Alternatives to fossil jetfuel and related challenges CLIB Forum... · Squalane (from Biofene) will be first product on commercial sale Also envisioned are industrial lubricants,

© Fraunhofer UMSICHT

Folie 1

Alternatives to fossil jetfuel and related

challengesCLIB Duesseldorf – 17.11.2011

[email protected]

Manager of Biofuels Business UnitFraunhofer UMSICHT

mailto:[email protected]


Folie 2

Biofuels Unit at UMSICHT – Vision and Scope of R&D

Development of catalytic processes

for Biofuels & Chemicals

Scale-up and Pilot Plant Operation

Employed raw materials are “mainly” bio-based:

Fat & oils, sugars, alcohols, hemi-cellulose, residues

Member of European Biofuels Technology Platform (workgroup conversion) www.biofueltp.eu

VISION : Creation of an affordable, sustainable future with chemistry

http://www.biofueltp.eu/

http://www.biofuelstp.eu/index.html


Folie 3

Process Development - Biofuels and Biorefinery

» Several reactors / distillation units«

Feed ~ 0,05 - 2 kg/h

Fully automated

EEx or similar protection

High temperature and pressure

Fast and affordable sample production

Screening of process conditions

Generation of cost and engineering data

Analytical profiling of fuels & chemicals


Folie 4

Statement of IATA*) on the development of Biojetfuel

Biofuels offer the greatest hope for aviation to reduce its carbon emissions. Savings of up to 80% are on the table if the industry can get it right.

There are tough challenges to overcome: aside from technical issues, biofuels must be competitive in price and available in quantity.

“It’s not only about emissions. Biofuels offer opportunities to developing countries**) to grow new livelihoods and reduce dependency on imported fossil fuels, as well as the obvious benefits to the environment and the industry. These are compelling reasons for governments to get on board.”

If airlines wait until the price is right and commercial quantities are available,biofuels might never happen

*) IATA Magazine AIRLINES International December 2010 - Jan 2011 **) e.g. 2010 Workshop Mexico “Bioturbosina” http://plandevuelo.asa.gob.mx

*) Paul Steele, IATA Aviation Environment Director

http://plandevuelo.asa.gob.mx/


Folie 5

The fuel price challenge

www.iata.org/economics Sep. 2011

1100 $/t

More than 30% of operating costs are due to fuel

http://www.iata.org/economics


Folie 6

Facts and boundary conditions for Biojetfuel*)

Aviation is the strongest growing transport sector (~ 4,5% annually)

3% of man-made and 12% of transport CO2-emissions are due to aviation

EU27: air-traffic consumes 53, major airlines 20 mil. tons Kerosene (world =200)

Logistic infrastructure (refineries, pipelines, “oil”) is not evenly distributed

Very strong growth of aviation activities is expected in Southeast Asia

CO2-tax (EU-ETS) and introduction of Biofuels for aviation are game changers

EU target is 2 mil. tons (sustainable) Kerosene by 2020

Current norm for Biojetfuel ist ASTM D7566-11a (Aug. 2011)

Biofuels are state-of-the art for cars – for aviation they are in their infancy !

http://ec.europa.eu/energy/technology/events/2011_05_18_biofuels_in_aviation_en.htmhttp://www.biofuelstp.eu/air.html

http://ec.europa.eu/energy/technology/events/2011_05_18_biofuels_in_aviation_en.htm

http://www.biofuelstp.eu/air.html


Folie 7

Value Chain for Biojetfuel

The focus is on the most important parts of the value-chain

RawMaterials

&Inbound

Logistics

Production Int. Logistics,

R&D, QC,Formulation,Blending

Marketing& Sales

Branding Certification

OutboundLogistics

StoragePipelines

PrimaryCustomer

SecondaryCustomer

Partner(s) Raw materials Large/Small Technology Development, IP, Manufacturing, Catalysts

Technology integration (preferred is ‘drop-in’)


Folie 8

Chemistry of jetfuel – distribution of hydrocarbons

" C15 "

