OBP Thermochemical Conversion R

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OBP Thermochemical ConversionRD Activities

• David C. Dayton, NREL
• Thermochemical Area Leader
• Thermochemical Conversion
• Roadmap Workshop
• January 9, 2007

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The Presidents Biofuels Initiative The 30x30
Vision
main difference is in the primary catalysis system
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Opportunities for Thermochemical Biofuels

• Challenge Develop thermochemical technologies
  that are technically and economically feasible at
  the appropriate scale for reasonably available
  biomass resources

• L. Scully The Business Case for Coal
  Gasification with Co-Production, July 2006
• 30x30 Vision document and references therein

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Why Thermochemical Conversion?

• Mitigates risk of achieving 1.07 by 2012 by
  providing process alternative
• Utilize entire biomass resource base to achieve
  30x30
• Forest Residues not optimum for BC (27)
• Option for processing off-spec or non-fermentable
  biomass resources or de-localized resources
• Lignin-rich residues from BC account for 20-30
  of fermentable biomass (18 - 20 billion gal/yr
  of EtOH)
• Regionally specific biomass conversion options
• Maximize Fuel Production in Future Integrated
  BC/TC biorefineries by converting lignin-rich
  residues to fuel

Billion Ton Vision High Yield Increase
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Thermochemical Conversion Vision 1.07
Thermochemical Ethanol by 2012

• Near-term (mixed alcohol synthesis)
  thermochemical conversion of low-cost feedstocks
  (1.07)
• Overcoming Technical Barriers
• Industry Deployment strategy
• CAPEX reduction

2012 target Ethanol yield 76 gal/dry ton MESP
1.07 with higher alcohols sold at 1.15/gal
fuel value
Gasification
Forest Residues 2,000 dMT/day
Alcohol Synthesis
Syngas
Ethanol 58.5 MM gal/yr
Higher Alcohols
n-Propanol, n-Butanol, n-Pentanol 10.3 MM gal/yr
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30x30 Advanced Integrated Biorefinery
ScenarioMaximize Biofuel

• Mid-term (30x30)
• Biorefinery residues in integrated BC/TC plants
• Maximize biofuel production

Corn Stover 10,000 dMT/day
Residues 2,140 dMT/day
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30x30 Advanced Integrated Biorefinery Scenario
E85 Refinery

• Long-term (30x30)
• Selective Thermal Transformation (improve yields
  and selectivity)

Ethanol yield 94 gal/dry ton stover Gasoline
yield 90 gal/dry ton of lignin (13 gal/ton of
stover) (Plant total Ethanol equivalent yield
118 gal/dry ton stover)
Minimum gasoline selling price 0.51/gal
gasoline (Minimum Ethanol equivalent selling
price 0.35/galEtOH) Plant Minimum Ethanol
equivalent selling price 0.57/gal EtOH
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OBP Goal 1.07 Thermochemical Ethanol by 2012

• Quantitative RD Targets
• Measurable success
• Link AOP Inputs to Targets
• Focus future solicitations
• Technology improvements translate into MESP
  reductions based on Mixed Alcohol Process Model
• Risk Mitigation Alternative process options in
  the event RD Targets are not achieved

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Technical Barrier Areas for 1.07 Thermochemical
Ethanol
Gas Cleanup Conditioning has the largest
economic impact
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Research state-of-technology assessments for
thermochemical ethanol production to reach the
1.07/gallon market target
Minimized water use by air cooling instead of
evaporative cooling Energy self-sufficient
process
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MESP cost breakdown highlighting RD Progress
toward 1.07
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Gasification RD for 1.07 Thermochemical
Ethanol Target

• Gas Cleanup and Conditioning Tar Reforming
  Catalyst Development
• Consolidated tar and light hydrocarbon reforming
  to reduce capital and operating costs
• Advanced Catalysts and Process Improvements for
  Mixed Alcohol Synthesis
• Increase single pass conversion efficiency (38.5
  to 50)
• Improve selectivity (80 to 90)
• Improve yields at lower synthesis pressure
• Fundamental Gasification Studies
• Technical validation of comparable syngas quality
  from biorefinery residues and wood residues

