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The BtL-Project RENEW
of the European Union
Managed by VW
Dr. Eckart Heinl
Group Research
VOLKSWAGEN AG
Volkswagen, 4.11.2004, Autovision
Key Data
renewable fuels for advanced powertrains
finance:
budget 20 M€
funding 10 M€
duration:
4 years
start: 01 / 2004
partners:
31 from 8 countries
core group: VW, DC, Renault, Volvo, Choren, Cutec,
Chemrec, Abengoa, EC renewable energy
coordinator: Dr. Frank Seyfried, Volkswagen AG
Volkswagen, 4.11.2004, Autovision
Motivation
voluntary commitment of European car manufacturers (ACEA)
CO2-emissions [g/km]
Gasoline
+ Diesel
Diesel
ACEA
new passenger car fleet
180
target
140
g/km
160
- 25%
140
1995
Volkswagen, 4.11.2004, Autovision
2000
year
2005
Motivation
biofuels
natural gas
2015
2020
5,75%
7%
8%
15 %
2%
5%
10%
10 %
Total
2020
5%
LPG
H2
new proposal
2010
-
2%
5%
a few %
7,75%
14%
23%
> 30 %
increasing support of renewable energies by the EU
• mid term:
blends of conventional fuels with biofuels and “Gas to Liquids”; natural gas partly supported by EU
and energy industry
• long term:
priority of hydrogen as sustainable fuel by policy and industry
Volkswagen, 4.11.2004, Autovision
Motivation/Objectives
• Integrated approach ACEA / EC fuel directive
– current biofuels have not the potential to substitute fossil fuels in
significant amounts
– the full plant usage has best biofuel potential
• Objectives
– evaluation of most efficient conversion technology - ecological (LCA)
and economical
– substitution potential for biofuels
– biofuel specification for current and future ICEs
– commonly agreed strategic recommendations
Volkswagen, 4.11.2004, Autovision
Biomass
Gasification
SynGas: CO + H2
Fuel Synthesis
SunDiesel
HCCI-fuel
Volkswagen, 4.11.2004, Autovision
DME
Life Cycle Assessment
bench mark of known routes
Scope
Ethanol
Structure
Volkswagen, 4.11.2004, Autovision
SP 4
Optimisation of
bioethanol production
SP 3
DME production
- from black liquor -
SP 2
Optimised processes for
FT- fuel
Optimised fuels for new
drive trains
SP 1
SP 5
Biomass and process
assessment
- biomass potential
- life-cycle assessment
- economical impact
- suitability for ICEs
- production assessment
Training
2 summer schools
SP 6
SP 1 Fuel Optimisation
Objectives
production of optimised BtL fuel for conventional diesel
engines and new combustion processes
Partner and responsibilities
• UET
fuel production
• DC
common rail engine tests
• VW
unit injection (PD) engine tests
• Renault
tests on a HCCI engine test bench
• CERTH
upgrading the product
• ITN
analysing the fuels
Volkswagen, 4.11.2004, Autovision
SP 1 Fuel Optimisation
• Commonly agreed fuel specifications:
kerosene
density
kerosene high
diesel
diesel wide
range
0.77…0.83g/ml 0.77…0.83g/ml 0.82…0.85g/ml 0.75…0.83g/ml
LHV*density 35…36 MJ/l
35…36 MJ/l
35…36 MJ/l
35…36 MJ/l
IBP
> 150°C
> 150°C
> 200°C
> 150°C
FBP
< 200°C
< 260…280°C
< 320…370°C
< 320…370°C
cetan no.
41…45
40…45
52…54
> 51
aromates
< 1%
< 1%
< 1%
< 1%
• 300 l of kerosene high and 600l of diesel have just been delivered to DC
• 600 l of kerosene high have just been delivered to VW
• 150 l of naphtha (FBP < 150°C) have just been delivered to Renault
Volkswagen, 4.11.2004, Autovision
Results SP 1
overview: GTL fuels vs conventional fuel
synthetic GTL fuels / main characteristics :
- GTL10 : cetane equivalent to conventional / usual Diesel, but highly volatile
- GTL 20 : “intermediate” volatility, but with noticeably higher cetane
Item
Density 15°C
Distillation :
IBP
10%
50%
90%
95%
FBP
Cetane number
Volkswagen, 4.11.2004, Autovision
Unit
GTL 10
kg/m3
°C
°C
°C
°C
°C
°C
-
672,6
43
61
95
126
166
45-55
“Naphta”
GTL 20
“Kerosine”
736,1
152,5
159,5
167,0
185,5
208
64,5
Usual Diesel
( 124 A )
834
162
196
272
337
348
359
54
Results SP 1
preliminary results about fuel effects in a HCCI-engine
influence of GTL fuels on soot emissions
power (BMIP) increase at constant 3700 r.p.m. with 3 different intake manifold
pressures
2,0 bar
2,4 bar
3,5
3,5
3700 rpm
3700 rpm
3700 rpm
3
3
2,5
2,5
2,5
2
1,5
Soots ( FSN )
3
Soots ( FSN )
Soots ( FSN )
2,7 bar
3,5
2
1,5
2
1,5
1
1
1
0,5
0,5
0,5
0
0
5
6
7
8
9
BMIP ( BarAbs
)
Power (J/m3)
10
11
0
5
7
9
BMIP ( BarAbs )
Power (J/m3)
11
13
5
7
9
BMIP ( BarAbs )
Power (J/m3)
Usual Diesel
Usual Diesel
Usual Diesel
GTL10
GTL10
