ON-FARM PYROLYSIS TO REFINABLE CRUDE BIO-OIL · PDF fileON-FARM PYROLYSIS TO REFINABLE CRUDE...

ON-FARM PYROLYSIS TO ON FARM PYROLYSIS TO REFINABLE CRUDE BIO-OIL AND VALUABLE COPRODUCTSVALUABLE COPRODUCTS

A.A. BOATENGA.A. BOATENGUSDA-ARS, Eastern Regional Research Center, 600 E.

Mermaid Lane, Wyndmoor, PA 19038, USA

ARS Action Plan

USDA/ARS NP Bi & E • USDA/ARS NP 213 –Bioenergy & Energy Alternatives

• Thermochemical Conversion Component w/ Sub-component on Pyrolysis @ Wyndmoor

• Vision: Address Research Gaps towards 2ndpgeneration Biofuel/Bio-char Commercialization

2009 Boateng 2

NP 213 Biofuels Goals (Bio & Thermo)3 ( )

• Develop technology for sustainable p gyexploitation of energy from agriculture.

• Develop technology that improves energy Develop technology that improves energy efficiency of agricultural systems

• Provide technological support for • Provide technological support for commercialization of liquid transportation fuel production from agricultural materials

2009 Boateng 3

fuel production from agricultural materials

Biomass Conversion Pathwaysy

F-T LiquidsH2

SYNGASThermochemicalConversion

2H2 + CO

Biomass Pyrolysis Bio-oil

Bio-char

Liquid Fuels/Chemicals

Soil Amendment/Solid Fue

Sugars EthanolBiochemicalConversion

Fermentation

LigninConversion

PYROLYSIS - ADVANTAGES

• Amenable to small scale

• On Farm Scale Advantage• On-Farm Scale Advantage

• Energy density

L i t i• Less energy intensive

• Relatively simpler system design

U d bl di l• Up-gradable to diesel

• Infrastructure exists for its refinery

2009 Boateng 5

• Charcoal vision

Bio-Oil & Bio-Char Production @ ERRC

Traditional ARS Feedstocks ( i ll l )(Lignocelluloses)

• Wood (commercial feedstock also FS)

• On-the-farm Scale (energy crops Ag Residues)On the farm Scale (energy crops, Ag. Residues)

– Perennial grasses: Warm (SG) & Cool Season (RCG)

– Legumes: alfalfa, soybean

• Opportunity Fuel Feedstock

l– Bagasse – sugarcane, guayule

– Lignin

Chicken Litter

2009 Boateng 7

– Chicken Litter

ARS PYROLYSIS UNIT

2009 Boateng 8

Pyrolysis CRIS Project 2009 - 2014y y j 9 4

• Produce refinable crude bio-oil and valuable coproducts (Biochar Vision) from sustainable resourcesresources

• Distributed, on or near farm scale pyrolysis• Methods/Approaches:• Methods/Approaches:

– Stabilize bio-oil by catalytic and non-catalytic approaches

– Meet specifications for use as boiler fuel or refinablecrude oils.

– Produce suitable soil-amending, C-sequestering biochar

2009 Boateng 9

Produce suitable soil amending, C sequestering biochar

Pyrolysis Teamy y

Primary Location: Wyndmoor, PA2.5 SY5

Post-doctoral Fellows• 2

Related CRIS ARS wideRelated CRIS ARS-wide• Peoria, IL• New Orleans, LA

2009 Boateng 10

New Orleans, LA

Institute of Wood Technology and Wood Biology (HTB),Hamburg, Germany

Contribution to Panel Discussion

tcbiomass 2009, 16-18 September 2009Chicago, IL, USA

Dietrich Meier

Institute of Wood Technology and Wood Biology (HTB)

Pyrolysis Process Modifications

BIO-OILDrying< 10 %

Grinding< 3 mm

Pyrolysis

Charseparation

Cool &collect

GasBIOMASS

CokePretreat• Whole biomass

- Remove ash- Add catalyst

• Separate bio-polymersinto cellulose and lignin

- Pulping- Biorefineries

Pyrolyse• Vary parameters

- Temperature- Time- Pressure- Atmosphere

• Add catalysts

Upgrade• Physically

- Staged condens.- Extraction

• Chemically- React, derivatize- De-oxygenate- Gasify to syngas

Institute of Wood Technology and Wood Biology (HTB)

Latest Developments in Germany

Pyrolysis for syngas => Diesel, DME– CHOREN– BIOLIQ (FZK)

Pyrolysis for liquid => Power/Heat– PYTEC

High pressure liquefaction– IBH Engineering

Institute of Wood Technology and Wood Biology (HTB)

CHOREN Industries sundiesel® (8000 kg/h)

