Alternatives to fossil jetfuel and related challenges CLIB Forum... · Squalane (from Biofene) will...
Transcript of Alternatives to fossil jetfuel and related challenges CLIB Forum... · Squalane (from Biofene) will...
© Fraunhofer UMSICHT
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Alternatives to fossil jetfuel and related
challengesCLIB Duesseldorf – 17.11.2011
Manager of Biofuels Business UnitFraunhofer UMSICHT
© Fraunhofer UMSICHT
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Biofuels Unit at UMSICHT – Vision and Scope of R&D
Development of catalytic processes
for Biofuels & Chemicals
Scale-up and Pilot Plant Operation
Employed raw materials are “mainly” bio-based:
Fat & oils, sugars, alcohols, hemi-cellulose, residues
Member of European Biofuels Technology Platform (workgroup conversion) www.biofueltp.eu
VISION : Creation of an affordable, sustainable future with chemistry
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Process Development - Biofuels and Biorefinery
» Several reactors / distillation units«
Feed ~ 0,05 - 2 kg/h
Fully automated
EEx or similar protection
High temperature and pressure
Fast and affordable sample production
Screening of process conditions
Generation of cost and engineering data
Analytical profiling of fuels & chemicals
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Statement of IATA*) on the development of Biojetfuel
Biofuels offer the greatest hope for aviation to reduce its carbon emissions. Savings of up to 80% are on the table if the industry can get it right.
There are tough challenges to overcome: aside from technical issues, biofuels must be competitive in price and available in quantity.
“It’s not only about emissions. Biofuels offer opportunities to developing countries**) to grow new livelihoods and reduce dependency on imported fossil fuels, as well as the obvious benefits to the environment and the industry. These are compelling reasons for governments to get on board.”
If airlines wait until the price is right and commercial quantities are available,biofuels might never happen
*) IATA Magazine AIRLINES International December 2010 - Jan 2011 **) e.g. 2010 Workshop Mexico “Bioturbosina” http://plandevuelo.asa.gob.mx
*) Paul Steele, IATA Aviation Environment Director
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The fuel price challenge
www.iata.org/economics Sep. 2011
1100 $/t
More than 30% of operating costs are due to fuel
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Facts and boundary conditions for Biojetfuel*)
Aviation is the strongest growing transport sector (~ 4,5% annually)
3% of man-made and 12% of transport CO2-emissions are due to aviation
EU27: air-traffic consumes 53, major airlines 20 mil. tons Kerosene (world =200)
Logistic infrastructure (refineries, pipelines, “oil”) is not evenly distributed
Very strong growth of aviation activities is expected in Southeast Asia
CO2-tax (EU-ETS) and introduction of Biofuels for aviation are game changers
EU target is 2 mil. tons (sustainable) Kerosene by 2020
Current norm for Biojetfuel ist ASTM D7566-11a (Aug. 2011)
Biofuels are state-of-the art for cars – for aviation they are in their infancy !
http://ec.europa.eu/energy/technology/events/2011_05_18_biofuels_in_aviation_en.htmhttp://www.biofuelstp.eu/air.html
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Value Chain for Biojetfuel
The focus is on the most important parts of the value-chain
RawMaterials
&Inbound
Logistics
Production Int. Logistics,
R&D, QC,Formulation,Blending
Marketing& Sales
Branding Certification
OutboundLogistics
StoragePipelines
PrimaryCustomer
SecondaryCustomer
Partner(s) Raw materials Large/Small Technology Development, IP, Manufacturing, Catalysts
Technology integration (preferred is ‘drop-in’)
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Chemistry of jetfuel – distribution of hydrocarbons
" C15 "
" C11 "
" C10 "
" C8 "
" Aromatics "
" Polyaromatics "
C11 C12C10 C13C9
C14C15
C8
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Topics covered in this presentation
a) “State-of-the-art” – Alternative Fuels > see also IATA report 2010 > serious alternatives are evaluated by ASTM
b) Selected Alternative New Approaches
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“State-of-the-art” – Alternative Fuels via Fischer-Tropsch
Fischer-Tropsch Processes: CTL, GTL, BTL
Basis Steps to Biojetfuel (FT):
„Sourcing“ of coal, (natural) gas, biomass / waste *)
Gasification of feedstock to syngas (CO/H2) and ash (!)
