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HTU 2000

SUCCESSFULLY USING BIOMASS TO HARNESS RENEWABLE ENERGY IN AN EFFICIENT AND COST-EFFECTIVE WAY. J.E. Naber and F. Goudriaan (BIOFUEL BV). HTU 2000. PERSPECTIVES FOR ENERGY FROM BIOMASS. 1990 2040 ENERGY DEMAND, EJ/a 350 1000

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HTU 2000

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  1. SUCCESSFULLY USING BIOMASS TO HARNESS RENEWABLE ENERGY IN AN EFFICIENT AND COST-EFFECTIVE WAY J.E. Naber and F. Goudriaan (BIOFUEL BV) HTU 2000

  2. PERSPECTIVES FOR ENERGY FROM BIOMASS 1990 2040 ENERGY DEMAND, EJ/a 350 1000 FOSSIL FUELS, „ 255 480 RENEWABLES „ 80 >400 HYDROPOWER „ 20 50 WIND „ - 70 SOLAR „ - 130 BIOMASS „ 60 >200

  3. POTENTIAL FOR ENERGY FROM BIOMASS FROM POTENTIALLY AVAILABLE 250 EJ/YR LAND AREA @ 15 TON(DB)/HA.YR (ENERGY FARMING ON 10 HA) BIOMASS RESIDUES 70 EJ/YR (FORESTRY, WHEAT, RICE, SUGAR CANE, CORN, ETC. 9

  4. HISTORY OF HTU 1982 - 1988 Process R&D, Shell Laboratory, Amsterdam 1994 - 1997 Technical-Economic evaluation of HTU technology Nov 1997 - July 2000: PROCESS DEVELOPMENT PROJECT EET-1

  5. WHAT IS HTU ? o Conditions: 300 - 350 C; 120 - 180 bar reaction time 5 - 20 minutes liquid water present Feedstocks: All types of biomass, domestic, agricultural and industrial residues, wood Also wet feedstocks, no drying required Chemistry: Oxygen removed as Carbon Dioxide Products 45 Biocrude(%w on feedstock, dry basis) 25 Gas (> 90% CO2) 20 H2O 10 dissolved organics (e.g., acetic acid, methanol) Thermal efficiency: 70 - 90 %

  6. HTU Product Biocrude Heavy organic liquid Not miscible with water Oxygen content 10 - 18 %w LHV 30 -35 MJ/kg Applications Biocrude as such: (co)combustion in coal- and oil- fired power stations After upgrading (hydrogenation): premium diesel fuel; kerosene luboil base stock chemicals feedstock (cracker)

  7. HTU PRODUCT FLEXIBILITY • Direct combustion as a liquid • (replacement of fossil fuels) • Combustion as a solid fuel • (cofiring with coal) • Emulsified fuel (type “Orimulsion”) • Replacement of charcoal • Upgraded product

  8. HTU PROCESS BLOCK SCHEME air Flue gas Cat. DeNOx External Fuel Furnace Gas turbine, CC electr. Feedstock Gas Light biocrude Pretreat- ment Pump system HEATING SECTION HTU REACTOR PRODUCT SEPARATION To Upgrading (HDO) Hvy biocrude Waste water power station electr. Anaerobic digestion Biogas CHP electr., heat electricity concentrated minerals sol’n demineral. Clean water

  9. Block scheme of HTU pilot pant Block scheme of HTU pilot plant Biomass 10-20 kg/hr (db) CO2 330 °C 180 bar Condensor Gas /liquid separator gases Preheater/Reactor 1 Reactor 2 Cooler High pressure pump 1 bar biocrude/water collection Pressure reducer Cooler storage storage

  10. THERMAL EFFICIENCY Definition: th = (LHV of biocrude output) * 100 % (LHV of feed) + (LHV from external fuel) For present process design: th = 55.62 * 100% = 74.9 % 72.98 + 1.3 (Theoretical maximum for this case is 78.6 %)

  11. Upgrading of biocrude by HDO • Principle of catalytic Hydrodeoxygenation has been • demonstrated • Upgrading cost compensated by higher product value • Diesel fraction has excellent ignition properties • Potential applications: • Transport fuel • Kerosine • Fuel in high-efficient gas turbine • Feedstock for chemicals (via ethylene cracker) • Etc. etc.

