McGill – Polytechnique Chemical Engineering Research Day

Improving resource efficiency to address climate change

Revision 1

Jocelyn Doucet, P.Eng., Ph. D. CEO Pyrowave

Adjunct Pr. Dept. Chem Engineering, Polytechnique

© Jocelyn Doucet, 2016

Blue box

The problem Climate change is real

Observed changes (according to GIEC, 2014)

Warming of the climate system is unequivocal, and since the 1950s, many of the observed changes are

unprecedented over decades to millennia. The atmosphere and ocean have warmed, the amounts of snow and

ice have diminished, and sea level has risen.

IPCC report, 2014

Blue box

The cause Temperature is changing

Observed changes Temperature is changing and some of the causes are directly related to Greenhouse gas emissions and

changes made by humans (anthropogenic forcings) such as modification of land or use of aerosols.

IPCC report, 2014

Blue box

Approaches to reducing GHG “Engineer” approaches to reducing GHG

Input to process Process Output from process

Waste to Energy

Biomass vs fuel Energy efficiency,

Improved yields/selectivities

Post capture

CO2 sequestration

Effluent treatment

Waste remediation

The problem is “closing the loop”

Most is wasted

Some is reused

Energy

Blue box

Interconnected web Our industrial world relies on resource-based energy sources

Energy Goods Ressources

P P

P

P

P

Waste to energy

approaches to produce

energy

Energy is produced

through resources

CO2

P

Blue box

How nature approaches this? Nature is not energy efficient but resource efficient by design

Mass must be

conserved – need for

being ressource

efficient

Unlimited amount of

energy supply

Blue box

How can we close the loop? Let’s look at a tree to see how nature deals with mass conservation

Blue box

How can we close the loop? First let’s see what needs to be recovered

Blue box

How can we close the loop? First let’s see what needs to be recovered

Blue box

From a system perspective The tree balance is closed on mass, open on energy

Photosynthesis

Tree

growth

Decay

Decomposition

O2

UV light

Heat

CO2

Nutrients

Schrodinger, E. “What is life? The physical aspects of a living cell”, Cambridge University Press, Cambridge, UK, 1944.

𝑺𝑪𝑶𝟐

𝑺𝑮𝑳𝑼 𝑺𝑰𝑹

𝑺𝑺𝑹

𝑺𝑶𝟐

Entropy balance 𝟔𝑺𝑪𝑶𝟐

+ 𝟔𝑺𝑯𝟐𝑶 + 𝑺𝑺𝑹 − 𝑺𝑮𝑳𝑼 − 𝟔𝑺𝑶𝟐− 𝑺𝑰𝑹 > 𝟎

Energy balance 𝟔∆𝑯𝑪𝑶𝟐

+ 𝟔∆𝑯𝑯𝟐𝑶 − ∆𝑯𝑮𝑳𝑼 − 𝟔∆𝑯𝑶𝟐+ 𝑬𝑺𝑹 − 𝑬𝑰𝑹 = 𝟎

Mass balance 𝟔𝑪𝑶𝟐 + 𝟔𝑯𝟐𝑶 → 𝑪𝟔𝑯𝟏𝟐𝑶𝟔 + 𝟔𝑶𝟐

𝜂 max =∆𝑯𝑮𝑳𝑼

𝑬𝑺𝑹≈ 42%

𝜂 p ≈ 12 − 15%

𝑬𝑺𝑹

𝑬𝑰𝑹

Blue box

Analogy Trees can be seen as manufacturing plants in closed loop

Photosynthesis

Tree

growth

Decay

Decomposition

O2

UV light

Heat

CO2

Nutrients

Mass recovery: 100%

All the

mascrostructures are

decomposed and

elements returned back

to the ecosystem

Sugar

synthesis

UV light

O2

Macrostructures

& nutrients

Blue box

Analogy with polymers Our industrial ecosystem is “open”

Decay

Decomposition

UV light

Heat Constant need for

making new monomers

and extracting new

resources

Sugar

synthesis

UV light

O2

& nutrients

Photosynthesis

Monomer

synthesis

Energy

Energy

Landfill Extraction

Energy Heat

Macrostructures

Blue box

Reducing our consumption Closing the loop on resources reduces the amount of energy required

Polymer

transformation

Usage

Extraction

Monomer

synthesis Heat

Heat

Polymer synthesis

When we think of it:

« Increasing polymer

demand by 2 means that

energy requirement rises

proportionally by a factor

of 2 »

𝑬𝒎𝒐𝒏𝟎

𝑬𝒆𝒙𝟎

𝑬𝒑𝒐𝒍𝟎

Blue box

Ressource efficiency is key Reducing energy needs by closing the loop

Polymer synthesis

Polymer

transformation

Usage

Landfill

Extraction

Monomer

synthesis Heat

Heat

Heat

𝑬𝒎𝒐𝒏𝟎

𝑬𝒆𝒙𝟎

𝑬𝒑𝒐𝒍𝟎

Blue box

Ressource efficiency is key Reducing energy needs by closing the loop

Polymer synthesis

Polymer

transformation

Usage

Extraction

Monomer

synthesis Heat

Heat

Heat

Decomposition

to monomers

Heat

Energy efficiency:

