Bio-Methanol from Forest Product Industry byproducts
Development status and commercial challenges 19 November 2013 Ingvar Landälv and Rikard Gebart* Luleå University of Technology
1
* Presenter
1
Agenda • • • • • • •
2
Background The role of the forest products industry Potential for fuels from the forest Technology readiness level Matching fuel and vehicle evolution Well-to-wheel efficiency and production costs What is stopping us?
Background Solar/Wind/Geothermal based
Biomass based
Fossil based Time
3
Drivers for renewable fuels • Climate change from greenhouse gases (GHG) • Environmental Issues • Energy Security of Supply
4
“Interest Indicators” EBTP was formed when interest was on its peek HIGH
2000 United States EU 27
5
Source: ILa
To truly globally motivate a change to renewables
Copenhagen Summit IPCC
LOW 1990
Formation of EBTP
Level of Engagement & Action
Concern regarding GHG Climate Impact Concern regarding security of supply
2010
2020
Climate Change Concern
6
Source: IPCC Approved Summary for Policymakers, 27 September 2013
Climate Change Concern/2
7
Source: IPCC Approved Summary for Policymakers, 27 September 2013
Security of supply– “fracking” revolution has improved SoS but it is still a fossil fuel
Source: ASPO Newsletter, September 2008
8
Source: crudeoilpeak.info, October 2013
Source: Robert Rapier and BP, October 2013
Potential problems with fracking • • • • •
9
Contamination of groundwater Leakage of a strong greenhouse gas (methane) Exposure to toxic chemicals Depletion of ground water Fracking-induced earthquakes
Emissions from the Transport Sector Fuel 15%
11%
Road traffic Aviation
73%
Shipping
SOx
NOx CO2
27%
15%
42%
12% 74%
5% 10
Source: ScandiNAOS AB
54%
73%
1%
Upcoming regulations for Marine Fuels Source: ScandiNAOS AB
IMO NOx Technical code
g NOx/kWh 16
NOx Tier II -‐ 2011 (Global) 14
NOx Tier III -‐ 2016 (NOx emission c ontrol areas)
12
10
8
6
4
2
rpm
0 0
11
100
200
300
400
500
600
700
800
900
1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Synthetic fuels via gasification opens up for many alternatives CO2
*
Coal
Natural gas
Ammonia Gasification Followed by cooling and preliminary cleaning
Gas cleaning & Conditioning
Biomass
Black liquor
SYNGAS
Liquid residues
FT Diesel
Mixed Alcohols Hydrogen
Gasoline
Methanol
Acetic acid
Ethanol
DME
Methane
Esters & Ethers
Waste
• High efficiency • Feedstock flexible 12
Urea
Formaldehyde Olefins
In focus in this presentation CO2
*
Coal
Natural gas Biomass
Black liquor
Ammonia Gasification Followed by cooling and preliminary cleaning
Gas cleaning & Conditioning
SYNGAS
Liquid residues
FT Diesel Urea
Mixed Alcohols Hydrogen
Gasoline
Methanol
Acetic acid
Ethanol
DME
Methane
Esters & Ethers
Waste
Formaldehyde Olefins
13
Methanol & DME are “Relatives” DME is dehydrated methanol Methanol
+ Methanol
14
DME
+ Water
The role of the forest product industry Solar/Wind/Geothermal based
Biomass based
Fossil based Time
15
Major Biomass Flow from the Forest Today TODAY
Forest Logs
Pulp Wood
Saw mill Wood Products
Pulp Mill
Recovery Boiler
Pulp Mill Pulp
16
Major Biomass Flow from the Forest With the BLG* Based Biorefinery Concept TOMORROW (1) Logs
Forest Forest Residual
Pulp Wood
Saw mill Wood Products
Recovery Pulp and Fuel Generation Mill
Recovery Combined Boiler
Pulp Mill Pulp * BLG: Black Liquor Gasification 17
Fuel
Major Biomass Flow from the Forest including Direct Biomass Gasification TOMORROW (2)
Forest
Logs
Pulp Wood
Forest Residual
Saw mill Wood Products
Recovery Pulp and Fuel Generation Mill
Recovery Combined Boiler
Pulp Mill Pulp
18
Fuel
Direct Biomass conver sion
Fuel
A typical Pulp Mill of Today 1
Power and heat
2
Chem. recovery
Pulp
Pulp Wood Black liquor
2 1
Recovery Boiler Utility Boiler
19
The Pulp Mill turned to a Biorefinery With the Chemrec Concept 1
Power and heat
2
Chem. recovery
3
Fuel
4
Extra renewable energy
Pulp
Pulp Wood Black liquor
2
1
Utility Boiler
Power and Steam
20
Renewable energy
4
Black Liq. Gasific.
