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Berkshire Energy Laboratory

Berkshire Energy Laboratory. Status Update November 21, 2008 Thomas Horgan. Outline. Residential Scale Methanol Fuel Synthesis Advanced Research Topics Biomass Fuel Synthesis by Ionic Liquids Syngas by Catalytic Gasification Next Steps Other Topics. Residential Liquid Fuel Synthesis.

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Berkshire Energy Laboratory

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  1. Berkshire Energy Laboratory Status Update November 21, 2008 Thomas Horgan

  2. Outline • Residential Scale Methanol Fuel Synthesis • Advanced Research Topics • Biomass Fuel Synthesis by Ionic Liquids • Syngas by Catalytic Gasification • Next Steps • Other Topics

  3. Residential Liquid Fuel Synthesis • Classic Methanol Production (Wood Alcohol) Steam partially condense to Turpentine (0.3 kg/Tonne) 150C, 7.5 Atm, 1h 3 to 5 days Sawdust Digester Pressing Fermen- tation Liquor H2SO4 100 Proof methanol 57.1% by Vol 73 liter/tonne dry wood Steam Yeast Boiler H2O Sawdust

  4. Residential Liquid Fuel Synthesis • Industrial Methanol Production Steam Natural Gas Desulph SMR 2H2 + CO CH3OH 50 Atm, 270C Copper Oxide Catalyst H = -92 kJ/mol Coal or Biomass Gasifier Cleaning Steam O2, Air Syngas (H2, CO (CO2, N2)) Compressor Methanol Convertor Cooling/ Distillation methanol Syngas Recycle Loop Purge Gas

  5. Residential Liquid Fuel Synthesis • Small Scale Syngas Based MeOH System • Assume Capacity: 200 lbs wood per day (1 cord ~ 4,000 lbs), 10 GPD MeOH • 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 • Outlet Temp: 50/75C after cyclone/filter • Acceptable for MeOH synthesis? $2300 Assembled $1400 Not Assm http://www.allpowerlabs.org

  6. Residential Liquid Fuel Synthesis • Small Scale Syngas Based MeOH System • Compressor/Raise Temp • MeOH Converter • CO2+CO+5H22CH3OH+H2O+Heat • Cu-Zn, 50 Atm, 270C • Issues with Heat Removal • 25% per pass efficiency (multi pass) • Adiabatic vs Isothermal Reactors • Needs to be cooled, flashed • Residential scale reactor options?

  7. Residential Liquid Fuel Synthesis • Small Scale Syngas Based MeOH System • Distillation • Crude Methanol contains dissolved CO, CO2, H2, N2 and volatile organics (acetone, ethers, esters) • May be acceptable for some engines/turbines ? • Distilled for chemical grade • Need to deal with off gasses

  8. Residential Liquid Fuel Synthesis • Small Scale Syngas Based MeOH System • Methanol Gas Generator • MeOH acceptable gasoline substitute • poor cold starts, better efficiency/heat removal • Lower volumetric heating value • Seal wear • Pramac S7500 Deluxe Electric Start Generator With Honda Gx390 Engine , 6.1 kW • $2,000, Home Depot • 31 x 22 x 25 inches, 200 lbs • 8 gal tank, 10 hrs on gasoline • 5 hrs on methanol

  9. Residential Liquid Fuel Synthesis • Community Power Corp - Littleton, Co • Small/Medium Scale Wood Generators • Commercial 25kW, 75kW and 100 kW systems available $225 to $400k. • Custom 5kW system ~ $150k • 2 lbs of woodchips per kWh • Footprint for 25kW system: 8’ x 8’ x 20’ • Small/Medium Scale Prototype FT System (Farm) • Fully Operational. Press release in two weeks • 50 gal transportation diesel per ton woodchips • Gasifier Footprint: 8’ x 8’ x 40’ • FT Module Footprint: 8’ x 8’ x 20’

  10. Biomass Fuel Synthesis By Ionic Liquids • Dissolution of biomass: Potential first step to many new, low energy, homogeneous conversion routes • Dimitris Argyropoulos, NC State • Four patent applications • Has one letter of intent (hedging) . Company specifically interested in catalytic cracking • Actively seeking investment partner (wants to develop, not publish) • $150k for 4 years, $200k for 3 years

  11. Biomass Fuel Synthesis By Ionic Liquids • 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, < 150C, < 30min) • Safety: Low vapor pressure and highly recyclable. Some are combustible. Many are toxic if released to the environment.

  12. Biomass Fuel Synthesis By Ionic Liquids • 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

  13. Biomass Fuel Synthesis By 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

  14. Syngas By 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

  15. Syngas By Catalytic Gasification • PNNL 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) • Direct Fischer Tropsch Synthesis to Trans Fuels • Design and control studies to narrow product range

  16. Next Steps • Note: Recommend work w/ Argyropoulos on Ionic Liquids, not Elliot (change memo) • Plant visits and tours • PNNL – discuss catalytic syngas gasification work. See labs, processes, etc. • NREL – discuss lab capabilities/collaboration opportunities? • Community Power Corp – 10 minutes from NREL. We’re invited. • NC State – More detailed understanding of practical use of ionic liquids • Residential Scale Methanol Synthesizer • Develop detailed drawings, BOM, etc (model in Aspen?) • Source other gasifiers • Understand issues with crude methanol/distillation • Source or design small scale MeOH converter • Others…

  17. Other Topics

  18. Economics & Energy Analysis • Energy

  19. Economics & Energy Analysis • Economics

  20. Huber Process • Professor George Huber – Umass, Amherst • Has developed catalytic pyrolysis process for ‘Green Gasoline’ • As of last e-mail, has already licensed technology (unclear) • Have not connected by phone • Green Gasoline Process • Converts powdered cellulose at 600C, over zeolite catalyst to aromatic mix • Not really a gasoline (actual gasoline is less than 25% aromatics) • Useful as a blend • Not yet tested on actual cellulose/biomass

  21. Methanol to Gasoline (Mobil Process) • Process Flow Sheet 320C Alumina 400/420C Light HC, CO2, H2

  22. Gasification Technologies • Updraft Gasifier • Advantages • Simple, low cost process • Able to handle biomass with a high moisture and high inorganic content (e.g.,municipal solid waste) • Proven technology • Disadvantages • Syngas contains 10-20% tar by weight, requiring extensive syngas cleanupbefore engine, turbine or synthesis applications • Downdraft Gasifier • Advantages • Up to 99.9% of the tar formed is consumed, requiring minimal or no tar cleanup • Minerals remain with the char/ash, reducing the need for a cyclone • Proven, simple and low cost process • Disadvantages • Requires feed drying to a low moisture content (<20%) • Syngas exiting the reactor is at high temperature, requiring a secondary heat recovery system • 4-7% of the carbon remains unconverted

  23. Gasification Technologies • Bubbling Fluidized bed • Advantages • Yields a uniform product gas • Exhibits a nearly uniform temperature distribution throughout the reactor • Able to accept a wide range of fuel particle sizes, including fines • Provides high rates of heat transfer between inert material, fuel and gas • High conversion possible with low tar and unconverted carbon • Disadvantages • Large bubble size may result in gas bypass through the bed • Circulating Fluidized bed • Advantages • Suitable for rapid reactions • High heat transport rates possible due to high heat capacity of bed material • High conversion rates possible with low tar and unconverted carbon • Disadvantages • Temperature gradients occur in direction of solid flow • Size of fuel particles determine minimum transport velocity; high velocities may result in equipment erosion • Heat exchange less efficient than bubbling fluidized-bed

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