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CHEMICAL$ & Fuels from Biomass Norm Olson P.E. Program Director, BECON Facility Biomass Energy...
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Transcript of CHEMICAL$ & Fuels from Biomass Norm Olson P.E. Program Director, BECON Facility Biomass Energy...
CHEMICAL$ & Fuels from
Biomass
Norm Olson P.E.Program Director, BECON Facility
Biomass Energy CONversion
Iowa Energy Center
www.energy.iastate.edu
The Iowa Energy Center’s MissionThe Iowa Energy Center’s Mission
• Broad Scope– complex connections
to many issues– focusing on Iowa– energy efficiency– renewable energy– education
• all groups• all ages• all sectors of the
economy
• Broad Scope– complex connections
to many issues– focusing on Iowa– energy efficiency– renewable energy– education
• all groups• all ages• all sectors of the
economy
HistoryHistory• Created by the 1990 Iowa Energy
Efficiency Act– Funded by surcharge on intrastate electric
& gas sales– Conducts and sponsors demonstration,
education, training and research through partnerships and competitive grants with Iowa’s colleges, universities & private non-profits
• Created by the 1990 Iowa Energy Efficiency Act– Funded by surcharge on intrastate electric
& gas sales– Conducts and sponsors demonstration,
education, training and research through partnerships and competitive grants with Iowa’s colleges, universities & private non-profits
Twin PillarsEnergy Efficiency
$7.5 billion – Res., Comm., Inds.20% savings in all buildings$1.5 billion annual savings$9 billion construction activity64,000 person-year new jobs
Alternative Fuels
NH3 fuel$5.8 billion locally produced fuels$3 billion fuel production facilities # New jobs?
Biorefinery$120 billion new economic output $30 billion new jobs (25%)425,000 new jobs (manufacturing)
– energy efficient building systems
– Demonstration, training and research
– tours– meeting/class space
Demonstration/Training/Research Facilities
Energy Resource Station (ERS)
Demonstration/Training/Research Facilities
BECON (Biomass Energy CONversion)
renewable energy/ biomass to fuels and chemicals
• demonstration and research
• tours
• meeting/class space
renewable energy/ biomass to fuels and chemicals
• demonstration and research
• tours
• meeting/class space
World Energy Facts
Oil Experts See Supply Crisis in Five Years
International Energy Agency
July 10, 2007
April 27, 2007
172 Militants Planning Attack on Oil Fields Arrested in Saudi Arabia
Friday, April 27, 2007
Crude Oil Reserves
Compiled from “Worldwide Look at Reserves and Production,” Oil & Gas Journal, Vol. 104, No. 47 (December 18, 2006), pp. 24-25.
World Crude Oil Reserves Jan 2007
1,317.4 billion barrels 7,749 quads
(Coal: 22,171 quads)
(NG: 5.500 quads)
OPEC Share (68%)
Natural Gas Reserves
APupdated 9:26 a.m. CT, Wed., Jan. 7, 2009KIEV, Ukraine - Russia shut off all gas supplies to Europe through Ukraine on Wednesday — leaving more than a dozen countries scrambling to cope during a winter cold snap. Prime Minister Vladimir Putin publicly endorsed the move and urged that international observers be brought into the energy dispute.
World Total: 5500 Tcf, 5500 quads(Petroleum: 7749 quads)(Coal: 22,171 quads)
Source: PetroStrategies, Inc.
(3.3%)
Coal Reserves
USDoE - EIA, unpublished data, Coal Reserves Database (April 2007). World Energy Council, 2004 Survey of Energy Resources, Eds. J. Trinnaman and A. Clarke (London, UK: Elsevier, December 2004).
World Recoverable Coal Reserves, Jan 2003
997.7 billion short tons22,171 quads
Oil: 7,749 quadsNG: 5.500 quads
Organisation for Economic Co-operation and Development
Enough Biomass?2002 Consumption Quads
Petroleum 38.11
Natural Gas 23.37
Coal 22.18
Nuclear 8.15
Renewable 5.25
Corn potential (including stalk, 10 bil. bu.) 8.40
The Ideal Alternative Fuel
• Can be produced from any raw energy source (i.e. wind, solar, biomass, coal, nuclear, hydro etc.)
• Is cost effective• Has significant storage and delivery systems already
in place• Is environmentally friendly• Can be used in any prime mover (i.e. diesel engines,
fuel cells, SI engines, gas turbines, etc.)• Has a proven, acceptable safety record • Produced in the U.S.
Ammonia Basics 1
• Ammonia (NH3) can be produced from any raw energy source, including all fossil, renewable and nuclear sources.