Syngas
Syngas to fuels
3 Fuels
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Some basics about • Black Liquor is a Liquid – – – –
Easy to feed to a pressurized gasifier Can be atomized to fine droplets Rapid gasification rates Stable properties over time
• Black Liquor is an efficient gasification fuel – – –
Full carbon conversion at ~1000 deg C Virtually no tar formation Low methane formation
• Black Liquor is available in large quantities – – –
21
World BL capacity about 660 TWh/y Corresponds to production of ~ 10 billion gal gasoline equivalents per year Typically 250-300 MW of BL per pulp mill
Black Liquor
Potential for fuels from the forest products industry Solar/Wind/Geothermal based
Biomass based
Fossil based Time
22
BL Energy is a large renewable energy source in some areas of the World e.g. Sweden
23
Nr
Mill owner, name
Nominal capacity
1
Billerud, Karlsborg
2
SCA, Munksund
3
Smurfit Kappa, Lövholmen
1450
4
SCA, Obbola
1000
5
Husum, M-Real
750
1100
1965
6
Husum, M-Real
700
2000
1978
7
Husum, M-Real
1100
1300
1988
8
Domsjö, Domsjö
375
1958
9
Domsjö, Domsjö
375
1964
10
Dynäs, Mondi
915
1978
11
Östrand, SCA
3300
2006
12
Iggesund, Holmen
520
900
1966
13
Iggesund, Holmen
520
900
1967
14
Vallvik, Rottneros
760/1000
1200
1974/1999
15
Korsnäs, Korsnäs
865
1330
1968
1213
16
Korsnäs, Korsnäs
1550
1550
1987
17
Skutskär, StoraEnso
585
650
1967
18
Skutskär, StoraEnso
1900
2800
1976
14 15 16 17 18
19
Frövi, Korsnäs
520
1260
1970
20
Skoghall, Stora Enso
2200/(3350)
21
Gruvön, Billerud
2500/(3300)
22
Billingsfors, Munksjö
230
330
1976
23
Bäckhammar, Wermland Paper
570
750
1976
24
Aspa, Munksjö
510
1200
1973
25
Skärblacka, Billerud
1250
1850
1976
26
Värö, Södra
2500
2002
27
Mönsterås, Södra
4000
1996
28
Mörrum, Södra
2000
1250
Current capacity 1500
600
Year of start-up 1980 1965
1950
1972 2007
2005 2000
2260
1995
Approx: 5000 MW Black Liquor 1
Close to 20 large plants
2 3
4
5 6 7 8 9 10 11
20 23 21 22 24
19
25 27
26 28
BL Energy in Europe = clusters of mills together having a large boiler capacity
Approx: 20 000 MW Black Liquor
= important single mill
Some 65 large plants
24
BL Energy is a substantial energy source in some states in the US e.g. Georgia
More than 100 suitable pulp mills In North America with 200-400 MW of Black Liquor per plant
25
In the World: approx. 80 000 MW Black Liquor or 250 – 300 large plants
Biomass to Automotive Fuels: Replacement Potential within EU-25 in 2040 Used today
Potential added to 2040
Potential today
Energy in transports 2002 Total biomass potentials 2040 Transport share DME / MeOH FTD
0
28% substitution of 2002 consumption
17% substitution of 2002 consumption
500
1000
1500
2000
2500
3000
3500
4000
4500
(TWh/year)
Source: EU project Renew within FP6 and EUCAR/Concawe/JRC (2005) 26
5000
Technology readiness level for BioDME Solar/Wind/Geothermal based
Biomass based
Fossil based Time
27
The BioDME Project Demonstration of BioDME production and its use as fuel in heavy duty (HD) trucks www.biodme.eu
Syngas
Lubricants, Additives Grant funding:
28
DME Synthesis
Distribution, Stations
Fuel system equipment
Vehicle Manufacturing and Testing
Some facts about the BioDME project DME Production capacity:
4 tons / day
Pipe installation:
~10 000 m
Hand valves & on/off valves:
~1400 pieces
Instruments:
~450 pieces
Vessels:
~30 pieces
Heat exchangers:
~25 pieces
Process Plant Foot Print
20 x 30 m
