Transcript Biowaste to Bioenergy through Gasification

February 1, 2011
Biomass Program Review IBR & Infrastructure
Dr. Douglas M. Goodale, PI
Executive Summary
 Develop a simple approach to convert wastes to
energy.
 Direct pathway to liquid fuels or combined heat and
electrical power (CHP).
 Despite significant hurdles, all testing is complete
and the project is progressing to closure.
 Project will be complete by Dec. 31st, 2011 and
within the original budget.
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Quad Chart Overview
Timeline
Project Start Date
Project End Date
Mechanical turnover
Start-up planned
Commissioning
Percent complete
6/1/08
12/31/11*
N/A
6/1/11
6/1/11
90%
Project Development
Current status
on target
Cost
within budget
Schedule
within schedule
Project scope
no change
Project complete 12/31/11
* No-cost extension request in process
Budget
Total Project Funding
DOE Share
Contractor Share
Funding Received by FY
10/1/08 – 9/30/09
10/1/09 – 9/30/10
10/1/10 – 2/1/11
Project Participants
Collaborations
W2E USA, Inc.
$1,279,200 Intellectual property W2E USA, Inc.
$0
Project Management-Doug Goodale
Construction Management
N/A
$767,520
Start-up and Commissioning - W2E
$511,680
Operations -W2E & SUNY Cobleskill
$0
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Spend Plan
$1,400,000
$1,200,000
$1,000,000
$800,000
$600,000
$ Rec'd DOE
$ Spent SUNY
$400,000
$200,000
$0
FY09 FY10
FY10 FY10
FY10 FY11
Q1 Q2
Total
Q3
Q4
Q1
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Project Overview4
Task
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4
6
8
10
Months
12 14
16
18
20
22
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1
2
26
Finish installation
at SUNY
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3
4
3
5
1 start
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date 3-12-10
Arrival date 3-20-11
Original Target Completion
Actual Completion
Install at SUNY
3 Closing date 3/31/11
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no cost variance
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Major Technical Hurdle
 The complexity of the bench scale gasifier requires
locating in specially designed building.
 Funding was secured from the State of New York for a
new building to locate the gasifier on the SUNY
Cobleskill campus.
 Center for Environmental Science and Technology
(CEST) was completed in Nov. 2010, requiring all hot
testing to be done at the point of equipment
manufacture in India.
 All hot testing was completed and the equipment is
currently in transit to the SUNY Cobleskill campus.
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No Cost Extension
 Installation of the prototype gasifier in the CEST is a
deliverable.
 Shipment of equipment from India was delayed until
the building was complete and available.
 Two no-cost extensions were requested to fund
installation and meet deliverables.
 The current request for a no-cost extension would
allow complete installation of the gasifier in the CEST
by Dec. 31, 2011.
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Commercial Cost
 This technology is ideally suited for 100 kW to 5 MW
of electrical generation capacity.
 The projected cost for engineering, permitting,
construction, and commissioning of a 1 MW waste to
combined heat and power facility is estimated at 7
million USD.
 A 1 MW facility converts about 15,500 tons of waste
annually into enough electrical energy to power 680
residential dwellings (85% utilization).
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Project Approach
1. Establish & commission innovative gasification system
2. Test the system – determine system efficiency
3. Adjust system, retest and recalculate efficiency
4. Completion of each task served as a go/no-go
milestone
5. Relocate system to campus upon completion of CEST
facility
6. Prepare for system scale-up
7. Maintain synchronization with DoD grants
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Technical Accomplishments
 Milestones -chronologically by accomplishment date
(Each milestone represented a “go/no go” decision)
1. Installation of gasifier at point of origin
2. Gasifier operation
3. Data analysis
4. System install on campus (anticipated)
08/11/09
12/31/10
02/28/11
12/31/11
 Project objectives

All objectives are met except on-campus installation
 Technical Accomplishments (most important)