Status• Test phase of components

Involved Partners• CHOREN Industries• Daimler• Volkswagen• Shell

Institute of Wood Technology and Wood Biology (HTB)

Bioliq® Process, FZK (500 kg/h)

Institute of Wood Technology and Wood Biology (HTB)

D.M.2 (Blue Tower Herten), 200 kg/h

Off-gases

Flue gases

Product gas

Steam

Biomass

PYROLYZER

REFORMER

PREHEATER

COMBUSTORAsh

Involved Partners• H2NRW• D.M.2

Status• Test phase• New porject with 2600 kg/h)

Institute of Wood Technology and Wood Biology (HTB)

BTO® Process pilot plant (250 kg/h)

Involved Partners•PYTEC•TEC•vTI•Universities

Status•Optimization tests

•Pyrolysis plant•Diesel engine

•Malliß Project ongoing (48 tpd)

Institute of Wood Technology and Wood Biology (HTB)

Debarked Wood

Organosolv-Lignin (13.4 %)

Fibers (56.8 %)

Hydrolysis-Lignin (15.4 %)

Mono-saccharides(39.2 %)

Pulping Process

EnzymaticHydrolysis

Other Products:Xylose: 5.8 %Acetic Acid: 6.3 %Formic Acid: 1.0 %Furfural: 1.2 %

Organic Solution

Lignin Precipitation

Fractionate: German Biorefinery Project

Σ of Products:81.3 % b.on Wood

Biomass Pyrolysis: Issues/OpportunitiesFranco BerrutiFranco Berruti

Institute for Chemicals and Fuels from Alternative Resources

The University of Western OntarioLondon Ontario CANADALondon, Ontario, CANADA

1. Distributed versus Centralized Biomass ProcessingProcessing

2. Feedstock Opportunities3. Bio-Oil/Bio-Char Utilization4. Upgrading5. Economics

1

C1. Distributed versus Centralized Biomass Processing

• Feedstock availability (generation area, )seasonality, quality, consistency, homogeneity)

• Feedstock pre-processing (fresh, dry, torrefaction, grinding, storage)torrefaction, grinding, storage)

• Feedstock gathering and transportation costs

F d t k t / ti• Feedstock storage/preservation

• Processing technology and scale (is there a sufficient market?))

• Products quality (moisture, particulates, heteroatoms) and stability

2

2. Feedstocks Opportunities

Wine GrapeCorn

Sugarcane Forest Resources

Wine  Bio ethanol Sugarcane Juice Pulp and Paper

Grape Skins and Seeds12.2 million tonnesworldwide

Dried Distiller’s Grains35 million tonnes in North America

Sugarcane Bagasse500 million tonnesworldwide

Forestry Residue280 million tonnesworldwideworldwide North America worldwide worldwide

3

3. Bio-Oil and Bio-Char Utilization

• Food Flavours

• Pharmaceuticals and Nutraceuticals

• Pesticides

• Chemicals

• Fuel oil substitute

• Refined Fuels

• Fertilizers

4

4. Upgrading

Primary separation by fractional condensation• Primary separation by fractional condensation

• Neutralization and Stabilization

• Hydrodeoxygenation (HDO)Hydrodeoxygenation (HDO)

• Esterification

• Gasification + Fischer-Tropschp

• Catalytic Cracking

• Fermentation

• Water Adsorption

• Integration into conventional petroleum refineries

5

5. Economics

• Transportation: what do we want to transport?

• Primary processing technology: energy input/output

• Bio-oil handling and storage: stability? corrosion?

S ti hi h l t ?• Separation: any high value components?

• Catalysts: costs? do they maintain their activity?

• Hydrogen: costs? where does it come from? how much?

• Net CO2 emission reduction and carbon credits

6

Net CO2 emission reduction and carbon credits

INTEGRATED HEAT, ELECTRICITY AND BIO-OIL

PRODUCTION

TCBi 2009 P l i P l

PRODUCTION

TCBiomass 2009 – Pyrolysis Panel09-17-2009Jani Lehto

2

NewsMetso and UPM develop biomass based bio-oil production

Metso and UPM have developed a new concept for the production ofbiomass-based bio-oil to replace fossil fuels in heating and powerbiomass based bio oil to replace fossil fuels in heating and powergeneration. Test production will begin at Metso's test plant in Tampere,Finland, in June 2009.

Bio-oil can be manufactured by UPM's renewable energy power plantshi h i d ith it bl b il d f ti l t i lwhich are equipped with a suitable boiler and functional raw material

management. The raw material of the bio-oil is wood biomass – harvestingresidues and sawdust, which is a by-product of the forest industry.Combining bio-oil production to an existing biomass based power plantcreates significant cost and efficiency advantages as well as newg y gbusiness.