Construction cost:
29
~ $28 million
DP-1 unit
The
Black Liquor Oxygen
Gasification Carbon filter
plant
Block Flow Diagram
CO shift
Amine wash
Gas conditioning
H2S / CO2 to pulp mill incinerator
Have produced good quality MeOH
& Cleaning MeOH Synthesis 2
Syngas Compressor
Sulphur guard
MeOH Synthesis 1
Raw Methanol
First single-pass MeOH synthesis featuring > 95% yield MeOH (recycled)
DME day tanks
DME Product
Off gases DME synthesis
DME storage
DME synthesis & product purification 30
Water
> 500 ton DME
Successful production of BioMeOH and BioDME Methanol sample from intermediate methanol production step
31
As per November 19 2013: • > 500 tons BioDME produced • Plant in operation > 5 000 h • Gasifier in operation > 20 000 h
Long-haul HD vehicles and fleet operators consume about 25% of total Swedish fuel consumption • • • •
~30 stations needed for basic coverage in Sweden (HD) Investment about 180.000 Euro per Filling Station Distribution system easily accomplished Utilizes LPG technology, modified for DME Today: 4 stations Stockholm BioDME filling Station
180 000€ Investment 32
SWEDEN
Field Test Status per November 19, 2013
Extended field test
33
Technology readiness level for other alternatives Solar/Wind/Geothermal based
Biomass based
Fossil based Time
34
LTU Green Fuels: Planning for 2013-2016 WP1 Pilot scale experiments WP2 Catalytic gasification WP3 Solid fuel gasification WP4 Novel syngas cleaning WP5 Catalytic conversion WP6 Containment materials WP7 Field tests WP8 Electrofuels and new concepts
WP3
Powder
ETC EF gasifier
Torrefied Mtrl Cleaning
Pyrolysis oil WP2
BioMeOH WP4
Black Liquor WP6
WP7
Membranes
25-30 bar
> 100 bar
BioDME
DP-1 Plant Active C Abs
WG Shift
WP1 H2
O2
Amine Wash
MeOH Synth.
CO, H2
Electrolysis
Existing facilities Future development The Renewable Syngas Highway
DME Synth.
Catalytic Process Development
WP8
35
Others
CO2 Fuel Cells H 2O
Distillation
WP5
Matching fuel and vehicle demand Solar/Wind/Geothermal based
Biomass based
Fossil based Time
36
A way to meet the demand from a growing MeOH/BioDME Fuel Market Biomass
Pyrolysis Liquefact. Methanol plant
1
MeOH
Nutrients
e
t
2 h
n a
Gasification MeOH
Pulp mill
MeOH
Renewable MeOH
Industrial Energy gas
nn
DME
M
Gasification of biomass
Gasification
Fossil MeOH
Ports
Biomass
Waste
Biomass
Natural gas
DME
n
o
l
Distribution
Chemical industry Heavy transports Marine sector 37
Production and Distribution of Renewable and Fossil DME. One Scenario DME Fuel Station BioMethanol Production
Direct use of BioMeOH
DME Production DME Terminals Direct use of BioMeOH
Fossil MeOH 38
Well-to-wheel efficiency and production costs Solar/Wind/Geothermal based
Biomass based
Fossil based Time
39
Well-to-Wheel CO2 emissions and energy consumption for different conversion pathways Conventional gasoline
Fuels 2010
Conventional diesel RME: Gly as chemical
400
RME: Gly as animal feed
CTL
Syn-diesel: CTL Syn-diesel: GTL
WTW GHG emissions (g CO2 eqv / km)
300
Syn-diesel: Farmed wood Syn -diesel: Waste wood, Black liqour DME: CTL
Gasoline and diesel
200
DME: GTL
GTL-Syndiesel
DME: Waste wood, Black liqour
GTL-DME
100
EtOH: Wheat, Straw CHP, DDGS as AF
Biomass Gasification
EtOH: Sugar cane (Brazil) EtOH: Wheat, Straw CHP, DDGS as fuel EtOH: Farmed wood
0 0
-100
100
200
300
Chemrec Black Liquor Gasification
400
500
600
EtOH: Wheat straw EtOH, Wheat, Lignite CHP, DDGS as AF EtOH, Wheat, Lignite CHP, DDGS as fuel
