Transcript Berkshire Energy Laboratory

Status Update
November 21, 2008
Thomas Horgan
Outline
 Residential Scale Methanol Fuel Synthesis
 Advanced Research Topics
 Biomass Fuel Synthesis by Ionic Liquids
 Syngas by Catalytic Gasification
 Next Steps
 Other Topics
Residential Liquid Fuel Synthesis
 Classic Methanol Production (Wood Alcohol)
Steam partially condense to Turpentine (0.3 kg/Tonne)
150C, 7.5 Atm, 1h
3 to 5 days
Sawdust
H2SO4
Digester
Pressing
Steam
H2O
Liquor
Yeast
Boiler
Sawdust
Fermentation
100 Proof methanol
57.1% by Vol
73 liter/tonne dry wood
Residential Liquid Fuel Synthesis
 Industrial Methanol Production
Steam
Natural Gas
Desulph
Coal or Biomass
SMR
Gasifier
Cleaning
Steam
2H2 + CO CH3OH
50 Atm, 270C
Copper Oxide Catalyst
H = -92 kJ/mol
O2, Air
Syngas (H2, CO (CO2, N2))
Compressor
Purge
Gas
Methanol
Convertor
Syngas Recycle Loop
Cooling/
Distillation
methanol
Residential Liquid Fuel Synthesis
 Small Scale Syngas Based MeOH System
 Assume Capacity: 200 lbs wood per day (1 cord ~ 4,000
lbs), 10 GPD MeOH
 Downdraft Gasifier
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Outside dimensions (w/ hopper): 4ft h x 1.5ft d
Syngas production rate: ~ 35 ft3/lb of 15% wood
Max Capacity: ~700 lbs wood/day - 1000 ft3/h
Outlet Temp: 50/75C after cyclone/filter
Acceptable for MeOH synthesis?
$2300 Assembled
$1400 Not Assm
http://www.allpowerlabs.org
Residential Liquid Fuel Synthesis
 Small Scale Syngas Based MeOH System
 Compressor/Raise Temp
 MeOH Converter
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CO2+CO+5H22CH3OH+H2O+Heat
Cu-Zn, 50 Atm, 270C
Issues with Heat Removal
25% per pass efficiency (multi pass)
Adiabatic vs Isothermal Reactors
Needs to be cooled, flashed
Residential scale reactor options?
Residential Liquid Fuel Synthesis
 Small Scale Syngas Based MeOH System
 Distillation
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Crude Methanol contains dissolved CO, CO2, H2, N2 and
volatile organics (acetone, ethers, esters)
May be acceptable for some engines/turbines ?
Distilled for chemical grade
Need to deal with off gasses
Residential Liquid Fuel Synthesis
 Small Scale Syngas Based MeOH System
 Methanol Gas Generator
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MeOH acceptable gasoline substitute
 poor cold starts, better efficiency/heat removal
Lower volumetric heating value
Seal wear
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Pramac S7500 Deluxe Electric Start Generator With Honda Gx390 Engine ,
6.1 kW
$2,000, Home Depot
31 x 22 x 25 inches, 200 lbs
8 gal tank, 10 hrs on gasoline
5 hrs on methanol
Residential Liquid Fuel Synthesis
 Community Power Corp - Littleton, Co
 Small/Medium Scale Wood Generators
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Commercial 25kW, 75kW and 100 kW systems available $225 to $400k.
Custom 5kW system ~ $150k
2 lbs of woodchips per kWh
Footprint for 25kW system: 8’ x 8’ x 20’
 Small/Medium Scale Prototype FT System (Farm)
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Fully Operational. Press release in two weeks
50 gal transportation diesel per ton woodchips
Gasifier Footprint: 8’ x 8’ x 40’
FT Module Footprint: 8’ x 8’ x 20’
Biomass Fuel Synthesis By Ionic Liquids
 Dissolution of biomass: Potential first step to many
new, low energy, homogeneous conversion routes
 Dimitris Argyropoulos, NC State
 Four patent applications
 Has one letter of intent (hedging) . Company specifically interested in
catalytic cracking
 Actively seeking investment partner (wants to develop, not publish)
 $150k for 4 years, $200k for 3 years
Biomass Fuel Synthesis By Ionic Liquids
 Ionic Liquids
 Air and moisture stable salts – electrically conductive, low vapor pressure,
liquid at room temp
 Composed of 100% ions - large organic cat ions (~1018), small inorganic
anions (much less)
 Applications: Stable solvents, acid scavenging, cellulose processing,
petrochemical synthesis, transport medium, many others
 Dissolve wood & other organics (0.2 to 2mm, < 150C, < 30min)
 Safety: Low vapor pressure and highly recyclable. Some are combustible.
Many are toxic if released to the environment.