FT-synthesis of fuel: mixture of alkanes, naphtha, olefins
Hydroprocessing of mixture (hydro-treating & -cracking)
Separation of fuel mixtures by distillation
*) A combination of coal and biomass is possible too
> 50% of fuel costs are due to investment
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“State-of-the-art” – Alternative Fuels from Fats and Oils*)
So-called Hydrogentated Vegetable Oil (HVO) or Hydroprocessed Renewable Jet (HRJ)
Basis steps to Biojetfuel (HRJ):
„Sourcing” and multistep purification of plant / waste oils
Synthesis: Hydrotreating, Hydrocracking, Isomerisation
Separation of fuel mixtures by distillation
Major players are Neste Oil and UOP
Most advanced green technology at the moment
> 50% of fuel costs are due to raw materials
*)sustainable feedstock: camelina, jatropha, animal and frying residues
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Limiting factor vegetable oils
Data from: http://www.fas.usda.gov/oilseeds/circular/Current.asp
World Vegetable Oils
1030507090
110130150170
2007 2008 2009 2010 2011
Year
Mil.
Ton
s Total veg. oilsRapeseedSoybeanPalm Oil
Palm oil is (at least currently) a wanted feedstock for food and biofuels (Diesel and Kerosene)
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Competition for palm oil
Palm oil utilization (world)
www.biodieselspain.es Informe de mercado semanal 21, 2007
Energy
Cosmetics, Soaps
Food
Without subsidies palm oil will probably not go into fuels
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New Alternative Fuels considered by ASTM (not in D7566)
Synthesized Kerosenes Aromatics (SKA)- e.g. alkylated benzenes (important for elastomeric seals and fuel lubricity)
Fischer-Tropsch aromatics can currently not be used
Hydroprocessed synthetic paraffinic kerosene derived from fermented alcohols. Initially focused on iso-butenol. Now other variations will be considered as well
Co-mingling petroleum and biomass in refinery hydroprocessing to optimize efficiencies is currently not allowed. Separate processing and blending is required.
Synthetic biology - genetically engineered micro-organisms convert sugar to pure hydrocarbons
Pyrolysis of cellulosic biomass to synthetic crude products for additional (Hydro-)processing to yield biofuels
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Jetfuel via “synthetic biology” - Amyris
http://www.aero-news.net/index.cfm?do=main.textpost&id=5e919f97-bc2c-4ef8-b7bb-c1ff71d34f22
Bioconversionof sugar cane
H2
BiofeneTM (Farnesene)
Production in Biomin in Piracicaba as a JV with Grupo São Martinho (Brazil)
Squalane (from Biofene) will be first product on commercial sale
Also envisioned are industrial lubricants, polymers, kerosene
Analysis of sustainability for Amyris jetfuel from sugarcane is currently funded by Boeing, Embraer, Inter-American Development Bank (IBD)
ASTM screening for farnesane jetfuel has been started
Farnesane (Isomers)
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The land, distribution and logistic challenge
According to OECD (2007) the earth provides
1,5 billion ha farmland 3,4 billion ha grassland 4 billion ha forest
