Integrated Home Energy from Waste

1
Integrated Home Energy from Waste Biomass

• Tom Horgan and Noa Simons
• February 6, 2009

2
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

3
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

4
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?

5
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

6
Introduction

• Reality
• Majority of research dollars to bioethanol and
  biodiesel
• 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)

7
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

8
The State of Energy

• Usage Losses

https//eed.llnl.gov/flow/images/LLNL_Energy_Chart
300.jpg
9
The State of Energy

• World Oil Reserves Proven vs Unproven

http//en.wikipedia.org/wiki/Oil_reserves
10
The State of Energy

• Market Opportunity

http//www.eia.doe.gov/
11
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 - 43.5 MJ/kg (lt 50)
• FT Diesel - 42.8 MJ/kg (lt 60)
• 5 to 15x more input energy

http//www.eia.doe.gov/
12
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)

13
Research Summary

• Fischer Tropsch Synthesis
• Gasification
• Synthesis
• Upgrading

14
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)

15
Research Summary

• Methanol Synthesis

Desulph
SMR
Natural Gas
2H2 CO? CH3OH 50 Atm, 270C Copper Oxide
Catalyst ?H -92 kJ/mol
Gasifier
Cleaning
Coal or Biomass
Steam
O2, Air
Syngas (H2, CO (CO2, N2))
Compressor
Methanol Convertor
Cooling/ Distillation
Methanol
Syngas Recycle Loop
Purge Gas
MTG Process
16
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

17
Research Summary

• Methanol to Gasoline

2CH3OH? CH3OCH3 H2O
320C Alumina
CH3OCH3 ? H2O C2 C5, alkenes, cycloalkanes,
aromatics
400/420C Zeolite
Light HC, CO2, H2
18
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).

19
Research Summary

• Gasification
• First step in FT, methanol, MTG, FC, generator
• Biomass is heated under low oxygen conditions
  (Atmospheric, gt 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)

20
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
21
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.

22
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

23
Research Summary

• Economic/Energy Comparison

24
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

25
Integrated Home Energy

• Household Mass Balance (Family of 4)

Food Water Paper Plastics
MSW
8 Kg/day 91 MJ/day
Water Sewage
290 GPD 0.1 Solids 7 MJ/day
Average Usage 320 MJ/day Waste 100 MJ/day
(30)
26
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/
27
Integrated Home Energy

• Concept

Wood Chips
Syngas
MSW
Water Sewage
Air
Slag
28
Integrated Home Energy

• Concept

2 kW Syngas Generator
Wood Chips, MSW, Sewage
Energy Storage
Syngas
Air
Slag
Start Up
29
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 lt 1
• BTLTF Particulate tar free, H2/CO tunable,
  N2/CO2 free

30
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

31
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

32
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

33
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_En
  gineering_UK.pdf
• http//www.croreyrenewable.com/index.html
• http//www.associatedphysics.com/ProdServices/Gasi
  fication.html
• http//www.phoenixenergy.net/
• http//gasbiopower.com/home
• http//www.primenergy.com/Gasification_idx.htm
• Many more

34
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
  

35
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 gt 30 Electric, gt 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

36
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

37
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, lt 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, lt 10,000

38
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, lt 100,000
• Phase 4 Advanced Concept Development
• Transportation Fuel Synthesis
• Evaluate CO2 and N2 removal technology
• Evaluate microchannel technology
• 3 to 5 years , lt 1 million

39
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

40
Conclusions

• Integrated home energy system is marketable
  technology (lt 10K in 5 years)
• Gasification development supports future, large
  scale work
• Need a lab and team to search the biomass
  research database

41
Backup Slides
42
The State of Energy

• Fuel Value

http//www.eia.doe.gov/
43
The State of Energy
1 of All Biomass On Earth ( 50 cubic miles
proven reserves as of 2008)

http//spectrum.ieee.org/jan07/4820
44
Research Summary

• Fischer Tropsch Synthesis-
• Gasification covered as a separate topic
• FT Synthesis Reaction Chemistry

45
Research Summary

• Fischer Tropsch Synthesis-
• Product Distribution

• Low Temp FT
• 200/240C
• Cobalt
• ?waxes
• Hi Temp FT
• 300/350C
• Iron
• ?liquids

46
Research Summary

• Fischer Tropsch Synthesis-
• Reactor Design Types

47
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_1
  1_7_08.doc

48
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/B
ioproductsfromSyngas/Methanol/Default.htm
49
Research Summary

• Gasification Reactors - Industrial

50
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

51
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

52
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

53
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

54
Research Summary

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

55
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, lt
  150C, lt 30min)
• Safety Low vapor pressure and highly
  recyclable. Some are combustible. Many are
  toxic if released to the environment.

56
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, lt
  150C, lt 30min)
• Safety Low vapor pressure and highly
  recyclable. Some are combustible. Many are
  toxic if released to the environment.

57
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

58
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

59
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)

60
Research Summary

• Economic/Energy Comparison

61
Research Summary

• Gasification Reactions

62
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

63
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

64
Berkshire Energy Lab

• Robust Gasifier - Concept 1

Mechanical Grinder/Mixer
Dryer/ Pellitizer
Gasifier
Biomass Res Solid Waste Sewage Sludge
Solvent?
Char/Slag
Cyclone/ Scrubber
Shift
Syngas
H2 Sensor
Steam Control Temp Control
65
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?

66
Distributed Energy Systems

• Slide on Plug Power (Saratoga Energy) financials
  partner?
• Slide comparing liquid fuels to electricity why
  methanol wont work
• Picture of unit

67
Lab Start-Up Costs

• Equipment needed (go to Fischer Scientific)
• Site selection (NY, Lenox?)
• New hires - skills needed (funding)
• Partnerships to build

68
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/