Bionic µFuel Catalytic Microwave Depolymerisation

MWDPREVISION 2014/2

Catalytic Microwave Depolymerizationefficient conversion of organic feedstock into fuels

4/19/2014 © 2008-2013 Bionic Fuel Knowledge Partners Inc., Oswego, NY

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µfuel

BIONICS GUIDING PRINCIPLE

Direct conversion of Biomass and Waste Materialsinto Electric Power and Transportation Fuel offer the most realistic immediate response to Depletion of fossil resources, Rising demand in the developing world and Over boarding mountains of Waste.

Climate Change and exploding Fuel Prices require a bold response.


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FOSSIL FUEL RESERVES ARE LIMITED…

2007

Consumption

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…AND UNEQUALLY DISTRIBUTED


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CLIMATE CHANGE IS HERE


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A SOLUTIONS THAT WORKS TODAY Many technologies are discussed, but few are directly available. Many solutions proposed require a complete system change of technologies,

infrastructure, and lifestyle with severe consequences. The time required for that kind of change is simply not available to avert a major global disaster. Mankind needs solutions NOW that can later be merged with the implementation of long term plans

and technologies. The global fleet of traditionally powered vehicles is still increasing with a life cycle horizon of 20-25

years.

Only a creative mix of all possibilities available short term can tackle the imminent threats. It is the time NOW to initiate a first wave of change while continued preparations for a long term shift to

complete sustainability occur.

BIONIC energy solutions stand for a fast track change with a unique, highly flexible technology that is ready for commercial implementations. Technically efficient Environmentally clean Financially sound


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BTL/WTL TECHNOLOGIES

First Generation approaches not efficient enough Plant oils Biodiesel Biogas Bioethanol Traditional pyrolysis

Second Generation approaches mostly in pilot stage Gasification and FT proving challenging Direct liquefaction (Advanced pyrolysis) Catalytic MWDP Synthetic fuels including bio-synthesis Cellulosic ethanol


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MWDP = DIRECT LIQUEFACTION = DEPOLYMERISATION

For thousands of years it was known that under certain conditions biomass converts into gas, oil and char. Today the process is called pyrolysis or sometimes thermal depolymerisation. It requires energy input (heat) and an oxygen-free environment. Scientists explain the formation of fossil fuels with the natural occurrence of a similar process.

In the 1920s it was established, that in the presence of metal catalysts this process becomes more efficient and controllable. For that reason we now call it thermo catalytic depolymerisation or TCDP. A similar process is used successfully since the early forties to improve refinery yields in the production of Diesel and Petrol.

BIONIC has, for the first time, combined TCDP with the independent depolymerisation capabilities of advanced microwave radiation. The combination resulted in Bionic’s unique MWDP (microwave depolymerization) process which overcomes many fundamental engineering issues of TCDP applications.

Very efficient catalysts are available today in the form of “designer zeolites” facilitating the development of an effective and economical MWDP process and plant design.

Compared to other pyrolysis technologies Bionic’s MWDP design is extremely versatile converting many types of feedstock into proven high quality liquid and solid drop-in fuels.


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Microwave Depoly-merization (MWDP)

Catalytic Depolymerization

CatalyticFlash PyrolysisFlash Pyrolysis

Traditional Methods• Very short residence time (seconds)• High temperatures (600 – 900°C)• Elevated pressure

Advanced Methods• Medium residence times (45-60 min)• Low temperatures (280 – 350°C)• Low pressure

µfuelCatalytic MWDPNext Generation Hybrid Depolymerization Method

MicrowaveFast Pyrolysis

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MWDP WITHIN DIRECT LIQUEFACTION TECHNLOGIES

SECOND GENERATION BIOFUELS

Second generation biofuels overcome practically all environmental and social issues raised the first generation.

The complete plant or biomass waste is used instead of only extracted plant oils. Valuable plant oils can be returned to the food chain or higher value bio-products.

