Bio-Methanol from Forest Product Industry byproducts

Transcription

1 Bio-Methanol from Forest Product Industry byproducts Development status and commercial challenges 19 November 2013 Ingvar Landälv and Rikard Gebart* Luleå University of Technology 1 * Presenter 1

2 Agenda Background The role of the forest products industry Potential for fuels from the forest Technology readiness level Matching fuel and vehicle evolution Well-to-wheel efficiency and production costs What is stopping us? 2

3 Background Solar/Wind/Geothermal based Biomass based Fossil based Time 3

4 Drivers for renewable fuels Climate change from greenhouse gases (GHG) Environmental Issues Energy Security of Supply 4

5 Interest Indicators Concern regarding GHG Climate Impact Concern regarding security of supply Level of Engagement & Action HIGH EBTP was formed when interest was on its peek LOW United States EU 27 Formation of EBTP Copenhagen Summit IPCC To truly globally motivate a change to renewables 5 Source: ILa

6 Climate Change Concern 6 Source: IPCC Approved Summary for Policymakers, 27 September 2013

7 Climate Change Concern/2 7 Source: IPCC Approved Summary for Policymakers, 27 September 2013

8 Security of supply fracking revolution has improved SoS but it is still a fossil fuel Source: ASPO Newsletter, September Source: crudeoilpeak.info, October 2013 Source: Robert Rapier and BP, October 2013

9 Potential problems with fracking Contamination of groundwater Leakage of a strong greenhouse gas (methane) Exposure to toxic chemicals Depletion of ground water Fracking-induced earthquakes 9

10 Emissions from the Transport Sector Fuel 11% 15% Road traffic 73% Aviation Shipping 12% 15% CO2 42% NOx 54% 73% SOx 27% 1% 74% 5% 10 Source: ScandiNAOS AB

11 Upcoming regulations for Marine Fuels Source: ScandiNAOS AB g NOx/kWh IMO NOx Technical code NOx Tier II (Global) 12 NOx Tier III (NOx emission control areas) rpm 11

12 Synthetic fuels via gasification opens up for many alternatives CO 2 * Coal FT Diesel Liquid residues Natural gas Biomass Black liquor Gasification Followed by cooling and preliminary cleaning Gas cleaning & Conditioning SYNGAS Ammonia Mixed Alcohols Hydrogen Methanol Ethanol Urea Gasoline Acetic acid DME Waste Methane Esters & Ethers High efficiency Feedstock flexible Formaldehyde Olefins 12

13 In focus in this presentation CO 2 * Coal FT Diesel Liquid residues Natural gas Biomass Black liquor Gasification Followed by cooling and preliminary cleaning Gas cleaning & Conditioning SYNGAS Ammonia Mixed Alcohols Hydrogen Methanol Ethanol Urea Gasoline Acetic acid DME Waste Methane Esters & Ethers Formaldehyde Olefins 13

14 Methanol & DME are Relatives DME is dehydrated methanol Methanol DME + + Methanol Water 14

15 The role of the forest product industry Solar/Wind/Geothermal based Biomass based Fossil based Time 15

16 Major Biomass Flow from the Forest Today TODAY Logs Saw - mill Wood Products Forest Pulp Wood Pulp Boiler Mill Recovery Pulp Mill Pulp 16

17 Major Biomass Flow from the Forest With the BLG* Based Biorefinery Concept TOMORROW (1) Logs Saw - mill Wood Products Forest Pulp Wood Pulp Boiler Mill Combined Recovery and Fuel Generation Recovery Pulp Mill Pulp Forest Residual Fuel * BLG: Black Liquor Gasification 17

18 Major Biomass Flow from the Forest including Direct Biomass Gasification TOMORROW (2) Logs Saw - mill Wood Products Pulp Forest Pulp Wood Pulp Boiler Mill Combined Recovery and Fuel Generation Recovery Pulp Mill Forest Residual Fuel Direct Biomass conver sion Fuel 18

19 A typical Pulp Mill of Today 1 Power and heat 2 Chem. recovery Pulp Pulp Wood 1 2 Black liquor Utility Boiler Recovery Boiler 19

20 The Pulp Mill turned to a Biorefinery With the Chemrec Concept 1 Power and heat 2 Chem. recovery 3 Fuel 4 Extra renewable energy Pulp Pulp Wood 2 Black liquor 1 Utility Boiler 20 Power and Steam Renewable energy 4 Black Liq. Gasific. Syngas Syngas to fuels 3 Fuels

21 Some basics about Black Liquor is a Liquid Easy to feed to a pressurized gasifier Can be atomized to fine droplets Rapid gasification rates Stable properties over time The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again. Black Liquor Black Liquor is an efficient gasification fuel Full carbon conversion at ~1000 deg C Virtually no tar formation Low methane formation Black Liquor is available in large quantities World BL capacity about 660 TWh/y Corresponds to production of ~ 10 billion gal gasoline equivalents per year Typically MW of BL per pulp mill 21