GTL10
GTL20
GTL20
GTL20
Volkswagen, 4.11.2004, Autovision
11
13
SP 2 Process Optimisation
Objectives
optimised process for Fischer-Tropsch fuel production
Partner and responsibilities
•
•
•
•
•
•
•
•
CUTEC
FZK
BKG, TUV
IGNG
ITN
EdF
CERTH
VW
fluidised bed gasification, FT-fixed bed reactor
pyrolysis and entrained flow gasification
gas treatment and FT-synthesis
exergetic analysis
analysis of the fuels
process integration and upscaling
catalyst development
suitability of fuel from engine tests
Volkswagen, 4.11.2004, Autovision
SP 2 Process Optimisation
comparison of: - entrained flow and fluidised bed gasification
- different FT reactor concepts
biomass
conditioning
gasification
gas cleaning
Fischer Tropsch reactor
*)
Burner insert
Cooling wall
Refractory
lining
Ramming
mass
Cooling water
Cooled
reactor
outlet
Partial quench
unit
Gas outlet
Volkswagen, 4.11.2004, Autovision
assessment of
different process
routes for FischerTropsch BtL-fuels
*)Source: FUTURE Energy GmbH
SP 2 Process Optimisation
gas engine
and
generator
gasification
and
gas cleaning
additional
gas cleaning
compressor
Güssing power plant
8 MW th. ; 2.5 MW el.
Fischer
Tropsch
reactor
cloride and
sulphur
removal
raw
product
Fischer Tropsch synthesis in side stream
• development of flow chart and interaction with biomass CHP
• gas cleaning
• design of slurry reactor
Volkswagen, 4.11.2004, Autovision
off gas
SP 3 Black Liquor Gasification
Objectives
detail engineering of DME production from black liquor
Partner and responsibilities
• Chemrec & STFI
evaluation of pilot plant data and simulation
- full scale (250-300 MWth) and
• Södra Cell
• VTEC
• Ecotraffic
- demonstration scale (45 MWth ) plant
evaluating the impact of the unit in a
pulp mill host plant
performing heavy duty engine tests
developing a distribution strategy for the
products
Volkswagen, 4.11.2004, Autovision
SP 3 Black Liquor Gasification
forest
pulp
wood
biomass
transformer
forest
residual
combined recovery
and fuel synthesis
pulp
mill
fuel (DME)
pulp
Volkswagen, 4.11.2004, Autovision
smart issue:
present high value biomass
(black liquor) is replaced by
minor value biomass (forest
residues) for energy purposes
in the pulp mill
• basic engineering finished
• 2 alternatives in DME production
are assessed at the moment: two
steps or one step by Haldor
Topsoe
• start of construction: mid 2005
SP 4 Bioethanol Production
Objectives
optimisation of bioethanol production
Partner and responsibilities
• Abengoa
assessment of the common enzymatic pathway as
a benchmark
• AICIA
consideration of the thermochemical pathway,
including gasification-, and catalyst tests as well as
final process simulation and optimisation
Volkswagen, 4.11.2004, Autovision
SP 5 Biofuel Assessment
Objectives
biofuel assessment
Partner and responsibilities
• EC BREC
assessment of biomass resource and potentials
• ESU-services Life Cycle Analysis
• IEE
assessment of micro- and socio-economics
• EEE
technical assessment
• PSI
thermochemical gaseous fuel production
Volkswagen, 4.11.2004, Autovision
Results SP 5
potential of straw, wood
and energy crops has been
evaluated for the EU 25
using literature and
statistical data
RENEW_EU-25 geography
NORTH
UK and Ireland
e.g.: straw:
cereal straw
771 PJ
permanent crops residues 74 PJ
maize
61 PJ
total
906 PJ
EAST (CEE-8)
WEST
Alpine
region
SOUTH
22 Mtoe
20…60% are available for energy/~ local conditions
Volkswagen, 4.11.2004, Autovision
Results SP 5
Cereals straw
Maize residues
+ AT)
alpineAlpine
(CH (CH
+ AT)
Permanent crops res.
GR, SP, IT, PR, BG,
south: South:
GR,SP,IT,PR,BG,
RO
RO
Logging residue
Thinning residue
Wood ind. by-products
UK UK
+ +IRIR
E-crops (100% set-aside)
GR, FR, BE, Lux, NL
west:West:
GE,FR,BE,Lux,NL
FIN, SE, DK
north:North:
FIN,SE,DK
CEE-8
CEE-8
PJ/year
00
200
200
400
400
600
600
800 1000
1000
800
1200
1200
total: 3632 PJ (86 Mtoe)
Volkswagen, 4.11.2004, Autovision
1400
1400
1600
1600
Conclusion
biomass
potential
Europe
optimised fuel
first fuel tests
2004
commonly agreed
process evaluation strategic
recommendations
- costs
- efficiency
- ecology
process
parameters
2005
Volkswagen, 4.11.2004, Autovision
2006
provision
and costs
assessment
2007
recommendations
2008
For further informations:
www.renew-fuel.com
Thank you for your attention!
Volkswagen, 4.11.2004, Autovision