  12. HDO process scheme NH3, H2S H2O To refininery pool Recycle gas compressor C1-C4 gas Hydrogen Naphtha HDO reactor system Air transport Kerosine Separator section Fractionator Biocrude (fromHTU) Diesel fuel for Road transport Gas oil electricity >370oC residue Lubricating oil; chemical feedstock

  13. 8 rest products energy farming 7 + 60 6 + 40 Biocrude cost, $/GJ 5 First Plant + 20 Future plant 4 $ per ton CO2 avoided 3 0 Coal (2 $/GJ) / Crude Oil (12 $/bbl) Replacement 2 - 20 1 0 -1 0 1 2 3 Feedstock price, $/GJ COST OF BIOCRUDE AND COST OF AVOIDING ONE TON OF CO2 ; EFFECT OF FEEDSTOCK PRICE

  14. Total Product Cost, $/GJ 10 rest products energy farming 8 First Plant 6 Premium Diesel ex crude oil of 25 $/bbl 4 Future plant 2 0 -2 -1 0 1 2 3 Biomass HTU Feedstock Price, $/GJ PRODUCTION OF TRANSPORTATION FUELCost of HTU plus HydroDeOxygenation

  15. HTU R&D PROGRAM • GO / NO GO ITEMS • Pressurizing • Continuous integrated operation of pilot plant • CRITICAL ITEMS • Heating - up • Oil/water separation • Product properties / applications • Effluent treatment • DATA FOR DESIGN • Phase equilibria • Physical properties, esp. at reactor/separator conditions

  16. Process Development • Work in autoclaves, • 10 ml, 1 liter, 2 liter • Testing of feedstocks and process conditions • Continuous pilot plant • capacity 20 kg/hour (dry basis) • commissioning 1 July 1999 • first product prepared: 24 November 1999

  17. Development project EET-1 • Mission: Design data for demonstration plant, • validated in continuous pilot plant • Time period: 1 November 1997 - 31 July 2000 • Cost and funding: • Subsidy 3 M $ • (Dutch Min. of Economic Affairs, EET programme) • Stork E&C (Now Jacobs) 1 • Shell Nederland 1 • TNO, BTG, Biofuel 1 • Total 6 M $

  18. PROJECT ACTIVITIES PROJECT ACTIVITIES 1. Autoclave experiments - TNO 2. Reactor Engineering - BTG 3. Waste water treatment - TNO 4. Process Modeling - TNO (Tech Univ Delft) 5. Feedstock characterisation - BTG 6. Feed introduction equipment - Biofuel 7. Pilot plant design & contruction - TNO (Contractor) 8. Pilot plant operation - TNO 9. Product research - BTG 10. Materials selection - Biofuel (Contractor) 11. Commercial design & cost - Jacobs Engineering Nederland 12. Operational project support - Biofuel 13. Business development - Biofuel 14. Chemical analyses - TNO 15. Project management & coordination - Biofuel

  19. PROCESS DESIGN CASE STUDY Basic process design by Jacobs Engineering Nederland Process scheme, Mass & Heat Balances: ASPEN PLUS flowsheeter All disciplines involved, incl. layout Case study: Feedstock: Sugar beet pulp, 22 %w dry matter Intake Capacity: 130,000 tonnes/year (dry basis) Focus on heat integration, thermal efficiency

  20. RESULTS OF EET-1 PROJECT • Pilot plant construction completed • Pilot plant operation: - process principles verified • - most initial problems solved • - 200 kg biocrude produced • Pressurizing of feedstock successfully proven with commercial prototype pump • Data on thermodynamics and phase equilibria obtained; model operational • Waste water treatment routes defined • Product: various applications explored • Process design and cost estimation completed • Fundamental research to start: NWO – Japan project.

  21. EET-2 PROJECT:FINAL PROCESS DEVELOPMENT Mission: Extended operation of pilot plant with commercial feeds Product application development Time period: 2002 – 2005 Cost and funding: Subsidy: 3.6 MFl Dutch Government, EET programme TNO + BTG + Biofuel: 1.2 St. Shell Research 0.5 To be decided 1.9 Total project cost 7.2 MFl

  22. COMMERCIAL HTU DEMONSTRATION PLANT (1) Study by Jacobs Engineering Nederland, 2000 Location: Large Waste Processing Company, The Netherlands Feedstock: Organic Wet Fraction (ONF) of domestic waste Capacity: 81,300 tonnes of ONF per year 62,500 tonnes of washed ONF+ per year (= 25,000 tonnes per year dry basis) Production: 14,470 t/yr Biocrude (incl ash) = 10,630 t/yr DAF Combustion in power plant gives 5.5 MWe

