Integrated Home Energy from Waste & Biomass

Tom Horgan and Noa Simons February 6, 2009

Outline

• Executive Summary • Introduction – Preconception, Expectations, Distributed Generation • Research Summary – The State of Energy: Crude vs BTLTF – Conversion Route Energy & Economic Comparisons – Pyrolysis, Liquefaction, MTG, FT Synthesis – Gasification: Analysis & Modeling – Catalytic gasification, ionic liquids – Integrated Home Energy System

Outline

• Integrated Home Energy System (IHES) – Concept Description – Component Functions/technologies – Phased Development Plan – Estimated timeline/cost • Additional Topics – How do we find the “google in a haystack” • Wrap Up

Executive Summary

• We propose to build and market an integrated home energy system .

– Multifeed – Biomass, MSW, Sewage – “Clean Gasification” based – Multiple energy conversion options (CHP fuel cell, Gas Gen, LF) • Rationale: – Lean (saves $), Green (recycle), Mean (self sufficiency) – Clean Gasification - Enabling Technology for BTLTF – Direct competition with crude products unrealistic • Additional Discussion – Biomass Research database is massive. How do we find the “Google in a haystack”?

Introduction

• Preconception – Alternative energy field was exploding with oil prices reaching $150/barrel in 2008 – Modern science applied to BLTTF (Biomass To Liquid Transportation Fuel) has yielded research databases full of new concepts ready for advancement & commercialization • Expectation – Search databases, 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)

Introduction

• Distributed Generation – Electricity generation ~33% efficient nationwide – Household waste contains 30% of total energy used • 50 kg/day can supply remaining electricity with heat in excess – Core gasification technology development required for all biomass conversion processes – Homeowner saves money, goes green and increases sense of self sufficiency

The State of Energy

• Usage & Losses https://eed.llnl.gov/flow/images/LLNL_Energy_Chart300.jpg

The State of Energy

• World Oil Reserves – “Proven” vs “Unproven” http://en.wikipedia.org/wiki/Oil_reserves

The State of Energy

• Market Opportunity http://www.eia.doe.gov/

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 43.5 MJ/kg (~80%) – Diesel 42.8 MJ/kg (~85%) • Biomass/Solids – 6/20 MJ/kg – MTG Gasoline – FT Diesel 43.5 MJ/kg (< 50%) 42.8 MJ/kg (< 60%) • 5 to 15x more input energy http://www.eia.doe.gov/

Research Summary

• Liquefaction & Pyrolysis – Do not synthesize transportation grade fuel without upgrading (undeveloped) – Pyrolysis oils are product is 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)

Research Summary

• Fischer Tropsch Synthesis – Gasification – Synthesis – Upgrading

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 SMR Coal or Biomass Steam O2, Air Gasifier Cleaning Syngas (H2, CO (CO2, N2)) Compressor Methanol Convertor Syngas Recycle Loop Purge Gas 2H2 + CO  CH3OH 50 Atm, 270C Copper Oxide Catalyst  H = -92 kJ/mol Cooling/ Distillation Methanol MTG Process

Research Summary

• Methanol Synthesis – Methanol Demand • 37%  • 21%  • 14%  formaldehyde (resins/glues for particle board and ply wood) MTBE (gasoline additive that reduces exhaust emissions) 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

2CH 3 OH



CH 3 OCH 320C Alumina 3 + H 2 O CH 3 OCH 3



H 2 O + C 2 – C 5 , 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 (H 2 , CO, others)

Research Summary

• Gasification Reactors – Small Scale – Downdraft Gasifier • Outside dimensions (w/ hopper): 4ft h x 1.5ft d • Syngas production rate: ~ 35 ft 3 /lb of 15% wood • Max Capacity: ~700 lbs wood/day - 1000 ft 3 /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

• Ionic Liquids – Dissolution of wood –

Argyropoulos to Write Proposal on…

• Dissolution of Sludge • Catalytic Cracking of Pyrolysis Products • Catalytic Gasification –

To be included in future discussions with NREL

Research Summary

• Economic/Energy Comparison

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

Integrated Home Energy

• Household Mass Balance (Family of 4) Food Water Paper Plastics Water Sewage

Average Usage: ~320 MJ/day Waste: ~ 100 MJ/day (~30%)

MSW

8 Kg/day ~91 MJ/day 290 GPD 0.1% Solids ~ 7 MJ/day

Integrated Home Energy

• Quick Energy Calcs (Avg Household, 4 people) – Usage: 320 MJ/day 60% Electric, 40% Thermal – Annual Cost: $1800 (~ $5/day) – Waste = 30% of Total Usage (92% MSW, 8% Sewage) – Fuel Value Comparison ($/1000 MJ, Trillion MJ) – Conclusion: Make Electricity from MSW, Wood, Coal or NG http://www.eia.doe.gov/

Integrated Home Energy

• Concept Wood Chips Water Sewage MSW Mechanical Grinder/Mixer Dewater

Syngas

WGS Dryer/ Pellitizer Gasifier N2/CO2 Removal Cleaning/ Scrubbing Air Slag

Integrated Home Energy

• Concept Wood Chips, MSW, Sewage Air Slag Mechanical Grinder/Mixer Dewater Dryer/ Pellitizer Gasifier WGS N2/CO2 Removal Cleaning/ Scrubbing

