Transcript Biomass Energy CONversion Facility

CHEMICAL$ & Fuels
from
Biomass
Norm Olson P.E.
Program Director, BECON Facility
Biomass Energy CONversion
Iowa Energy Center
www.energy.iastate.edu
The Iowa Energy Center’s Mission
• Broad Scope
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complex connections
to many issues
focusing on Iowa
energy efficiency
renewable energy
education
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all groups
all ages
all sectors of the
economy
History
• Created by the 1990 Iowa Energy
Efficiency Act
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Funded by surcharge on intrastate electric
& gas sales
Conducts and sponsors demonstration,
education, training and research through
partnerships and competitive grants with
Iowa’s colleges, universities & private nonprofits
Twin Pillars
Energy Efficiency
$7.5 billion – Res., Comm., Inds.
20% savings in all buildings
$1.5 billion annual savings
$9 billion construction activity
64,000 person-year new jobs
Alternative Fuels
NH3 fuel
$5.8 billion locally produced fuels
$3 billion fuel production facilities
# New jobs?
Biorefinery
$120 billion new economic output
$30 billion new jobs (25%)
425,000 new jobs (manufacturing)
Demonstration/Training/Research
Facilities
Energy Resource Station (ERS)
– energy efficient building
systems
– Demonstration, training
and research
– tours
– meeting/class space
Demonstration/Training/Research
Facilities
BECON (Biomass Energy
CONversion)

renewable energy/ biomass
to fuels and chemicals
• demonstration and research
• tours
• meeting/class space
World Energy Facts
Oil Experts
See Supply
Crisis in Five
Years
International
Energy
Agency
July 10, 2007
April 27, 2007
172 Militants Planning Attack on Oil
Fields Arrested in Saudi Arabia
Friday, April 27, 2007
Crude Oil Reserves
World Crude Oil Reserves
Jan 2007
1,317.4 billion barrels
7,749 quads
(Coal: 22,171 quads)
(NG:
5.500 quads)
OPEC Share (68%)
Compiled from “Worldwide Look at Reserves and Production,” Oil
& Gas Journal, Vol. 104, No. 47 (December 18, 2006), pp. 24-25.
Natural Gas Reserves
AP
updated 9:26 a.m. CT, Wed., Jan. 7, 2009
KIEV, Ukraine - Russia shut off all gas supplies to
Europe through Ukraine on Wednesday — leaving
more than a dozen countries scrambling to cope
during a winter cold snap. Prime Minister Vladimir
Putin publicly endorsed the move and urged that
international observers be brought into the energy
dispute.
(3.3%)
Source: PetroStrategies, Inc.
World Total: 5500 Tcf, 5500 quads
(Petroleum: 7749 quads)
(Coal: 22,171 quads)
Coal Reserves
World Recoverable Coal
Reserves, Jan 2003
997.7 billion short tons
22,171 quads
Oil: 7,749 quads
NG: 5.500 quads
Organisation for Economic Co-operation and Development
USDoE - EIA, unpublished data, Coal Reserves Database (April 2007). World Energy Council, 2004 Survey of Energy Resources, Eds. J.
Trinnaman and A. Clarke (London, UK: Elsevier, December 2004).
Enough Biomass?
2002 Consumption
Quads
Petroleum
38.11
Natural Gas
23.37
Coal
22.18
Nuclear
8.15
Renewable
5.25
Corn potential (including stalk, 10 bil. bu.)
8.40
The Ideal Alternative Fuel
• Can be produced from any raw energy source (i.e.
wind, solar, biomass, coal, nuclear, hydro etc.)
• Is cost effective
• Has significant storage and delivery systems already
in place
• Is environmentally friendly
• Can be used in any prime mover (i.e. diesel engines,
fuel cells, SI engines, gas turbines, etc.)
• Has a proven, acceptable safety record
• Produced in the U.S.
Ammonia Basics 1
• Ammonia (NH3) can be produced from any raw
energy source, including all fossil, renewable and
nuclear sources.
• Ammonia is cost competitive with gasoline as a
transportation fuel
• Ammonia has extensive, worldwide transportation
and storage infrastructure already in place
• Ammonia is very environmentally friendly when used
as a transportation fuel and produces only N2 and
H20 at the tailpipe with low-cost emissions controls.