𝜼′ = 𝑦 −Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛

For 𝜼′ > 𝟎, we need a monomer

yield governed by:

Energy/ressource intensive

portion

𝑬𝒑𝒐𝒍

𝑬′𝒎𝒐𝒏

𝑬𝒅𝒆𝒄

𝑬𝒆𝒙′

𝑦 >Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛

𝐲 Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥

Δ𝐻𝑚𝑜𝑛

∗ Δ𝐻𝑥 refers to energy needed by task 𝑥 per ton of used polymer

Blue box

In the case of polystyrene What type of process is needed to have good efficiency?

Polymer synthesis

Polymer

transformation

Usage

Extraction

Monomer

synthesis

Decomposition

to monomers

Energy efficiency:

𝜼′ = 𝑦 −Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛

𝐲 Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥

Δ𝐻𝑚𝑜𝑛

Polystyrene process

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛 ≈ 40 − 80𝐺𝐽/𝑡𝑜𝑛

See if we have yields of

50% on monomer

Δ𝐻𝑑𝑒𝑐 ≤ 20 − 40 𝐺𝐽/𝑡𝑜𝑛

Blue box

Approach summary What can be learnt from Nature’s experience

There are mainly two approaches to

reducing GHG emissions

a) Disconnecting energy sources

from fossil resources (e.g. sun,

hydro)

b) Reduce emissions by closing the

loop : ressource efficiency

1 kg Final product

(Polystyrene)

1.03 kg

Crude in ground

Monomer

Δ𝐻𝑑𝑒𝑐

0.5

0.5 kg

𝑬𝟎 = Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛

1/2

Blue box

How do we do this? We derived the approach, what is in the box?

At Kengtek I was more involved with

Pyrolysis processes

a) Tire pyrolysis

b) Used motor oil

c) Biomass

d) Plastics

Was wondering if that was the

decomposition process we looked for.

Polymer synthesis

Polymer

transformation

Decomposition

to monomers

Pyrolysis?

Polymer

transformation

Blue box

Past objectives of pyrolysis Closing loop on mass by converting into fuel

Decay

Waste to fuel

Heat

Monomer

synthesis

O2

Polymer synthesis

Energy

Extraction

Energy

Heat

Energy

The past approach was to

break down molecules to

« fuel »

Research was about:

a) Reducing tars formation

b) Reducing water

But this approach does not

close the loop

Blue box

Waste to fuel Does not close the resource loop

Energy Goods Ressources

*UN Food and Agriculture Organization (FAO)

P

P

P

P

P

P Waste to energy

approache uses waste

as energy

Resource efficiency is

re-using resources for

production of goods

How could we do this?

Oil (75%)

Gas (15%)

Char (10%)

Styrene

Light oil

Wax/Paraffin

Plastic

Microwaves converts input into valuable recycled products

Blue box

How could we do this? We derived the approach, what is in the box?

We were doing various microwave

pyrolysis experiments on plastics with

Polytechnique and:

a) We noticed that high styrene/EB

portions were found sometimes

b) Wondered where it came from?

c) Realized it came from

a) Lignin

b) Polystyrene

c) ABS plastics

Blue box

Research objectives Increasing selectivity on monomers

Objective was then to increase selectivity towards styrene and see if the

economics made sense

a) Styrene monomer has good market value ($1.00-$1.50/kg)

b) Is a commodity on the market

c) Great demand on the market

d) Can be re-used as is to form polymers

Final yields: 75%-85% monomers

Total energy consumption: 0.7 kWh/kg (2.5 GJ/ton)

Blue box

The loop by the numbers We have a potential candidate for the work

Polymer synthesis

Polymer

transformation

Usage

Extraction

Monomer

synthesis

Decomposition

to monomers

Energy efficiency:

𝜼′ = 𝑦 −Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛

𝟕𝟓% 2.5 𝐺𝐽/𝑡𝑜𝑛

Δ𝐻𝑒𝑥

Δ𝐻𝑚𝑜𝑛

Polystyrene process

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛 ≈ 40 − 80𝐺𝐽/𝑡𝑜𝑛

𝑦 = 75% − 85%

Δ𝐻𝑑𝑒𝑐 = 2.5 𝐺𝐽/𝑡𝑜𝑛

𝜼′ ≈ 𝟕𝟎% − 𝟖𝟎%

Blue box

Scale up? Next question is, how do we scale-up pyrolysis?

