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IH²* Technology Biomass Directly to Transportation Fuels
Dr. Alan Del Paggio CRI Catalyst Company, Houston, Texas Integrated Hydropyrolysis & Hydroconversion
*IH² is a registered trademark of GTI
Presentation at
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Disclaimer
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IH2 technology = flexibility
n Location
n designed for stand-alone operation n no requirement for refining infrastructure n self-sufficient, self-sustaining facility built where biomass is
n Feedstock
n forestry, agricultural and sorted municipal residues (up to 20% plastic) n different feedstocks can be run alone in campaigns or mixed together
n Integration with existing facilities
n can be built standalone or be integrated with mill/refinery
n Product
n can produce finished fuel or stable intermediate for refinery upgrading n product can be fractionated to petrol/diesel or naphtha/jet/marine distillate
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Executive summary IH² technology …
n is feedstock-flexible (forestry, agriculture and sorted municipal residues up to 20% plastics)
n is a continuous catalytic thermochemical process
n uses traditional petrochemical and refining hardware
n produces affordable renewable hydrocarbon transportation fuels (petrol, jet, diesel, marine distillate)
n clean burning n up to 72% bio-energy recovery n up to 92% Green House Gas reduction n meet various international fuel standards
n has been under development since 2009
n is being demonstrated at 5 tonnes of feedstock/day at Shell Technology Center Bangalore
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Discussion topics
n 1. IH2 process
n 2. IH2 products
n 3. Technology Status
n 4. Economics
n 5. Addenda: case studies
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Bubbling Fluidized Bed (BFB) used in boilers & gasifiers
Refinery Operations 1. IH2 process Configuration flexibility
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Mill Operations
FUEL GASOLINE
DIESEL JET FUEL
COMPRESSOR
BIOMASS WOOD CHIPS
ALGAE MSW
AGRICULTURAL RESIDUE
HYDROGEN PLANT
BIOCHAR
SEPARATOR
FUEL
WAT
ER
GA
S
HYDRO - PYROLYSIS
REA
CTO
R
HYDRO - CONVERSION
REA
CTO
R
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1. IH2 process Feedstock flexibility
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Soft Wood 27-28% Hard Wood 26% Mixtures Hard/Soft Wood 26-27% Soft Wood with 30% Bark 26-27% Mulberry Sticks 25% Jatropha Trimmings 24-25% Forest Litter Blends 22-26%
Bagasse 26-28% Cane Tops/Trash 28-30% Rice Straw 22-23% Empty Fruit Bunch 24% Oil Palm Frond 24% Duckweed 30% Algae (Wild) 46% Algae (High Lipid) >50% Domestic Grasses >26% Cotton Stalks 24% Castor Stalks 26% De-Oiled Castor Cake 25%
Fuel Yield (wt% feed MAF*)
Fuel Yield (wt% feed MAF*)
*MAF = Moisture, Ash-free Basis **RDF = Refuse Derived Fuel
Forestry Agricultural
Cellulosic / Lignocellulosic biomass is nearly half oxygen by weight, so making hydrocarbons from biomass has, at most, 50wt% yield. Exceptions include fats/
vegetable oils and lipids with 20 wt% oxygen.
