Chicago Chapter AIChE 09-15-2009

8/8/2019 Chicago Chapter AIChE 09-15-2009

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GTI Biorenewables

Vision, Challenges, Programs,and Status

Terry Marker, Vann Bush, Eddie Johnston, Bill Liss, Jack Lewnard

Chicago Chapter AIChE September 15, 2009

August 2009


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AIChE September 15 2009 2

Business Confidential 2

AIChE September 15 2009

Biofuels Turning Up The Heat

>Introduction to GTI

>Biogas

>Biomass pre-treatment

>Thermochemical conversion optionsHydropyrolysis

Gasification

> Gas clean-up> Syngas, fuel, and/or power

>tcBiomass Conference


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What We Do

>GTI solves important energy challenges, turningraw technology into practical solutions that

create exceptional value for our customers in theglobal marketplace.

Energy Solutions Delivered


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> Not-for-profit research,with 65+ year history

> Facilities

18 acre campus near Chicago

200,000 ft2,28 specialized labs

> $60 million in revenue

> Staff of 250

> A growing business> 1000 patents; 500 products

> Commercial partners take ourtechnologies to market

Energy & Environmental Technology Center

Flex-FuelTest

FacilityOffices& Labs

Our Company at a Glance


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Reducing carbon emissions to the environment


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> Fastest growing area in energy R&D Global R&D spending up 20% in 2006 Corporate $9.1B; Govt $7.2B

> Increased domestic (and continuinginternational) concerns about energyindependence, sustainability, globalwarming, and need to hedge fossil prices

Renewable Energy - Premises

Biofuels required to meet mandated RPS, renewable fuel targets in

many states and countries, with increasing interest from suppliersand users for green natural gas


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Biogas- Natures Oldest Renewable

> Manure or waste to methane via anaerobicdigestion ideal for low-solids streams

> First recorded us in Assyria ca 10 BC to heatbath water

> Millions of small systems in China and India

> US and Europe primarily using biogas for power

generation; missed opportunity for higher-valueuses


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Biogas Composition and Potential

> Biogas basics Produced from anaerobic digestion of

biomass, typically dilute organicwaste stream

Digesters for manure, mixed agwaste, wastewater treatment, and

landfills Composition 30-60% methane;

water-saturated with CO2 as primarycontaminant

Other contaminants specific to feed

> 1-2 TCF biogas total US recoverableresource

> EU comparable or higher, butmarket further developed

Human Related U.S. Methane Emissions

(in TgCO2 equivalent)

Coal Mining

Landfills

Natural Gas

Systems

Enteric

Fermentation

Other

Manure

Management

Wastewater

Treatment

Source: US Emis sions Inventory 2005


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AIChE September 15 2009 9Business Confidential 9AIChE September 15 2009

GTI Biogas Projects

> Altamont Landfill to LNG for Garbage Truck Fleet

Livermore CA, Waste Management and Linde

> Gills Onion to Fuel Cell

Digester Gas, FuelCell Energy Fuel Cells

> Landfill Gas to Hydrogen

> Pipeline Quality Renewable Gas from Dairy Waste Conversion

Utilities Participating (PG&E)

Guidance Paper on Gas Quality Issues


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Biogas Challenges

> Push EU mandates to redirect organic waste from landfill, ban sludge and manure spreading, and

required access to gas and electric grid for renewable energy

US mandated biogas recovery from landfills and wastewater treatment plants

US emerging regulations on manure

> Pull Renewable Portfolio Standards and favorable incentives (currently only when used for electricity)

Project developers and gas industry interested in pipeline quality gas

> Gas contract higher value than power contract, albeit with higher capital cost

> Creates transportable low-carbon fuel so electric utilities can reposition fossil NGCCpower plants as green facilities, meet RPS requirements, and access renewable credits

> CO2 credits from GHG abatement add 10% to product value

> Addressing the higher-value pipeline gas market requires a newapproach to gas processing and harmonized gas quality specifications

> Selling gas into the gas grid requires robust, fully-qualified, packagedsolution encompassing compression, clean-up, and instrumented custodytransfer


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Biomass Pretreatment Project

Develop a process to render any ligno-cellulosic biomass intomaterial amenable to efficient gasification or pyrolysis.

