Transcript Sewage Sludge to Fuel - Adirondack Trout & Salmon

Integrated Home Energy from
Waste & Biomass
Tom Horgan and Noa Simons
February 6, 2009
Outline
• Executive Summary
• Introduction
• Research Summary
• Integrated Home Energy System (IHES)
• Wrap Up
Executive Summary
• We propose to build and market an integrated
home energy system.
– Multi-fuel (Biomass, MSW, Sewage), “Clean Gasification” based
– Multiple energy conversion options (CHP, Gas Gen, LF, FC) with
ability to run from NG/LPG if available
• Rationale:
– Lean (saves $), Green (recycle), Mean (self sufficiency)
– Clean Gasification - Enabling Technology for BTLTF
(Biomass To Liquid Transportation Fuel)
– Direct competition with crude products unrealistic
Introduction
• Preconception
– Alternative energy field was exploding with oil prices
reaching $150/barrel in 2008
– Modern science applied to BLTTF has yielded many
new concepts ready for advancement &
commercialization
– New technologies could make old concepts more
viable
• Expectation
– Research literature, talk to scientists, down-select
concepts, develop business plan and commercialize
Introduction
• Reality
– Majority of research dollars to bioethanol and bio“diesel”
– Liquefaction, pyrolysis - low grade fuels for heating
• Low fraction of alkanes, upgrading methods in research phase
– FT synthesis only proven route to diesel
• Highly Capital Intensive (pure syngas), nonselective
– Methanol is doable – trouble as a transportation fuel
– MTG considered failed technology (durene)
– Gasification technology major obstacle for all three
• Inefficient (drying), expensive (multistep cleaning)
– Energy density of green biomass ¼ of crude (out of the
ground)
– Electricity is more valuable than liquid fuels
Introduction
• Distributed Generation
– Electricity is the most valuable form of energy
– Electricity generation only ~33% efficient nationwide
(line losses)
– Household waste contains 30% of total energy used
– On site generation saves money, is green and enables
sense of self sufficiency
• Critical Technology
– Core technology development for distributed generation
is same for all biomass conversion processes
(gasification, cleaning, drying)
• Integrated Home Energy from Biomass & Waste
The State of Energy
• Market Opportunity (2008 Data)
http://www.eia.doe.gov/
The State of Energy
• Usage & Losses
https://eed.llnl.gov/flow/images/LLNL_Energy_Chart300.jpg
The State of Energy
• World Oil Reserves
• Estimates on proven reserves are historically low (reserve
growth) and have been “running out” since the 30’s
• Unproven (P50) and untapped reserves available (arctic)
• Prices may not rise a quickly as predicted
http://en.wikipedia.org/wiki/Oil_reserves
The State of Energy
1% of All Biomass
On Earth
(~ 50 cubic miles
proven reserves as
of 2008)
Note: All of the
dewatered sludge
in NYS contains
enough energy for
~ 30 gas stations
http://spectrum.ieee.org/jan07/4820
The State of Energy
• Comparing Fossil & Biomass Fuel Conversion
– Fossil Fuel: Millions of years worth of algae (crude) &
biomass (coal) cooked and condensed by the earth
– Biofuels: Wood, sludge, farm waste, etc that needs to
be dried and converted
• Crude Oil (raw) – 42.7 MJ/kg
– Gasoline – Diesel -
43.5 MJ/kg (~80%)
42.8 MJ/kg (~85%)
• Biomass/Solids – 6 to 20 MJ/kg
– MTG Gasoline – FT Diesel -
43.5 MJ/kg (< 50%)
42.8 MJ/kg (< 60%)
• 5 to 15x more input energy for BTLTF
http://www.eia.doe.gov/
The State of Energy
• Market Volatility
http://www.eia.doe.gov/
Research Summary
• Research efforts…
– Focused on evaluation of BTLTF technologies
such as Fischer Tropsch, Methanol, MTG