US RDF 29-30% Indian RDF** 28-30% EU Industrial Waste 27-29% EU RDF** 29-30% Mixed EU RDF**/Wood 27-28% Paper 22-24% Cardboard 20-24% Lawn clippings 22-26%
Fuel Yield (wt% feed MAF*) Municipal
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Road transport fuels vs aviation / marine fuels
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1. IH2 process – two modes of operation
0
20
40
60
80
100
15 65 115 165 215 265 315 365 415 BOILING POINT
AMOUNT
0
20
40
60
80
100
15 65 115 165 215 265 315 365 415 BOILING POINT
AMOUNT
Road fuels mode Aviation / Marine fuels mode
Cut point varies 150–200°C
Petrol 55–70 vol%
Diesel 30–45 vol%
Cut points 120–280°C
Jet 35–40 vol%
Naphtha 45–50 vol%
Marine Distillate 10–20 vol%
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GASOLINE / PETROL
Meets ASTM D4814-16d E10 blend for regular grade EN 228: Petrol – Jan 2009 E10 blend for regular grade Blend stock (RON) otherwise
BS VI compliant E6 blend for regular grade
EN 590:2009+A1:2010
DIESEL
Meets ASTM D975-15c
BS VI compliant
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2. IH2 products: road transport fuels are high quality ‘drop in’
Petrol is currently undergoing ASTM qualification; EN and BS qualification to follow in 2019
Diesel is currently undergoing ASTM qualification; EN and BS qualification to follow in 2019
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2. IH2 products: jet mode fuels are high quality ‘drop in’
Suitable components for Solvents Steam cracker feed Reformer feedstock – bioBTX Gasoline blending…
NAPHTHA JET FUEL
World-wide Civil Jet Fuel Grade Jet A/A-1 (e.g. ASTM D1655)
Matches the Table 1 Performance Criteria for:
Fuels are currently in ASTM D4054 approvals process
MARINE DISTILLATE
Meets ISO 8217 2017 specs Meets DMB/DFB specs (Very low S) High on DMA/DFA density (fixable); High on DMB/DFB density (fixable) Exceeds Residual Fuel Spec
Fuels are currently being evaluated
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Scal
e
2009 2012 2013 2014 2015 2016 2017 2018 2019 2022
LAB SCALE 1L/week
GTI CHICAGO
PILOT SCALE 20L/day
(10000+ hrs) GTI CHICAGO
Started Up
DEMO SCALE 2000L/day
Shell BANGALORE
3. Technology status In development since 2009 TRL = Technology Readiness Level (next slide)
COMMERCIAL SCALE >200,000L/day
IH2-500tpd
8 FIRST ADOPTERS* LAND REQUIREMENT
15HA FOR 1000 TPD STANDALONE PLANT LESS LAND REQUIRED WHEN INTEGRATED
TRL 1-3
TRL 4-6
TRL 6-8
TRL 9
LAB SCALE up to 1L/week
MBU 180+ Runs Shell BANGALORE
PILOT SCALE 7L/day
(7000+ hrs) Shell BANGALORE
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3. Technology status: TRLs 0 IDEA unproven concept, no testing has been performed
1 BASIC RESEARCH you can now describe the needs but have no evidence
2 TECHNOLOGY FORMULATION ocncept and application have been formulated
3 NEEDS VALIDATION you have an initial ‘offering’, stakeholders like your slideware
4 SMALL SCALE PROTOTYPE built in a laboratory environment (‘ugly’ prototype)
5 LARGE SCALE PROTOTYPE tested in intended environment
6 PROTOTYPE SYSTEM tested in intended environment close to expected performance
7 DEMONSTRATION SYSTEM operating in operational environment at pre-commercial scale
8 FIRST COMMERCIAL SYSTEM all technical processes & systems in commercial ready state
9 FULL COMMERCIAL APPLICATION technology generally available to all customers
IDEA
PROTOTYPE
VALIDATION
PRODUCTION
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3. Technology status Demonstration plant in India has completed Phases I-III, now in Phase IV
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Phase I: Demonstrate feeding, 1st stage operation, char removal using site supplied hydrogen at 1 tonne/day rate
Phase II: Maximize rate using site supplied hydrogen (3.2 tonne/day) Phase III: Repeat Phase I/II with HMU online (1.5 tonne/day) Phase IV: Maximize rate (5+ tonne/day) on internal hydrogen only Success declared when Phase IV conditions produce stable operation and product quality matches pilot data.