• Ammonia has been successfully demonstrated in SI
engines, CI engines, and fuel cells.
Ammonia Basics 2
• High U.S. cost is due to high cost of U.S.
natural gas
• The U.S. imported over 50% of it’s nitrogen
fertilizer for the first time in 2004
• Ammonia high cost partially due to highly
seasonal nature of use (inefficient use of
infrastructure)
• Ammonia has been produced from coal in
Beulah, North Dakota for decades. China
has huge coal to ammonia capacity.
Dakota Gasification
Over 20 years of producing
natural gas, ammonia and
other valuable chemicals
from US coal.
Al Lukes - $4.50 Nat. Gas
from new coal gasification
plants.
Fuel Costs
• June 2003 Chemical Market Reporter*
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Ammonia - $200/metric ton*
Gasoline - $1.20/gallon
Methanol - $0.79/gallon*
Ammonia - $270/short ton
Ethanol - $1.25/gallon* ($2.70, 9/05)
Gasoline - $2.00/gallon
Wind - $0.035/kwh x 2 (electrolyzer)
Gasoline - $2.50/gallon
Ethanol - $2.70/gallon (9/05)
$/MMBtu
$10.01
$10.52
$13.68
$14.86
$16.44
$17.54
$20.51
$21.92
$35.51
Future Compatibility
Hydrogen + Nitrogen
Ammonia
Storage & Delivery – Pipeline, Barge, Truck, Rail
Stationary Power
Fertilizer
Transportation
Ammonia Pipeline
Ammonia Storage & Transport
Freedom Car Targets
w/ 2005 NH3 Comparison
2005
Parameter
Units
2007 2010 2015 NH3
Spec. Energy
kWh/kg
1.5
2
3
3.0
Energy Density kWh/L
1.2
1.5
2.7
2.7
6
4
2
3.1
3
1.5
1.5
1.7*
Storage Cost
$/kWh
Fuel Cost $/gal. Gas equiv
*$280/ton
ENERGY DENSITIES
35
30
25
20
MJ/Liter
Carbon Energy Density
H2 Energy Density
15
10
5
0
Gasoline
Methane
Methanol
Liq
Hydrogen
10Ksi H2
Liq NH3
Solid Urea
50% SOH
High “energy density” in ammonia and ammonia solutions
Economic Impacts
Petroleum Imports (2003): ~ 13 million bpd
= $118 b/year @ $25/bbl, $236 @ $50, $354 b@$75, $472 b @$100
2006 U.S. Trade Deficit - $763 billion
2003 Gasoline Consumption – 8,756,000 bbl/day
15.3 x 1015 Btu/year = 850 million ton/year ammonia
1250 new plants @ 650,000 ton/year each
$562 billion investment @ $450 million/plant
375,000 new jobs
$5 billion new tax revenue/year (employees only)
Back to BECON
BECON
The Ideal Biomass System
• Soil tilth improved – no erosion loss, increased soil organic
carbon content
• Nutrients and micronutrients returned to soil
• Fertilizer made from plant residue in same field
• Use of currently available planting, harvesting storage
techniques
• No fossil fuel use
• Cost effective
• Local economic development
• Biorefinery concept – multiple products (food, chemicals, fuel
additives) energy efficient, low air/water emissions, low water
use
Ideal Annual Crop System – Silage Harvest
Ideal Annual Crop System – Silage Storage
Ideal Annual Crop System – Cover Crop
www.leopold.iastate.edu/.../cover.htm
Wisconsin
Ideal Annual Crop System – Processing
Local Processing – All nutrients (PKN,
micronutrients) returned to soil. Closed loop.
Nutrients
University of Nebraska Nitrogen is one of sixteen chemical elements essential for plant growth (1). Green plants must be able to assimilate all sixteen
nutrients to carry on cell growth and metabolic activities.
Plants get oxygen (O), carbon (C), and hydrogen (H) from the air and water, the other nutrients are taken from the soil.
Nitrogen (N), phosphorus (P), potassium (K), are sometimes referred to as the primary nutrients while calcium (Ca), magnesium
(Mg), and sulfur (S) are referred to as secondary nutrients. Another seven essential nutrients are taken up in much smaller
quantities and are collectively referred to as micro-nutrients. These are: boron (B), chlorine (Cl), copper (Cu), iron (Fe),
manganese (Mn), molybdenum (Mo), and zinc (Z). Table 1 lists the total crop removal of soil nutrients to produce a 150 bushel
corn crop.