About 440 Mil. ha arable land is still available
80% of the available arable land is located in Latin America and Africa
50% of the available land is distributed over 7 countries:Angola, Congo, Sudan, Brazil, Argentina, Bolivia, Columbia
Refineries and infrastructure are not located where the available land is
Hence, waste and off-gases e.g. CO/CO2 are to be used to generate fuels
Biomass production not in need of land is desirable – e.g. ALGAE, WASTE
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EU project focus on algae in 2010 was on Biodiesel*)
*) e.g. ALLGAS-project incl. UMSICHT
Demonstration of large scale sustainable production of bio-fuels based on low cost microalgae cultures (10-ha-site)
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General challenges for algae-based biofuels
New SPECS for algae oil raw material are required
So far norms have been developed for vegetable oils
Many components in algae like PUFA-, phospholipids are much higher than in vegetable oils
New components like chlorophyl, carotenoids, hydrocarbons, sugarlipids and minerals are encountered
New ways of pretreatment and QC are to be developed
Many different types of algae exist, some algae are food
Cost for dry algae are ~ 1,5*) - 4 €/kg (20-30 % are oil)
*) Norsker, Wijfels, Barbosa (2010): 100 ha plant (incl. CAPEX & OPEX) tube / panel or open pond reactor with many PE-parts, free of charge CO2
and nutrients, optimized stirring and pumping system
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Cracking of waste fats/oils - e.g. Greasoline Technology*)
GasolineKeroseneDieselLPG-GasCokeCO2 /CO/H2
Part of Pilot PlantCrude Algaeoil
*) funded by BMU and EU; spin-off in Aug. 2011
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Jetfuel from lignocellulose (waste)
Redrawn from „production of jet and diesel fuel range alkanes from waste hemi-cellulose derived aqueous solutions (Huber et al. 2010)“
Critical success factor is „APR-Technology“ (Virent )
O
OHOH
n
OOH
OH
OHHO
OO
OO O
+OO
O
OOO
OOOH
Hydrolysis Dehydration
Condensation
Mild Hydrogenation
+ H2O - H2O
+H2
OOOH
Hydrotreating
+H2
Tridecane " C13 "
+
Condensation
OO
Aqueous Phase Reforming
© Fraunhofer UMSICHT
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Biofuels from alcohols – Swedish Biofuels
*) http://www.swedishbiofuels.se/wp- content/themes/swedishbiofuels/press/swedish_biofuels_v_ah.pdf
*) http://www.greenaironline.com/news.php?viewStory=1348
Biobased gasoline, diesel and jetfuel produced by condensation of lower alcohols made by fermentation
Recently cooperation with LanzaTech for BioJetfuel announced *)
Carbon monoxide (CO) is converted to ethanol (LanzaTech), followed by “chemical condensation” to alkanes (Swedish Biofuels)
Jetfuel evaluation by ASTM us under consideration **)
Technology package is not completely transparent (from patents)
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Fitting “it” into a refinery
New Technology
Crude distillates or gas mixture
Redrawn
fron Wikipedia
Atm
osph
eric
Dis
tilla
tion
Vac
uum
D
istil
latio
n
Asphalt BlowingAir Asphalt
Del
ayed
Cok
er
Vacuum Residuum
Claus Sulfur Plant
Hydrotreater
Amine Treating
