Rapid Thermal Processing (RTPTM)A Proven Pathway to Second Generation Biofuels
TAPPSA CONFERENCE
Durban, 20 October 2010
Kari Liukko
Honeywell Confidential 2
Contents
• Introduction• What is driving for 2nd generation biofuels?• Rapid Thermal Processing (RTPTM)• Pyrolysis Oil Applications• Conclusions• Q&A
What is driving for 2nd generation biofuels?
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2nd Generation Biofuels
• Non-food crop based lignocellulosic feedstock– Forest and agricultural residual biomass– Algal biomass
• Feedstock plays a key role– Availability– Sustainability – Quality– Cost-efficient supply
• Offer an interesting opportunity for pulp & paper, power generation and other industries to– Become fossil fuel free– Reduce CO2 emissions
– Generate new business• Price development of crude oil?• Price development of CO2 permits?
• Taxation and subsidies?
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World Energy Outlook
• The world energy challenge is enormous– Global energy demand will increase 1.5 % per year until 2030
• From 12 (2007) to 16 Billion tons oil equivalent– CO2 emissions, Gt/year 28.8 (2007) 40.2 (2030) – CO2 emission price, $/ton CO2 ~15 (2009) 50 (2020)– Oil price, $/barrel 60 (2009) 115 (2030)
• Investments in low-carbon technology are needed– To reduce dependency in fossil fuels– To reduce CO2-emissions in to the atmosphere
• 1000 ppm CO2 vs. 450 ppm CO2 scenario• Global temperature rising by +6 °C vs. +2 °C
• Key segments• Buildings – energy efficiency• Power Generation and Industry
– Low carbon energy and Carbon Capture and Storage (CCS) • Transportation
– Biofuels
Source: World Energy Outlook 2009, International Energy Agency (IEA)
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The EU Climate and Energy Package
• Known as 20-20-20 targets- A reduction in EU greenhouse gas emissions of at least 20% below 1990
levels - A 20% reduction in primary energy use compared with projected levels, to
be achieved by improving energy efficiency- 20% of EU energy consumption to come from renewable resources
Source: European Union/European Commission
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Biofuels for Transportation in EU
Source: EurObserv’ER 2010
12 MtOE2009
Mainly 1st generation biofuels!
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The Future of Aviation
Source: Airbus, 2010
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Honeywell Renewables Vision• Building on Honeywell UOP technology and expertise• Produce real “drop-in” fuels instead of fuel additives/blends• Leverage existing refining, transportation, energy, biomass handling infrastructure to
lower capital costs, minimize value chain disruptions, and reduce investment risk.• Focus on path toward second generation feedstocks & chemicals
“Other” Oils: Camelina, Jatropha
Lignocellulosic biomass,
algal oils
Second Generation
Oxygenated Biofuels
BiodieselEthanol
Hydrocarbon Biofuels
JetDiesel Gasoline
FirstGeneration
Natural oils fromvegetables and
greases
Fuel & Power
Fuel & Power
Renewable Energy
UOP Proprietary
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LIGNO-CELLULOSIC
BIOMASS
BIO-CHEMICAL
THERMO-CHEMICAL
Lignin & Extractives
Cellulose
HemicelluloseStarch
Fermentation
Sugars
Biomaterials
Ethanol
Algal, Jatropha,Camelina
Esterification
Pyrolysis
Gasification Fischer-Tropsch
Upgrade Green JetGreen Diesel
Pyrolysis Oil
Phase separ.Distillation
Heat, Electricity, SteamChemicals
Bioenergy
Forest res.Agriculture res.Re-cycled wood
Green JetGreen Diesel
RTP, Rapid Thermal ProcessingModular units for 100 to 1.000 ton bone dry metric ton/day
Honeywell UOP/Eni Ecofining
Envergent Technologies RTPTM
Honeywell UOP Renewables, Gas Processing, RefiningRentech (Fischer-Tropsch synthehis)
Pyrolysis UpgradeCommercial availability expected 2012
Honeywell Core Technologies for 2nd Generation Biofuels
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Potential of Pyrolysis Oil SA
Source: IEA, European Market Sutudy for BioOil (Pyrolysis Oil), 2006
Rapid Thermal Processing (RTPTM)
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Fast Pyrolysis
• Has been identified as one innovative value chain in European Industrial Bioenergy Initiative (EIBI)
• Cost-efficient pathway to second generation biofuels• Interesting findings in Canada
– Pyrolysis gives highest ROCE in stand-alone and integrated applications (FPAC, Forest Products Association of Canada 2010)
Source: Forest Products Association of Canada
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Envergent TechnologiesHoneywell UOP / Ensyn Joint Venture