22 Potential for fuels from the forest products industry Solar/Wind/Geothermal based Biomass based Fossil based Time 22

23 23 BL Energy is a large renewable energy source in some areas of the World e.g. Sweden Nr Mill owner, name Nominal capacity Current capacity Year of start-up 1 Billerud, Karlsborg SCA, Munksund Smurfit Kappa, Lövholmen SCA, Obbola Husum, M-Real Husum, M-Real Husum, M-Real Domsjö, Domsjö Domsjö, Domsjö Dynäs, Mondi Östrand, SCA Iggesund, Holmen Iggesund, Holmen Vallvik, Rottneros 760/ / Korsnäs, Korsnäs Korsnäs, Korsnäs Skutskär, StoraEnso Skutskär, StoraEnso Frövi, Korsnäs Skoghall, Stora Enso 2200/(3350) Gruvön, Billerud 2500/(3300) Billingsfors, Munksjö Bäckhammar, Wermland Paper Aspa, Munksjö Skärblacka, Billerud Värö, Södra Mönsterås, Södra Mörrum, Södra Approx: 5000 MW Black Liquor Close to 20 large plants

24 BL Energy in Europe = clusters of mills together having a large boiler capacity = important single mill Approx: MW Black Liquor Some 65 large plants 24

25 BL Energy is a substantial energy source in some states in the US e.g. Georgia More than 100 suitable pulp mills In North America with MW of Black Liquor per plant 25 In the World: approx MW Black Liquor or large plants

26 Biomass to Automotive Fuels: Replacement Potential within EU-25 in 2040 Used today Potential today Energy in transports 2002 Potential added to 2040 Total biomass potentials 2040 Transport share DME / MeOH 28% substitution of 2002 consumption FTD 17% substitution of 2002 consumption (TWh/year) Source: EU project Renew within FP6 and EUCAR/Concawe/JRC (2005) 26

27 Technology readiness level for BioDME Solar/Wind/Geothermal based Biomass based Fossil based Time 27

28 The BioDME Project Demonstration of BioDME production and its use as fuel in heavy duty (HD) trucks Syngas DME Synthesis Fuel system equipment Lubricants, Additives Distribution, Stations Vehicle Manufacturing and Testing Grant funding: 28

29 Some facts about the BioDME project DME Production capacity: 4 tons / day Pipe installation: Hand valves & on/off valves: ~ m ~1400 pieces Instruments: Vessels: Heat exchangers: ~450 pieces ~30 pieces ~25 pieces Process Plant Foot Print 20 x 30 m Construction cost: ~ $28 million 29

30 DP-1 unit Carbon filter Black Liquor Oxygen Gasification CO shift Gas conditioning Amine wash & Cleaning The Block Flow Diagram H 2 S / CO 2 to pulp mill incinerator plant Have produced good quality MeOH MeOH Synthesis 2 Syngas Compressor Sulphur guard MeOH Synthesis 1 Raw Methanol First single-pass MeOH synthesis featuring > 95% yield MeOH (recycled) Off gases DME Product DME day tanks DME synthesis DME storage DME synthesis & product purification Water 30 > 500 ton DME

31 Successful production of BioMeOH and BioDME Methanol sample from intermediate methanol production step As per November : > 500 tons BioDME produced Plant in operation > h Gasifier in operation > h 31

32 Long-haul HD vehicles and fleet operators consume about 25% of total Swedish fuel consumption ~30 stations needed for basic coverage in Sweden (HD) Investment about Euro per Filling Station Distribution system easily accomplished Utilizes LPG technology, modified for DME Today: 4 stations Stockholm BioDME filling Station SWEDEN Investment 32

33 Field Test Status per November 19, 2013 Extended field test 33

34 Technology readiness level for other alternatives Solar/Wind/Geothermal based Biomass based Fossil based Time 34

35 WP2 LTU Green Fuels: Planning for Powder Torrefied Mtrl Pyrolysis oil Black Liquor WP6 DP-1 Plant ETC EF gasifier Cleaning WP3 Active C Abs WP4 Membranes bar > 100 bar WG Shift WP1 Pilot scale experiments WP2 Catalytic gasification WP3 Solid fuel gasification WP4 Novel syngas cleaning WP5 Catalytic conversion WP6 Containment materials WP7 Field tests WP8 Electrofuels and new concepts Amine Wash MeOH Synth. DME Synth. WP7 Distillation Others BioMeOH BioDME WP1 O 2 H 2 CO, H 2 WP8 Catalytic Process Development WP5 Existing facilities Future development Electrolysis Fuel Cells CO 2 35 The Renewable Syngas Highway H 2 O

