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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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