• Ammonia is cost competitive with gasoline as a transportation fuel
• Ammonia has extensive, worldwide transportation and storage infrastructure already in place
• Ammonia is very environmentally friendly when used as a transportation fuel and produces only N2 and H20 at the tailpipe with low-cost emissions controls.
• Ammonia has been successfully demonstrated in SI engines, CI engines, and fuel cells.
Ammonia Basics 2
• High U.S. cost is due to high cost of U.S. natural gas
• The U.S. imported over 50% of it’s nitrogen fertilizer for the first time in 2004
• Ammonia high cost partially due to highly seasonal nature of use (inefficient use of infrastructure)
• Ammonia has been produced from coal in Beulah, North Dakota for decades. China has huge coal to ammonia capacity.
Dakota Gasification
Over 20 years of producing natural gas, ammonia and other valuable chemicals from US coal.
Al Lukes - $4.50 Nat. Gas from new coal gasification plants.
Fuel Costs• June 2003 Chemical Market Reporter*
$/MMBtu• Ammonia - $200/metric ton* $10.01• Gasoline - $1.20/gallon $10.52• Methanol - $0.79/gallon* $13.68• Ammonia - $270/short ton $14.86• Ethanol - $1.25/gallon* ($2.70, 9/05) $16.44• Gasoline - $2.00/gallon $17.54• Wind - $0.035/kwh x 2 (electrolyzer) $20.51• Gasoline - $2.50/gallon $21.92• Ethanol - $2.70/gallon (9/05) $35.51
Future Compatibility
Hydrogen + Nitrogen
Ammonia
Storage & Delivery – Pipeline, Barge, Truck, Rail
Stationary Power Fertilizer Transportation
Ammonia Pipeline
Ammonia Storage & Transport
Freedom Car Targets w/ 2005 NH3 Comparison
2005
Parameter Units 2007 2010 2015 NH3
Spec. Energy kWh/kg 1.5 2 3 3.0
Energy Density kWh/L 1.2 1.5 2.7 2.7
Storage Cost $/kWh 6 4 2 3.1
Fuel Cost $/gal. Gas equiv 3 1.5 1.5 1.7*
*$280/ton ammonia
High “energy density” in ammonia and ammonia solutions
0
5
10
15
20
25
30
35
MJ/Liter
Gasoline Methane Methanol LiqHydrogen
10Ksi H2 Liq NH3 Solid Urea 50% SOH
ENERGY DENSITIES
Carbon Energy Density
H2 Energy Density
Economic ImpactsPetroleum Imports (2003): ~ 13 million bpd
= $118 b/year @ $25/bbl, $236 @ $50, $354 b@$75, $472 b @$100
2006 U.S. Trade Deficit - $763 billion
2003 Gasoline Consumption – 8,756,000 bbl/day
15.3 x 1015 Btu/year = 850 million ton/year ammonia
1250 new plants @ 650,000 ton/year each
$562 billion investment @ $450 million/plant
375,000 new jobs
$5 billion new tax revenue/year (employees only)
Back to BECON
BECON
The Ideal Biomass System• Soil tilth improved – no erosion loss, increased soil organic
carbon content • Nutrients and micronutrients returned to soil• Fertilizer made from plant residue in same field• Use of currently available planting, harvesting storage
techniques• No fossil fuel use• Cost effective• Local economic development• Biorefinery concept – multiple products (food, chemicals, fuel
additives) energy efficient, low air/water emissions, low water use
Ideal Annual Crop System – Silage Harvest
Ideal Annual Crop System – Silage Storage
Wisconsin
Ideal Annual Crop System – Cover Crop
www.leopold.iastate.edu/.../cover.htm
Local Processing – All nutrients (PKN, micronutrients) returned to soil. Closed loop.
Ideal Annual Crop System – Processing
Nutrients
University of Nebraska - Nitrogen is one of sixteen chemical elements essential for plant growth(1). Green plants must be able to assimilate all sixteen nutrients to carry on cell growth and metabolic activities. Plants get oxygen (O), carbon (C), and hydrogen (H) from the air and water, the other nutrients are taken from the soil. Nitrogen (N), phosphorus (P), potassium (K), are sometimes referred to as the primary nutrients while calcium (Ca), magnesium (Mg), and sulfur (S) are referred to as secondary nutrients. Another seven essential nutrients are taken up in much smaller quantities and are collectively referred to as micro-nutrients. These are: boron (B), chlorine (Cl), copper (Cu), iron (Fe), manganese (Mn), molybdenum (Mo), and zinc (Z). Table 1 lists the total crop removal of soil nutrients to produce a 150 bushel corn crop.
