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Wood to green gasoline using Carbona gasification and Topsoe TIGAS processesDOE Project DE-EE0002874
Presented at 8th IEA Bioenergy - Task 42 Biorefining in Chicago IL, October 4-6, 2010Niels R. Udengaard, Haldor Topsoe, Inc.
Acknowledgment & disclaimer
Acknowledgment: This material is based upon work supported by the Department of Energy, Golden Field Office, under Award Number DE-EE0002874.
Special thanks to the team members on this project for their contributions to this presentation:
Richard Knight, Project Manager, Gas Technology InstituteJim Patel, Project Manager, Carbona/AndritzJesper H. Jensen, Project Manager, Haldor Topsoe A/SKip Walston, Project Manager, ConocoPhillipsPekka Jokela, Project Manager, UPM-Kymmene
Disclaimer: This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.
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Haldor Topsoe
Year of establishment: 1940Ownership: Haldor Topsoe Holding A/S (100%)
Annual revenue (2009): About 1 billion USDNumber of employees (2009): About 2100
The Topsoe group is devoted to -
� Research and development in heterogeneous catalysis
� Production and sale of catalysts
� Licensing of technology
� Equipment supply
� Engineering and construction of plants based on catalytic processes
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Catalyst supply
� All catalysts developed in-house
� All catalysts manufactured in own facilities– Frederikssund, Denmark
– Pasadena, Texas
� Alumina base materials produced in-house
Frederikssund
Pasadena TX
Fundamental & applied researchprocess & catalyst development
� R&D is multi-disciplined– Fundamental research– Catalyst development
– Catalyst manufacturing– Pilot plant studies– Process development
– Process impact studies– Equipment development
– Computer modelling
� Topsoe annually applies 10-12% of gross revenues to support these R&D efforts
Basic ResearchFundamental Studies
Catalyst Characterisation
Industry
Scale-upPilot Operation
Computer Modelling
CatalystFormulation
ProcessDevelopment
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Process demonstration units
Business areas
� The refining industry
� The fertilizer industry
� The environmental and power industry
� The heavy chemical and petrochemical industries
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Wood to green gasoline project
U.S. Department of EnergyGolden Field Office
Liz Moore, Program Manager
Government share:$ 25,000,000
Cost share:$ 9,771,659
Period of performance:12/28/09 through 12/31/14
Project team members
-Haldor Topsoe is a leading
worldwide supplier of catalysts
and catalytic technology for fuel
conversion and upgrading.
-Provides: TIGAS process, syngas
cleanup including tar reforming
and conversion; overall project
management
-Carbona is a supplier of biomass
gasification and gas cleanup plants
-Provides: fluidized-bed
gasification, tar reforming,
commercialization support
-GTI is the developer of this
gasification technology and
owner/ operator of pilot plant test
facility
-Provides: design, construction,
and operation of pilot plant plus
modeling, data analysis,
commercialization support
- UPM-Kymmene is one of the
world’s largest pulp and paper
companies with more than 100
production facilities.
-Provides: gathering, handling and
transporting of wood; 1st
commercial plant site
- ConocoPhillips is a leading oil
refiner & contributor to TIGAS
-Provides: Liquids fuels handling,
transportation and marketing,
sample characterization, pilot
plant design, construction,
operation and scale-up assistance
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Project organization
Haldor Topsoe Inc. Niels R. Udengaard, PI
TIGAS, Catalyst/ProcessFinn Joensen
Executive Steering CommitteeAnders N. Olsen, CEO, HT Inc.
Vann Bush, Managing Director, GTIKari Salo, Managing Director, Carbona Inc.
Merl Lindstrom, VP, ConocoPhillipsPetri Kukkonen, Director, Biofuels, UPM
ConocoPhillipsScott McQueen, PM
Kip Walston, Engineering
UPMPekka Jokela, Manager, Biofuels
Carbona USAJim Patel, PM
GTIRick Knight, PM
Flex Fuel OperationsAndrew Kramer
EngineeringHekki Virto
Test OperationsAndras Horvath
Project ExecutiveBruce Bryan, R&D Director, Gasification
Test Planning/Analysis/ModelingDr. R. Slimane
Flex Fuel EngineeringDr. A.J. Aderhold
Gas ProcessingDennis Leppin, Howard Meyer
DOECOTR
TIGAS, Build/OperateArne Knudsen
Haldor Topsoe A/SJesper Hojer Jensen, PM
Project ExecutivePer K. Bakkerud, VP, New Technologies
Project objective
� Demonstrate a technology for thermochemicalconversion of woody biomass to gasoline
� Pilot plant will feed 21 ton/day of pelletized woody biomass
� Pilot plant will produce 23 BPD of gasoline blendstock
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Project work tasks