Many several attempts in the past – most

unsuccessful (Arras, Siemens):

a) Business problems • Low value of output (methanol, syngas, ethanol,

fuel)

• Permitting and authorizations

• Social perception

• COSTS!!! • Market is burnt.

b) Technical problems • Heat/mass transfer problems

• Selectivity decreases with scale

• Handling (waste is light)

Blue box

How nature scales up Acting locally to adapt to local reality

Distributed model Operating multiple small units and collecting output

Waste Converted

At Client’s Site Into Oil (250-600 Tons/Year)

Mitigated

Technological Risk

• Collect oil from sites and

ship for fractionation

• Monomer and waxes

delivered to clients

• New products shipped

to transformers

• Finished resins to

customers

Blue box

Analogy with plastics Adapting locally to different feedstocks with/without retardant

Post consumer

(no fire retardant)

Catalytic

process

Centralized Panels (Fire retardant) Effluent treatment

(Br removal)

Blue box

Analogy with plastics Local solutions are more adapted to local reality

Decentralized Panels (Fire retardant)

Post consumer

(no fire retardant)

Treatment

(Br removal)

Catalytic

process

Local

Decomposition

Local

Decomposition Good oil

Blue box

The impact of feedstock Acting locally improves overall yield and efficiency

𝑦

𝟏𝟎𝟎%

Input Monomer Monomer Input

PS

/Mo

no

𝑥 ∙ 𝑦 𝒙%

If input contains 𝒙% of

polystyrene

𝟏𝟎𝟎% Decentralized Centralized

𝜼′ = 𝒙 ∙ 𝒚 −Δ𝐻𝑑𝑒𝑐

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛

Blue box

What is the overall impact? Including logistics/handling and energy

Initial partnership with CIRAIG

Blue box

Life Cycle Assessment Mixed plastics impacts using distributed pyrolysis vs landfill

Δ𝐻𝑑𝑒𝑐,𝑃𝑆 = 3.5 𝐺𝐽/𝑡𝑜𝑛

Δ𝐻𝑑𝑒𝑐,𝑀𝑃 = 4 𝐺𝐽/𝑡𝑜𝑛

𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛 = 48 𝐺𝐽/𝑡𝑜𝑛

𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛 = 60 𝐺𝐽/𝑡𝑜𝑛

Emissions reduction Mixed: -0.4 ton/ton

Polystyrene: -1.75 ton/ton

Blue box

Accounting for all aspects Through CIRAIG LCA

Polymer synthesis

Polymer

transformation

Usage

Extraction

Monomer

synthesis

Decomposition

to monomers

𝑦𝑃𝑆, 𝑦𝑀𝑃 Δ𝐻𝑑𝑒𝑐,𝑃𝑆 Δ𝐻𝑑𝑒𝑐,𝑀𝑃

Δ𝐻𝑒𝑥

Δ𝐻𝑚𝑜𝑛

Polystyrene process

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛 = 60 𝐺𝐽/𝑡𝑜𝑛 Mixed plastics process

Δ𝐻𝑒𝑥 + Δ𝐻𝑚𝑜𝑛 = 48 𝐺𝐽/𝑡𝑜𝑛 𝑦𝑃𝑆 = 75% − 85%

𝑦𝑀𝑃 = 50% − 70%

Contamination: 𝑥 = 0.9

Δ𝐻𝑑𝑒𝑐,𝑃𝑆 = 3.5 𝐺𝐽/𝑡𝑜𝑛

Δ𝐻𝑑𝑒𝑐,𝑀𝑃 = 4 𝐺𝐽/𝑡𝑜𝑛

𝜼′𝑷𝑺 ≈ 𝟔𝟓% − 𝟖𝟎%

𝜼′𝑴𝑷 ≈ 𝟑𝟓% − 𝟔𝟎%

Blue box

Conclusion Looking at how nature deals with waste was insightful

• Resource efficiency is driving evolution in Nature: energy is free and non-resource based

• Inspiring from Nature will yield solutions that are resource efficient

• Closing the loop on resources shows :

• Significant reduction in energy needs

• Reduction of GHG emissions since energy is resource-derived (mostly).

• Scaling up: trying to scale up by adding more units created a logistic problem: but this new

problem is easier to solve than the initial problem

Blue box

Conclusion Opening thoughts for Research Day

• From a research perspective, think of how you could find analogies to help you solve the

problem

• Analogies with nature, space, other domains (medical, cinema, etc)

• Read about other subjects, go to out-of-your-field conferences to see how others solve

their problems and if they share similarities.

• Derive a simple metric to kill an idea quick.

• Try to think of solving a complex problem simply even if it creates another problem: this new

problem might be easier to address

• Most of the time, the trivial solutions are taken out because they create other problems: if

those new problems are simpler, why not?

McGill – Polytechnique Chemical Engineering Research Day

Improving resource efficiency to address climate change

36

Jocelyn Doucet, P.Eng., Ph. D. CEO Pyrowave

Adjunct Pr. Dept. Chem Engineering, Polytechnique

© Jocelyn Doucet, 2016