(1) Cobalt has not been proven essential for higher plant growth but nodulating bacteria need it for fixing atmospheric nitrogen
in legumes. It therefore sometimes will appear in a listing of essential nutrients.
Outreach
•A cooperative education/training agreement, led by DMACC,
has been developed with all 15 Iowa Community Colleges
•Nearly 8000 people have either toured BECON or heard the
BECON presentation since 1999.
•Visitors from most states and over 30 foreign countries
•BECON is a National Biodiesel Training Center
•Numerous state and Federal legislators, Presidential
candidates and former U.S. President George Bush have
visited BECON
Conversion Systems
Biomass Conversion Systems
Feedstock Processing
Biological Conversion
Thermochemical Conversion
Anaerobic
Digestion/Composting
High Solids Unit
(Composting)
Feedstock
Processing
Low Solids Unit
Scrubber
Methane to
Engine
Generator
Or
Ammonia
Alcohol Production II
High-sugar
energy crop
Harvest,
acidification, &
inoculation
Multi-farm
Storage &
Fermentation
C6H1206
yeast
enzymes
2C2H50H + 2CO2
Local Processing Center
Distillation
Drying/Vapor
Recovery
Ethanol
Residue
Saleable
By-product
Gasification
Scrubber
Feedstock
Processing
Syn-gas
To Engine Generator
Gasifier
To Ash Disposal
Pyrolysis
Feedstock
Processing
Pyrolysis
Waste Disposal
Refining
Syn-oil
Bio-Chemicals
Biodiesel Production
Chemical Reactor
Vegetable Oils
Alcohol
Biodiesel
Glycerin
Vegetable Oils + Alcohol
catalyst
Biodiesel + Glycerin
Supercritical Fluids
Biomass
High Pressure Fluid
High Pressure Reactor
Product
Supercritical Fluid Chart
Combined Systems
Fermentation
Unit
Dairy Facility
Greenhouse
Anaerobic
Digestion Unit
CO2
Heat
Electricity
Fuel Cell
Unit
Iowa Biorefinery
Bio-Refinery Model
MGP - Lakota
Biomass Feedstocks
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Agricultural Residues
Food Processing Wastes
Livestock Production Wastes
Municipal Solid Waste
Obsolete Seed Corn
Wood Waste
Feedstock Costs
• Cost of corn stover ~
3 cents/lb. ($60/ton)
Corn @ $3.50/bushel ~ 7 cents/lb
• Consists mainly of C, H and O
• Cost of petroleum ~
8 cents/lb ($25/barrel)
16 cents/lb ($50/barrel)
24 cents/lb ($75/barrel)
32 cents/lb ($100/barrel)
40 cents/lb ($125/barrel)
48 cents/lb ($150/barrel)
• Consists mainly of C and H
• Organic chemicals are mainly C, H
Feedstock Availability
• 20-30 million tons of corn stover annually in Iowa
Iowa Annual Fossil Fuel Use (EIA, 1999)
• 23.4 million tons of coal
• 5.1 million tons of natural gas
• 4.7 million tons of gasoline
• 3.0 million tons of diesel fuel
45 million tons of “Big Three” organic chemicals (ethylene,
propylene, benzene) used in US annually.
Biomass Components
Cellulose
Hemicellulose
Lignin
Starch
Sugar
Oil
Extractives
Ash
Crude Oil Components
Benzene
Toluene
Xylene
1,2,3,4 –
Tetramethylbenzene
Heavy metals
Sulfur
Napthalene
Alkyl
benzenes
Paraffins
Etc., etc., etc.
A Little History
• Oil came in at $1.50/barrel in the mid1940’s ($0.0045/pound)
• Corn was approximately $1.50/bushel in
1950 (approx. $0.03/pound)
Historical Corn Prices
Source: National Corn Growers Association
Forward to the Past
• Prior to the 1940’s most chemicals were plant
derived
• Celluloid, Cellophane, Bakelite, rayon, paints,
adhesives
• Henry Ford Vegetable Mobile
• Fermentations to ethanol, butanol, propanol
and other alcohols was common prior to the
1940’s.