" C11 "

" C10 "

" C8 "

" Aromatics "

" Polyaromatics "

C11 C12C10 C13C9

C14C15

C8


Folie 9

Topics covered in this presentation

a) “State-of-the-art” – Alternative Fuels > see also IATA report 2010 > serious alternatives are evaluated by ASTM

b) Selected Alternative New Approaches


Folie 10

“State-of-the-art” – Alternative Fuels via Fischer-Tropsch

Fischer-Tropsch Processes: CTL, GTL, BTL

Basis Steps to Biojetfuel (FT):

„Sourcing“ of coal, (natural) gas, biomass / waste *)

Gasification of feedstock to syngas (CO/H2) and ash (!)

FT-synthesis of fuel: mixture of alkanes, naphtha, olefins

Hydroprocessing of mixture (hydro-treating & -cracking)

Separation of fuel mixtures by distillation

*) A combination of coal and biomass is possible too

> 50% of fuel costs are due to investment


Folie 11

“State-of-the-art” – Alternative Fuels from Fats and Oils*)

So-called Hydrogentated Vegetable Oil (HVO) or Hydroprocessed Renewable Jet (HRJ)

Basis steps to Biojetfuel (HRJ):

„Sourcing” and multistep purification of plant / waste oils

Synthesis: Hydrotreating, Hydrocracking, Isomerisation

Separation of fuel mixtures by distillation

Major players are Neste Oil and UOP

Most advanced green technology at the moment

> 50% of fuel costs are due to raw materials

*)sustainable feedstock: camelina, jatropha, animal and frying residues


Folie 12

Limiting factor vegetable oils

Data from: http://www.fas.usda.gov/oilseeds/circular/Current.asp

World Vegetable Oils

1030507090

110130150170

2007 2008 2009 2010 2011

Year

Mil.

Ton

s Total veg. oilsRapeseedSoybeanPalm Oil

Palm oil is (at least currently) a wanted feedstock for food and biofuels (Diesel and Kerosene)

http://www.fas.usda.gov/oilseeds/circular/Current.asp


Folie 13

Competition for palm oil

Palm oil utilization (world)

www.biodieselspain.es Informe de mercado semanal 21, 2007

Energy

Cosmetics, Soaps

Food

Without subsidies palm oil will probably not go into fuels

http://www.biodieselspain.es/


Folie 14

New Alternative Fuels considered by ASTM (not in D7566)

Synthesized Kerosenes Aromatics (SKA)- e.g. alkylated benzenes (important for elastomeric seals and fuel lubricity)

Fischer-Tropsch aromatics can currently not be used

Hydroprocessed synthetic paraffinic kerosene derived from fermented alcohols. Initially focused on iso-butenol. Now other variations will be considered as well

Co-mingling petroleum and biomass in refinery hydroprocessing to optimize efficiencies is currently not allowed. Separate processing and blending is required.

Synthetic biology - genetically engineered micro-organisms convert sugar to pure hydrocarbons

Pyrolysis of cellulosic biomass to synthetic crude products for additional (Hydro-)processing to yield biofuels


Folie 15

Jetfuel via “synthetic biology” - Amyris

http://www.aero-news.net/index.cfm?do=main.textpost&id=5e919f97-bc2c-4ef8-b7bb-c1ff71d34f22

Bioconversionof sugar cane

H2

BiofeneTM (Farnesene)

Production in Biomin in Piracicaba as a JV with Grupo São Martinho (Brazil)

Squalane (from Biofene) will be first product on commercial sale

Also envisioned are industrial lubricants, polymers, kerosene

Analysis of sustainability for Amyris jetfuel from sugarcane is currently funded by Boeing, Embraer, Inter-American Development Bank (IBD)

ASTM screening for farnesane jetfuel has been started

Farnesane (Isomers)

http://www.aero-news.net/index.cfm?do=main.textpost&id=5e919f97-bc2c-4ef8-b7bb-c1ff71d34f22