(1) Cobalt has not been proven essential for higher plant growth but nodulating bacteria need it for fixing atmospheric nitrogen in legumes. It therefore sometimes will appear in a listing of essential nutrients.
Table 1.Total Crop Removal, lb/acre of Essential Soil Nutrients by a 150 bushel corn crop. Nitrogen 200
Phosphorous (P
2
O5) 85
Potassium (K
2
O) 200 Calcium 42 Magnesium 44 Sulfur 25 Zinc 0.15 Iron 0.10 Manganese 0.08
Boron 0.06 Copper 0.05 Molybdenum 0.03 Chlorine unknown
Outreach•A cooperative education/training agreement, led by DMACC, has been developed with all 15 Iowa Community Colleges
•Nearly 8000 people have either toured BECON or heard the BECON presentation since 1999.
•Visitors from most states and over 30 foreign countries
•BECON is a National Biodiesel Training Center
•Numerous state and Federal legislators, Presidential candidates and former U.S. President George Bush have visited BECON
Conversion SystemsConversion Systems
Biomass Conversion Systems
Feedstock ProcessingFeedstock Processing
Thermochemical ConversionThermochemical ConversionBiological ConversionBiological Conversion
Anaerobic Anaerobic Digestion/CompostingDigestion/Composting
Feedstock Processing
High Solids Unit(Composting)
Low Solids UnitScrubberScrubber
Methane to Engine
GeneratorOr
Ammonia
Distillation
Ethanol
Residue
SaleableBy-product
Drying/Vapor Recovery
Multi-farm Storage &
Fermentation
Harvest, acidification, &
inoculation
High-sugar energy crop
Local Processing CenterLocal Processing Center
Alcohol Production II
C6H1206
yeast
enzymes2C2H50H + 2CO2
GasificationGasification
Feedstock Processing To Engine Generator
To Ash Disposal
Gasifier
ScrubberSyn-gas
PyrolysisPyrolysis
Feedstock Processing
Waste Disposal
Pyrolysis Refining
Syn-oilBio-Chemicals
Biodiesel ProductionBiodiesel ProductionChemical Reactor
Vegetable Oils
Alcohol
Glycerin
Biodiesel
Vegetable Oils + AlcoholVegetable Oils + Alcohol Biodiesel + Glycerincatalyst
Supercritical Fluids
High Pressure Reactor
Biomass
High Pressure Fluid
Product
Supercritical Fluid Chart
Combined Systems
Greenhouse
Anaerobic Digestion Unit
Fermentation Unit
Fuel Cell Unit
Electricity
Heat
CO2
Dairy Facility
Iowa Biorefinery
Bio-Refinery Model
MGP - Lakota
Biomass Feedstocks
• Agricultural Residues
• Food Processing Wastes
• Livestock Production Wastes
• Municipal Solid Waste
• Obsolete Seed Corn
• Wood Waste
Feedstock Costs• Cost of corn stover ~ 3 cents/lb. ($60/ton)
Corn @ $3.50/bushel ~ 7 cents/lb
• Consists mainly of C, H and O
• Cost of petroleum ~ 8 cents/lb ($25/barrel) 16 cents/lb ($50/barrel)
24 cents/lb ($75/barrel) 32 cents/lb ($100/barrel)
40 cents/lb ($125/barrel)48 cents/lb ($150/barrel)
• Consists mainly of C and H • Organic chemicals are mainly C, H
Feedstock Availability• 20-30 million tons of corn stover annually in Iowa
Iowa Annual Fossil Fuel Use (EIA, 1999)• 23.4 million tons of coal • 5.1 million tons of natural gas• 4.7 million tons of gasoline• 3.0 million tons of diesel fuel
45 million tons of “Big Three” organic chemicals (ethylene, propylene, benzene) used in US annually.
Biomass Components
CelluloseHemicelluloseLigninStarchSugarOilExtractivesAsh
Crude Oil Components
SulfurNapthaleneAlkyl benzenesParaffins
Benzene TolueneXylene1,2,3,4 – TetramethylbenzeneHeavy metals
Etc., etc., etc.
A Little History
• Oil came in at $1.50/barrel in the mid-1940’s ($0.0045/pound)
• Corn was approximately $1.50/bushel in 1950 (approx. $0.03/pound)
Historical Corn Prices
Source: National Corn Growers Association
Forward to the Past
• Prior to the 1940’s most chemicals were plant derived
• Celluloid, Cellophane, Bakelite, rayon, paints, adhesives
• Henry Ford Vegetable Mobile• Fermentations to ethanol, butanol, propanol
and other alcohols was common prior to the 1940’s.
