Transcript THE SHELL HYDROTHERMAL UPGRADING PROCESS ( HTU ) …

SUCCESSFULLY USING BIOMASS TO
HARNESS RENEWABLE ENERGY IN AN
EFFICIENT AND COST-EFFECTIVE WAY
J.E. Naber and F. Goudriaan
(BIOFUEL BV)
HTU 2000
BIOFUEL B.V.
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PERSPECTIVES FOR ENERGY FROM BIOMASS
1990
2040
EJ/a
350
1000
FOSSIL FUELS,
„
255
480
RENEWABLES
„
80
>400
HYDROPOWER
„
20
50
WIND
„
-
70
SOLAR
„
-
130
BIOMASS
„
60
>200
ENERGY DEMAND,
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POTENTIAL FOR ENERGY FROM BIOMASS
FROM POTENTIALLY AVAILABLE
LAND AREA @ 15 TON(DB)/HA.YR
9
(ENERGY FARMING ON 10 HA)
BIOMASS RESIDUES
(FORESTRY, WHEAT, RICE,
SUGAR CANE, CORN, ETC.
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250 EJ/YR
70 EJ/YR
HISTORY OF HTU

1982 - 1988
Process R&D, Shell Laboratory, Amsterdam
1994 - 1997
Technical-Economic evaluation of HTU technology
Nov 1997 - July 2000:
PROCESS DEVELOPMENT PROJECT EET-1
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WHAT IS HTU ?
Conditions:
300 - 350 o C; 120 - 180 bar
reaction time 5 - 20 minutes
liquid water present
Feedstocks:
industrial
All types of biomass, domestic, agricultural and
residues, wood
Also wet feedstocks, no drying required
Chemistry:
Oxygen removed as Carbon Dioxide
Products
45 Biocrude (%w on feedstock, dry basis)
25 Gas (> 90% CO2)
20 H2O
10 dissolved organics (e.g., acetic acid, methanol)
Thermal efficiency: 70 - 90 %
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HTU
Biocrude

Product
Heavy organic liquid
Not miscible with water
Oxygen content 10 - 18 %w
LHV 30 -35 MJ/kg
Applications
Biocrude as such: (co)combustion in coal- and oil- fired power stations
After upgrading (hydrogenation): premium diesel fuel; kerosene
luboil base stock
chemicals feedstock (cracker)
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HTU PRODUCT FLEXIBILITY
• Direct combustion as a liquid
(replacement of fossil fuels)
• Combustion as a solid fuel
(cofiring with coal)
• Emulsified fuel (type “Orimulsion”)
• Replacement of charcoal
• Upgraded product
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HTU

PROCESS BLOCK SCHEME
air
Flue gas
Cat. DeNOx
External
Fuel
Furnace
Gas turbine, CC
Feedstock
Pretreatment
electr.
Gas
Pump
system
HEATING
SECTION
HTU
REACTOR
Light biocrude
PRODUCT
SEPARATION
To Upgrading
(HDO)
Hvy biocrude
Waste
water
Anaerobic
digestion
electricity
demineral.
power station
Biogas
CHP
concentrated
minerals sol’n
Clean
water
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electr.
electr.,
heat
Block
Block
scheme
scheme
of of
HTU
HTU
pilot
pilot
pant
plant
Biomass
CO2
10-20 kg/hr (db)
330 °C
Condensor
180 bar
Gas /liquid
separator
High
pressure
pump
Preheater/ Reactor 2
Reactor 1
gases
Cooler
1 bar
Cooler
Pressure reducer
biocrude/
water
collection
storage
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storage
THERMAL EFFICIENCY
Definition:
 th
=
(LHV of biocrude output)
* 100 %
(LHV of feed) + (LHV from external fuel)
For present process design:
 th =
55.62
72.98 + 1.3
* 100% = 74.9 %
(Theoretical maximum for this case is 78.6 %)
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Upgrading of biocrude by HDO
• Principle of catalytic Hydrodeoxygenation has been
demonstrated
• Upgrading cost compensated by higher product value
• Diesel fraction has excellent ignition properties
• Potential applications:
• Transport fuel
•
•
•
•
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Kerosine
Fuel in high-efficient gas turbine
Feedstock for chemicals (via ethylene cracker)
Etc. etc.
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HDO process scheme
NH3, H2S
H2O
Recycle gas
compressor
C1-C4 gas
To refininery
pool
Hydrogen
Naphtha
Biocrude
(fromHTU)
HDO
reactor
system
Separator
section
electricity
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Fractionator
Kerosine
Air transport
Gas oil
Diesel fuel for
Road transport
>370oC
residue
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Lubricating oil;
chemical feedstock
COST OF BIOCRUDE AND COST OF AVOIDING ONE TON OF CO2 ;
EFFECT OF FEEDSTOCK PRICE
rest products
energy farming
7
+ 60
6
+ 40
5
First Plant
+ 20
4
Future plant
3
0
2
Coal (2 $/GJ) / Crude Oil (12 $/bbl) Replacement
- 20
1
0
-1
0
1
Feedstock price, $/GJ
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2
3
$ per ton CO2 avoided
Biocrude cost, $/GJ
8
PRODUCTION OF TRANSPORTATION FUEL
Cost of HTU plus HydroDeOxygenation
Total Product Cost, $/GJ
10
rest products
energy farming
8
6
Premium Diesel ex crude oil of 25 $/bbl
4
First Plant
Future plant
2
0
-2
-1
0
1
2
Biomass HTU Feedstock Price, $/GJ
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3