Syngas

Start Up 2 kW Syngas Generator Energy Storage

Integrated Home Energy

• IHES Component Functions – Feed preparation/pretreatment • Wood (20%): Chipped/dried • MSW (50%): Ground/dried (pellitized?) • Sewage (99%): Dewatered, dried, ground – Gasification • Supply Heat & Syngas – Generator: Particulate & tar free – FC: Particulate & tar free w/ CO < 1% – BTLTF: Particulate & tar free, H2/CO tunable, N2/CO2 free

Integrated Home Energy

• IHES Component Functions – Combined Heat & Power • Gasifier: Heat for drying & residence • Generator: Electricity to residence & storage • FC: Electricity to residence and storage. Heat to residence and drying – Energy Storage • Battery Pack: – Provide start up power – Provide power when no fuel available

Integrated Home Energy

• Component Technologies – Mechanical grinding/mixing/shredding • Wide availability at industrial scale • Biomass Shredders may also work for MSW • Residential Scale Shredder ~ $600 (Home Depot) • Continued research on integrated designs – Feed Drying • Feed drying improves efficiency but not required for biomass (probably required for MSW) • Heat produced exceeds household demands • Integrated heat exchanger to provide drying energy

Integrated Home Energy

• Component Technologies – Pelitizing • Cost of Pellitizing shredded MSW may be offset by efficiency & gas quality improvements • More research – implement in later phases • Manure Briquettes – http://www.aesenergy.net/news/cow-manure-to energy.html

– Dewatering • Required if sewage is used but energy content does not justify expenditure

Integrated Home Energy

• Component Technologies – Gasification • Specs: Atmospheric, air blown, direct heated, 5kW • Numerous technologies available. Requires full scale evaluation process for down selection – – – – – – 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

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

• Overall Approach – Contact NREL for Concept Evaluation – Visit Community Power & NREL 2/15 – Evaluate additional gasification technologies for residential scale and down select

Integrated Home Energy

• Phased Development Plan – Phase 1: Proof of Concept • Simple DD Gasifier/Gas Generator – Downselect gasifier & gas generator technology – Purchase chipper/gasifier/generator & test in Saratoga – 3 to 6 months, < $15,000 – Phase 2: Prototype Development • MSW Gasification/Gas Generator – Develop/test methods of MSW prep for gasification – Assess need for pellitizer/additional drying/advanced cleaning – Develop prototype skins/frame/etc – Purchase additional gasifier – 2 to 4 months, < $10,000

Integrated Home Energy

• Phased Development Plan – Phase 3: Advanced Concept Development • Advanced Gasification – Purchase H2, CO sensor or GC – Integrate shift catalyst/steam and controls – Test on fuel cell in cooperation with Plug Power – 1 to 2 years, < $100,000 – Phase 4 – Advanced Concept Development • Transportation Fuel Synthesis – Evaluate CO2 and N2 removal technology – Evaluate microchannel technology – 3 to 5 years , < $1 million

Additional Discussion

• How do we find the “google in a haystack”?

• How do we get people to come to us with ideas?

• Rapid Concept Evaluation • Berkshire Energy Laboratory

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/

The State of Energy

1% of All Biomass On Earth (~ 50 cubic miles proven reserves as of 2008) http://spectrum.ieee.org/jan07/4820

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

References: “Bio-syngas production with low concentrations of CO2 and CH4 from microwave-induced pyrolysis of wet and dried sewage sludge” by Diminguez et al (2007) http://www.adktroutguide.com/files/Weekly_Update_11_7_08.do

c

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

• Gasification Reactors - Industrial

Research Summary

• Residential Systems – Develop commercially viable residential scale product for conversion of wood/biomass to electricity – System Concepts • Gasifier/SynGas Generator • Gasifier/Methanol Convertor/Generator • Gasifier/Fuel Cell

Research Summary

• Residential Systems - System Concepts – Gasifier/SynGas Generator • Advantages: – Simple concept – Relatively easy to implement on a small scale – Been tried and implemented • Disadvantages – Low efficiency – Low heating value of syngas – Long term operational issues due to tars and particulates – Attempted by Community Power Corp & rejected on cost – XX Kwh/chord of wood

Research Summary

• Residential Systems - System Concepts – Gasifier/Methanol Convertor/Generator • Advantages: – Liquid Fuel – Clean Burning Methanol • Disadvantages – Complex concept – Undeveloped – Estimate XX Kwh/chord of wood

Research Summary

• Residential Systems - System Concepts – Gasifier/Fuel Cell • Advantages: – High efficiency CHP – Easy implementation • Disadvantages – FC Reliability – Syngas Quality – Estimate XX Kwh/chord of wood

Research Summary

• Residential Systems - System Concepts – Gasifier/Fuel Cell • Modeling Results

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 (~10 18 ), 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 (~10 18 ), 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

• Economic/Energy Comparison

Research Summary

• Gasification Reactions

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 Solvent?

Dryer/ Pellitizer Gasifier Char/Slag Cyclone/ Scrubber Shift Steam Control Temp Control H2 Sensor

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/