Biogas, liquid manure
EtOH, Wheat, NG GT+CHP, DDGS as AF EtOH, Wheat, NG GT+CHP, DDGS as fuel Biogas, municipal waste
-200 Total WTW energy (MJ / 100 km)
Source: WtW study Eucar/Concawe/JRC 2005, 2010 Vehicles (basis for EU RED/FQD default values) 40
DME: Farmed wood
Ethanol (pure)
Biogas, liquid manure Biogas, dry manure
DME Properties No C - C bonds and high H/C ratio Very high cetane number => A suitable diesel fuel Non toxic Rapid degradation in air Used as propellant gas in spray cans Similar handling as LPG (liquid at 5 bars) Potential for very low exhaust emissions (burns soot free) “Multi source - multi purpose”
41
Price Levels of some Key Energy Commodities Commodity Crude at 110 USD/bbl
€ / MWh (approx.)
0 20 40 60 80
47
Gasoline at refinery gate, NW Europe (0.5€/lit / 0.6€/lit)
56 / 67
Diesel at refinery gate, NW Europe (0.5€/lit / 0.6€/lit)
51 / 61
Nat. Gas at 2 - 4 USD/MMBtu
5 - 11
LNG, NW Europe at LNG hub
25 - 30
(based on 4 USD / MMBtu)
42
Methanol, NW Europe (200 €/t)
36
DME (based on methanol price + 5%)
37 - 38
Cost of biomass, typical Europe / US
20/10
Advanced biofuels
80-120
So what is stopping us from taking off? Solar/Wind/Geothermal based
Biomass based
Fossil based Time
43
“....but we need the stable long-term investment conditions......” 130
€ / MWh
120 Today’s cost for advanced biofuels In Europe
110 100
100 €/MWh = ~4.4 USD/g.g.e.
90 80
Dies
e
so l/ga
line
70 60 50
Long term stable legislation is required to cope with the difference
40 30
de ~ cru
20 10 2000 44
LOW
2010
2020
2030
Summary and Conclusions • The FP industry has the potential to become large scale producers of BioDME and BioMeOH • The black liquor to BioDME/BioMeOH route is ready for full scale implementation • Other feedstocks to BioDME/BioMeOH is expected to be ready for commercialisation within 5 years time • Fossil MeOH and DME can be produced at costs lower than today’s diesel fuel but green MeOH/DME has a slightly higher cost • The shipping industry is preparing to convert from high sulfur bunker oil to ultraclean MeOH with an associated distribution infrastructure • Distribution systems for on land and marine fuels can largely use the same overall infrastructure • Long term (> 10 years) stable basis for investment decisions is needed • Renewable fuels will not be commercially viable until all fuels have to pay a price for their environmental impact 45
Proposed base for Conference Statement q Communicate forth fully the message that methanol and DME are excellent fuels, have the best WtW efficiencies and can be produced at low cost from many different feedstocks q Accelerate work for increased methanol use in the transport fuel sector through change in fuel standard EN 228 allowing higher level of methanol in gasoline than current 3% q Set the objective for Europe to follow the Chinese roadmap where M85 is already approved and M15 is expected to be approved within short q On EU and member state levels establish stable, long term, system that puts a price for all fuels in proportion to their environmental impact
• Transition should start now • It takes decades to phase out old vehicles • It takes decades to build up large scale production • It takes decades to change biomass harvesting systems 46
Research partners and sponsors from 2001 until today
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