Gasification

Pyrolysis

Fuel gas Power Liquid fuels Chemicals

Versatile PretreatmentTechnology

We must use forestry and agriculturalbiomass sources to reach biofuel goals.

Logistics of biomass supply is a major

economic and carbon intensity hurdle.

Higher energy density bio-feedstock wouldallow larger, more economic process scale.

Gasification and pyrolysis both benefit fromfeedstock consistency.


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Treatment of Pine Chips

Before After

C, % 51.4 68.3

H, % 5.9 5.1

O, % 42.1 25.9

Ash, % 0.39 0.27

HHV (dry),

Btu/lb

8,500 11,800

Treated material is friable and easily pulverized.

Preliminary energy balance shows 86% recovery

of energy as treated solids.


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Chemistry Issues for BiomassPyrolysis

High temperature uncontrolled thermal reaction, makes free radicals,

causes condensation reactions making condensed ring polynuclear

aromatics and olefins and polymerization retrograde reactions make

compounds harder to upgrade with hydroconversion

No significant reduction in oxygen in pyrolysis step, pyrolysis oil and wood

have the same % oxygen and same heating content on BTU/lb basis

Structure needs hydrogen to reduce olefins, avoid condensation reactions

and avoid retrograde reaction

Biomass does not have polynuclear aromatics to start with but we create

them in pyrolysis step


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Typical Structure of Lignin

Perfect structure for conversion to

gasoline and aromatics

Carbon= 64%Hydrogen =6%

Oxygen= 30%


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Integrated Hydropyrolysis andHydroconversion (IH2 )

Fast biomass heat up maximizes liquid yield Hydroconversion with catalysts produces low-oxygen, low-acidity liquids Polynuclear aromatic components are not formed Self-sufficient process requires no supplemental water or hydrogen High-quality renewable gasoline and diesel products are produced

0

10

20

30

40

50

60

70

80

90

100

Petroleum Diesel GTI RG Petroleum Gasoline

gCO2eq.

/MJ Fuel Combustion

Fuel Transportation

Fuel ProductionTransportation of Feedstocks

Feedstock Production, RMA

Feedstock Chemicals

CONVERSION OF BIOMASS DIRECTLY INTO GASOLINE AND DIESEL

Over 90% lowergreenhouse gases inrenewable gasoline

from IH2

processcompared topetroleum-basedfuels


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Product Property Comparison

Fast Pyrolysis Oil IH2 product

% Oxygen 50


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Gasification: High Temperature Option

SNG


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GTI-Carbona Fluidized-BedBiomass Gasifier

High carbon conversion, 95-98%+

Capability to gasify a wide variety of

fuels, including coal/biomass mixtures

Simple design with safe, reliable

operation

Air-blown, enriched-air or oxygen-blown

operation

Atmospheric to 30+ bara

Operates at a lower temperature than a

slagging gasifier (to 1000 C)

Longer metal component and refractory

life Good turndown capability, 30 50%

Demonstrated at commercial scale by

Carbona

OXYGEN or


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GTI/Carbona Biomass Feedstocks


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Capacity,

Tons

/day

1

10

100

1000

1970 1975 1980 1985 1990 1995 2000 2005

24

80

30

100

8x150

40

HP Biomass

HP Coal

LP Coal

10

8

40

20

Flex-FuelShanghaiMaui

FinlandRENUGASChicago

UGAS Pilot and PDU - Chicago

2010

165

DenmarkChina

2x300

Scale-up History ofGTI Gasification Technology


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Flex-Fuel Test Facility:Pilot-Scale Fluidized Bed Gasifier

Pilot-scale process R&D

Periodic test campaigns

~30 testing staff

Biomass 20 tpd w/air; 40 tpd w/oxygen

Gasification Pressure to 27 bara

Extensive On-line Syngas Analysis Systems


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100 ton per day Bioenergy Demo Plantin Maui, Hawaii using bagasse80 ton per day Gasification Pilot Plant in