Organic Chemicals vs Fuels
$/Pound
Chemical
• Ethylene
(1)
• Propylene (2)
• Acetic Acid (20)
• Citric Acid (74)
• Ethanol ($1.20 - 2.50/gal)
• Paper (printer)
• Ammonia ($200 – 600/ton)
Fuel
• Natural Gas ($0.50 – 1.00/ccf)
• Gasoline ($1.00 - 3.00/gal)
• Coal ($1 - 2/million Btu)
2000
2008
0.25
0.21
0.48
0.85
0.19
0.80
0.10
0.64
0.12
0.16
0.01
0.24
0.48
0.02
0.68
0.40
0.30
Plant Based Chemicals
Chemical
Production
Cost/Lb
Plant
M. Tons
Petro.
Plant
%
Furfural
0.3
0.75
0.78
97.0
Adhesives
5.0
1.65
1.40
40.0
Fatty Acids
2.5
0.46
0.33
40.0
Surfactants
3.5
0.45
0.45
35.0
Acetic Acid
2.3
0.33
0.35
17.5
Plasticizers
0.8
1.50
2.50
15.0
30.0
0.50
2.00
1.8
Plastics
Source: ILSR
More Plant Based Chemicals
Polylactic acid
Plastarch
Poly-3-hydroxybutyrate (PHB)
Sorona: 1,3 propanediol (PDO), (Dupont)
Mirel: PHA, (Metbolix, ADM)
Ethyl lactate (low VOC solvent)
Ethylene, propylene
Butanol
Acetone
100’s of new pharmaceuticals
Getting There from Here
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Corn stalks - C,H,O
Sugars - C,H,O
Ethanol - C2H6O
Ethylene - C2H4
Ethylene Dichloride - C2H4Cl2
Vinyl Chloride - C2H3Cl
PVC
Getting There from Here
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Corn stalks - C,H,O
Sugars
Propanol
Propylene
Acrylonitrile
Polyacrylonitrile
Carbon Fiber
Getting There from Here
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Corn stalks - C,H,O
Sugars
Acetone
Chlorine Gas + CO
Bisphenol A
Phosgene
Polycarbonate
Biofuels 2007
• 42 Ethanol Plants in Iowa – 1st Nationally
• 3.3 Billion Gallon
• 14 Biodiesel Plants in Iowa – 1st Nationally
• 0.3 Billion Gallon
Some Big-time Players
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Dow/Cargill – polylactic acid – Blair, NE
Dupont/Pioneer
Monsanto/Dekalb
Shell
Follow the Money
1910
Inputs
Inputs
T,P&M
T,P & M
Farmer
Farmer
Inputs
Inputs
T,P&M
T,P & M
Farmer
Farmer
1990
Source: ILSR
Rural Economic Potential
1999
Iowa Ag. And Food Exports
24 MT Stover @ $0.02/lb.
Iowa Gross State Product
24 MT Stover @ $2.50/lb.
$3.5 Billion
$86 Billion
2004
$4.7 Billion
$1.0 Billion
$111 Billion
$120 Billion
Breakfast Cereal $1-$3/Pound
Clothing - $10-$100’s/Pound
Plastic Tanks - $2.00/pound
RMI Hypercar $5-$10/ pound
Auto-making and associated businesses employ oneseventh of U.S. workers (approaching two-fifths in
some European countries) and represent one-tenth of
America's consumer spending.
W. Washington U.
GM’s Autonomy
GM’s Effort
Henry Ford’s soybean plastic
Key Benefits
• Developing systems to economically produce chemicals and
fuels from biomass will spur rural economic development
• Adding value to agricultural products will enhance the
profitability of many Iowa industries
• Demonstrating full-scale biomass conversion systems
promotes increased adoption of these technologies
• Developing new products and technologies with export
potential will strengthen Iowa’s economy (consulting)
• Producing and using biochemicals is more environmentally
sound than producing and using petrochemicals
• Combining biomass research, demonstration, education and
training at one facility helps focus this work and enhances
exposure
What’s it Going to Take?
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Yankee Ingenuity
Research and Demonstration
Pioneer Spirit
Fortitude
Foresight
Wisdom
Integrated Systems
Political Support
Wake-up Call
WTO: China Overtakes U.S. in Exports
Asian nation set to become world’s biggest
exporter by 2008
The Associated Press
Updated: 9:50 a.m. CT April 12, 2007
Agriculture Looks Good