– Uncovered issues with gasification that
prohibited commercialization
– Shifted to catalytic gasification and ionic liquids
as means of addressing issues
– Settled on distributed generation as the most
promising route to profitability in biomass
conversion
Research Summary
• Conclusions
– Competing with crude on transportation fuels is
a very tall order
– Electricity has higher value and is easier to
achieve w/ biomass
– Gasification is core technology for both BTLTF
and electricity generation
– Distributed generation competes with electricity
on site using waste & wood (or NG)
– Integrated Home Energy System (IHES)
Research Summary
• Future & Concurrent Research
– Robust Gasification
• Gasification drawbacks are major impediment to
commercialization
• Conversion processes all require clean syngas
(particulate and tar)
• Conversion processes require different H2/CO ratio
• Microchannel FT synthesis requires pure H2/CO
(free of N2 and CO)
• Robust gasifier concept incorporates advanced
cleaning, CO2/N2 filtration and shift catalyst for
control of H2/CO ratio
• Solution for all gasification processes
Integrated Home Energy
• Household Mass Balance (Family of 4)
Food
Water
Paper
Plastics
MSW
Water
Sewage
Average Usage: ~320 MJ/day
Waste: ~ 100 MJ/day (~30%)
290 GPD
0.1% Solids
~ 7 MJ/day
8 Kg/day
~91 MJ/day
Integrated Home Energy
• Concept (micro CHP)
Wood
Chips
Syngas
Feed Prep
MSW
Dewater
WGS
Dryer
N2/CO2
Removal
Gasifier
Cleaning/
Scrubbing
Water
Sewage
Air
Slag
Integrated Home Energy
• IHES Concept
– IHES is micro CHP Unit that supplies heat and
power to residence
– Gasifier accepts MSW and Biomass
feedstocks
– NG/LPG can also fuel generator and be used
for start up energy/emergency back up
– Net metering provides opportunity for net
positive gain
Integrated Home Energy
• Business Case (Avg Household, 4 people)
–
–
–
–
Usage: 320 MJ/day 60% Electric, 40% Thermal
Annual Cost: $1800
Waste = 30% of Total Usage (92% MSW, 8% Sewage)
Assume 60% gasifier efficiency, 30% electric and 70%
thermal recovery
• Gasify all MSW and 50kg wood per day
• All electricity supplied with heat in excess
• Wood cost = ~ $330 annually
– Annual Savings = $1800 - $330 = $1470
– NG could supplement in absence of wood
http://www.eia.doe.gov/
Integrated Home Energy
• IHES Component Development
– Feed preparation/pretreatment
• Chipper/shredder must be able to prepare both
wood and MSW
• Grind/mixing for uniform gasification
– Dewatering
• Advanced dewatering for on site sewage
treatment (much later development)
– Drying
• Recover internal heat to pre-dry feed for
improved efficiency
Integrated Home Energy
• IHES Component Development
– Gasifier
• Must supply heat & syngas from a variety of waste
and biomass feedstocks
– Gas Cleaning
• Cyclone, cold water quench followed by sand filter.
Research advanced methods.
• CO2/N2 membrane filtration (much later
development for microchannel FT)
– Water Gas Shift
• Design and implement WGS for H2/CO control
Integrated Home Energy
• IHES Component Development
– Energy Storage
• Battery module for start up.
• NG functionality can also support start up and back
up capability
– Controls & Software
• Control methods for WGS (control steam on outlet
temp)
• Control methods for heat rejection
• Control methods for load following (much later
development)
Integrated Home Energy
• Phased Development Plan
– Phase 1: Proof of Concept with Advanced Gasification
Development (6 months)
• Assemble and test a simple downdraft gasifier/gas
generator system on wood (Zanoni)
– Downselect and purchase gasifier, gas generator, chipper, etc
– Research/validate wood gasification (mc, wood type, etc).