Organic Chemicals vs Fuels $/Pound 2000 2008
Chemical• Ethylene (1) 0.25 0.64• Propylene (2) 0.21• Acetic Acid (20) 0.48 0.68• Citric Acid (74) 0.85• Ethanol ($1.20 - 2.50/gal) 0.19 0.40• Paper (printer) 0.80• Ammonia ($200 – 600/ton) 0.10 0.30Fuel• Natural Gas ($0.50 – 1.00/ccf) 0.12 0.24• Gasoline ($1.00 - 3.00/gal) 0.16 0.48• Coal ($1 - 2/million Btu) 0.01 0.02
Plant Based Chemicals
Chemical Production Cost/Lb Plant
M. Tons Petro. Plant %
Furfural 0.3 0.75 0.78 97.0
Adhesives 5.0 1.65 1.40 40.0
Fatty Acids 2.5 0.46 0.33 40.0
Surfactants 3.5 0.45 0.45 35.0
Acetic Acid 2.3 0.33 0.35 17.5
Plasticizers 0.8 1.50 2.50 15.0
Plastics 30.0 0.50 2.00 1.8
Source: ILSR
More Plant Based Chemicals
Polylactic acid
Plastarch
Poly-3-hydroxybutyrate (PHB)
Sorona: 1,3 propanediol (PDO), (Dupont)
Mirel: PHA, (Metbolix, ADM)
Ethyl lactate (low VOC solvent)
Ethylene, propylene
Butanol
Acetone
100’s of new pharmaceuticals
Getting There from Here
• Corn stalks - C,H,O• Sugars - C,H,O
• Ethanol - C2H6O
• Ethylene - C2H4
• Ethylene Dichloride - C2H4Cl2• Vinyl Chloride - C2H3Cl
• PVC
Getting There from Here
• Corn stalks - C,H,O
• Sugars
• Propanol
• Propylene
• Acrylonitrile
• Polyacrylonitrile
• Carbon Fiber
Getting There from Here
• Corn stalks - C,H,O• Sugars• Acetone Chlorine Gas + CO• Bisphenol A Phosgene• Polycarbonate
Biofuels 2007
• 42 Ethanol Plants in Iowa – 1st Nationally• 3.3 Billion Gallon
• 14 Biodiesel Plants in Iowa – 1st Nationally• 0.3 Billion Gallon
Some Big-time Players
• Dow/Cargill – polylactic acid – Blair, NE
• Dupont/Pioneer
• Monsanto/Dekalb
• Shell
InputsT,P&MFarmer
InputsT,P&MFarmer
Follow the Money
1990
1910
Source: ILSR
Inputs
T,P & M
Farmer
Inputs
T,P & M
Farmer
Rural Economic Potential
1999 2004
Iowa Ag. And Food Exports $3.5 Billion $4.7 Billion 24 MT Stover @ $0.02/lb. $1.0 Billion
Iowa Gross State Product $86 Billion $111 Billion24 MT Stover @ $2.50/lb. $120 Billion
Breakfast Cereal $1-$3/Pound
Clothing - $10-$100’s/Pound
Plastic Tanks - $2.00/pound
RMI Hypercar $5-$10/ poundAuto-making and associated businesses employ one-seventh of U.S. workers (approaching two-fifths in some European countries) and represent one-tenth of America's consumer spending.
W. Washington U.
GM’s Autonomy
GM’s Effort
Henry Ford’s soybean plastic
Key Benefits
• Developing systems to economically produce chemicals and fuels from biomass will spur rural economic development
• Adding value to agricultural products will enhance the profitability of many Iowa industries
• Demonstrating full-scale biomass conversion systems promotes increased adoption of these technologies
• Developing new products and technologies with export potential will strengthen Iowa’s economy (consulting)
• Producing and using biochemicals is more environmentally sound than producing and using petrochemicals
• Combining biomass research, demonstration, education and training at one facility helps focus this work and enhances exposure
What’s it Going to Take?
• Yankee Ingenuity• Research and Demonstration• Pioneer Spirit• Fortitude• Foresight• Wisdom• Integrated Systems• Political Support
Wake-up Call
WTO: China Overtakes U.S. in Exports Asian nation set to become world’s biggest exporter by 2008
The Associated PressUpdated: 9:50 a.m. CT April 12, 2007
Agriculture Looks Good