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Production processes for bio-fuels
Fuel production from biological material Process
owerview
Dipl.-Ing. Walter Vanselow Rendsburg , 7.
September 2006
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Topics
1. IBH The company 2. Production of fuels from
biomass(oil plants, solid biomass, sugar and
starch plants, wet/pasty biological matter,
bio-ethanol) 3. Actual commercial production
processes(vegetable oil, biodiesel, ethanol,
gasificationsynthesis) 4. IBH target Direct
liquefaction (status of development) 5.
Bio-fuels Comparision yield and production
costs 6. Example calculation parts of bio-fuels
in the fuel market 7. Taxation of bio-fuels
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IBH The company

• Founded in 1972 as experts for piping planing and
  calculation in chemistry, industry and power
  plants
• Further development of the business areassince
  the 80th
• Increased engagement in energy and environmental
  technology since 2001
• Locations Ludwigshafen and Rendsburg
• Approx. 85 employees
• Managing director and shareholderSiegfried Münch

IBH The company
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We are ...

• ... an accepted and competent partner
• for engineering and project management
• in plant construction, plant operation and plant
  service
• in energy and environmental technology
• in water and wastewater technology
• Our core competence we have in the areas
• Chemistry
• Industry
• Power plants and nuclear power plants
• Pharmacy
• Environment

IBH The company
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IBH Everything in one hand

• Our Turnkey Scope

IBH The company
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Kind of biomass

• Production of fuels from ...
• Oil plants
• Soild biomass
• Sugar and starch plants
• Biological wet material and sludges
• Ethanol

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Production from oil plants
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Production from solid biomass
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Production from sugar and starch plants
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Production from wet biomass and biological sludges
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Production of fuel and fuel additives from ethanol
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Production of bio-fuels

• Actual commercial produktion processes
• Vegetable oil
• Biodiesel
• Bio-ethanol
• (Biomass gasification Fischer-Tropsch-Synthesis)

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Vegetable oil as fuel
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Vegetable oil as fuel

• Vegetable oil is still a niche market compared
  to biodiesel
• But 18 large oil mills in Germany (Rape oil
  production 2005 2.35 m tonne, without oil
  import)
• Infrastructure unincisive 196,000 tonne of
  vegetable oil were used in Germany as fuel
  in 2005 
• The german grid of public vegetable oil fuel
  stations has only ca. 250 stations
• Fuel costs of vegetable oil are clearly lower
  than the costs of diesel
• Additional costs for engine upgrading and
  numerous oil changes

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Biodiesel as fuel
catalyst
Oil/fats methanol
biodiesel glycerine
ca. 90 ca. 10 ca. 90
ca. 10
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Biodiesel as fuel
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Biodiesel as fuel

• Biodiesel is no longer seen as a niche
  application (ca. 30 production plants, incl.
  planning/construction)
• Infrastructure is in high gear 1.8 m tonne
  Biodiesel were used as fuel in Germany in
  2005
• Further 600,000 tonne were used in mixtures (up
  to 5) with conventional diesel in Germany
• In 2006 3.4 m tonne are expected ca. 12 of
  the diesel consumption in 2005 (28.6 m tonne
  diesel in 2005)
• The German grid of biodiesel fuel stations
  consists of ca. 1,900 stations
• Fuel costs are higher compared to vegetable oil,
  but lower than for diesel
• No costs for upgrading in case of approved
  vehicles

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Bio-ethanol as fuel
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Bio-ethanol as fuel
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Bio-ethanol as fuel
1 Garbage/waste input, sorting and storage 2
Crushing of the organic fraction 3 Silo for
organic waste lfraction for 4-5 days 4 Gasifier
for production of synthesis-raw-gas 5 Syngas
cleaning
6 Syngas compression step 1 7 Syngas compression
step 2 8 Synthesis unit (catalytical ethanol
production) 9 Cooling with heat recovery 10
Molecular sieve for water separation 11 Storage
tank for "Fuel-ethanol"
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Bio-ethanol as fuel

• Bio-ethanol is still a nice application in
  Germany (ca. 6 production plants, incl.
  planning/construction)
• Infrastructure unincisive In 2005 226,000 tonne
  ethanol were used in form of ETBE as
  antiknock additive in gasoline instead of
  MTBE in Germany
• Beside the additive application in the German
  oil industry, a few E85-fuel stations were
  erected since 2005
• High octane number (124) as fuel or fuel
  additive
• Applicable as mixture with 90 gasoline and 10
  ethanol (E10) without engine modification
  (EU-Guideline 5 ethanol)
• 100 ethanol (E100) and E85 only applied in
  "Flexible-Fuel- Vehicles" (Brasilien,
  Schweden)