Tampere, Finland using biomass & coal

Biomass Gasifier Projects

165 ton per day CHP Plant inSkive, Denmark using wood

40 ton per day Flex-Fuel Test Facilityin Des Plaines, IL for biomass & coal

1992 1994

2006 2003


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Synthesis Gas Process

FuelTreatment Gasification

HydrocarbonReforming

Particle,Alkali

Removal

Shift

HydrogenSeparation

Hydrolysis,Acid GasRemoval

TraceRemoval

Synthesis,Upgrading

PowerCHP

Methanol

DMEAlcoholsFT DieselGasoline

H2

SNG

GTI R&D

Biomass

pretreatment,

pyrolysis

GTI U-GAS,

RENUGAS,

GPE bluegas,

PWR Compact

Gasifier

Ultra-Clean

GTI Catalysts,

Tar Reforming

Morphysorb,

UCSRP,

CrystaSulf (+DO)

Ultra-Clean

Membranes

UCSRP,

CrystaSulf-DO

Ultra-Clean Catalyst

Coal

Biomass

Coal and Biomass


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Engineering New Catalysts For In-Process Elimination Of Tars

Scope: Engineer new catalyst forms, use GTI submerged combustion melter to economicallyproduce optimized catalysts for the reduction or elimination of tars in biomass gasification,evaluate catalysts for in-bed tar reduction in Flex-Fuel Test Facility (FFTF)

Status: Created new technologies for producing catalysts. Successfully demonstrated catalystperformance in lab trials with steam reforming of methane and with naphthalene as a

surrogate biomass tar. Conducted baseline tests in FFTF. Proceeding to second phase for

manufacture and testing of catalyst formulations.

Value: Create lower-cost, high-performing catalysts for tar

reduction in biomass gasifiers

founded1836

AlfredUniversity

0 5 10 15 20 25 30 35 40 45 50Elapsed Time, h

70

75

80

85

90

95

100

NaphthaleneRedu

ction,

%

Reactor Temperature900C

850C

800C

750C

NAPHTHALENE DECOMPOSITION

50

60

70

80

90

100

0 20 40 60 80 100

Elapsed Time, h

STEAM REFORMING OF METHANE (800C)

MethaneConvers

ion(%)

Ni Metal

Olivine

Ni-olivine Catalyst


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> Laboratory Screening of H2 MembranesCeramic membranes

Metallic membranes

> Field Prototype Tests

Biomass gasifier Integrated system

> guard-shift-membrane

H2 flux, purity targets

Hydrogen Production from Biomass

hydrogen

feed

Porous supportmembraneCopper seal coated by carbon

SCHOTT


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Pilot Testing Program at GTI

2nd Generation Biofuel Production from Woodby Fluidized Bed Gasification and F-T


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Skive, DenmarkCombined Heat & Power Project

Fuel storage

Heat accumulator

Fuel receiving and storage

Gasification plant

GASIFIER

GAS FILTER

GASCOOLER

GAS ENGINES

TARREFORMER

BIOMASS

AIR & STEAM

ASH

FLY ASH

BOILER

TO STACK

WATER

GAS SCRUBBING GAS BUFFERTANK

POWER

6 MWe

DISTRICT HEATING12 MWth


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tcbiomass International Conference

>AIChE Special Rate:

$450 one day pass

$900 three day conference registration

Brochures/information at registration desk


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Summary

Many renewable bio-energy options; producing fungible productsthat integrate with existing energy infrastructure is key

Anaerobic digestion of low-solids wastes is energeticallyfavorable; biogas applications active area of RD&D

Biomass pre-conditioning likely required for large-scaleaggregation for renewable fuels

Gasification of high-solids biomass is energetically favorableroute to syngas, fuels, and CHP

GTI is developing integrated hydropyrolysis route to address low-temperature liquid fuels production

tcbiomass is a great opportunity to learn more

Documents

Chicago Chapter AIChE 09-15-2009