The catalysts used are easy to produce or naturally available in abundance across the globe.

The new technologies have positive energy balances saving 60% -90% of GHG emissons compared to fossil energy sources.

In certain situations a Bionic µfuel system can become carbon negative due to near indefinite carbon sequestration in the soil.

New agricultural and agriforestry technologies are being developed to supply feedstock sustainably.


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OTHER CONCEPTS COMPARABLE TO MWDP

Main representatives of second generation biofuels: Fischer-Tropsch-Process

Complex, two stage process Low energy efficiency, unsolved technical issues

Various types of Pyrolysis Numerous technology vaiants Technical engineering issues, high temperatures Major upgrading issues of pyrolysis oil

Thermo Catalytic Depolymerisation Technical engineering issues, feedstock limitations

Cellulosic Ethanol Processes Not commercially ready

Emzymatic Bioreactor technologies Not ready, scaling issues, no drop-in fuels


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IMPACT OF MWDPThe MWDP process modifies the moelcular composition of the energy contained in the carbo hydrates of the feedstock by converting them into oil, char and gases, all with an exceptionally high energy content.

In other words:

Solid fuel contained in biomass and waste is converted to liquid and coke which are storable for an indefinite time. The resulting prooducts can be burned later for heat or power or upgraded to transportation fuels including jet fuel.

Toxic organic materials contained in some plastic waste are mostly transformed into salts and thus neutralized.

Minerals contained in the feedstock remain unchanged and are ready for further processing or direct use.


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THE PRINCIPLE BEHIND MWDPIrradiation of the feedstock with advanced microwaves in the presence of certain catalystscreates mechanically unstable hydrocarbon molecules causing a vibrating movement. This phenomenon results in the eventual breakdown (cracking) of larger molecules. They evaporate from the reaction mass as an oil vapour.

The oil vapours are then condensed and cleaned. Where required, additional petrochemical upgradingis added to meet applicable fuel standards. The final product is a high quality fuel with the properties of diesel or jet fuel.

That fuel is storable and cold resistant. It can be used as transportation fuel, heating oil or blended with mineral oils. It is also a valuable intermediate raw product for the petro chemical industry.


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KEY MWDP APPLICATION AREAS Biomass to bio-crude:

Decentralized conversion of energy crops Forestry and agriculture waste Decentralized processing of press cakes Processing of sugar beet and molasses

Waste materials to gasoil: Processing of high calorific waste fractions (HCF, RDF) Processing of MSW Processing of scrap tires Processing of organic hazardous waste

Processing of fossil hydrocarbons: Refinery residue cleanup Soil decontamination and cleanup of oil spills Processing of tar sands and oil shale


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ENERGY FROM WASTE

Valuable energy products can be extracted through the intelligent use of waste materials.Typcally more than 70% of MSW (municpal solid waste) drymass can be converted into fuel with the MWDP process.

Instead of landfills or destroying waste through enormously expensive and complex incineration still producing large amounts of greenhouse gases, the MWDP technology allows for a much more efficient disposal.


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ENERGY FROM BIOMASS


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Wood

Wood chips Wood pellets

Most Biomass can be chopped and pelletized

Brushes

Grasses

To achieve optimal results most feedstock types are first shredded or grinded. Humid materials should be dried. Materials are then mixed with the catalyst and pelletized before they are fed into the reactor.

This approach has many advantages by standardizing size and consistency for further processing when entering the microfuel reactor. Processing of scrap tires is the oneexception to that rule.