– Assemble/test and develop heat rejection, gas cleaning
• Advanced Gasifier Development (Horgan)
– Test & Development, MSW gasification methods
– Evaluate methods of feed prep, required temperatures, etc
– Research/development/test CHP functionality
Integrated Home Energy
• Phased Development Plan
– Phase 1: Cost Estimates*
• Hardware
–
–
–
–
Purchase 2 gasifiers, NG generator (~ $10 to 15K)
Misc tools/test equipment ($1 to $3K)
One Computer - Zanoni ($1K)
Additional Hardware for BOP ($3 to 5K)
• Salaries: 2 x $90K * 0.5 = $90K
• Rental: $1 to $1.5K /per month = $6 to $9K
• Total: ~ $120,000
* Should have Zanoni do this right
Integrated Home Energy
• Phased Development Plan
– Phase 2: Prototype Demonstration with More Gasification
Development (6 months)
• Integrate advanced gasification, generator and CHP
loop into homogeneous unit (Zanoni)
– Validate CHP functionality/software & controls
– Develop detail drawings, design system layout & enclosure
– Assemble and test prototypes
• Advanced Gasifier Development (Horgan)
– Test & Development of integrated shift for H2/CO control
– Research/development of membrane CO2/N2 removal
Integrated Home Energy
• Phased Development Plan
– Phase 2: Cost Estimate
• Hardware:
– Custom designed gasifier & system components ($100 to
$150K)
– NG Generator ($3K)
– Shift reactor, software & controls ($15K)
• Software: Solid Works ($10K)
• Salaries: 2 x $90K * 0.5 = $90K
• Rental: $1 to $1.5K /per month = $6 to $9K
• Total: ~ $235/285K
Integrated Home Energy
• Intellectual Property
– Multifuel, gasification based CHP system for
residential use
– Robust Gasifier: multi-fuel, with H2/CO control
and advanced cleaning technology
• Patents
– Multiple patents for multi-fuel gasifier with
specific processing methods
– None found for IHES system as conceived
Integrated Home Energy
• Competition
– No direct competition in Multi-fuel, gasification
based residential scale systems
– Community Power Corp – Wood fueled
systems for farms/light industrial
– Main competition Micro CHP NG Systems
• Marathon Engine Systems: NG Micro CHP for hot
water systems
• Freewatt: Forced hot air w/ 1.2 kW Honda
Generator – heat following
http://www.marathonengine.com
Conclusions
• Integrated home energy system is
marketable technology (< $10K in 5 years)
• Gasification development supports future,
large scale work
• Need a lab and team to search the biomass
research database
Backup Slides
The State of Energy
• Fuel Value
http://www.eia.doe.gov/
Research Summary
• Liquefaction & Pyrolysis
– Do not synthesize transportation grade fuel
without upgrading (undeveloped)
– Pyrolysis oils are corrosive
– Biopetrol model is liquefaction of sludge to fuel
oil/burn on site – business plan claims 1yr ROI
– Dynamotive works with multiple customers on
retrofitted applications (bigger/stainless steel
pumps, motors etc)
– Storrs process (describe & why shut down)
Research Summary
• Fischer Tropsch Synthesis
– Gasification
– Synthesis
– Upgrading
Research Summary
• Fischer Tropsch Synthesis– Gasification – covered as a separate topic
– FT Synthesis Reaction Chemistry
Research Summary
• Fischer Tropsch Synthesis– Product Distribution
•Low Temp FT
200/240C
Cobalt
waxes
•Hi Temp FT
300/350C
Iron
liquids
Research Summary
• Fischer Tropsch Synthesis– Reactor Design Types
Research Summary
• Fischer Tropsch Synthesis– Chain growth a function of temp, pressure, catalyst
type & condition, reactor design
– Exothermic reactions lead to poor temp control and
wide distributions
– Slurry reactors are best but suboptimal
– Microchannel reactors may play but still new (Velocys)