Product quality is as expected
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Plant size
Feed Cost INR/t
TIC – high $ 289 M TIC – low $ 228 M IRR @ Sales Price (INR/L) IRR @ Sales Price (INR/L) 40 45 50 40 45 50
1,000 tpd 1,500 17.6% 20.5% 23.5% 22.4% 26.2% 30.1% 3,000 15.3% 18.2% 21.1% 19.4% 23.1% 26.9% 4,500 12.9% 15.8% 18.7% 16.4% 20.1% 23.8%
Plant size
Feed Cost INR/t
TIC – high $ 190 M TIC – low $ 151 M IRR @ Sales Price (INR/L) IRR @ Sales Price (INR/L) 40 45 50 40 45 50
500 tpd 1,500 12.1% 14.3% 16.3% 15.3% 17.8% 20.4% 3,000 10.3% 12.5% 14.6% 13.1% 15.7% 18.3% 4,500 8.4% 10.8% 12.9% 10.9% 13.6% 16.2%
Plant size
Feed Cost INR/t
TIC – high $ 368 M TIC – low $ 292 M IRR @ Sales Price (INR/L) IRR @ Sales Price (INR/L) 40 45 50 40 45 50
1,500 tpd 1,500 21.3% 24.8% 28.3% 27.0% 31.5% 36.2% 3,000 18.5% 21.9% 25.4% 23.3% 27.8% 32.3% 4,500 15.7% 19.1% 22.5% 19.8% 24.1% 28.6%
4. Economics Indicative Indian economics based upon FEL-2 (±30%) estimates (no char sales)
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500 tpd 1000 tpd 1500 tpd
PLANT SIZE
8%
12%
16%
20%
24%
28%
32%
36%
FEL-2 Total Installed Cost (TIC) & Opex Estimates Used TIC = Total Direct Cost (TDC) plus HO Charges, Engineering, Freight, Indirect Costs, Escalation, Contingency, etc. Opex includes fixed costs at loal rates & all variables costs, including catalyst. Assumes 40% equity and 60% debt financed at 10% interest (Indian case) No Excise duty included. No GST included. No credits or subsidies included. Owner’s costs may vary.
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For more information…
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www.cricatalyst.com/IH2
www.youtube.com/watch?v=Ea4RjMXPbR4
youtu.be/2ZBluxJelbw www.youtube.com/watch?v=lwct7PKVGcc
www.gastechnology.org/Solutions/Pages/Using-thermal-catalytic-processes-to-produce-gasoline-and-diesel-fuels.aspx
www.biofuelsdigest.com/bdigest/2017/11/15/2-25-per-gallon-biohydrocarbon-fuels-unsubsidized-biozin-licenses-ih2-technology-heads-for-commercial-scale-in-norway/
www.biofuelsdigest.com/bdigest/2016/01/05/low-cost-drop-in-renewable-fuels-licensing-activity-is-picking-up-fast-for-ih2/
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Case Studies: 1. India agricultural residues 2. Thailand agricultural residues 3. Indonesia agricultural residues 4. Singapore municipal residues 5. Bangkok municipal residues
Addenda
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Case study 1: India agricultural residues
“Promoting Low Carbon Transport in India, Second-Generation Biofuel Potential in India, Sustainability and Cost Considerations.” P. Purohit, G. Fischer; IIASA Laxenburg, Austria. UNEP Study published June 2014.
1M tonne/day IH2 plant capacity 28B gpy ‘drop in’ hydrocarbon fuel 42% of crude oil import (4.4M bpd) 2017 223-285M tonnes CO2 avoided/annum
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produced used residual IH2®fuelAgriResidue Mton/yr Mton/yr Mton/yr moisture* kt/yrRicestraw 10.7 1.09 9.64 10% 2030Ricehusk 4.6 3.68 0.92 12% 189Caneleaves/tops 7.81 0.82 6.99 9% 1485CaneBagasse 7.64 7.64 0 51% 0Cornleaves/stalks 3.27 0.16 3.11 40% 437Corncobs 0.96 0.74 0.16 42% 22Cassavaroots 4.17 0 4.17 59% 396Palmtrunk 1.44 0 1.44 48% 174Palmleaves/branch 10.5 0.33 10.2 78% 525PalmEFB 2.39 1.42 0.97 59% 94Palmfiber 1.42 1.42 0 39% 0Palmshell 0.3 0.3 0 12% 0Rubbertreeroot,stump,branch 0.81 0.07 0.74 55% 78Soyleaves,stems 0.21 0.01 0.2 11% 42Mungleaves,stems 0.11 <0.01 0.11 11% 23