  23. COMMERCIAL HTU DEMONSTRATION PLANT (2) BASIS for ECONOMICS Capital: Washing plant 13 M Nfl HTU plant 37 Total capital 50 M Nfl Availability: year 1: 40 % (of 8000 h/yr) year 2: 60 % year 3: 80 % years 4-15: 100 % Maintenance and overhead: 4% and 1% of capital/yr Operation: Worst case

  24. COMMERCIAL HTU DEMONSTRATION PLANT (3) Total capital required 50 M Nfl CO2 reduction plan: minus 7.5 M Nfl EWAB: minus 3.0 Net capital: 39.5 M Nfl Effect of VAMIL minus 13.8 M Nfl Effect of EIA minus 5.5 M Nfl Net Investment 20.2 M Nfl TOK: Loan of 20.2 Mfl @ 7% interest, repayment in 10 years

  25. COMMERCIAL HTU DEMONSTRATION PLANT (4) NPV, M Nfl License fee (p.m.) TOK (techn ontwikkelings krediet) (21.6) over first 10 years Operating cost washing plant (24.8) Operating cost HTU plant (30.2) Biocrude sales 10.4 75% of equiv. coal price Fee for ONF 80.7 (= 100 Nfl/ton ONF) Total project NPV 14.5 NPV=0 if ONF fee= 77 Nfl/ton Effect of REB buy-back 32.2 NPV incl REB 46.7 NPV=0 if ONF fee= 39 Nfl/ton NPV = Net present value of project over 15 years, discounted cash flow with 7% interest rate

  26. Technology Development Path( S - curve) Fully Commercial Commercial Prototype Next S- curve Process Development Improved scientific base Techn./Econ. Feasibility Process Scouting Scientific Base / Explanatory

  27. NEXT S - CURVE • Focussed fundamental studies on principles • Chemical and physical characteristics of biomass feedstocks in relation to hydrothermal conversion • (Wageningen Agricultural University) • Organic chenmistry: Reaction paths and kinetics with representative components and conditions • (Delft University of Technology) • Reaction engineering models/ complex kinetics • (Twente University) • Thermodynamics • (Delft University of Technology)

  28. HTU-related work in Japan NIRE: Dr. Shin-ya Yokoyama Ms. Dr. Tomoko Ogi Publications since 1985 Upgrading of biomass residues and sewage sludge For sewage sludge: continuous bench scale unit, 15 kg/h, ca. 1988 process development unit, 5 tons/day Cooperation with: Japan Organo Co., Ltd, Dr. Akira Suzuki; contacts since 1991 Ebara corp. Institute for cellulose Industry, Bandung Indonesia, publication 1998

  29. NWO – Japan Project NWO = Dutch Government Agency for Fundamental Scientific Research Commemoration of 400 years contacts Japan – the Netherlands Multimillion Treaty on fundamental research on renewable energy. Netherlands: 4 out of 20 projects are on HTU fundamentals Japan: Involvement of NIRE

  30. 5000 4000 3000 2000 1000 -6 -4 -2 0 2 4 6 AVAILABILITY OF ORGANIC RESIDUES IN THE NETHERLANDS Cumulative kton/year (db) Gasification, Pyrolysis HTU energy farming (NL) straw potato leaves beet leaves wood cuttings verge grass houshold waste food ind. waste wood waste 0 Price ( $/GJ )

  31. HTU OPPORTUNITIES 1 - The Netherlands • Industrial organic waste and residues 1.8 Million tons/a (db) • Organic household waste 1.1 ,, • Poultry litter 0.5 ,, • Manure 2.0 ,, • (combination with anaerobic digestion) • TOTAL 5.4 Million tons/a (db)

  32. HTU OPPORTUNITIES 2 - Europe • Agricultural / Industrial Residues 200 Million tons/a (db) • (Source: Eurec agency, 1996) • Short-term niches for HTU: • - Olive Oil Industry 3 - 5 Million tons/a (db) • - Organic household waste 26ktons/a (db) per • (from centralized waste separation) 250,000 inhabitants • - Residues from sugar and beer production.

  33. HTU OPPORTUNITIES 3 - World • Agricultural and industrial residues 4,000 Million tons/a (db) • (Source: “Renewable Energy; sources for (approx. 70 EJ/a) • fuels and electricity”, 1993) • Future organic household waste 800 Million tons/a (db) • (own tentative estimate) • Short-term niches for HTU: • - Organic household waste • - Bagasse (> 100 Mtons/a) • - Forestry residues from existing plantations • - Coir dust

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