Metso and UPM have developed the bio-oil production concept incooperation with the Technical Research Centre of Finland (VTT) and withfunding of the Finnish Funding Agency for Technology and Innovationfunding of the Finnish Funding Agency for Technology and Innovation(Tekes). The technology used in combined bio-oil and renewable energyproduction is patented. It can be seen as continuation of the combinedheat and power production concept developed in Finland.

© Metso

Metso press release June 8, 2009

3Joint Venture• A new novel integrated wood based bio-oil concept will be

developed. The concept includes whole business chainbeginning from feedstock purchase and pre-treatment to bio-oil production, transportation, storage and end use

• The whole value-chain is represented in coalition- UPM as a supplier of raw material and end-userpp- Metso Power as an equipment supplier- VTT as a technology and research partner

• Integrated fast pyrolysis process is identified as aneconomically viable liquid biofuel concept to reduce CO2-emissions in several different studies1

________________________________________________________________________________________

1) McKeough P., Solantausta Y. et al., Techno-economic analysis of biotrade chains. Upgraded biofuels from Russia and Canada to the Netherlands, VTT Research Notes 2312, Espoo, 2005

1) Sipilä E., Vasara P. et al., Feasibility and market potential of pyrolysis oils in european pulp

© Metso

and paper industry, Proceedings of the 15th European Bioenergy Conference and Exhibition, Berlin, 2007

4Outline for Joint Venture

• Phased joint venture- 2 phases for years 2007-2010

- Phase 1: Concept development and pilot preparation

• Phase 2: PilotingPhase 2: Piloting- Metso test plant at Tampere, Finland- Extensive test runs during 2009-2010- Bio-oil utilization tests to replace HFO and LFO during

2009-2010

• Next step: Commercial size demonstration

© Metso

5

Pyrolysis Pilot

• Metso’s test plant at Tampere, Finland- Main boiler 4 MWth CFB-pilot- Pyrolysis input ~2 MW (~ up to 7 tons/d of bio-oil)Pyrolysis input 2 MW ( up to 7 tons/d of bio oil)

• Pyrolysis unit utilizes the hot sand in the fluidized bed boiler as a heat source

• Pyrolysis gases are condensed into bio-oil and theremaining solids, including sand and fuel char, returnedto the fluidized bed boiler. In the boiler, the char andNCG are combusted to produce heat and electricity

Pil t l t d• Pilot plant ready- Hot commissioning done, bio-oil production

successfully started- Extensive test runs during 2009-2010

© Metso

g

Quality Control Through Whole Fuel Chain 6

PYROLYSISFEEDSTOCK LIQUID END-USEPROCESSING

BIOMASS GAS, LIQUID, CHAR FUEL OIL

Moisture follow-upFuel analyses

On-line monitoring of gas, water and solids

Specifications

© Metso

7

UPM Concept

PyrolysisPyrolysisBioBio--oiloil

StumpsStumps WaterWatertreatmenttreatment

CHPCHPplantplant

StumpsStumps

ResiduesResidues

WoodWoodhandlinghandling

Paper millPaper millPulpPulp

woodwood

Paper mill unitsPaper mill units

Additional unitsAdditional units

Material flowMaterial flowgg oodood Material flowMaterial flow

Energy flowEnergy flow

S htt // bi f l t / 2/ df /H S hl t df

© Metso

Source: http://www.biofuelstp.eu/spm2/pdfs/Hans_Sohlstrom.pdf

8

Metso Fast Pyrolysis Unique Characteristics

• Integrated process- Old infra can be used (retrofits)- New infra can be optimized- Reduced investment

• Integrated heat, electricity and bio-oil productionproduction

• Plant optimization- Design- Operation

• High efficiency

• Scale-up

• No fossil fuel consumptionp

• No waste streams

• Metso: full scope supplier

© Metso

© Metso

TCBiomass 2009 – Pyrolysis Panel09-17-2009Jani Lehto

INTEGRATED HEAT, ELECTRICITY AND BIO-OIL

PRODUCTION

© Metso

2

NewsMetso and UPM develop biomass based bio-oil production

Metso and UPM have developed a new concept for the production ofbiomass-based bio-oil to replace fossil fuels in heating and powergeneration. Test production will begin at Metso's test plant in Tampere,Finland, in June 2009.

Bio-oil can be manufactured by UPM's renewable energy power plantswhich are equipped with a suitable boiler and functional raw materialmanagement. The raw material of the bio-oil is wood biomass – harvestingresidues and sawdust, which is a by-product of the forest industry.Combining bio-oil production to an existing biomass based power plantcreates significant cost and efficiency advantages as well as newbusiness.