Proved system will convert biowaste into bioenergy
 Bench Marks
1. Met 90% of project objectives since last report
2. Achieved all technical targets
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Project Status
% Complete
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Task 1 - Cold Testing, Calibration, Installation at SUNY
Task 2 - Operations Plan, Data Analysis Plan, Operations
Task 3 - Model for Ag Wastes, Scale Up Criteria, Model
Validation, Process Improvements
Complete
Incomplete
Task 4 - Institutional and Farm Models
Task 5 - Project Management
Final Reporting
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View Video of Bench Scale Gasifier to
be Installed at Cobleskill Campus
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Summary of Test Results
Average
Hay - 30% O2
% Target of
Efficiency
% Target of
Heating Value
Hay - Air
Cow Manure - Air
Wood - Air
0.0%
25.0%
50.0%
75.0%
100.0%
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Project Relevance
 Thermochemical Conversion Platform in section
3.2.2 of the Biomass Multi-Year Program Plan.
 Thermochemical Gasification Route
 Processes high moisture and high ash biomass with
minimal or no preparation.
 Operates on air, enriched air, or pure oxygen at
atmospheric pressure without catalysts.
 Effective and simple scrubbing method.
 Agricultural Residues Pathway
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Project Relevance
 Project Meets (see sections 3.2.2.3 and 3.2.2.4)
 WBS 3.1 – Feedstock Thermochemical Platform Interface
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3.1.1 Feedstock Variability
3.1.2 Processing Interface
 WBS 3.2 – Thermochemical Processing Core R&D
 3.2.1 Biomass gasification
 3.2.5 Syngas clean-up and conditioning
 3.2.6 Fuels Synthesis (Future)
 WBS 3.3 – Thermochemical Process Integration Core R&D


3.3.1 Thermochemical Processing Integration
3.3.2 Thermochemical Platform Analysis
 WBS 3.4 – Fundamentals and New Concepts.
 3.4.1 Advanced Thermochemical Processing
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Success Factors and Challenges
 Critical Success Factors
 Minimal feedstock preparation and management.
 Chemistry of gas is sufficient for synthesis into other
energy forms.
 Challenges
 Hot testing had to be completed in India to avoid
unreasonable delays.
 Results need to be validated in the US.
 Equipment installation on the SUNY Cobleskill campus
(currently in transit from India).
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Benefits
 Wastes can be simply converted to a clean energy
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form (gas, liquid, electrical, and heat).
Reduces the disposal of agricultural and municipal
wastes.
Any waste that is flammable can be used as a
feedstock.
Process produces a flammable gas, which can be for
heating and electrical generation, or synthesized into
a liquid fuel.
Gas is scrubbed prior to use, allowing for
combustion that is cleaner than natural gas.
The only byproduct from the process is ash.
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Expected Outcomes
 Numerous small waste to energy facilities can be
installed near the points of waste generation
 Reduces emissions from trucking.
 Reduces load on the grid (transmission losses, distributed
power, etc.)
 Electrical power is fed onto the grid, waste heat can be
used for space and water heating purposes.
 Syngas is rich in hydrogen and is easily separated for
use in support of a hydrogen economy.
 Syngas can be synthesized into liquid biofuels either by
chemical or biological pathways (various alcohols, DME,
Fischer-Tropsch).
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Commercial Viability
 Can be very profitable since a tipping fee is charged
to receive the waste.
 Suitable wastes (agricultural, cafeteria, municipal
solid, sludge, etc) are in ample supply and disposal
is costly.
 Income streams include tipping fees, gaseous fuels,
liquid fuels, electrical generation, and offsetting fossil
fuel usage by using waste heat.
 This technology is creditable since very little or no
feedstock preparation is required.
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1 MW Combined Heat and Power Generating
Facility on SUNY Cobleskill Campus
 1 MWe operating at 85% utilization will generate
7.45 million kW-hrs per year (54% of total campus
usage).
 Partial or complete heating of the campus is
possible, depending on the generating technology
used.
 Generating on-site and using waste heat offsets
emissions from large generating stations.
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Economics of 1 MWe CHP
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Electrical generation: 7450 MW-hr at 85% utilization
Electrical Savings: $335 K at $0.045 per kW-hr
Natural Gas Savings: $375 K at $7.53 per Dth
Operating Costs: ($930 K) at $125 per MW-hr
Tipping Fees for Wastes: $1,008 K at $65 per ton, 15,500
ton/year
 Net Income EBITDA: $788 K per year.
 Simple ROI: 8.9 years for $7 million USD plant cost.
 Environmental sustainability with minimal water usage or
disposal, 1.3 MW gross to net 1 MWe.
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Technology Transfer
New Curriculum
Title:
Degree:
Approval:
HEGIS Code:
Program code:
Environmental & Energy Technologies
Bachelor of Technology
NYS Education Department Aug 2010
0115
33972
Training Seminars - examples
 Distance Learning
 Short Courses
 One-day training
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Project Summary
 Relevance: Project aligns with DOE’s Biomass Multi

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
Year Program Plan.
Approach: Project aligns with Thermochemical
Platform Objectives, but there is more R&D to be done.
Accomplishments: Proved biowastes can be
converted to bioenergy with minimal feedstock
preparation.
Success factors: Deliverables were completed despite
the challenges of installation on the campus.
Run Tests: Successfully completed in India.
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Thank You
Douglas M. Goodale, PhD
[email protected]
Biowaste to Bioenergy through Gasification
Principal Investigator
SUNY Cobleskill
Cobleskill, New York 12043
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