• Formed in October 2008• Provides pyrolysis oil technology for fuel oil substitution and electricity generation• Channel for Honeywell UOP R&D program to upgrade pyrolysis oil to
transportation fuels
• Leading process technology licensor~$2 billion in sales, 3000 employees
• Co-inventor of FCC (Fluid Catalytic Cracking) technology
• Modular process unit supplier
• Global reach via Honeywell & UOP sales channels
• Over twenty years of commercial fast pyrolysis operating experience
• Developers of innovative RTPTM fast pyrolysis process
• Seven commercial RTPTM units designed and operated
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Rapid Thermal Processing (RTPTM) Technology
Commercially Proven Patented TechnologyENV 5233-04
Pyrolysis Oil
Solid Biomass
510°C, <2 seconds Biomass converted to
liquid pyrolysis oil Fast fluidized bed, sand
as heat carrier High yields; >70 wt%
liquid on woody biomass
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Pyrolysis Oil to Energy & Fuels Vision
Phased Commercialization
Fast Pyrolysis
Electricity Production
Transport Fuels
(Gasoline, Jet, Diesel)
Fuel Oil Substitution
Ava
ilable
for S
ale
Co
mm
ercially
availab
le in 2
012
Biomass
Ag ResidueAg Residue
Pyrolysis Oil
Forest FiberForest Fiber
Energy/Fuels
P P
P P
Energy/Fuels
P P
P P
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RTPTM Delivery & Scope of Supply
• Standard sized modular units offered– 100, 200, 400 and 1000 Bone Dry
Metric Tons per Day (BDMTPD)– Design adjusted to meet site
specific requirements• Design based on hardwood
sapwood– If alternate feedstock being
processed, unit performance to be re-rated
– Unit performance is guaranteed• Broad modular experience in
refining, petrochemical and oil & gas industries
Modular Delivery Provides Faster Execution
and Higher Reliability
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RTPTM Operating History & Commercial Experience
• Commercialized in the 1980’s• 7 units designed and operated in the US & Canada• Continuous process with >90% availability
Significant Commercial Experience
PlantYearBuilt
Operating Capacity (Metric Tonnes Per Day)
Location
Manitowoc RTPTM – 1 1993 30 Manitowoc, WI, USA
Rhinelander RTPTM – 1 1995 35 Rhinelander, WI, USA
Rhinelander Chemical #2 1995 2 Rhinelander, WI, USA
Rhinelander RTPTM – 2 2001 45 Rhinelander, WI, USA
Rhinelander Chemical #3 2003 1 Rhinelander, WI, USA
Petroleum Demo # 1 2005 300 barrels per day Bakersfield, CA, USA
Renfrew RTPTM – 1 (Owned and operated by Ensyn)
2007 100 Renfrew, Ontario, Canada
Note: design basis for wood based plants assumes feedstocks with 6 wt% moisture content.
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Feedstock Sources
Cellulosic Feedstocks Widely Available
• Forestry and Pulp and Paper• Wood chips, sawdust, bark• Forestry residues
• Agricultural• Residues – corn stover, expended fruit
bunches from palm (EFB), bagasse• Purpose-grown energy crops –
miscanthus, elephant grass• Post-consumer
• Construction and Demolition Waste, Categories 1&2
• Municipal solid waste (future)
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Feed Handling / Preparation
RTP Storage
Raw BiomassUp to 40 wt%
Moisture
Prepared Biomass“As Fed”5 – 6wt% Moisture
0.125 to 0.25"Pyrolysis Oil
“As Produced”Feed Handling
• Water is a heat sink• Dried to 5-6 wt%
moisture content for efficient RTPTM reactor operation
• Size impacts heat transfer• Biomass sized to 0.125-
0.25 inch (3-6 mm)• Capacity of unit
expressed on bone dry feed basis• BDMTPD• Zero water content
RTPTM is Self-Sustaining – Excess Heat Dries Raw Biomass
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RTPTM Product Yields
Feed, wt%
Whitewood Hardwood 100
Typical Product Yields, wt% Dry Feed
Pyrolysis Oil 70
By-Product Vapor 15
Char 15
Second Generation Feedstock Flexible With High Yields of Pyrolysis Oil
Biomass Feedstock Type
Typical Pyrolysis Oil Yield, wt% of Dry Feedstock
Hardwood 70 – 75
Softwood 70 – 80
Hardwood Bark 60 – 65
Softwood Bark 55 – 65
Corn Fiber 65 – 75
Bagasse 70 – 75
Waste Paper 60 – 80
400 BDMTPD of Whitewood Hardwood
Yields For Various Feeds
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RTPTM Pyrolysis Oil Properties
Suitable for Energy Applications
Comparison of Heating Value of Pyrolysis Oil
and Typical Fuels
• Pourable, storable and transportable liquid fuel
• Energy densification relative to biomass• Contains approximately 50-55% energy
content of fossil fuel• Requires separate storage from fossil
fuels
Fuel MJ / LitreBTU / US
Gallon
Methanol 17.5 62,500
Pyrolysis Oil 19.9 71,500
Ethanol 23.5 84,000
Light Fuel Oil (#2) 38.9 139,400
Pyrolysis Oil Applications