HTU
R&D PROGRAM
GO / NO GO ITEMS
• Pressurizing
• Continuous integrated operation of pilot plant
CRITICAL ITEMS
• Heating - up
• Oil/water separation
• Product properties / applications
• Effluent treatment
DATA FOR DESIGN
• Phase equilibria
• Physical properties, esp. at reactor/separator conditions
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Process Development
Work in autoclaves,
• 10 ml, 1 liter, 2 liter
• Testing of feedstocks and process conditions
Continuous pilot plant
• capacity 20 kg/hour (dry basis)
• commissioning 1 July 1999
• first product prepared: 24 November 1999
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Development project EET-1
Mission:
Design data for demonstration plant,
validated in continuous pilot plant
Time period:
1 November 1997 - 31 July 2000
Cost and funding:
Subsidy
3 M$
(Dutch Min. of Economic Affairs, EET programme)
Stork E&C (Now Jacobs)
Shell Nederland
TNO, BTG, Biofuel
Total
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1
1
1
6M$
PROJECT ACTIVITIES
PROJECT ACTIVITIES
1. Autoclave experiments
2. Reactor Engineering
3. Waste water treatment
4. Process Modeling
5. Feedstock characterisation
6. Feed introduction equipment
7. Pilot plant design & contruction 8. Pilot plant operation
9. Product research
10. Materials selection
11. Commercial design & cost
12. Operational project support
13. Business development
14. Chemical analyses
15. Project management & coordination -
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TNO
BTG
TNO
TNO (Tech Univ Delft)
BTG
Biofuel
TNO (Contractor)
TNO
BTG
Biofuel (Contractor)
Jacobs Engineering Nederland
Biofuel
Biofuel
TNO
Biofuel
PROCESS DESIGN CASE STUDY
Basic process design by Jacobs Engineering Nederland

Process scheme, Mass & Heat Balances: ASPEN PLUS flowsheeter
All disciplines involved, incl. layout
Case study:
Feedstock:
Intake Capacity:
Sugar beet pulp, 22 %w dry matter
130,000 tonnes/year (dry basis)
Focus on heat integration, thermal efficiency
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RESULTS OF EET-1 PROJECT
• Pilot plant construction completed
• Pilot plant operation:
- process principles verified
- most initial problems solved
- 200 kg biocrude produced
• Pressurizing of feedstock successfully proven with commercial prototype pump
• Data on thermodynamics and phase equilibria obtained; model operational
• Waste water treatment routes defined
• Product: various applications explored
• Process design and cost estimation completed
• Fundamental research to start: NWO – Japan project.
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EET-2 PROJECT:
FINAL PROCESS DEVELOPMENT
Mission:
Extended operation of pilot plant with commercial feeds
Product application development
Time period:
2002 – 2005
Cost and funding:
Subsidy:
3.6 MFl
Dutch Government, EET programme
TNO + BTG + Biofuel:
St. Shell Research
To be decided
Total project cost
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1.2
0.5
1.9
7.2 MFl
COMMERCIAL HTU

DEMONSTRATION PLANT (1)
Study by Jacobs Engineering Nederland, 2000
Location:
Large Waste Processing Company, The Netherlands
Feedstock: Organic Wet Fraction (ONF) of domestic waste
Capacity: 81,300 tonnes of ONF per year
62,500 tonnes of washed ONF+ per year
(= 25,000 tonnes per year dry basis)
Production: 14,470 t/yr Biocrude (incl ash) = 10,630 t/yr DAF
Combustion in power plant gives 5.5 MWe
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COMMERCIAL HTU

