Drop-in gasoline from wood in an integrated biorefinery: pilot operations under way

> Andrew Kramer (Gas Technology Institute) Rick Knight (Gas Technology Institute) Jesper Jensen (Haldor Topsoe A/S) Jim Patel (Andritz Carbona)

> Gasification Technologies Conference 2013 Colorado Springs, Colorado October 13-16, 2013

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Disclaimer

This material is based upon work supported by the Department of Energy, Golden Field Office, under Award Number DE-EE0002874. This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

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Why Gasoline?

>Motor fuels account for 34% of CO2 emissions

>There are >250 million cars and light-duty trucks on the road

>95% of them run on gasoline

Biomass conversion is the only near-term option to directly replace gasoline with a renewable alternative

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Biomass-to-tank pathway

>Thermochemical gasification

>Conversion of resulting synthesis gas to motor fuel

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Biomass-to-tank pathway

>Thermochemical gasification

>Conversion of resulting synthesis gas to motor fuel

>Woody biomass gasoline blendstock ─ Product compatibility with existing infrastructure.

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Biorefinery Project Team

-Business: gasification & gas cleanup -Provides: fluidized-bed gasification, syngas cleanup and reforming, commercialization support

-Business: R&D and process testing -Provides: design, construction, and operation of pilot plant plus modeling, data analysis, commercialization support

- Business: pulp and paper -Provides: gathering, handling and transporting of wood, 1st commercial plant site

-Business: refining & downstream -Provides: design assistance, fuel characterization, engine & fleet testing

-Business: catalysts & catalytic processes -Provides: TIGAS process, syngas reforming catalysts, overall project management

-Core financial support -Technical guidance and oversight -Project management guidance and oversight

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Process basics

BIOMASS GASIFIER

BIOMASS

STEAM

O2

ASH REMOVAL

SYNGAS REFORMER

HEAT RECOVERY

ASH

WASTE WATER

SCRUBBER

CO2

O2

SYNGAS

GASIFICATION

WATER

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Process basics

BIOMASS GASIFIER

CO2

ASH REMOVAL

SYNGAS REFORMER

HEAT RECOVERY

SYNGAS COMPRES-

SOR

MORPHY-SORB® AGR

SCRUBBER

SWEETENED SYNGAS

GASIFICATION ACID GAS REMOVAL

BIOMASS

STEAM

O2 ASH

WASTE WATER

CO2

O2 WATER

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Process basics

BIOMASS GASIFIER

ASH REMOVAL

SYNGAS REFORMER

HEAT RECOVERY

SYNGAS COMPRES-

SOR

MORPHY-SORB® AGR

SYNGAS PURIFICAT-

ION

DME SYNTHESIS

GASOLINE SYNTHESIS

PRODUCT SEPARATORS

GASOLINE PRODUCT

LPG BYPRODUCT

SCRUBBER

WASTE WATER

TAIL GAS

GASIFICATION

TIGAS

ACID GAS REMOVAL

CO2

STEAM

O2 ASH

WASTE WATER

CO2

O2

BIOMASS

WATER

RECYCLE TO GASIFIER

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Process basics

BIOMASS GASIFIER

CO2

O2

ASH REMOVAL

SYNGAS REFORMER

HEAT RECOVERY

ASH

SYNGAS COMPRES-

SOR

MORPHY-SORB® AGR

SYNGAS PURIFICAT-

ION

DME SYNTHESIS

GASOLINE SYNTHESIS

PRODUCT SEPARATORS

GASOLINE PRODUCT

WASTE WATER

LPG BYPRODUCT

RECYCLE TO GASIFIER

OXYGEN PLANT

WATER TREATMENT

SCRUBBER

ON-SITE POWER GEN

CO2

STEAM

ACID GAS REMOVAL GASIFICATION

TIGAS TAIL GAS

BIOMASS

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Gasification (Andritz-Carbona)