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Pyrolysis Oil Energy Applications
Multiple Applications for Pyrolysis Oil, a Renewable Fuel Available Today
• Replacement of fossil fuel for heat/steam generation
• Co-firing with coal• Production of green
electricity• Alternate revenue stream
from external sale• Future upgrading to
transportation fuels
FuelBurner
GasTurbine
StationaryDieselEngine
Heat
ElectricityCHP
GreenGasoline,
GreenDiesel &
Green Jet
Hydro-cracking/Dewaxing
SyngasGasification
OptimizedUOP
UpgradingTechnology
RTPUnit
FischerTropsch
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Pyrolysis Oil: Alternate Revenue Stream
• Development of pyrolysis oil as a well-defined commodity critical to success– Producer and consumer
confidence• ASTM standard specification for
use of pyrolysis oil in industrial burners is a key first step
PROPERTY VALUE TEST METHOD
Gross Heat of Combustion, MJ/kg Point, oC
15 min ASTM D240
Pyrolysis Solids Content, wt%
2.5 max ASTM D7544, Annex I
Water Content, wt%
30 max ASTM E203
pH report ASTM E70
Kinematic Viscosity, cSt @ 40 °C
125 max ASTM D445
Density, kg/dm3 @ 20 °C
1.1 – 1.3 ASTM D4052
Sulfur Content, wt%
0.05 max ASTM 4294
Ash Content, wt% 0.25 max ASTM 482
Flash Point, oC 45 min ASTM D93, Procedure B
Pour Point, oC -9 max ASTM D97
ASTM D7544, Standard Specification for Pyrolysis Liquid Biofuel
Comparison of Cost of Selling PyOil vs. Making PyOil
0
0,2
0,4
0,6
0,8
1
Selling PyOil Making PyOil
$U
S/U
S G
allo
n
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Pyrolysis Oil vs. Fossil Fuel LCA
Pyrolysis Oil Production foot printsimilar to fossil energy alternativesAssumed biomass transport distances 200 km for logging residues 25 km for short rotation forest crops
Pyrolysis Oil Life Cycle foot printGreener than other alternatives Carbon neutral combustion emission 70-88% lower GHG emissions SOx emissions similar to Natural Gas
Comparison of GHG EmissionsCradle to Delivered Energy
0
20
40
60
80
100
120
PetroleumCrude Oil
HardCoal
gC
O2
eq/M
J
NaturalGas
CanadianOil SandsCrude Oil
PyOilfrom
LoggingResidues
PyOilfrom
Willow
PyOilfrom
Poplar
Energy ExtractionGHG Emissions
Comparison of GHG EmissionsCradle to Delivered Energy, and Burned
0
20
40
60
80
100
120
PetroleumFuel Oil
HardCoal
gC
O2
eq/M
J
NaturalGas
PyOilfrom
LoggingResidues
PyOilfrom
Willow
PyOilfrom
Poplar
Life Cycle GHG Emissions
through combustion
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Pyrolysis Oil: Upgrading to Green Transportation Fuels
• Objectives– Remove oxygen molecules– Reduce acidity and viscosity– Break up molecules to make
gasoline and diesel/jet precursors– Commercialization expected in 2012
• Solution– Thermochemical upgrading;
leverage UOP’s extensive hydroprocessing experience
– Continuous, reliable guaranteed process, per current refinery standards
Achieved in Lab, Working on Scale-up
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Integrated Biorefinery Demo - Biomass to Transport Fuels
• Honeywell UOP received $25M DOE grant
• Plant to be built at Tesoro/Hawaii refinery, operated by UOP
• Will include RTPTM and pyrolysis oil upgrading
• 2nd Generation feedstocks to include– Corn Stover– Cane Bagasse– Grasses– Sugar Corn– Algae Biomass– Forest Residue
• Demonstration to be complete in three years
Biomass
Utilities
Integrated Bio-Refinery (IBR) Complex
H2
GenerationUnit
PyrolysisOil
ConversionUnit
RapidThermal
ProcessingUnit
Gasoline
Kerosene
Diesel
Steam
Wastewater
Spent Air
Fuel
Water
Air
1 tonne per day
4 Barrels per day
Biomass
Utilities
Integrated Bio-Refinery (IBR) Complex
H2
GenerationUnit
PyrolysisOil
ConversionUnit
RapidThermal
ProcessingUnit
Gasoline
Kerosene
Diesel
Steam
Wastewater
Spent Air
Fuel
Water
Air
1 tonne per day
4 Barrels per day
Integrated Bio-Refinery (IBR) Complex
H2
GenerationUnit
PyrolysisOil
ConversionUnit
RapidThermal
ProcessingUnit
Gasoline
Kerosene
Diesel
Steam
Wastewater
Spent Air
Fuel
Water
Air
1 tonne per day
4 Barrels per day
Conclusions
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Conclusions• Global and European climate targets address the
need of renewable energy, 2nd generation biofuels and low-carbon technologies
• RTPTM is commercially proven, mature technology ready for industrial use
– Seven units designed and operated
• Reliable operation with 90% on-line availability
• Designed to maximize pyrolysis oil yield, 70 wt% based on hardwood sapwood feed
• Cost competitive with fossil fuel oil
• Engineering and modular delivery by world-renowned industry leader
• Upgrading technology to transportation fuels expected to be available in 2 years