Folie 16

The land, distribution and logistic challenge

According to OECD (2007) the earth provides

1,5 billion ha farmland 3,4 billion ha grassland 4 billion ha forest

About 440 Mil. ha arable land is still available

80% of the available arable land is located in Latin America and Africa

50% of the available land is distributed over 7 countries:Angola, Congo, Sudan, Brazil, Argentina, Bolivia, Columbia

Refineries and infrastructure are not located where the available land is

Hence, waste and off-gases e.g. CO/CO2 are to be used to generate fuels

Biomass production not in need of land is desirable – e.g. ALGAE, WASTE


Folie 17

EU project focus on algae in 2010 was on Biodiesel*)

*) e.g. ALLGAS-project incl. UMSICHT

Demonstration of large scale sustainable production of bio-fuels based on low cost microalgae cultures (10-ha-site)


Folie 18

General challenges for algae-based biofuels

New SPECS for algae oil raw material are required

So far norms have been developed for vegetable oils

Many components in algae like PUFA-, phospholipids are much higher than in vegetable oils

New components like chlorophyl, carotenoids, hydrocarbons, sugarlipids and minerals are encountered

New ways of pretreatment and QC are to be developed

Many different types of algae exist, some algae are food

Cost for dry algae are ~ 1,5*) - 4 €/kg (20-30 % are oil)

*) Norsker, Wijfels, Barbosa (2010): 100 ha plant (incl. CAPEX & OPEX) tube / panel or open pond reactor with many PE-parts, free of charge CO2

and nutrients, optimized stirring and pumping system


Folie 19

Cracking of waste fats/oils - e.g. Greasoline Technology*)

GasolineKeroseneDieselLPG-GasCokeCO2 /CO/H2

Part of Pilot PlantCrude Algaeoil

*) funded by BMU and EU; spin-off in Aug. 2011


Folie 20

Jetfuel from lignocellulose (waste)

Redrawn from „production of jet and diesel fuel range alkanes from waste hemi-cellulose derived aqueous solutions (Huber et al. 2010)“

Critical success factor is „APR-Technology“ (Virent )

O

OHOH

n

OOH

OH

OHHO

OO

OO O

+OO

O

OOO

OOOH

Hydrolysis Dehydration

Condensation

Mild Hydrogenation

+ H2O - H2O

+H2

OOOH

Hydrotreating

+H2

Tridecane " C13 "

+

Condensation

OO

Aqueous Phase Reforming


Folie 21

Biofuels from alcohols – Swedish Biofuels

*) http://www.swedishbiofuels.se/wp- content/themes/swedishbiofuels/press/swedish_biofuels_v_ah.pdf

*) http://www.greenaironline.com/news.php?viewStory=1348

Biobased gasoline, diesel and jetfuel produced by condensation of lower alcohols made by fermentation

Recently cooperation with LanzaTech for BioJetfuel announced *)

Carbon monoxide (CO) is converted to ethanol (LanzaTech), followed by “chemical condensation” to alkanes (Swedish Biofuels)

Jetfuel evaluation by ASTM us under consideration **)

Technology package is not completely transparent (from patents)

http://www.swedishbiofuels.se/wp-content/themes/swedishbiofuels/press/swedish_biofuels_v_ah.pdf

http://www.swedishbiofuels.se/wp-content/themes/swedishbiofuels/press/swedish_biofuels_v_ah.pdf

http://www.greenaironline.com/news.php?viewStory=1348


Folie 22

Fitting “it” into a refinery

New Technology

Crude distillates or gas mixture

Redrawn

fron Wikipedia

Atm

osph

eric

Dis

tilla

tion

Vac

uum

D

istil

latio

n

Asphalt BlowingAir Asphalt

Del

ayed

Cok

er

Vacuum Residuum

Claus Sulfur Plant

Hydrotreater

Amine Treating

Merox Treater

Catalytic Reformer

Hydrotreater

Hydrotreater

Alkylation

Merox Treaters

Gas Processing

Hydrotreater Isomerization Plant

Hyd

rocr

acke

r

Gas

olin

e B

lend

ing

Poo

l

Flui

d C

atal

ytic

C

rack

er (F

CC

)