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Biomass gasification Fischer-Tropsch-Synthesis
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Carbo-V-Plant (alpha-plant) Freiberg
1998 contruction and commisioning of the 1-MWth
pilot plant in Freiberg. Until end of 2004
operation time gt17,000 hours.
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Carbo-V-Plant (beta-plant) Freiberg
September 2003 commissioning Carbo-V-prototype
plant with 45 MWth in Freiberg. In April 2003 the
first synthetic fuel was produced from wood
chips. Expected production capacity in 2007
15,000 tonne fuel (SunFuel) per year
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IBH target Direct liquefaction
Technical simulation of the natural crude oil
production
Formation of "renewable crude oil" from biomass
and waste
Formation of fossile crude oil
Natural process pressure temperature salts (microb
es)
Technical process pressure (80 bar) or
pressureless temperature (450C) catalysts
Duration ca. 1-5 min.
Duration 1 m to 600 m years
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Transformation of carbohydrate to hydrocarbon
carbohydrate biomass component
2 C6H12O5
C12H26
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Tabellenbeispiel
Application spectrum of the IBH DoS-Processes
Liquid raw materials and fuels from biomass and
waste
"LP DoS" Process
Vegetable oil Vegetable fats
Animal fat Bone fat
Waste tires Rubber waste
Electr. power
Plastic waste
Heat
Poor lignin energy crops
Sewage sludge
Meat and bone meal
Bran
Fuels
"HP DoS" Process
Bio waste Green cuttings
Lignin rich energy crops
Straw
Wood
Raw materials
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"LP DoS" continuous pilot plant
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Tabellenbeispiel
"LP DoS" Test results (examples)
Rape oil
Gasoline
Diesel
Diesel
fraction
fraction
original
Pyrolysis oil
For comparison
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"HP DoS" Plant (mass and energy balance)
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"HP DoS" Test results (analysis)
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"HP DoS" continuous pilot plant
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Bio-fuels Comparison yield and production costs
Efficiency 40-55 33-50 45-54 40-47 70-7
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Yield l/ha/a 5.000 4.200 1.600 2.000 6.700
Hu MJ/kg 21,1 27,7 37 42,5 38
Costs /l Diesel 0,77 0,72 0,60 0,70 0,35
Density kg/l 0,8 0,8 0,9 0,85 0,85
Yield toe/ha/a 2,0 2,2 1,3 1,7 5,2
Costs /l 0,36 0,44 0,55 0,70 0,31
Process Methanol Ethanol RME FT-Diesel DoS-Di
esel
Efficiency (energetic) (product heating value
Process energy) / heating value raw material
1 toe (ton of oil equivalent) 41,87 GJ /l
Diesel /l Diesel equivalent /36,1
MJ Origin for conventional process comparison
DaimlerChrysler-Study, June 2002
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Calculation example bio-fuel rates in the fuel
market
Possible bio-fuel production in Germany
Total agricultural area thereof field area, ca.
69 of total area thereof closed area, ca. 10
of field area
17,100,000 ha 11,800,000 ha 1,180,000 ha
Assumption Closed area 20 of field
area Possible average plant yield Yield of
biomass per year
3,540,000 ha 15.0 t/ha 53,100,000 t/a
Fuel yield by means of the DoS-Process, ca.
35 Everage fuel yield per hectare, ca.
18,585,000 t/a 6,105 l/ha
Fuel demand per year in Germany Expectation of
ESSO-AG in 2005 Gasoline Diesel Light
heating oil Total demand
28,000,000 t/a 30,000,000 t/a 31,300,000
t/a 89,300,000 t/a
Rates of bio-fuels from agriculture Rates in
relation to vehicle fuels Rates in relation to
total demand
32.04 20.81
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Taxation for bio-fuels
German Parliament gets down to business
with taxation for bio-fuels The German
Parliament has made the final decision on the
taxation of pure bio-fuels on 30th of June 2006.
According to this pure biodiesel will be taxed
with annually increasing taxes, starting on 1st
of August 2006. The starting tax rate shall be 9
Cent per litre and will be annually increased by
at least 6 Cent per litre, starting 2008. In 2012
the tax rate shall reach 45 Cent per litre.
Regarding pure vegetable oil fuel the tax
liability starts in 2008 with 10 Cent per litre
and will also be increased annually until the
total tax liability has been reached in 2012.
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Thank you for your attention !!!
Overview bio-fuels