– The more pure the syngas the better (even for CO2
and N2)
– Dilute syngas leads to large reactors (higher cost)
Research Summary
• Methanol Synthesis
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
Cooling/
Distillation
Methanol
Syngas Recycle Loop
MTG Process
Research Summary
• Methanol Synthesis
– Commercial Production mainly from NG (coal)
– Max Thermal Efficiency ~65%
• Single pass 25%, Exothermic, Thermo constraints
http://bioweb.sungrant.org/Technical/Bioproducts/Bioproducts+from+Syngas/Methanol/Default.htm
Research Summary
• Methanol Synthesis
– Methanol Demand
• 37%  formaldehyde (resins/glues for particle board and ply wood)
• 21%  MTBE (gasoline additive that reduces exhaust emissions)
• 14%  acetic acid (chemicals for adhesives, coatings and textiles)
– Used directly as a fuel…
•
•
•
•
•
Burns cleaner than gasoline (Higher Octane)
Corrosive to engine parts, gaskets, etc
Slower burning (advance ignition time)
Cold starting an issue (lower vapor pressure)
Absorbs water
Research Summary
• Methanol to Gasoline
2CH3OH CH3OCH3 + H2O
320C Alumina
CH3OCH3  H2O + C2 – C5, alkenes,
cycloalkanes, aromatics
400/420C Zeolite
Light HC, CO2, H2
Research Summary
• Methanol to Gasoline
– Product Composition
– The aromatic portion is at the high end of the
gasoline spec (6/29%)
– Aromatics are about 20% Durene – low melting
point (icing). Separation is expensive.
– Actual efficiency 44% (Hamiton).
Research Summary
• Gasification
– First step in FT, methanol, MTG, FC, generator
– Biomass is heated under low oxygen
conditions (Atmospheric, > 600C)
– Steam sometimes added
– Volatile material driven of leaving char, steam
and tars
– Char reacts with air and steam to form syngas
(H2, CO, others)
Research Summary
• Gasification Reactions
Research Summary
• Gasification Reactors – Small Scale
– Downdraft Gasifier
•
•
•
•
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 (320 MJ/h)
Outlet Temp: 50/75C after cyclone/filter
$2300 Assembled
$1400 Not Assembled
http://www.allpowerlabs.org
Research Summary
• Gasification - Issues
– Gasification rated primary barrier to commercialization
of BTLTF System
• Very pure syngas required (essentially H2/CO)
– Systems diluted with N2, CO2 lead to large reactors
– Substantial Cleaning & Scrubbing required
– Biomass variability leads to syngas variability
• Holy Grail: Robust Gasification
– Gasification System that receives ANY carbonaceous
feedstock and returns pure syngas with tunable H2/CO
ratio.
Research Summary
• Gasification Reactors - Industrial
Research Summary
• Economic/Energy Comparison
Research Summary
• Economic/Energy Comparison
Research Summary
• 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.
Research Summary
• 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.
Research Summary
• Argyropoulos Patents
– Low Energy Pyrolysis of Wood – WO 2008/098036 A1
• 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
– Fast Pyrolysis: Pretreated w/ organic solvents, 425/500C (2s), tar, char,
liquids (200+ intermediates)
– Low Energy Glucose from Wood for BioEthanol– US 2008/053139
• 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
Research Summary
• 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
• Petrochina – Gasoline by alkylation of C4 olefins with iso-butane in
ionic liquids
Research Summary
• Catalytic Gasification
– Project Concepts
• Low Energy Catalytic Biomass Syngas Gasification
– Investigate routes with lower temps and pressures. Preprocessing.
• Low Energy Catalytic Sludge Syngas Gasification
– Investigate routes with lower temps and pressures. Preprocessing.