1. Budget Period 1 - pilot plant design
1.1 Preparatory activities
1.2 Independent reviews (EIR & IPR)
1.3 Preliminary process design
1.4 Engineering design
1.5 BP1 management and documentation
2. Budget Period 2 - pilot plant installation and testing
2.1 Procurement and installation
2.2 Pilot plant testing (Shakedown, Test #1, Test #2, Test #3)
2.3 Pilot plant laboratory support (as needed)
2.4 Technology evaluation
2.5 BP2 management and documentation
Pilot plant block diagram
CARBONA/ANDRITZ
GASIFICATION
TIGAS SYNGAS-TO-
GASOLINE
PROCESS
Steam
Recycled
syngas
BIOMASS
Ash
O2
Gas
cleanup &
treatment
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Carbona gasifier
BIOMASS
ASH
AIR
HOT PRODUCT GAS
CYCLONE
FLUIDIZED BED
GRID
ASH REMOVALSCREW
FEEDING SCREW
FEED HOPPER
GASIFICATIONREACTOR
6 MW POWER12 MW DISTRICT HEAT
Skive Gasification CHP PlantBFB GASIFIER
2 GAS BOILER
GAS ENGINE FLARE
3 GAS ENGINES
BFB GASIFIER
3 GAS ENGINES
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Topsoe TIGAS synthesis
Gasoline
C3-C4
Water
Gasoline Synthesis
Separation
Off-gas
Synthesis Gas
from AGR
MeOH/DME Synthesis
MP MP SteamSteam
DME synthesis reactions
– ∆H (kJ/mol)
2H2 + CO = CH3OH 90.7
2CH3OH = CH3OCH3 + H2O 23.6
CO + H2O = CO2 + H2 41.1
3H2 + 3CO = CH3OCH3 + CO2
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Optimal conversion to DME
0%
20%
40%
60%
80%
100%
0.5 1 1.5 2 2.5H2 / CO Ratio
mol-%
DME MeOHH2O
CO2
H2
CO
H2/CO
(60 bar ; 250ºC)
MeOH/DME synthesis conversion
0
10
20
30
40
50
60
70
0 10 20 30 40 50 60 70 80
MeOH / DME
MeOH
Co
nve
rsio
n (
CO
+CO
2)
Pressure (bar)
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TIGAS synthesis
CH3OCH3 = 2 “-CH2-” + H2O
(DME) (gasoline)
Topsoe TIGAS demonstration units
Gasoline Pilot PlantFrederikssund, Denmark
lb/h scale
Single-tube MeOH/DME reactor (BWR)
Adiabatic gasoline reactor
20000+ runhours
TIGAS Pilot PlantHouston, Texas - 6 bpd & 8000+ runhours
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1(Bay 3)
2
3 4 5
1(Bay 2)
1(Bay 1)
Pilot plant demonstration siteGTI Energy &
Environmental
Technology CampusDes Plaines, Illinois
1. Advanced GasificationTest Facility-Bay 1: Carbona syngasconditioning system
-Bay 2: PWR Gasification System
-Bay 3: open 5-story test bay (available for TIGAS)
2. Flex-Fuel Test Facility-Carbona biomass gasification system
3. Morphysorb®
-Absorption/strippingfor CO2 & H2S removal
4. SulfaTreat®
-Sorbent-based sulfur scavenger
5. High-pressure oxygen and nitrogen supply
Feedstock
� Feedstock: pelletized mixed wood waste – composition based on UPM's
Blandin Mill commercial case
– 25% purchased mill residue (Rapids Energy Center)
– 26% in-woods chips, logging residue
– 49% non-merchantable roundwood
� Blandin Forestry Wood Procurement organization purchases fuel
– Local pellet mill will pelletize, screen, and bag mixed feedstock
� The wood will be shipped to GTI pilot plant as needed in “Super Sacks”which are weather resistant and waterproof and will be stored in an enclosed covered storage.
– Contents will be analyzed before shipment and as used to assure no changes in critical properties
– Past experience in shipping test fuel feedstock from Finland to Chicago validates assumption of feedstock stability
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Pilot plant test plan summary
� Tests to be conducted:– 08/12-09/12: Shakedown –
sequentially test main plant sections leading to integrated steady-state operation for up to 96 hrs
– 09/12-12/12: Test #1 – Independent Engineer Test (decision point) followed by steady-state operation totaling up to 480 hrs
– 06/13-08/13: Test #2 – increase severity to maximize throughput & gasoline production at steady state for up to 480 hrs
– 08/13-10/13: Test #3 – apply optimal conditions learned from previous tests to achieve steady-state operation for up to 720 hrs
2012
Q3
2012
Q4
2013
Q1
2013
Q2
2013
Q3
2013
Q4
6-month gap
for prior
facility
commitments
15-month total pilot plant operation
Gasoline characterization & testing
� Analysis:– Detailed hydrocarbon analysis
– Specific gravity
– D86 distillation
– Reid vapor pressure (RVP)
– Octane engine test
– Gum test
– Copper strip corrosion
– Silver strip corrosion
� Engine testing at Southwest Research Institute
� Fleet testing
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Commercial biorefinery
Assumptions:Feed rate – 4,000 MT/day of wood @ $ 35/MTProduction – 5,960 bpd of gasoline + 265 bpd of LPGAnnual capital expenditure – 12.75% of TIC
3.372.70Production cost, $/gallon
300.0240.0Total production cost
3.23.2Catalysts & solvents
9.09.0Power
44.233.1G&A, tax and insurance
55.241.4Labor and others
47.647.6Cost of wood
140.8105.7Capital cost
GreenfieldCo-locationAnnual cost, $
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