Biomass Fuel Synthesis By Ionic Liquids
 Argyropoulos Patents
 Low Energy Pyrolysis of Wood – WO 2008/098036 A1
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IL Pyrolysis: Wood dissolved in IL, 190/200C (20 min), 10% more tar, 12%
less char , 10% higher/more selective yield of distillates than Fast Pyrolysis
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Fast Pyrolysis: Pretreated w/ organic solvents, 425/500C (2s), tar, char, liquids
(200+ intermediates)
 Low Energy Glucose from Wood for BioEthanol– US 2008/053139
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IL dissolved wood is easily hydrolyzed by enzymes to release Glucose for
production of bioethanol
 Polymers and Composites from Dissolved Wood – US 2008/053151
 IL dissolved wood can be blended with co-polymers, polymers and functional
additives to form eco-friendly (degradable) composites
Biomass Fuel Synthesis By Ionic Liquids
 Potential for Transportation Fuel Synthesis
 IL Pyrolysis produces a much narrower range of hydrocarbons with
higher potential for catalytic cracking to trans fuels
 Sludge dissolution and homogenous processing to fuels
 Catalytic Gasification of Dissolved Wood (Syngas)
 Other undiscovered routes to aliphatics/aromatics
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Petrochina – Gasoline by alkylation of C4 olefins with iso-butane in ionic
liquids
Syngas By Catalytic Gasification
 Syngas Methods
 Noncatalytic Supercritical: (450/600C, 4000/6000 PSIG)
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Hi Cap Cost, Limited Biomass testing
 Low Temp Catalytic (225/265C, 400/800 PSIG, Pt or Ni)
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Simple organics, not tried on biomass
 Fuel Gas Methods
 Catalytic Hydrothermal (350C, 3000PSIG, Ru or Ni)
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Good carbon conversion, biomass & sludge
 Supercritical Carbon Catalyzed (600C, 3700PSIG)
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Good carbon conversion, coke, ash, plugging
Syngas By Catalytic Gasification
 PNNL Project Concepts
 Low Energy Catalytic Biomass Syngas Gasification
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Investigate routes with lower temps and pressures. Preprocessing.
 Low Energy Catalytic Sludge Syngas Gasification
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Investigate routes with lower temps and pressures. Preprocessing.
 Catalytic Fuel Gas Gasification w/ Reforming
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Steam vs. Autothermal, Modeling for feasibility (efficiency/cost)
 Direct Fischer Tropsch Synthesis to Trans Fuels
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Design and control studies to narrow product range
Next Steps
 Note: Recommend work w/ Argyropoulos on Ionic Liquids, not Elliot
(change memo)
 Plant visits and tours
 PNNL – discuss catalytic syngas gasification work. See labs, processes, etc.
 NREL – discuss lab capabilities/collaboration opportunities?
 Community Power Corp – 10 minutes from NREL. We’re invited.
 NC State – More detailed understanding of practical use of ionic liquids
 Residential Scale Methanol Synthesizer
 Develop detailed drawings, BOM, etc (model in Aspen?)
 Source other gasifiers
 Understand issues with crude methanol/distillation
 Source or design small scale MeOH converter
 Others…
Other Topics
Economics & Energy Analysis
 Energy
Economics & Energy Analysis
 Economics
Huber Process
 Professor George Huber – Umass, Amherst
 Has developed catalytic pyrolysis process for ‘Green Gasoline’
 As of last e-mail, has already licensed technology (unclear)
 Have not connected by phone
 Green Gasoline Process
 Converts powdered cellulose at 600C, over zeolite catalyst to aromatic mix
 Not really a gasoline (actual gasoline is less than 25% aromatics)
 Useful as a blend
 Not yet tested on actual cellulose/biomass
Methanol to Gasoline (Mobil Process)
 Process Flow Sheet
320C
Alumina
400/420C
Light HC, CO2, H2
Gasification Technologies
 Updraft Gasifier
 Advantages
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Simple, low cost process
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Able to handle biomass with a high moisture and high inorganic content (e.g.,municipal solid waste)
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Proven technology
 Disadvantages
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Syngas contains 10-20% tar by weight, requiring extensive syngas cleanupbefore engine, turbine or
synthesis applications
 Downdraft Gasifier
 Advantages
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Up to 99.9% of the tar formed is consumed, requiring minimal or no tar cleanup
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Minerals remain with the char/ash, reducing the need for a cyclone
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Proven, simple and low cost process
 Disadvantages
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Requires feed drying to a low moisture content (<20%)
Syngas exiting the reactor is at high temperature, requiring a secondary heat recovery system
4-7% of the carbon remains unconverted
Gasification Technologies
 Bubbling Fluidized bed
 Advantages
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Yields a uniform product gas
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Exhibits a nearly uniform temperature distribution throughout the reactor
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Able to accept a wide range of fuel particle sizes, including fines
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Provides high rates of heat transfer between inert material, fuel and gas
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High conversion possible with low tar and unconverted carbon
 Disadvantages
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Large bubble size may result in gas bypass through the bed
 Circulating Fluidized bed
 Advantages
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Suitable for rapid reactions
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High heat transport rates possible due to high heat capacity of bed material
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High conversion rates possible with low tar and unconverted carbon
 Disadvantages
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Temperature gradients occur in direction of solid flow
Size of fuel particles determine minimum transport velocity; high velocities may result in
equipment erosion
Heat exchange less efficient than bubbling fluidized-bed