DEMONSTRATION PLANT (2)
BASIS for ECONOMICS
Capital:
Washing plant
13 M Nfl
HTU plant
37
Total capital50 M Nfl
Availability: year 1:
40 % (of 8000 h/yr)
year 2:
60 %
year 3:
80 %
years 4-15:
100 %
Maintenance and overhead: 4% and 1% of capital/yr
Operation: Worst case
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COMMERCIAL HTU

DEMONSTRATION PLANT (3)
Total capital required
50
M Nfl
CO2 reduction plan:
EWAB:
Net capital:
minus
minus
7.5 M Nfl
3.0
39.5 M Nfl
Effect of VAMIL
Effect of EIA
Net Investment
minus
minus
13.8 M Nfl
5.5 M Nfl
20.2 M Nfl
TOK: Loan of 20.2 Mfl @ 7% interest, repayment in 10 years
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COMMERCIAL HTU

DEMONSTRATION PLANT (4)
NPV, M Nfl
License fee
TOK (techn ontwikkelings krediet)
Operating cost washing plant
Operating cost HTU plant
Biocrude sales
(p.m.)
(21.6)
(24.8)
(30.2)
10.4
Fee for ONF
Total project NPV
80.7
14.5
(= 100 Nfl/ton ONF)
NPV=0 if ONF fee= 77 Nfl/ton
Effect of REB buy-back
NPV incl REB
32.2
46.7
NPV=0 if ONF fee= 39 Nfl/ton
over first 10 years
75% of equiv. coal price
NPV = Net present value of project over 15 years, discounted
cash flow with 7% interest rate
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Technology Development Path
( S - curve)
Fully
Commercial
Commercial
Prototype
Next S- curve
Process
Development
Techn./Econ.
Feasibility
Scientific Base
/ Explanatory
Process
Scouting
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Improved
scientific base
NEXT S - CURVE
Focussed fundamental studies on principles
• Chemical and physical characteristics of biomass feedstocks
in relation to hydrothermal conversion
(Wageningen Agricultural University)
• Organic chenmistry: Reaction paths and kinetics with
representative components and conditions
(Delft University of Technology)
• Reaction engineering models/ complex kinetics
(Twente University)
• Thermodynamics
(Delft University of Technology)
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HTU-related work in Japan
NIRE:
Dr. Shin-ya Yokoyama
Ms. Dr. Tomoko Ogi
Publications since 1985
Upgrading of biomass residues and sewage sludge
For sewage sludge: continuous bench scale unit, 15 kg/h, ca. 1988
process development unit, 5 tons/day
Cooperation with:
Japan Organo Co., Ltd,
Dr. Akira Suzuki; contacts since 1991
Ebara corp.
Institute for cellulose Industry, Bandung Indonesia, publication 1998
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NWO – Japan Project
NWO = Dutch Government Agency for Fundamental Scientific Research
Commemoration of 400 years contacts Japan – the Netherlands
Multimillion Treaty on fundamental research on renewable energy.
Netherlands:
4 out of 20 projects are on HTU fundamentals
Japan:
Involvement of NIRE
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AVAILABILITY OF ORGANIC RESIDUES IN THE
NETHERLANDS
Cumulative
kton/year (db)
Gasification,
Pyrolysis
HTU
5000
energy farming
(NL)
4000
straw
potato leaves
3000
beet leaves
wood cuttings
verge grass
2000
houshold waste
1000
food ind. waste
0
wood waste
-6
-4
-2
0
2
4
Price ( $/GJ )
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6
HTU

OPPORTUNITIES
1 - The Netherlands
• Industrial organic waste and residues
• Organic household waste
• Poultry litter
• Manure
1.8 Million tons/a (db)
1.1 ,,
0.5 ,,
2.0 ,,
(combination with anaerobic digestion)
TOTAL
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5.4 Million tons/a (db)
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HTU  OPPORTUNITIES
2 - Europe
• Agricultural / Industrial Residues
200 Million tons/a (db)
(Source: Eurec agency, 1996)
• Short-term niches for HTU:
- Olive Oil Industry
- Organic household waste
(from centralized waste separation)
3 - 5 Million tons/a (db)
26 ktons/a (db) per
250,000 inhabitants
- Residues from sugar and beer production.
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HTU  OPPORTUNITIES
3 - World
• Agricultural and industrial residues
(Source: “Renewable Energy; sources for
fuels and electricity”, 1993)
• Future organic household waste
(own tentative estimate)
• Short-term niches for HTU:
- Organic household waste
- Bagasse (> 100 Mtons/a)
- Forestry residues from existing plantations
- Coir dust
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4,000 Million tons/a (db)
(approx. 70 EJ/a)
800 Million tons/a (db)