> Oxygen-blown

> Bubbling bed

> High thermal efficiency

> Low syngas tar contamination

BIOMASS

ASH

OXYGEN + STEAM

HOT PRODUCT GAS

CYCLONE

FLUIDIZED BED

GRID

ASH REMOVAL SCREW

FEEDING SCREW

FEED HOPPER

GASIFICATION REACTOR

BIOMASS GASIFIER

BIOMASS

STEAM

O2

CO2

Gasifier (lower section)

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Syngas Cleanup (Andritz-Carbona & Haldor Topsoe)

> Hot particulate filter

> Catalytic syngas reformer

> Converts C6+ tars and CH4 to CO and H2

Filter Candles

ASH REMOVAL

SYNGAS REFORMER

ASH O2

PULSE PIPING

GAS OUTLET

TUBESHEET

GAS INLET

ASH OUTLET

Reformer (upper section)

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Acid Gas Removal (GTI-Uhde)

> Syngas compression to 1000 psig (68 bara)

> Removes CO2 and H2S with Morphysorb® physical solvent

> High selectivity

CO2-rich acid gas

SYNGAS COMPRES-

SOR

ABSORBER

AGR Pilot Plant Syngas Compressor

STRIPPER

N2

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Topsoe Integrated Gasoline Synthesis (Haldor Topsoe)

> Unique high-conversion once-through

methanol/DME synthesis step

> Tail gas recycle results in essentially power-

neutral process

> Syngas conversion well over 90 percent

LPG BYPRODUCT

SYNGAS PURIFICAT-

ION

DME SYNTHESIS

GASOLINE SYNTHESIS

PRODUCT SEPARATORS

GASOLINE PRODUCT

WASTE WATER

TAIL GAS

TIGAS Module in Fab Shop

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2H2 + CO → CH

3OH

H2O + CO → H

2 + CO

2

CH3OH → ½ CH

3OCH

3 + ½ H

2O

nCH3OCH

3 → 2(CH

2)n + nH

2O

TIGAS Chemistry

Combined into a single step, which maintains low methanol concen-tration in the reactor

Gasoline synthesis

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Combined Synthesis Drives Yield

0

10

20

30

40

50

60

70

80

0 10 20 30 40 50 60 70 80

66:33:1

Co

nvers

ion

(CO

+C

O2)

MeOH

MeOH / DME

Pressure (bar)

Key Reactions: 4H

2 + 2CO

→ 2CH

3OH

2CH3OH → CH

3OCH

3 + H

2O

CO + H2O → CO

2 + H

2

------------------------------------------- 3H

2 + 3CO → CH

3OCH

3 + CO

2

Then in the gasoline reactor: CH

3OCH

3 2(CH

2) + H

2O

---------------------------------------------- 3H

2 + 3CO 2(CH

2) + H

2O + CO

2

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Gasoline Blendstock Properties

>Octane (R+M)/2 > 87

>Zero Sulfur

>Aromatics < 35 vol%, but benzene < 0.3 vol%

>Low RVP (~9 psi)

>Durene <2%

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Biomass-to-tank pathway

>Thermochemical gasification

>Conversion of resulting synthesis gas to motor fuel

>Woody biomass gasoline blendstock ─ Product compatibility with existing infrastructure.

>Pilot plant ─ 21 ton/day (19 MT/day) BD feedstock 23 bbl/day

(3700 L/day) product

─ Commissioning and shakedown: November 2012

─ Integrated long-term testing: March 2013 – April 2014

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Pilot Plant Block Flow Diagram