Merox Treater
Catalytic Reformer
Hydrotreater
Hydrotreater
Alkylation
Merox Treaters
Gas Processing
Hydrotreater Isomerization Plant
Hyd
rocr
acke
r
Gas
olin
e B
lend
ing
Poo
l
Flui
d C
atal
ytic
C
rack
er (F
CC
)
FCC Feed Hydrotreater
Petroleum Coke
Refinery Fuel
H2S Sulfur
H2S from Sour Water Stripper
LPG
Butanes
Fuel Gas
Gas
Other Gases
Light
Naphtha
Isomerate
Gas H2 Gas H2
Heavy
Naphtha
Gas H2
Reformate
Gas H2
Kerosene
Jet Fuel
Oil
Crude Jet Fuel and / or
KeroseneH2Gas
Diesel Oil
Atm
osph
eric
Bot
tom
s
Heavy Vacuum
Gas Oil
Heavy Vacuum Gas Oil
Light Vacuum
Gas Oil
Evacuated non-condensibles
AtmosphericGas Oil
Gas H2
Gas H2
Hydrocracked Gasoline
Diesel Oil
i-Butane
ButenesPentenes
Gas
Alkylate
Diesel Oil
Gas
Gas
Coker Naphtha
(after hydrotreating and reforming)
Naphtha FCC Gasoline
Gas H2
Fuel OilFCC Gas Oil
Coker Gas Oil
Refinery and products
Atm
osph
eric
Dis
tilla
tion
Vac
uum
D
istil
latio
n
Asphalt BlowingAir Asphalt
Del
ayed
Cok
er
Vacuum Residuum
Claus Sulfur Plant
Hydrotreater
Amine Treating
Merox Treater
Catalytic Reformer
Hydrotreater
Hydrotreater
Alkylation
Merox Treaters
Gas Processing
Hydrotreater Isomerization Plant
Hyd
rocr
acke
r
Gas
olin
e B
lend
ing
Poo
l
Flui
d C
atal
ytic
C
rack
er (F
CC
)
FCC Feed Hydrotreater
Petroleum Coke
Refinery Fuel
H2S Sulfur
H2S from Sour Water Stripper
LPG
Butanes
Fuel Gas
Gas
Other Gases
Light
Naphtha
Isomerate
Gas H2 Gas H2
Heavy
Naphtha
Gas H2
Reformate
Gas H2
Kerosene
Jet Fuel
Oil
Crude Jet Fuel and / or
KeroseneH2Gas
Diesel Oil
Atm
osph
eric
Bot
tom
s
Heavy Vacuum
Gas Oil
Heavy Vacuum Gas Oil
Light Vacuum
Gas Oil
Evacuated non-condensibles
AtmosphericGas Oil
Gas H2
Gas H2
Hydrocracked Gasoline
Diesel Oil
i-Butane
ButenesPentenes
Gas
Alkylate
Diesel Oil
Gas
Gas
Coker Naphtha
(after hydrotreating and reforming)
Naphtha FCC Gasoline
Gas H2
Fuel OilFCC Gas Oil
Coker Gas Oil
Atm
osph
eric
Dis
tilla
tion
Vac
uum
D
istil
latio
n
Asphalt BlowingAir Asphalt
Del
ayed
Cok
er
Vacuum Residuum
Claus Sulfur Plant
Hydrotreater
Amine Treating
Merox Treater
Catalytic Reformer
Hydrotreater
Hydrotreater
Alkylation
Merox Treaters
Gas Processing
Hydrotreater Isomerization Plant
Hyd
rocr
acke
r
Gas
olin
e B
lend
ing
Poo
l
Flui
d C
atal
ytic
C
rack
er (F
CC
)
FCC Feed Hydrotreater
Petroleum Coke
Refinery Fuel
H2S Sulfur
H2S from Sour Water Stripper
LPG
Butanes
Fuel Gas
Gas
Other Gases
Light
Naphtha
Isomerate
Gas H2 Gas H2
Heavy
Naphtha
Gas H2
Reformate
Gas H2
Kerosene
Jet Fuel
Oil
Crude Jet Fuel and / or
KeroseneH2Gas
Diesel Oil
Atm
osph
eric
Bot
tom
s
Heavy Vacuum
Gas Oil
Heavy Vacuum Gas Oil
Light Vacuum
Gas Oil
Evacuated non-condensibles
AtmosphericGas Oil
Gas H2
Gas H2
Hydrocracked Gasoline
Diesel Oil
i-Butane
ButenesPentenes
Gas
Alkylate
Diesel Oil
Gas
Gas
Coker Naphtha
(after hydrotreating and reforming)
Naphtha FCC Gasoline
Gas H2
Fuel OilFCC Gas Oil
Coker Gas Oil
Atm
osph
eric
Dis
tilla
tion
Vac
uum
D
istil
latio
n
Asphalt BlowingAir Asphalt
Del
ayed
Cok
er
Vacuum Residuum
Claus Sulfur Plant
Hydrotreater
Amine Treating
Merox Treater
Catalytic Reformer
Hydrotreater
Hydrotreater
Alkylation
Merox Treaters
Gas Processing
Hydrotreater Isomerization Plant
