural gas 9.1 Firewood 12.4 Mineral coal 1.1 Sugar cane products 19.0 Nuclear 1.7 Others 3.6 Total 51.6 Total 48.4
Biofuels and bioproducts involve dynamics that have not been seen before, such as demands driven by social and political issues rather than costumers and economics
Consolidated industry, Well-known technologies, Economically optimized. New industry, Emerging technologies, Searching for economical feasibility.
What can we do? Let s try to bridge these two distinct worlds!
Renewables co-processing in refining streams Chemical structure of castor oil (mamona) The hydrogenation of co-processed soybean oil in diesel slate streams produces propane as well as long chain paraffins, which have a high cetane number (HBio). Cetane boosters and propane are high value products in our refining scheme. The transesterification of soybean oil with methanol produces biodiesel and glycerine (product destination?)
Renewables co-processing in refining streams (Logistic comparison) Product Transportation Modal From To Soybean oil Soybean Extraction unit Biodiesel plant Truck Methanol Methanol plant Biodiesel plant Truck Biodiesel Biodiesel plant Product Dist. Facility Truck Diesel Refinery Product Dist. Facility Pipeline Product Transportation Modal From To Soybean oil Soybean Extraction unit Refinery Truck HBio Refinery Product Dist. Facility Pipeline
Renewables co-processing in refining streams Other aspects that also impact this business: Capex; Opex; Quality control; Storage facilities.
Renewables co-processing in refining streams The FCC Unit is a relevant source of propylene. In Brazil 30% of propylene production comes from refineries (2009). Propylene production at PETROBRAS refineries was 1100 kta in 2009. Only the Betim Refinery, in Minas Gerais State and the Manaus Refinery in Amazonas State are not producing it. Petrochemical FCCs produce C3s & C4s olefins. Ethylene can be produced in an FCC Unit, co-processing with ethanol (PI 0605675-0 & US 2008 0156692 A1)PI 0605675-0
Advantages of agriculture residues: Rural origin (from several crops) Availability Bio-oil from agriculture waste Low cost Fuel Bio-oil Heating Steam Generation Fast Pyrolysis Electric Power
Fast Pyrolysis Process Raw material: any lignocellulosic residue Products: bio-oil (liquid with several oxigenated compounds), CO, CO 2, water and energy Fluidized circulating beds (similar to an FCC) Cracking section Catalyst Regeneration section Sand is used as heat carrier Heat recovery section
Bio-oil processing possibilities FCC Gasoline Agriculture waste Pre-treatments: Drying Milling Fast Pyrolysis Bio-oil Steam Reforming Synthesis Gas Chemical Treatment Catalytic FCC Gasoline Pyrolysis Modified Bio-oil HDT Fuels
Case Study: Bio-oil co-processed in an FCC Unit Study premises: Price of agriculture waste: US$ 25/ton (premises) Agriculture waste transportation: max 40 km Study Output: Costs: Capex and Opex and Bio-oil Transportation Total product value > US$ 100/ton Positive NPV for 440 kta of agriculture residue processing unit
Conclusions
Conclusions Advantages of renewable feedstock co-processing in refining / petrochemical units, such as: Feedstock diversification; Reduction of carbon footprint; Gradual implementation of biofuels / bioenergetics (not disruptive); Direct integration of the bio-product to the final product; Better quality control of bio-products; Reduced investment for adapting the existent units; Lower investment for new facilities; Lower operation costs Lower logistic costs.
Conclusions Watch it! Sustainability - triple helix approach: Environment Social Economics