Tar Reformer Performance - Conversion
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RD Plan for 1.07 Thermochemical Ethanol
Production
2006
2008
2007
2009
Demonstrate conversion of 50 of non-methane (C2
higher) hydrocarbons that result in a syngas cost
of 7.15/MMBtu in 2007 (equivalent electricity
cost of 6.83 cents/KWh).
Validate technology capable of economically
converting biomass residues, pulping liquors or
waste fats and greases to synthesis gas or
bio-oils that are suitable for fuels and
chemicals production. The target is 5.81/MMBtu
in 2009 (equivalent electricity cost of 6.37
cents/KWh).
Demonstrate at pilot-scale technology capable of
economically converting biomass residues
(lignin), pulping liquors or waste fats and
greases to synthesis gas or bio-oils that are
suitable for fuels and chemicals production. The
target is 6.88/MMBtu in 2008 (equivalent
electricity cost of 6.73 cents/KWh).
Biorefinery residues - Indirect (atm)
gasification corn stover switchgrass wheat
straw lignin - 78 syngas efficiency H2/CO
1.0-1.5 CH415vol Tars 30 g/Nm3 benzene
1vol H2S 50-600 ppm NH3 and HCl unknown
Sorbent injection to maintain H2S levels 50 ppm
for syngas from biorefinery residues to reduce
sulfur deactivation of tar reforming catalysts.
Tar Reformer Efficiency CH4 50 Benzene
90 heavy tars 97 (79 CH4 conversion in
separate SMR)
H2/CO 1.2 Pressure 2000 psia Productivity
300 gMA/kg(cat)/hr EtOH Selectivity 70
Indirect (atm) gasification 78 syngas
efficiency H2/CO 1.0-1.5 CH48vol Tars 10
g/Nm3 benzene 0.1vol H2S 20 ppm NH3 and
HCl unknown
Reduce MOH catalyst cost to 0.0X/gal EtOH -
Demonstrate 500 hours catalyst lifetime (at XX
initial level based on MADR) at 2007 performance
with bottled syngas
Mixed Alcohol Design Report to provide benchmark
baseline technology for cost targets and RD
goals
Reduce tar reforming catalyst cost to 0.0X/gal
EtOH TOS/Regen ratio Y1 for cycles (MADR)
Improved hydrocarbon conversion efficiency
yields- 56 gal/dry ton EtOH 1.72/gal minimum
EtOH selling price (higher alcohols sold at 85
of market value) at 2.69/gal installed capital
costs.
Mixed Alcohol Synthesis - H2/CO 1.0 Pressure
1500 psia Productivity 600 gMA/kg(cat)/hr EtOH
Selectivity 75
FY07 budget baseline Research
state-of-technology based on syngas at
7.25/MMBtu - 56 gal/dry ton EtOH 2.02/gal
minimum EtOH selling price (higher alcohols sold
at 85 of market value) at 2.71/gal installed
capital costs. FY08 budget goal accelerated
Reduce the syngas cost to 5.40/MMBtu by FY 2012
corresponding to 1.07 per gallon of ethanol at
35 per dry ton of biorefinery residues (lignin)
with higher alcohol byproducts sold at 69 of
projected market value.
Validated 1.72/gal EtOH for integrated Cleanup
Conditioning MOH synthesis
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RD Plan for 1.07 Thermochemical Ethanol
Production
2010
2011
2012
Validate and demonstrate technology for the
cost-effective clean-up of biomass synthesis gas
leading to syngas costs of 5.40/MMBtu in 2010
(equivalent electricity cost of 6.23 cents/KWh).
Demonstrate the conversion of synthesis gas or
bio-oils, derived from biomass residues, pulping
liquors or waste fats and greases, to chemicals
or transportation fuels. The target is
5.25/MMBtu in 2011 (equivalent electricity cost
of 6.18 cents/KWh).
Validate the competitiveness of cellulosic
ethanol at 1.07 per gallon. Demonstrate mixed
alcohol yields for 76 gal/dry ton EtOH via
indirect gasification of lignin-rich biorefinery
residues at pilot-scale for 1.07 minimum ETOH
selling price (higher alcohols sold at fuel value
for 1.15/gal) at 2.31/gal installed capital
costs
Demonstrate biorefinery residues gasification for
5.40/MMBtu syngas cost
Indirect (atm) catalytic gasification 78
syngas efficiency H2/CO 1.0 CH4 5vol Tars
1 g/Nm3 benzene 0.04 vol H2S 20 ppmNH3
and HCl unknown
Improved Tar Reformer Efficiency CH4 80
benzene 99 heavy tars 99.9 Eliminate SMR
highest activity re-gained by regenerating
deactivated catalyst
Integrated operations for syngas cleanup and
conditioning target composition for fuel
synthesis CH4 3vol benzene 10 ppm Heavy tars
0.1 g/Nm3 H2S 1 ppm NH3 10 ppm HCl 10 ppb
Reduce tar reforming catalyst cost to 0.0X/gal
EtOH TOS/Regen ratio Y2 and cycles (MADR).
Demonstrate 500 hours mixed alcohol catalyst
lifetime (at XX initial level based on MADR) at
2009 performance with biomass syngas
Mixed Alcohol Synthesis - H2/CO 1.0 Pressure
1000 psia Productivity 900 gMA/kg(cat)/hr EtOH
Selectivity 90
Demonstrate 1000 hours catalyst lifetime (at XX
initial level based on MADR) at 2009 performance
with biomass syngas
Demonstrate mixed alcohol yields for 67 gal/dry
ton EtOH via indirect gasification of lignin-rich
biorefinery residues at pilot-scale for 1.07
minimum ETOH selling price (higher alcohols sold
at fuel value of 1.15/gal) at 2.31/gal
installed capital costs.
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FY07 TC Joule Milestones