• Catalytic Fuel Gas Gasification w/ Reforming
– Steam vs. Autothermal, Modeling for feasibility (efficiency/cost)
Research Summary
• Catalytic Gasification
– Syngas Methods
• Noncatalytic Supercritical: (450/600C, 4000/6000 PSIG)
– Hi Cap Cost, Limited Biomass testing
• Low Temp Catalytic (225/265C, 400/800 PSIG, Pt or Ni)
– Simple organics, not tried on biomass
– Fuel Gas Methods
• Catalytic Hydrothermal (350C, 3000PSIG, Ru or Ni)
– Good carbon conversion, biomass & sludge
• Supercritical Carbon Catalyzed (600C, 3700PSIG)
– Good carbon conversion, coke, ash, plugging
Berkshire Energy Lab
• Robust Gasification
– No suitable biomass gasification technology exists for
FT
– Require feedstock drying
– Syngas must be cleaned of particulates/tars
– H2/CO ratio must be fixed at 2
– Feedstock variability significantly impacts gas quality.
– Ability to gasify any carbonaceous feed is highly
beneficial (residential)
– May be a commercial product in itself
Berkshire Energy Lab
• Robust Gasifier - Concept 1
Biomass
Res Solid Waste
Sewage
Sludge
Mechanical
Grinder/Mixer
Dryer/
Pellitizer
Solvent?
Cyclone/
Scrubber
Gasifier
Char/Slag
Shift
H2 Sensor
Steam Control
Temp Control
Syngas
Distributed Energy Systems
• Residential scale gasification as part of
fundamental research
• Potential integration with Plug Power
fuel cells when 5 KW system reaches
$15k capex (~3 years)
• Methanol synthesis research - though
limited applications given conversions
needed
• OTHER?
Distributed Energy Systems
• Slide on Plug Power (Saratoga Energy)
financials – partner?
• Slide comparing liquid fuels to electricity
– why methanol won’t work
• Picture of unit
Lab Start-Up Costs
•
•
•
•
Equipment needed (go to Fischer Scientific)
Site selection (NY, Lenox?)
New hires - skills needed (funding)
Partnerships to build
Integrated Home Energy
• Notes
–
–
–
–
–
Compare w/ Community Power
Need to do gasification road show
Research Co2/N2 removal
Need to talk about CHP in gasifier vs FC
Energy storage? Charge batteries? What is efficiency
of battery charging and usage?
– “Microchannel Gasifier” – Gasify smaller amounts of
feed with faster throughput???
http://www.eia.doe.gov/
Integrated Home Energy
• Syngas Conversion Comparison
– Gas Generator
• Efficiency: Unknown on Syngas
• CHP: Gasifier yes, Generator no
• Other: Use NG generator, off-the-shelf gasifier
– Fuel Cell
• Efficiency: > 30% Electric, > 80% Overall, ~ 60% w/ Gasifier
• CHP: yes
• Other: built in desulph, tar cracking
– Liquid Fuels
• Efficiency: ~ 50% overall with significant development
• CHP: yes
• Other: Microchannel, N2/CO2 removal
Integrated Home Energy
• Component Technologies
– Gasification
• Specs: Atmospheric, air blown, direct heated, 5kW
• Numerous technologies available. Requires full
scale evaluation process for down selection
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–
–
–
–
–
http://noest.ecoundco.at/news/docs/1277_Biomass_Engineering_UK.pdf
http://www.croreyrenewable.com/index.html
http://www.associatedphysics.com/ProdServices/Gasification.html
http://www.phoenixenergy.net/
http://gasbiopower.com/home
http://www.primenergy.com/Gasification_idx.htm
• Many more…
Integrated Home Energy
• Component Technologies
– Gas Cleaning/Scrubbing
• Initial: Cyclone (particulate), cold water quench
followed by sand filter
• Research more advanced cleaning technologies for
later phases
– N2/CO2 Removal
• Enabling technology for residential scale
(microchannel) Fischer Tropsch process
• Membrane filter technology:
– http://www.mtrinc.com/co2_removal_from_syngas.html