FCC Feed Hydrotreater

Petroleum Coke

Refinery Fuel

H2S Sulfur

H2S from Sour Water Stripper

LPG

Butanes

Fuel Gas

Gas

Other Gases

Light

Naphtha

Isomerate

Gas H2 Gas H2

Heavy

Naphtha

Gas H2

Reformate

Gas H2

Kerosene

Jet Fuel

Oil

Crude Jet Fuel and / or

KeroseneH2Gas

Diesel Oil

Atm

osph

eric

Bot

tom

s

Heavy Vacuum

Gas Oil

Heavy Vacuum Gas Oil

Light Vacuum

Gas Oil

Evacuated non-condensibles

AtmosphericGas Oil

Gas H2

Gas H2

Hydrocracked Gasoline

Diesel Oil

i-Butane

ButenesPentenes

Gas

Alkylate

Diesel Oil

Gas

Gas

Coker Naphtha

(after hydrotreating and reforming)

Naphtha FCC Gasoline

Gas H2

Fuel OilFCC Gas Oil

Coker Gas Oil

Refinery and products

Atm

osph

eric

Dis

tilla

tion

Vac

uum

D

istil

latio

n


Del

ayed

Cok

er

Vacuum Residuum

Claus Sulfur Plant

Hydrotreater

Amine Treating

Merox Treater

Catalytic Reformer

Hydrotreater

Hydrotreater

Alkylation

Merox Treaters

Gas Processing


Hyd

rocr

acke

r

Gas

olin

e B

lend

ing

Poo

l

Flui

d C

atal

ytic

C

rack

er (F

CC

)


Petroleum Coke

Refinery Fuel

H2S Sulfur


LPG

Butanes

Fuel Gas

Gas

Other Gases

Light

Naphtha

Isomerate

Gas H2 Gas H2

Heavy

Naphtha

Gas H2

Reformate

Gas H2

Kerosene

Jet Fuel

Oil


KeroseneH2Gas

Diesel Oil

Atm

osph

eric

Bot

tom

s

Heavy Vacuum

Gas Oil


Light Vacuum

Gas Oil


AtmosphericGas Oil

Gas H2

Gas H2


Diesel Oil

i-Butane

ButenesPentenes

Gas

Alkylate

Diesel Oil

Gas

Gas

Coker Naphtha



Gas H2

Fuel OilFCC Gas Oil

Coker Gas Oil

Atm

osph

eric

Dis

tilla

tion

Vac

uum

D

istil

latio

n


Del

ayed

Cok

er

Vacuum Residuum

Claus Sulfur Plant

Hydrotreater

Amine Treating

Merox Treater

Catalytic Reformer

Hydrotreater

Hydrotreater

Alkylation

Merox Treaters

Gas Processing


Hyd

rocr

acke

r

Gas

olin

e B

lend

ing

Poo

l

Flui

d C

atal

ytic

C

rack

er (F

CC

)


Petroleum Coke

Refinery Fuel

H2S Sulfur


LPG

Butanes

Fuel Gas

Gas

Other Gases

Light

Naphtha

Isomerate

Gas H2 Gas H2

Heavy

Naphtha

Gas H2

Reformate

Gas H2

Kerosene

Jet Fuel

Oil


KeroseneH2Gas

Diesel Oil

Atm

osph

eric

Bot

tom

s

Heavy Vacuum

Gas Oil


Light Vacuum

Gas Oil


AtmosphericGas Oil

Gas H2

Gas H2


Diesel Oil

i-Butane

ButenesPentenes

Gas

Alkylate

Diesel Oil

Gas

Gas

Coker Naphtha



Gas H2

Fuel OilFCC Gas Oil

Coker Gas Oil

Atm

osph

eric

Dis

tilla

tion

Vac

uum

D

istil

latio

n


Del

ayed

Cok

er

Vacuum Residuum

Claus Sulfur Plant

Hydrotreater

Amine Treating

Merox Treater

Catalytic Reformer

Hydrotreater

Hydrotreater

Alkylation

Merox Treaters

Gas Processing


Hyd

rocr

acke

r

Gas

olin

e B

lend

ing

Poo

l

Flui

d C

atal

ytic

C

rack

er (F

CC

)


