Institute of Wood Technology and Wood Biology (HTB),

Hamburg, Germany

PYROLYSISPYROLYSIS ActivitiesActivities in Germanyin Germany

IEA BIOENERGY Task 34 - Pyrolysis15 September, 2009, Sheraton Chicago Hotel & Towers

Dietrich Meier

Institute of Wood Technology and Wood Biology (HTB)

Status of Pyrolysis Status of Pyrolysis ActivitiesActivities in Germanyin Germany

! Pyrolysis for syngas => Diesel, DME– CHOREN

– BIOLIQ (FZK)

! Pyrolysis for liquid => Power/Heat– PYTEC

– Haloclean

– PYREG

! High pressure liquefaction– IBH Engineering

Institute of Wood Technology and Wood Biology (HTB)

CHOREN - CHOREN - YesterdayYesterday

On 31.1.1990, 4 employees at the ORGREB Institute for Power Stations tookthe plunge into self-employed, setting up a company called Umwelt- undEnergietechnik Freiberg (UET) GmbH, the current CHOREN TechnologiesGmbH.

The portfolio of the young company included process technology forsteam fluidized bed drying, analyses services for optimizing power stationplant sand many other energy processes.A 1992 order to evaluate a

gasification process for waste products marked a turning point in the furtherdevelopment of the company. From that time on, the UET engineersconcentrated on refining and gasifying organic raw materials for energypurposes.

By 1993 the company was already applying for the first patents inthis field.The company changed direction. A joint venture between UET and amechanical engineering company in the state of Lower Saxony led to theformation of CRG Kohlenstoffrecycling Ges. mbH. It was the forerunner ofCHOREN. The company s declared aim was to make significant improvementsin using biomass for energy purposes through gasifying and refining. TheCarbo-V Process opened up an enormous opportunity. A new idea was born:

putting "the Sun into your fuel tank"!

Institute of Wood Technology and Wood Biology (HTB)

CHORENCHOREN recentlyrecently

The construction and start-up of a 1MWth Carbo-V pilot plant (AlphaPlant) in Freiberg in 1998 marked an important milestone. The

process was then thoroughly tested. Our engineers successfullyexperimented with a wide variety of feedstock including untreatedwood, various types of recycled lumbar, what is known as “drystabilate” from waste processing, meat and bone meal, black coaland lignite.

By the end of 2004, the plant had been operatingsuccessfully for more than 22,500 hours.In 1997 CRG and key UETmanagers acquired the workshops of the German Fuel Institute.They were then able to bring on board important expertise formanufacturing core equipment for various types of gasificationtechnology from within their own group of companies. The companynow responsible is called TAF, Thermische Apparate Freiberg GmbH,the current CHOREN Components GmbH. CRG later changed itsname to CHOREN Industries GmbH to reflect its new fields ofbusiness and was by then in a position to manage the completevalue chain from idea conception through to production processes.

Institute of Wood Technology and Wood Biology (HTB)

CHORENCHOREN recentlyrecently

In 2001 the company demonstrated that it was possible to convert

biomass into a raw Fischer-Tropsch product, even though initialamounts were very small.

A 150 kW gas engine also successfully ran on Carbo-V gasfor 600 hours.Other developments followed rapidly. In November2002 the foundation stone was laid for the construction of the first

industrial-scale Carbo-V prototype plant (with an capacity of 45MWth) for refining biomass (char production plant) at the Freibergsite. The construction work took only 10 months and the plant(Beta Plant) went into operation in September 2003.

The Alpha Plant was expanded to include an automotivefuel synthesis facility. As a result, CHOREN was able to produce thefirst synthetic automotive fuel from wood chips in April 2003. This

took place within a combined research project sponsored by theGerman Federal Ministry of Economics and Labor. Our cooperationpartners DaimlerChrysler AG and Volkswagen AG also joined theproject.

Institute of Wood Technology and Wood Biology (HTB)

CHOREN - CHOREN - TodayToday

CHOREN now has extensive know-how in gasifying biomass andmanufacturing synthetic automotive fuels. The many years ofdevelopment work are now starting to bear fruit. CHOREN haspositioned itself as a future producer of renewable syntheticautomotive fuels and for this purpose has established projectcompanies such as CHOREN Fuel Freiberg GmbH & Co. KGcurrently in the process of building the first scale up productionfacility.The building phase of World’s First Commercial Synthetic BiofuelProduction Plant has been successfully completed in April 2008.An important phase now follows - the commissioning of the plant,which will result in production of up to 18 million litres of BTL. Thecommissioning will take place in stages over several months. 113sub-systems in 26 main operating units will be put into operationindividually and then consequetively.But it is not only thecompany’s goals that have grown. The number of personnel hasincreased too. The number of employees in the CHOREN Grouppassed the 230 mark in early 2008.

