Acknowledgment & disclaimer

Transcription

1 Wood to green gasoline using Carbona gasification and Topsoe TIGAS processes DOE Project DE-EE Presented at 8 th IEA Bioenergy - Task 42 Biorefining in Chicago IL, October 4-6, 2010 Niels R. Udengaard, Haldor Topsoe, Inc. Acknowledgment & disclaimer Acknowledgment: This material is based upon work supported by the Department of Energy, Golden Field Office, under Award Number DE-EE Special thanks to the team members on this project for their contributions to this presentation: Richard Knight, Project Manager, Gas Technology Institute Jim Patel, Project Manager, Carbona/Andritz Jesper H. Jensen, Project Manager, Haldor Topsoe A/S Kip Walston, Project Manager, ConocoPhillips Pekka Jokela, Project Manager, UPM-Kymmene Disclaimer: This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof. 1

2 Haldor Topsoe Year of establishment: 1940 Ownership: Haldor Topsoe Holding A/S (100%) Annual revenue (2009): About 1 billion USD Number of employees (2009): About 2100 The Topsoe group is devoted to - Research and development in heterogeneous catalysis Production and sale of catalysts Licensing of technology Equipment supply Engineering and construction of plants based on catalytic processes 2

3 Catalyst supply All catalysts developed in-house All catalysts manufactured in own facilities Frederikssund, Denmark Pasadena, Texas Alumina base materials produced in-house Frederikssund Pasadena TX Fundamental & applied research process & catalyst development Industry Basic Research Fundamental Studies Catalyst Characterisation Scale-up Pilot Operation Computer Modelling Catalyst Formulation Process Development R&D is multi-disciplined Fundamental research Catalyst development Catalyst manufacturing Pilot plant studies Process development Process impact studies Equipment development Computer modelling Topsoe annually applies 10-12% of gross revenues to support these R&D efforts 3

4 Process demonstration units Business areas The refining industry The fertilizer industry The environmental and power industry The heavy chemical and petrochemical industries 4

5 Wood to green gasoline project U.S. Department of Energy Golden Field Office Liz Moore, Program Manager Government share: $ 25,000,000 Cost share: $ 9,771,659 Period of performance: 12/28/09 through 12/31/14 Project team members -UPM-Kymmeneis one of the world s largest pulp and paper companies with more than 100 production facilities. -Provides: gathering, handling and transporting of wood; 1 st commercial plant site -Haldor Topsoe is a leading worldwide supplier of catalysts and catalytic technology for fuel conversion and upgrading. -Provides: TIGAS process, syngas cleanup including tar reforming and conversion; overall project management -ConocoPhillipsis a leading oil refiner & contributor to TIGAS -Provides: Liquids fuels handling, transportation and marketing, sample characterization, pilot plant design, construction, operation and scale-up assistance -Carbonais a supplier of biomass gasification and gas cleanup plants -Provides: fluidized-bed gasification, tar reforming, commercialization support -GTI is the developer of this gasification technology and owner/ operator of pilot plant test facility -Provides: design, construction, and operation of pilot plant plus modeling, data analysis, commercialization support 5

6 Project organization DOE COTR UPM Pekka Jokela, Manager, Biofuels ConocoPhillips Scott McQueen, PM Kip Walston, Engineering Haldor Topsoe Inc. Niels R. Udengaard, PI Executive Steering Committee Anders N. Olsen, CEO, HT Inc. Vann Bush, Managing Director, GTI Kari Salo, Managing Director, Carbona Inc. Merl Lindstrom, VP, ConocoPhillips Petri Kukkonen, Director, Biofuels, UPM Carbona USA Jim Patel, PM GTI Rick Knight, PM Haldor Topsoe A/S Jesper Hojer Jensen, PM Project Executive Bruce Bryan, R&D Director, Gasification Project Executive Per K. Bakkerud, VP, New Technologies Engineering Hekki Virto Test Operations Andras Horvath TIGAS, Catalyst/Process Finn Joensen TIGAS, Build/Operate Arne Knudsen Flex Fuel Operations Andrew Kramer Test Planning/Analysis/Modeling Dr. R. Slimane Flex Fuel Engineering Dr. A.J. Aderhold Gas Processing Dennis Leppin, Howard Meyer Project objective Demonstrate a technology for thermochemical conversion of woody biomass to gasoline Pilot plant will feed 21 ton/day of pelletized woody biomass Pilot plant will produce 23 BPD of gasoline blendstock 6