THE MICROFUEL PROCESS WITH WOOD CHIPS


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Wood chips are firstpressed into pellets

MWDP Conversion

* µcrude is a ready blendstock, a direct fuel for CHP use or upgradable into standard Diesel fuel products** µchar is a highly valuable product for long term soil improvement and carbon sequestration or as a solid fuel

Conversion of wastewood into Diesel and Biochar

(Plus distilled water and light gases for internal use)

Products: Bionic µcrude* & µchar**

MWDP VS. TYPICAL PYROLYSIS TECHNIQUES

MWDP and typical pyrolysis are building on a similar chemo-physical principle:- Thermal decomposition of hydrocarbons under absence of oxygen -

Significant differences are setting MWDP apart: Very low temperature requirement of around 280°C, equal to torrefaction (which does

not produce any liquid phase) implies a high energy efficiency of MWDP. Significantly higher energy content of µcrude and µchar than any fast/flash pyrolysis

technology known (crude: 40-45 MJ/kg, char: 25-30 MJ/kg). MWDP bio-crude quality greatly supersedes any typical pyrolysis oil even from flash

pyrolysis, thus making it usable directly for heavy oil applications and as a blendstockwhile also upgradable to ASTM diesel and bio jetfuel (SPK).

MWDP yields (crude: 30-35%wt, char: 30-50%wt, gas: 10-30%wt) are incomparable with pyrolysis yields, due to factors like water and energy content and chemical composition.

MWDP oil yields for comparable feedstock are always better than those from other pyrolysis processes.

MWDP char quality is superior for technical applications.


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CURRENT MICROFUEL REACTOR PROGRAM

Bionic currently offers 4 reactor lines: The standard continuous reactor model MF480 has an output capacity of

up to 1200 l/h. A reduced version of the standard reactor MF192 with an output volume of

approx. 500 l/h (upgradable to MF480). A downscaled continuous MF60 with an output capacity of up to 150 l/h.

Semi-mobile, mountable in container frames Intended for special applications and as a demonstrator and test bed

A lab batch reactor for feedstock testing and analysis, R&D, scientific use and small demonstrations.

(NB: Above mentioned output volumes are approximate and exemplary for common, dry biomass feedstock. They can vary widely depending on feedstock properties like energy content)


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COMPLEMENTARY R&D ACTIVITIES

The following additional developments are close to approaching their commercialization status:

µCTL - A microwave driven process for clean liquefaction of coal and char. Innovative petrochemical processes for µcrude upgrading with the

distinct capability for economical conversion of smaller quantities of crude feeds into clean fuels meeting the highest clean fuel standards like ultra low sulfur diesel.

µsoil - An integrated organic soil enhancer and fertilizer production system based on a patented process licensed by Bionic to be used to upgrade the bionic char product with plant nutrients.


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A MICROFUEL LAB REACTOR

Inside

First Distillation

Raw Distillate4/19/2014 © 2008-2013 Bionic Fuel Knowledge Partners Inc., Oswego, NY

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CONTINUOUS REACTOR (PRINCIPLE DETAIL)


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PILOT REACTOR COMPONENTS


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FULLY OPERATIONAL MF60 PROTOTYPE


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The status in March 2014 At Brno industry fair receiving an award: “innovative product of the year”

• Since August 2013 this µfuel prototype is under rigorous testing directly at the manufacturing site.

• Many modifications and upgrades have been implemented.• Extended test runs further increase operational robustness.• External certification is being performed.

THE LATEST MF480 DESIGN


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A 4xMF480 CLUSTER


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MICROFUEL PLANT 4X CLUSTER


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MICROFUEL PLANT PROCESS FLOW


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FROM ORGANIC WASTE TO FUEL AND CHAR

Market

Diesel Fuel

Vegetable OilCrude OilRefined Oil

catalyst

5000 Ltr/hrcapacity


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µchar

Making efficient use of palm oil milling waste

FROM MUNICIPAL SOLID WASTE TO FUEL

Diesel fuel

municipal waste

Bionic µfuel plant >60% efficiency


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CONTACT INFORMATION


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Bionic Laboratories GmbHHelwigstr. 4164521 Gross-Gerau, Germany+49 1525 33 40 [email protected] our website at www.bionic-world.net

mailto:[email protected]

http://www.bionic-world.net/

Technology

Bionic µFuel Catalytic Microwave Depolymerisation