Institute of Wood Technology and Wood Biology (HTB)

CHOREN -CHOREN - 24 August 200924 August 2009

...Currently the world’s first commercial BTLproduction plant, the so called Beta plant, isstarting up in Freiberg. The production ofsynthesis gas is due to start in autumn ofthis year. Fuel production with an annualcapacity of 15,000 t of BTL is scheduled tobegin in early 2010...

Institute of Wood Technology and Wood Biology (HTB)

CHOREN - CHOREN - TomorrowTomorrow

With a targeted production output of 1 milliont/a, CHOREN intends to capture a considerableshare of the future market for renewablesynthetic biofuels. Five large-scale industrialproduction units, each with an annual production of

200,000 t/a, will be built in Germany and at the

same time the Carbo-V Process will becommercialized for use in combined heat andpower plants.

Institute of Wood Technology and Wood Biology (HTB)

CHOREN IndustriesCHOREN Industries sundieselsundiesel® (8000 kg/h)® (8000 kg/h)

Institute of Wood Technology and Wood Biology (HTB)

CHOREN - Alpha plant (operationalCHOREN - Alpha plant (operational sincesince 2003)2003)

Institute of Wood Technology and Wood Biology (HTB)

CHOREN AlphaCHOREN Alpha PlantPlant

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CHOREN - Beta plantCHOREN - Beta plant

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CHORENCHOREN BetaBeta Plant 2008Plant 2008

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CHORENCHOREN PyrolyzerPyrolyzer

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CHORENCHOREN Hight TemperatureHight Temperature GasifierGasifier with Tarwith TarOxidation andOxidation and Endothermic QuenchEndothermic Quench

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CHORENCHOREN Scale-upScale-up Beta=>Beta=>SigmaSigma

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CHORENCHOREN SigmaSigma 11 plannedplanned

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BioliqBioliq®® ProcessProcess, FZK (500 kg/h), FZK (500 kg/h)

Status

• Test phase of pyrolysis plant

Involved Partners

• FZK

• Lurgi

Institute of Wood Technology and Wood Biology (HTB)

BioliqBioliq Plant ConstructionPlant Construction

Institute of Wood Technology and Wood Biology (HTB)

D.M.2 (Blue Tower D.M.2 (Blue Tower HertenHerten), 200 kg/h), 200 kg/h

Off-gases

Flue gases

Product gas

Steam

Biomass

PYROLYZER

REFORMER

PREHEATER

COMBUSTOR

Ash

Involved Partners

• H2NRW

• D.M.2

Status

• Test phase

• New porject with 2600 kg/h)

Institute of Wood Technology and Wood Biology (HTB)

BTO®BTO® Process pilot Process pilot plant (250plant (250 kg/h)kg/h)

Involved Partners

•PYTEC

•TEC

•vTI

•Universities

Status

•Optimization tests

•Pyrolysis plant

•Diesel engine

•Malliß Project ongoing (48 tpd)

Institute of Wood Technology and Wood Biology (HTB)

BTO® Plant 2009BTO® Plant 2009

Institute of Wood Technology and Wood Biology (HTB)

PYTECPYTEC‘‘s Mallißs Malliß Project (48 Project (48 tpdtpd))

Transformators

Gasifier

Pyrolyser

Product recovery

Pyrolyser

Office

Storage material

Storage biooil

Storage wood chips

Dryer

Product treatment

8 x CHP

Storage char coal

Storage wood chips

Control room

washroom

Institute of Wood Technology and Wood Biology (HTB)

HalocleanHaloclean®® forfor ElectronicElectronic WasteWaste andandBiomassBiomass

Institute of Wood Technology and Wood Biology (HTB)

HalocleanHaloclean® (50 kg/h)® (50 kg/h)

Institute of Wood Technology and Wood Biology (HTB)

PYREGPYREG for Sewage Sludge for Sewage Sludge (40 kg/h)(40 kg/h)

Institute of Wood Technology and Wood Biology (HTB)

PYREGPYREG

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HPHP DoSDoS®® ProcessProcess (50 kg/h)(50 kg/h)

Biomass

Grinding

Drying

Preheating

Slurry Phase

Reactor

Recycle

Oil

Multi-stage

Phase

Separation

Residue

H2

Condensation

Phase Separation

H2 Recovery

Distillation

Condensation

Phase

Separation

Crude Oil

Water

Water

Ash

CO2

H2

H2-Production

Gas

Involved Partners

• IBH Engineering GmbH

• Technische Werke Ludwigshafen AG (TWL)

• Univ. Appl. Sci., Hamburg (Prof . Willner)

Status

• Test phase