• 1st qrtr FY07
• 3.6.1.1 Biomass Gasification to Mixed Alcohols
  Design Report
• (using indirect gasification). This will
  establish a cost and quality baseline for biomass
  syngas.
• Responsible Party - NREL
• Due 31-Dec-06
• 2nd qrtr FY07
• 3.2.5.2 Determine which promoters/additives
  provide a 2x improvement in catalyst sulfur
  tolerance (life of the reforming catalyst, in a
  syngas with sulfur). These catalysts must
  operating in an environment of 50-500ppm H2S.
• Responsible Party - NREL
• Due 31-MAR-07
• 3rd qrtr FY07
• 3.2.5.1 Syngas sulfur reduction using in-stream
  getters (sorbents)
• Responsible Party - NREL
• Due 30-Jun-07
• The 4th qrtr milestone is the Joule Target
• Demonstrate conversion of 50 of non-methane (C2
  higher) hydrocarbons that result in a syngas cost
  of 7.15/MMBtu in 2007 (equivalent electricity
  cost of 6.83 cents/KWh).
• Responsible Party - NREL

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FY08 Milestones and RD Targets
Demonstrate at pilot-scale technology capable of
economically converting biomass residues
(lignin), pulping liquors or waste fats and
greases to synthesis gas or bio-oils that are
suitable for fuels and chemicals production. The
target is 6.88/MMBtu in 2008 (equivalent
electricity cost of 6.73 cents/KWh).
Tar Reformer Efficiency CH4 50 Benzene
90 heavy tars 97 (79 CH4 conversion in
separate SMR)
Reduce MOH catalyst cost to 0.0X/gal EtOH -
Demonstrate 500 hours catalyst lifetime (at XX
initial level based on MADR) at 2007 performance
with bottled syngas
Improved hydrocarbon conversion efficiency
yields- 56 gal/dry ton EtOH 1.72/gal minimum
EtOH selling price (higher alcohols sold at 85
of market value) at 2.69/gal installed capital
costs.
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FY09 Milestones and RD Targets
Validate technology capable of economically
converting biomass residues, pulping liquors or
waste fats and greases to synthesis gas or
bio-oils that are suitable for fuels and
chemicals production. The target is 5.81/MMBtu
in 2009 (equivalent electricity cost of 6.37
cents/KWh).
Indirect (atm) gasification 78 syngas
efficiency H2/CO 1.0-1.5 CH48vol Tars 10
g/Nm3 benzene 0.1vol H2S 20 ppm NH3 and
HCl unknown
Reduce tar reforming catalyst cost to 0.0X/gal
EtOH TOS/Regen ratio Y1 for cycles (MADR)
Mixed Alcohol Synthesis - H2/CO 1.0 Pressure
1500 psia Productivity 600 gMA/kg(cat)/hr
EtOH Selectivity 75
Validated 1.72/gal EtOH for integrated Cleanup
Conditioning MOH synthesis
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FY10 Milestones and RD Targets
Validate and demonstrate technology for the
cost-effective clean-up of biomass synthesis gas
leading to syngas costs of 5.40/MMBtu in 2010
(equivalent electricity cost of 6.23 cents/KWh).
Demonstrate biorefinery residues gasification for
5.40/MMBtu syngas cost
Improved Tar Reformer Efficiency CH4 80
benzene 99 heavy tars 99.9 Eliminate SMR
highest activity re-gained by regenerating
deactivated catalyst
Demonstrate 500 hours mixed alcohol catalyst
lifetime (at XX initial level based on MADR) at
2009 performance with biomass syngas
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FY11 Milestones and RD Targets
Demonstrate the conversion of synthesis gas or
bio-oils, derived from biomass residues, pulping