Metso and UPM have developed the bio-oil production concept incooperation with the Technical Research Centre of Finland (VTT) and withfunding of the Finnish Funding Agency for Technology and Innovation(Tekes). The technology used in combined bio-oil and renewable energyproduction is patented. It can be seen as continuation of the combinedheat and power production concept developed in Finland.

Metso press release June 8, 2009

© Metso

3Joint Venture• A new novel integrated wood based bio-oil concept will be

developed. The concept includes whole business chainbeginning from feedstock purchase and pre-treatment to bio-oil production, transportation, storage and end use

• The whole value-chain is represented in coalition- UPM as a supplier of raw material and end-user- Metso Power as an equipment supplier- VTT as a technology and research partner

• Integrated fast pyrolysis process is identified as aneconomically viable liquid biofuel concept to reduce CO2-emissions in several different studies1

________________________________________________________________________________________

1) McKeough P., Solantausta Y. et al., Techno-economic analysis of biotrade chains. Upgraded biofuels from Russia and Canada to the Netherlands, VTT Research Notes 2312, Espoo, 2005

1) Sipilä E., Vasara P. et al., Feasibility and market potential of pyrolysis oils in european pulp and paper industry, Proceedings of the 15th European Bioenergy Conference and Exhibition, Berlin, 2007

© Metso

4Outline for Joint Venture

• Phased joint venture- 2 phases for years 2007-2010

- Phase 1: Concept development and pilot preparation

• Phase 2: Piloting- Metso test plant at Tampere, Finland- Extensive test runs during 2009-2010- Bio-oil utilization tests to replace HFO and LFO during

2009-2010

• Next step: Commercial size demonstration

© Metso

5

Pyrolysis Pilot

• Metso’s test plant at Tampere, Finland- Main boiler 4 MWth CFB-pilot- Pyrolysis input ~2 MW (~ up to 7 tons/d of bio-oil)

• Pyrolysis unit utilizes the hot sand in the fluidized bed boiler as a heat source

• Pyrolysis gases are condensed into bio-oil and theremaining solids, including sand and fuel char, returnedto the fluidized bed boiler. In the boiler, the char andNCG are combusted to produce heat and electricity

• Pilot plant ready- Hot commissioning done, bio-oil production

successfully started- Extensive test runs during 2009-2010

© Metso

6

Woodhandling

Pyrolysis

Watertreatment

CHPplant

Paper millPulp

wood

Stumps

Residues

Paper mill units

Additional units

Material flow

Energy flow

Bio-oil

UPM Concept

Source: http://www.biofuelstp.eu/spm2/pdfs/Hans_Sohlstrom.pdf

© Metso

7

• Integrated process- Old infra can be used (retrofits)- New infra can be optimized- Reduced investment

• Integrated heat, electricity and bio-oil production

• Plant optimization- Design- Operation

• High efficiency

• Scale-up

• No fossil fuel consumption

• No waste streams

• Metso: full scope supplier

Metso Fast Pyrolysis Unique Characteristics

© Metso

Biomass fast pyrolysis

Tony Bridgwater Bioenergy Research Group

Aston University, Birmingham B4 7ET, UK

Process and product flexibility

Mode Temp. Time Liquid Solid Gas

Fast ~ 500ºC 1-2 s 75% 12% 13%

Intermediate ~ 500ºC 10-30 s 50% 25% 25%Intermediate 500 C 10-30 s 50% 25% 25%

Torrefaction ~ 290ºC 10–30 mins 0% 82% 18%

Carbonisation ~ 400ºC Hours-days 30% 35% 35%

Gasification ~ 800ºC 1-20 s 5% 10% 85%

Process and product versatilityZeolite

cracking

Hydro-treating

HydrogenHydrogen separation

Fast ChemicalsFast pyrolysis Gasification

S TransportR fi iSC

Liquid

Electricity

Synthesis Transport fuels

RefiningSlurryChar

3

yHeat

Process routes to biofuels

F t l i C kiT f ti

Biomass

Gasification

Fast pyrolysis Cracking

Hydro-treat

Torrefaction

SyngasGasification treat

Fischer TropschMTG Mt synfuelMOGD

Methanol

Refining

G li di l k SNGGasoline, diesel, kerosene. SNG

Production cost of biofuels

80 0 €

90.0 €€ / GJ

Pdc = Pyrolysis decentralised

60.0 €

70.0 €

80.0 € FT = Fischer Tropsch synthesisG = GasificationMeOH = hydrocarbons via methanolP P l i t li d

40.0 €

50.0 €

Pdc + FT

Pc = Pyrolysis centralised

20.0 €

30.0 €

G + FTPc + FTG + MeOHPdc + FT

0.0 €

10.0 €

0 200,000 400,000 600,000 800,000 1,000,000, , , , , ,

Fuel production t/y