Peanutbeanleaves,stem 0.05 <0.01 0.05 11% 1038.7 5505
http://weben.dede.go.th/webmax/sites/default/files/24.png; *ash assumed to be 10% in each case
66k tonne/day IH2 plant capacity 1.9B gpy ‘drop in’ hydrocarbon fuel 15% of crude oil import 25-32M tonnes CO2 avoided/annum
Case study 2: Thailand agricultural residues
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Case study 3: Indonesia agricultural residues
436k tonne/day IH2 plant capacity 13.8B gpy ‘drop in’ hydrocarbon fuel 300% of imported gasoline 110-140M tonnes CO2 avoided/annum
*this corresponds to 326 million barrels/year of gasoline, jet and
diesel fuel. Pertamina expected to import 108 million barrels of
gasoline in 2018 per Reuters. 110-140 million tonnes/a CO2eq
saved
Residue
Crop Type %ofFFB (ton/year)
Palm EFB(t) 21.0% 21,018,829
Fibre(t) 15.0% 15,013,450
Shells(t) 6.5% 6,505,828
Frond 8,500,000
Trunk 34,100,000
Rice Husk 13,811,200
Straw 34,528,063
Sugar Bagasse 9,752,960
CaneTrash 4,500,000
Rubberwood 41,000,000
188,730,330
FuelProduced
(ton/year)
3,934,725
2,810,518
1,370,127
2,076,000
5,058,000
2,289,206
5,341,491
1,988,043
601,965
7,312,760
32,782,836*
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WasteType(2016)Waste
Disposedof(tonnes)
WasteRecycled(tonnes)
WasteGenerated(tonnes)
RecyclingRate(%)
Construc[onDebris 9,700 1,585,700 1,595,400 99%
Ferrousmetal 6,000 1,351,500 1,357,500 99%
Non-Ferrousmetals 1,300 95,900 97,200 99%
Usedslag 4,100 247,000 251,100 98%
Scraptyres 3,000 29,700 32,700 91%
Wood 119,100 411,600 530,700 78%
Hor[culturalWaste 111,500 209,000 320,500 65%
Paper/Cardboard 576,000 607,100 1,183,100 51%
Glass 57,600 14,700 72,300 20%
Ash&Sludge 199,000 28,300 227,300 13%
Food 679,900 111,100 791,000 14%
Tex[le/Leather 139,800 10,900 150,700 7%
Plas[cs 762,700 59,500 822,200 7%
Remainder(Stones,etc) 375,500 7,000 382,500 2%
Total 3,045,200 4,769,000 7,814,200 61%www.nea.gov.sg/energy-waste/waste-management/waste-statistics-and-overall-recycling www.ema.gov.sg/cmsmedia/Publications_and_Statistics/Publications/SES/2016/Singapore%20Energy%20Statistics%202016.pdf table 3.11
Case study 4: Singapore municipal residues
3k tonne/day IH2 plant capacity 100M gpy ‘drop in’ hydrocarbon fuel >13% of transport fuel consumed 2014 677-866k tonnes CO2 avoided/annum Ignores CH4 effects from MSW
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Total MSW in Thailand 26.85M t/y (73.6k t/d) generated 13.4M t/y (37k t/d) (50%) ‘incorrectly disposed’
7.15M t/y (27%) from serviced areas 6.38M t/y (24%) from unserviced areas
20.2k t/d MSW from 5 urban centers:
Bangkok (11.5k t/d) Chon Buri (2.5k t/d) Nakorn Ratchasima (2.3k t/d) Samut Prakarn (2.0k t/d) Khon Kaen (1.9k t/d)
27% of 20.2k t/d MSW = 5.4k t/d (Thailand) Target this material as feedstock for IH2 plant Assume 50% moisture, 10% ash = 2.5k MAF t/d 2.5k MAF t/day = 80M gallon fuel/year 27% of 11.5k t/d = 3.1k t/day (Bangkok) 1400 MAF t/day = 45M gallon fuel/year
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Thailand State of Pollution Report 2015, page 75. Pollution Control Department, Ministry of Natural Resources and Environment. PCD 06-062. ISBN 978-616-316-327-1
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Case study 5: Bangkok municipal residues