DOE Bioenergy Technologies Office (BETO) 2015 Project Peer Review

Green Gasoline from Wood Using Carbona Gasification and Topsoe

TIGAS Processes

March 24, 2015 Demonstration and

Market Transformation

Rick Knight Gas Technology Institute

This presentation does not contain any proprietary, confidential, or otherwise restricted information

Acronyms

AGR Acid Gas Removal DME Dimethyl ether GTI Gas Technology Institute HGF Hot gas filter HTAS Haldor Topsoe A/S (Denmark) HTI Haldor Topsoe Inc. (Houston TX) TIGAS Topsoe Improved Gasoline Synthesis UHGF Ultra-hot gas filter

2

Goal Statement

• To demonstrate and validate an economical integrated technology for thermochemical conversion of woody biomass into renewable drop-in gasoline

• This technology is applicable to many U.S. sites, with the potential to displace 2 billion gallons of petroleum-based transportation fuel annually and create thousands of U.S. jobs.

3

4

Quad Chart Overview

• Project start: March 31, 2010 • Project end: December 31, 2014 • 100% complete

• Barriers addressed – It-A. End-to-end process integration – Im-D. High risk of large capital

investment – It-E. Engineering modeling tools

Timeline

Budget: $34,388,775

Barriers

• Partners – DOE recipients: HTI (3%); GTI

(93%); Andritz Carbona (4%). • Other interactions/

collaborations – Pall Corp. and E·ON provided

engineering and testing of ultra-hot gas filter (UHGF)

– State of Illinois supported commissioning of AGR pilot unit

Partners FY10-FY12

FY13 FY14 FY15 Total

$1000

DOE $11,001 $9,696 $4,204 $99 $25,000

Project Cost Share

HTI $111 $683 $79 $46 $919

HTAS $2,381 $1,243 $727 $0 $4,351

GTI $132 $827 $577 $7 $1,543

Andritz $15 $35 $50 $25 $125

UPM $0 $488 $241 $0 $729

Phillips $188 $44 $1,025 $722 $1,979

Cost Share Total

$2,827 $3,320 $2,699 $800 $9,646

1 - Project Overview

• Haldor Topsoe interested in applying their TIGAS process to biomass-derived syngas for renewable fuel markets

• Prior work by GTI, Andritz Carbona, and UPM developed clean bio-derived syngas for Fischer-Tropsch synthesis

– Andritz Carbona owns rights to biomass gasification technology – GTI owns rights to Morphysorb® acid gas removal – GTI owns and operates gasification and gas cleanup pilot plant

• Haldor Topsoe, Andritz, UPM, and GTI teamed up with Phillips 66 to form a project team covering the entire supply chain

• Project team responded to IBR solicitation with ARRA funding

5

1 - Project Overview

• Pilot plant located at GTI in Des Plaines, IL • Wood pellet biomass feed is provided by UPM from their

Blandin, Minnesota facility • Biomass is converted into gasoline by the following steps:

– Andritz-Carbona gasification – Hot gas filtration and tar reforming – Morphysorb acid gas removal – Haldor Topsoe TIGAS gasoline

synthesis

• Design capacity of the pilot plant: – 21 tons of wood pellet feed per day – 23 barrels per day of gasoline

product

6

7

2 – Approach (Technical)

7

Pressurized Fluid Bed Gasifier

CO2

O2

Hot Gas Filter

Tar and Methane Reformer

Waste Heat Boiler

Ash

Syngas Compressor

Morphysorb® Acid Gas

Plant

Trace Contaminant

Removal

Methanol-DME

Synthesis

Gasoline Synthesis

Phase Separators

LPG

Oxygen plant

Water Treatment

Plant

Syngas Cooler/

Condenser

CO2

Steam

Acid

Gas R

em

oval

Gasification and Syngas Cleanup

TIGAS Gasoline Synthesis

Tail Gas

Woody Biomass

Gasoline

Green text denotes major biorefinery sections Gray blocks denote unit operations tested in pilot plant

On-Site Power

Generation

Flue gas

[Nat Gas]

Air

Wood Dryer

8

2 – Approach (Management)

• Critical success factors and challenges – Clean syngas for catalytic process steps – Stable integrated operation – Drop-in gasoline blendstock at competitive price

• Structure of management approach – Haldor Topsoe PM coordinates work thru partner PM’s – WBS extended to level 4 work packages (56 total) – Milestones, Deliverables, Go/No-Go decision points – Earned Value tracking extended to subcontractors and vendors – Risk Mitigation via weekly teleconferences, frequent face-to-face

meetings, preliminary & final HAZOP reviews, readiness reviews, post-test evaluation meetings

– Project Management assistance from Independent Engineer and Executive Steering Committee