36 Matching fuel and vehicle demand Solar/Wind/Geothermal based Biomass based Fossil based Time 36

37 A way to meet the demand from a growing MeOH/BioDME Fuel Market Natural gas Waste Biomass Pyrolysis Biomass Biomass Methanol plant Fossil MeOH Liquefact. Gasification Nutrients MeOH Gasification Pulp mill MeOH Renewable MeOH Gasification of biomass MeOH Ports 1 2 n nn Industrial Energy gas DME DME M e t h a n o l Distribution Chemical industry Marine sector Heavy transports 37

38 Production and Distribution of Renewable and Fossil DME. One Scenario DME Fuel Station BioMethanol Production DME Production Direct use of BioMeOH DME Terminals Fossil MeOH Direct use of BioMeOH 38

39 Well-to-wheel efficiency and production costs Solar/Wind/Geothermal based Biomass based Fossil based Time 39

40 Well-to-Wheel CO 2 emissions and energy consumption for different conversion pathways 400 CTL Fuels 2010 Conventional gasoline Conventional diesel RME: Gly as chemical RME: Gly as animal feed Syn-diesel: CTL WTW GHG emissions (g CO2 eqv / km) Gasoline and diesel GTL-DME Biomass Gasification GTL-Syndiesel Chemrec Black Liquor Gasification Total WTW energy (MJ / 100 km) Ethanol (pure) Biogas, liquid manure Syn-diesel: GTL Syn-diesel: Farmed wood Syn -diesel: Waste wood, Black liqour DME: CTL DME: GTL DME: Farmed wood DME: Waste wood, Black liqour EtOH: Wheat, Straw CHP, DDGS as AF EtOH: Sugar cane (Brazil) EtOH: Wheat, Straw CHP, DDGS as fuel EtOH: Farmed wood EtOH: Wheat straw EtOH, Wheat, Lignite CHP, DDGS as AF EtOH, Wheat, Lignite CHP, DDGS as fuel EtOH, Wheat, NG GT+CHP, DDGS as AF EtOH, Wheat, NG GT+CHP, DDGS as fuel Biogas, municipal waste Biogas, liquid manure Biogas, dry manure Source: WtW study Eucar/Concawe/JRC 2005, 2010 Vehicles (basis for EU RED/FQD default values) 40

41 DME Properties No C - C bonds and high H/C ratio Very high cetane number => A suitable diesel fuel Non toxic Rapid degradation in air Used as propellant gas in spray cans Similar handling as LPG (liquid at 5 bars) Potential for very low exhaust emissions (burns soot free) Multi source - multi purpose 41

42 Price Levels of some Key Energy Commodities Commodity / MWh (approx.) Crude at 110 USD/bbl 47 Gasoline at refinery gate, NW Europe (0.5 /lit / 0.6 /lit) 56 / 67 Diesel at refinery gate, NW Europe (0.5 /lit / 0.6 /lit) 51 / 61 Nat. Gas at 2-4 USD/MMBtu LNG, NW Europe at LNG hub (based on 4 USD / MMBtu) Methanol, NW Europe (200 /t) 36 DME (based on methanol price + 5%) Cost of biomass, typical Europe / US 20/10 Advanced biofuels

43 So what is stopping us from taking off? Solar/Wind/Geothermal based Biomass based Fossil based Time 43

44 ...but we need the stable long-term investment conditions / MWh /MWh = ~4.4 USD/g.g.e. Today s cost for advanced biofuels In Europe Diesel/gasoline ~ crude Long term stable legislation is required to cope with the difference LOW

45 Summary and Conclusions The FP industry has the potential to become large scale producers of BioDME and BioMeOH The black liquor to BioDME/BioMeOH route is ready for full scale implementation Other feedstocks to BioDME/BioMeOH is expected to be ready for commercialisation within 5 years time Fossil MeOH and DME can be produced at costs lower than today s diesel fuel but green MeOH/DME has a slightly higher cost The shipping industry is preparing to convert from high sulfur bunker oil to ultraclean MeOH with an associated distribution infrastructure Distribution systems for on land and marine fuels can largely use the same overall infrastructure Long term (> 10 years) stable basis for investment decisions is needed Renewable fuels will not be commercially viable until all fuels have to pay a price for their environmental impact 45

46 Proposed base for Conference Statement q Communicate forth fully the message that methanol and DME are excellent fuels, have the best WtW efficiencies and can be produced at low cost from many different feedstocks q Accelerate work for increased methanol use in the transport fuel sector through change in fuel standard EN 228 allowing higher level of methanol in gasoline than current 3% q Set the objective for Europe to follow the Chinese roadmap where M85 is already approved and M15 is expected to be approved within short q On EU and member state levels establish stable, long term, system that puts a price for all fuels in proportion to their environmental impact Transition should start now It takes decades to phase out old vehicles It takes decades to build up large scale production It takes decades to change biomass harvesting systems 46

47 Research partners and sponsors from 2001 until today 47