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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