8

9

3 – Technical Accomplishments/ Progress/Results

• The project team has met and exceeded technical objectives – Biorefinery was expanded, commissioned, and operated

successfully – Completed three test campaigns including internal recycles – Syngas cleanup was sufficient for gasoline production with no

catalyst deterioration – Predicted gasoline yield and quality was met under stable

integrated operation – Gasoline has been validated for EPA emissions and track-tested for

75,000 miles with no adverse findings

9

10

3 – Technical Accomplishments/ Progress/Results (continued)

10

• 61-65% syngas to motor fuel conversion (LHV energy basis)

• Engine emissions from 80% biogasoline blend were ‘substantially similar’ to standard gasoline

• Fleet test with 50% biogasoline blend logging 75,000 mi on each of 4 vehicle pairs

• Pilot results reduce technical risk sufficiently for licensors to offer commercial package

Target Actual

Biomass* fed, lb 317,230

Gasoline made, lb 31,560

LP gas made, lb 6,360

Gasoline + LPG yield,† lb fuels/ton maf biomass

312 284-320

Energy conversion, Btu fuels/Btu biomass, %

36.2 36-40

Octane (R+M)/2 >83 89-92

Aromatics, vol% <35 29-33

* 6.0 wt% moisture, 0.9 wt% ash † Corrected for syngas bleed to flare

COOLING & COMPRESSION

TAR REFORMER

DUST

HOT GAS FILTER

QUENCH WATER

BIOMASS

ASH

GASIFIER

O2, steam, CO2, recycle gas

SLIPSTREAM FILTER

3 – Technical Accomplishments/ Progress/Results (continued)

• Essential core of gasification & gas cleanup

• Gasifier ran reliably • Hot gas filter development

advanced through testing • Pall ceramic filters • Also validated 1300°F

version for higher efficiency

• Tar Reformer converted 85% of CH4, 99.0% of benzene, 99.5% of naphthalene

3 – Technical Accomplishments/ Progress/Results (continued)

• Reduced syngas CO2 from 40%+ to 2% for optimal yield

• Reduced H2S from 15-25 ppmv to 1-3 ppmv

• Acid gas is >90% CO2

• No significant solvent carryover

• Optimization parameters established

T-800

T-801

T-802

T-807

T-806

FT-802 FT-804 P-800

P-801

Sour Gas (from

compressor)

Sweet Gas (to TIGAS)

Acid Gas (Stripper off gas)

Flash Gas

Lean Solvent

Rich Solvent

Flashed Solvent

G34 G33

G31

L31

L32

L33

G32

3 – Technical Accomplishments/ Progress/Results (continued)

• Pilot testing validated catalyst activity, selectivity, and aging performance with biomass-derived syngas

• Improvements developed for startup and integration with BOP • Commercial application design basis established

L13

L12

L11

FT-9104

T-716Waste Water

T-717Gasoline

c

FT9907

c

FT9701

c

FT9705

G11

G12G13

FT-9501 G14

G15

FT-9702FT-9703

c

FT9905

R-901Hot GuardReactor

R-902MeOH/DME Reactor

R-903GasolineReactor

T-902HP Separator

T-903LP Separator

T-904Waste WaterFlush Drum

FT-9901 G17

To Gasifier(recycle gas)

G16

T-905Flare GASKO Drum

To Flare(recycle gas)

HE-905TrimHeater

HE-904 1,2Feed Effluent Exchanger

HE-907GasolineColler

HE-906Recycle Gas Preheater

FT-9803

CM-901Recycle Gas Compressor

HE-902Hot Guard Trim Heater

HE-901Hot Guard Feed/Effluent Exchanger

From Acid Gas RemovalSection HE-908

GasolineChiller

ASTM D4814 Min (Classes AA through D), 170

ASTM D4814 (AA through D), 131

ASTM D4814 (AA through D), 235

ASTM D4814 (AA through D), 365

ASTM D4814 (AA through D), 437

0

50

100

150

200

250

300

350

400

450

500

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Dis

tilla

tio

n T

em

pe

ratu

res,

(F)

at

% E

vap

ora

tive

DISTILLATION CURVES FOR THE BASE FUEL AND FOR WBG

ASTM D4814 Min (Classes AA through D) ASTM D4814 (AA through D)

BASE FUEL (EM-8723) CANDIDATE FUEL WBG (EM-8761-F)

3 – Technical Accomplishments/ Progress/Results (continued)

0

2

4

6

8

10

12

14

16

18

20

C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15+

MA

SS P

ERC

ENT

3 – Technical Accomplishments/ Progress/Results (continued)