Hyd
rocr
acke
r
Gas
olin
e B
lend
ing
Poo
l
Flui
d C
atal
ytic
C
rack
er (F
CC
)
FCC Feed Hydrotreater
Petroleum Coke
Refinery Fuel
H2S Sulfur
H2S from Sour Water Stripper
LPG
Butanes
Fuel Gas
Gas
Other Gases
Light
Naphtha
Isomerate
Gas H2 Gas H2
Heavy
Naphtha
Gas H2
Reformate
Gas H2
Kerosene
Jet Fuel
Oil
Crude Jet Fuel and / or
KeroseneH2Gas
Diesel Oil
Atm
osph
eric
Bot
tom
s
Heavy Vacuum
Gas Oil
Heavy Vacuum Gas Oil
Light Vacuum
Gas Oil
Evacuated non-condensibles
AtmosphericGas Oil
Gas H2
Gas H2
Hydrocracked Gasoline
Diesel Oil
i-Butane
ButenesPentenes
Gas
Alkylate
Diesel Oil
Gas
Gas
Coker Naphtha
(after hydrotreating and reforming)
Naphtha FCC Gasoline
Gas H2
Fuel OilFCC Gas Oil
Coker Gas Oil
Atm
osph
eric
Dis
tilla
tion
Vac
uum
D
istil
latio
n
Asphalt BlowingAir Asphalt
Del
ayed
Cok
er
Vacuum Residuum
Claus Sulfur Plant
Hydrotreater
Amine Treating
Merox Treater
Catalytic Reformer
Hydrotreater
Hydrotreater
Alkylation
Merox Treaters
Gas Processing
Hydrotreater Isomerization Plant
Hyd
rocr
acke
r
Gas
olin
e B
lend
ing
Poo
l
Flui
d C
atal
ytic
C
rack
er (F
CC
)
FCC Feed Hydrotreater
Petroleum Coke
Refinery Fuel
H2S Sulfur
H2S from Sour Water Stripper
LPG
Butanes
Fuel Gas
Gas
Other Gases
Light
Naphtha
Isomerate
Gas H2 Gas H2
Heavy
Naphtha
Gas H2
Reformate
Gas H2
Kerosene
Jet Fuel
Oil
Crude Jet Fuel and / or
KeroseneH2Gas
Diesel Oil
Atm
osph
eric
Bot
tom
s
Heavy Vacuum
Gas Oil
Heavy Vacuum Gas Oil
Light Vacuum
Gas Oil
Evacuated non-condensibles
AtmosphericGas Oil
Gas H2
Gas H2
Hydrocracked Gasoline
Diesel Oil
i-Butane
ButenesPentenes
Gas
Alkylate
Diesel Oil
Gas
Gas
Coker Naphtha
(after hydrotreating and reforming)
Naphtha FCC Gasoline
Gas H2
Fuel OilFCC Gas Oil
Coker Gas Oil
© Fraunhofer UMSICHT
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Summary and outlook
Big challenges are ahead of sustainable Biojetfuel
Cooperation of many “unfamiliar” players required to make Biojetfuels fly
Biofuels demand coupling of hitherto not linked value and supply chains (petrochemicals, agriculture, food, fodder, crop-sciences, biology, chemicals)
Sustainability requires to find a balance between ecological, economical and social targets, which are by nature contradictory (TRILEMMA)
Broad Biojetfuel evaluation by ASTM has been started, be prepared for surprises
Many new players try to get a foothold into the market - outcome uncertain
Prices for key commodities like energy, fuels and new commodities like CO2, algae, waste streams almost certain guarantee for an interesting journey ahead
© Fraunhofer UMSICHT
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Dr. Anna FastabendDr. Jürgen Grän-HeedfeldDipl.-Ing. Andreas MenneDipl.-Ing. (FH) Karl MellerDr. Anna GreveDipl.-Wirt.-Chem. Klaas BreitkreuzDr. Volker Heil
Leading R&D personnel at Business Unit Biofuels
Thank you for listening
© Fraunhofer UMSICHT
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Fraunhofer UMSICHT – Organization of Business Units
http://www.umsicht.fraunhofer.de/en.html
X = active in the field of Biorefinery / Fuels
X X X
X X
© Fraunhofer UMSICHT
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Sustainability Trilemma