liquors or waste fats and greases, to chemicals
or transportation fuels. The target is
5.25/MMBtu in 2011 (equivalent electricity cost
of 6.18 cents/KWh).
Indirect (atm) catalytic gasification 78
syngas efficiency H2/CO 1.0 CH4 5vol Tars
1 g/Nm3 benzene 0.04 vol H2S 20 ppmNH3
and HCl unknown
Reduce tar reforming catalyst cost to 0.0X/gal
EtOH TOS/Regen ratio Y2 and cycles (MADR).
Mixed Alcohol Synthesis - H2/CO 1.0 Pressure
1000 psia Productivity 900 gMA/kg(cat)/hr
EtOH Selectivity 90
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FY12 Milestones and RD Targets
Validate the competitiveness of cellulosic
ethanol at 1.07 per gallon. Demonstrate mixed
alcohol yields for 76 gal/dry ton EtOH via
indirect gasification of lignin-rich biorefinery
residues at pilot-scale for 1.07 minimum ETOH
selling price (higher alcohols sold at fuel value
- 1.15/gal) at 2.31/gal installed capital costs
Integrated operations for syngas cleanup and
conditioning target composition for fuel
synthesis CH4 3vol benzene 10 ppm Heavy
tars 0.1 g/Nm3 H2S 1 ppm NH3 10 ppm HCl
10 ppb
Demonstrate 1000 hours catalyst lifetime (at XX
initial level based on MADR) at 2009 performance
with biomass syngas
Demonstrate mixed alcohol yields for 76 gal/dry
ton EtOH via indirect gasification of lignin-rich
biorefinery residues at pilot-scale for 1.07
minimum ETOH selling price (higher alcohols sold
at fuel value - 1.15) at 2.31/gal installed
capital costs.
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TC Roadmap Workshop Objectives

• Objective Validate and identify Gaps in the
  Gasification/Mixed Alcohol RD Plan to achieve
  the 1.07 2012 goal
• How do we implement the 30x30 Vision
  recommendations?
• Fundamental Research Needs
• Process Engineering Improvements
• Process Intensification Opportunities
• Capital Intensity Reduction
• Output A roadmap for a Thermochemical
  Conversion RD Agenda that resembles Breaking
  the Biological Barriers to Cellulosic Ethanol to
  meet the 2012 goal and achieve the 30x30 Vision.

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Focus Area 1 Feed Handling, Preprocessing, and
Gasification

• Objective Identify an RD plan to deploy
  cost-effective biomass gasification technologies
• Questions to consider
• What are the scientific challenges that need to
  be met?
• What technical barriers must be overcome for
  the challenges identified?
• What RD needs to occur to overcome the
  barriers identified?
• What milestones and targets need to be met on
  the path identified to meet the goal by 2012?
• What is the threshold of investment for the
  outlined RD path to be?

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Focus Area 2 Gas Clean-up and Conditioning and
Fuel Synthesis

• Objective Identify an RD plan to deploy
  cost-effective integrated biomass
  gasification/fuel synthesis technologies
• Questions to consider
• What are the scientific challenges that need to
  be met?
• What technical barriers must be overcome for
  the challenges identified?
• What RD needs to occur to overcome the
  barriers identified?
• What milestones and targets need to be met on
  the path identified to meet the goal by 2012?
• What is the threshold of investment for the
  outlined RD path to be?

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• Questions and Discussion