7 Project work tasks 1. Budget Period 1 - pilot plant design 1.1 Preparatory activities 1.2 Independent reviews (EIR & IPR) 1.3 Preliminary process design 1.4 Engineering design 1.5 BP1 management and documentation 2. Budget Period 2 - pilot plant installation and testing 2.1 Procurement and installation 2.2 Pilot plant testing (Shakedown, Test #1, Test #2, Test #3) 2.3 Pilot plant laboratory support (as needed) 2.4 Technology evaluation 2.5 BP2 management and documentation Pilot plant block diagram BIOMASS Gas cleanup & treatment Ash O 2 Steam Recycled syngas CARBONA/ANDRITZ GASIFICATION TIGAS SYNGAS-TO- GASOLINE PROCESS 7

8 Carbona gasifier HOT PRODUCT GAS GASIFICATION REACTOR CYCLONE BIOMASS FEED HOPPER FLUIDIZED BED FEEDING SCREW GRID AIR ASH REMOVAL SCREW ASH Skive Gasification CHP Plant 6 MW POWER 12 MW DISTRICT HEAT BFB GASIFIER BFB GASIFIER GAS ENGINE FLARE 2 GAS BOILER 3 GAS ENGINES 3 GAS ENGINES 8

9 Topsoe TIGAS synthesis Off-gas Synthesis Gas from AGR MP Steam C 3 -C 4 Gasoline Water MeOH/DME Synthesis Gasoline Synthesis Separation DME synthesis reactions H (kj/mol) 2H 2 + CO = CH 3 OH CH 3 OH = CH 3 OCH 3 + H 2 O 23.6 CO + H 2 O = CO 2 + H H 2 + 3CO = CH 3 OCH 3 + CO 2 9

10 Optimal conversion to DME 100% 80% DME MeOH H 2 O mol-% 60% 40% CO 2 20% CO H 2 0% (60 bar ; 250ºC) H2 / CO Ratio H 2 /CO MeOH/DME synthesis conversion 70 Conversion (CO+CO 2 ) MeOH / DME MeOH Pressure (bar) 10

11 TIGAS synthesis CH 3 OCH 3 (DME) = 2 -CH H 2 O (gasoline) Topsoe TIGAS demonstration units TIGAS Pilot Plant Houston, Texas - 6 bpd & runhours Gasoline Pilot Plant Frederikssund, Denmark lb/h scale Single-tube MeOH/DME reactor (BWR) Adiabatic gasoline reactor runhours 11

12 Pilot plant demonstration site GTI Energy & Environmental Technology Campus Des Plaines, Illinois 1 (Bay 3) 1 (Bay 2) 1 (Bay 1) 2 1. Advanced Gasification Test Facility -Bay 1: Carbona syngas conditioning system -Bay 2: PWR Gasification System -Bay 3: open 5-story test bay (available for TIGAS) Flex-Fuel Test Facility -Carbona biomass gasification system 3. Morphysorb -Absorption/stripping for CO 2 & H 2 S removal 4. SulfaTreat -Sorbent-based sulfur scavenger 5. High-pressure oxygen and nitrogen supply Feedstock Feedstock: pelletized mixed wood waste composition based on UPM's Blandin Mill commercial case 25% purchased mill residue (Rapids Energy Center) 26% in-woods chips, logging residue 49% non-merchantable roundwood Blandin Forestry Wood Procurement organization purchases fuel Local pellet mill will pelletize, screen, and bag mixed feedstock The wood will be shipped to GTI pilot plant as needed in Super Sacks which are weather resistant and waterproof and will be stored in an enclosed covered storage. Contents will be analyzed before shipment and as used to assure no changes in critical properties Past experience in shipping test fuel feedstock from Finland to Chicago validates assumption of feedstock stability 12

13 Pilot plant test plan summary Tests to be conducted: 08/12-09/12: Shakedown sequentially test main plant sections leading to integrated steady-state operation for up to 96 hrs 09/12-12/12: Test #1 Independent Engineer Test (decision point) followed by steady-state operation totaling up to 480 hrs 06/13-08/13: Test #2 increase severity to maximize throughput & gasoline production at steady state for up to 480 hrs 08/13-10/13: Test #3 apply optimal conditions learned from previous tests to achieve steady-state operation for up to 720 hrs 2012 Q Q Q Q2 6-month gap for prior facility commitments 2013 Q3 15-month total pilot plant operation 2013 Q4 Gasoline characterization & testing Analysis: Detailed hydrocarbon analysis Specific gravity D86 distillation Reid vapor pressure (RVP) Octane engine test Gum test Copper strip corrosion Silver strip corrosion Engine testing at Southwest Research Institute Fleet testing 13

14 Commercial biorefinery Assumptions: Feed rate 4,000 MT/day of $ 35/MT Production 5,960 bpd of gasoline bpd of LPG Annual capital expenditure 12.75% of TIC Annual cost, $ Capital cost Cost of wood Labor and others G&A, tax and insurance Power Catalysts & solvents Total production cost Production cost, $/gallon Co-location Greenfield Thank you for your attention 14