Petroleum Coke

Refinery Fuel

H2S Sulfur


LPG

Butanes

Fuel Gas

Gas

Other Gases

Light

Naphtha

Isomerate

Gas H2 Gas H2

Heavy

Naphtha

Gas H2

Reformate

Gas H2

Kerosene

Jet Fuel

Oil


KeroseneH2Gas

Diesel Oil

Atm

osph

eric

Bot

tom

s

Heavy Vacuum

Gas Oil


Light Vacuum

Gas Oil


AtmosphericGas Oil

Gas H2

Gas H2


Diesel Oil

i-Butane

ButenesPentenes

Gas

Alkylate

Diesel Oil

Gas

Gas

Coker Naphtha



Gas H2

Fuel OilFCC Gas Oil

Coker Gas Oil

Atm

osph

eric

Dis

tilla

tion

Vac

uum

D

istil

latio

n


Del

ayed

Cok

er

Vacuum Residuum

Claus Sulfur Plant

Hydrotreater

Amine Treating

Merox Treater

Catalytic Reformer

Hydrotreater

Hydrotreater

Alkylation

Merox Treaters

Gas Processing


Hyd

rocr

acke

r

Gas

olin

e B

lend

ing

Poo

l

Flui

d C

atal

ytic

C

rack

er (F

CC

)


Petroleum Coke

Refinery Fuel

H2S Sulfur


LPG

Butanes

Fuel Gas

Gas

Other Gases

Light

Naphtha

Isomerate

Gas H2 Gas H2

Heavy

Naphtha

Gas H2

Reformate

Gas H2

Kerosene

Jet Fuel

Oil


KeroseneH2Gas

Diesel Oil

Atm

osph

eric

Bot

tom

s

Heavy Vacuum

Gas Oil


Light Vacuum

Gas Oil


AtmosphericGas Oil

Gas H2

Gas H2


Diesel Oil

i-Butane

ButenesPentenes

Gas

Alkylate

Diesel Oil

Gas

Gas

Coker Naphtha



Gas H2

Fuel OilFCC Gas Oil

Coker Gas Oil


Folie 23

Summary and outlook

Big challenges are ahead of sustainable Biojetfuel

Cooperation of many “unfamiliar” players required to make Biojetfuels fly

Biofuels demand coupling of hitherto not linked value and supply chains (petrochemicals, agriculture, food, fodder, crop-sciences, biology, chemicals)

Sustainability requires to find a balance between ecological, economical and social targets, which are by nature contradictory (TRILEMMA)

Broad Biojetfuel evaluation by ASTM has been started, be prepared for surprises

Many new players try to get a foothold into the market - outcome uncertain

Prices for key commodities like energy, fuels and new commodities like CO2, algae, waste streams almost certain guarantee for an interesting journey ahead


Folie 24

Dr. Anna FastabendDr. Jürgen Grän-HeedfeldDipl.-Ing. Andreas MenneDipl.-Ing. (FH) Karl MellerDr. Anna GreveDipl.-Wirt.-Chem. Klaas BreitkreuzDr. Volker Heil

Leading R&D personnel at Business Unit Biofuels

Thank you for listening


Folie 25

Fraunhofer UMSICHT – Organization of Business Units

http://www.umsicht.fraunhofer.de/en.html

X = active in the field of Biorefinery / Fuels

X X X

X X


Folie 26

Sustainability Trilemma

Documents

Alternatives to fossil jetfuel and related challenges CLIB Forum... · Squalane (from Biofene) will be first product on commercial sale Also envisioned are industrial lubricants,