16

4 – Relevance Biomass Program goals & objectives

• Key Biomass Program goal – Enable the production of biofuels nationwide and reduce

dependence on oil through the creation of a new domestic bioenergy industry supporting the EISA goal of 16 bgy of cellulosic biofuel by 2022

• This project: – Established design basis for a commercial plant to produce

57 million gal/year of drop-in renewable gasoline – 100 plants of this size would provide 36% of EISA cellulosic biofuel goal

for 2022

• Other key points – 95% of cars now on the road burn gasoline – No new infrastructure or automotive technology required – Agricultural wastes and energy crops can expand future resource base

16

17

4 – Relevance Sustainability and life cycle emissions

• Sustainability – Definition: the capacity of forests … to maintain their health,

productivity, diversity, and overall integrity, in the long run, in the context of human activity and use

– Feedstock will be mill wastes, forest residues, thinnings, brush, etc. – At least 60% more energy-efficient than burning in boilers

• Emissions – 73.7% reduction in GHG life-cycle emissions compared to conventional

gasoline – 1.0 million bbl of crude oil displaced per year for one plant – No hazardous solid or liquid wastes

17

18

4 – Relevance Impact on commercialization strategy

• DOE piloting identified key challenges to a commercial offering – Process control in fully integrated mode – Startups, shutdowns and emergency trips in different plant sections – Sensitivity of product yield and quality to operating conditions in

different plant sections – Catalyst lifetimes – Maintenance expectations – Confirmation of projected mass and energy balances – Performance of materials of construction – Confidence-building

18

19 19

Summary • Integrated wood to gasoline pilot plant established design basis for a

commercial plant to produce 57 million gal/year of drop-in renewable gasoline – 100 plants of this size would provide 36% of EISA cellulosic biofuel goal for 2022 – Projected gasoline production cost of $2.56 per gallon

• No new infrastructure or automotive technology required • GHG life-cycle emissions reduced by 73.7% compared to conventional

gasoline • Efficient and visible project management procedures with WBS down to level 4

work packages with well defined milestones, deliverables and decision points • Budget control with Earned Value tracking extended to subcontractors and

vendors • Three test campaigns were completed producing >10,000 gallons of gasoline • Bio-derived gasoline passed single-engine emission tests for EPA registration

– Phillips 66 applying for EPA registration of 80% blend • 75,000-mile track testing validated performance of 50% blend

– No adverse impacts on mileage or engine condition – Provides OEM acceptability of product

20

Additional Slides

21

(Not a template slide – for information purposes only)

• The following slides are to be included in your submission for Peer Evaluation purposes, but will not be part of your oral presentation –

• You may refer to them during the Q&A period if they are helpful to you in explaining certain points.

22

Responses to Previous Reviewers’ Comments

• Comment: 96-hr test is not long enough to properly vet the technology. Further testing is required.

– Response: Final test provided more data at optimized conditions, showing catalyst aging and stability with recycle

• Comment: PIs need to run the facility long enough to actually see longer-term performance, and to allow for the manufacture of sufficient product so as to allow for customer sampling and acceptance testing.

– Response: Sufficient product was made for single-engine emissions testing, gasoline characterization and evaluation by refiner, and 75,000-mile track testing of 50% blend in four vehicles.

Note: This slide is for the use of the Peer Reviewers only – it is not to be presented as part of your oral presentation. These Additional Slides will be included in the copy of your presentation that will be made available to the Reviewers.

23

Publications, Patents, Presentations, Awards, and Commercialization

Note: This slide is for the use of the Peer Reviewers only – it is not to be presented as part of your oral presentation. These Additional Slides will be included in the copy of your presentation that will be made available to the Reviewers.

1. IEA Bioenergy Task 42 – Biorefining - 8th Task Meeting, Chicago IL, October 4-6, 2010 2. National Science Foundation workshop on Separation challenges in thermo-catalytical

production of biofuels, Washington D.C., April 4-5, 2011 3. tcbiomass2011 Conference, Chicago IL, September 27-30, 2011 4. tcbiomass2013 Conference, Chicago IL, September 3-6, 2013 5. Gasification Technologies 2013 Conference, Colorado Springs CO, October 16-23, 2013 6. Biomass Indirect Liquefaction Strategy Workshop, DOE Bioenergy Technologies Office,

Golden CO, March 20 -21, 2014 7. IEA Bioenergy and AMF workshop, Copenhagen Denmark, May 20, 2014 8. 22nd European Biomass Conference and Exhibition, Hamburg Germany, June 23-26, 2014. 9. Symposium on Thermal and Catalytic Sciences for Biofuels and Biobased Products

(TCS2014), Denver CO, September 2-5, 2014. 10. 2014 International Bioenergy and Bioproducts Conference, Tacoma WA, September 17-19,

2014.