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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
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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.
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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
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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
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2 – Approach (Technical)
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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
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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
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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
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3 – Technical Accomplishments/ Progress/Results (continued)
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• 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)
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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
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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
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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
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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
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Additional Slides
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(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.
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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.