WEIGH HOPPER

LOCK HOPPER

FEED HOPPER

GASIFIER

BIOMASS

N2

CO2

STEAM

O2

SYNGAS FILTER

SYNGAS REFORMER

SYNGAS SCRUBBER

O2 WATER

FILTER SOLIDS

BED SOLIDS

BED MEDIA MAKEUP

SYNGAS COMPRES-

SOR

ACID GAS REMOVAL

SYNGAS PURIFICAT-

ION

GASOLINE SYNTHESIS

WASTE WATER TANK

SOUR GAS TO FLARE TAIL GAS TO FLARE

GASOLINE PRODUCT

WASTE WATER

WASTE WATER

RECYCLE TO GASIFIER

BIOMASS STORAGE

SILO

DME SYNTHESIS

PRODUCT SEPARAT-

ORS

GASOLINE TANK

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Biorefinery Facility

Feed System, Gasification,

Filtration

Gasoline synthesis

Acid Gas Removal

Oxygen, Nitrogen, and CO2 Supply

Cooling Tower

Gasoline & Waste Water

Tanks

Chiller Syngas

Compressor

Feedstock Unloading

Feed Storage Silo

Stack

Syngas Conditioning

Gasoline synthesis

Syngas conditioning

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>Wood pellets provided by

UPM Blandin Mill in Grand

Rapids, MN

>Source: bark-on aspen logs

>Pelletized at Indeck mill in

Ladysmith, WI

─ Represents mix of mill residue,

logging residue, & roundwood

─ Shipped to GTI in 22-ton

(20-MT) pneumatic trucks

Feedstock

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Pilot Project Status

> Project started · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Feb 2010

> Engineering completed · · · · · · · · · · · · · · · · · · · · · · · · · · Jun 2011

> Existing equipment upgrades

& new construction completed · · · · · · · · · · · · · · · · · · · · Oct 2012

> Commissioning & shakedown completed · · · · · · · · · · · · Jan 2013

> Long-term testing (3 campaigns)

─ Test #1 (completed) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Mar 2013

─ Test #2 (under way) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Oct 2013

─ Test #3 (future) · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Feb-Mar 2014

> Engine emissions tests &

moderate fleet testing · · · · · · · · · · · · · · · · · · · · · Nov 2013-Oct 2014

> Technology evaluation, readiness,

& commercialization plan · · · · · · · · · · · · · · · · · · · · · · Oct-Dec 2014

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Construction: TIGAS Bay

FLOOR EXCAVATED

NEW GRADE BEAMS & FLOOR

ROOF REMOVED

LOOKING UP FROM BAY 3 FLOOR

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Construction: TIGAS Lower Module

LIFTING FROM STAGING AREA UPRIGHTING MODULE

LIFTING ABOVE ROOF

LOWERING INTO BAY

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Construction: TIGAS Upper Module

LIFTING FROM STAGING AREA UPRIGHTING MODULE

LIFTING ABOVE ROOF

LOWERING INTO BAY

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Construction: Tank Farm

EXCAVATION FOR PAD

PAD, SUPPORTS, & CONTAINMENT POURED & CURED

TANK DELIVERY & SETTING

INSTALLATION COMPLETED

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Commercial Outlook

>Pilot plant will establish design basis for a commercial plant ─ 85 million gal (322 million L) per year of drop-in

renewable gasoline

─ 4 gasifiers convert 4000 MT/day of 20%-moisture biomass to syngas for one AGR train + one TIGAS train

─ 100 plants of this size would meet 24% of the EISA goal for 2022

─ 91.7% reduction in GHG life-cycle emissions compared to conventional gasoline

─ Preferred co-location with existing pulp & paper mill

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Commercial Outlook: California 2020 example

Source: AEO2013 - Report Number DOE/EIA-0383(2013) http://www.eia.gov/forecasts/aeo/

$4.11

$0.93

$1.83

$0.04

$0.04

$2.99

$4.11

$0.67

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Acknowledgment

> U.S. Department of Energy - EERE

> National Renewable Energy Laboratory

> With valuable contributions from:

─ Gas Technology Institute: Bruce Bryan, Jim Aderhold, Andy Kramer,

Stan Wohadlo, Pat Bishop, Mark Stevens, Rachid Slimane, Mike

Mensinger, and many others

─ Haldor Topsoe: Arne Knudsen, Samy Diab, Tommy Hansen, Nanna

Topsoe, Martin Sorensen, Finn Joensen, Rasmus Nielsen, and others

─ Andritz-Carbona: Heikki Virta, Vellu Pietarinen, Andras Horvath, Mika

Ketomaki

─ UPM: Pekka Jokela, Jim Marshall

─ Phillips 66: Kip Walston

─ SAIC: Herb Kosstrin, Clare Behrens