T TNO Environment, Energy and Process Innovation Crude oil from biomass with the HTU ® process...
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TNO Environment, Energy and Process Innovation
Crude oil from biomass with the HTU® processExample of an Early Stage Technology
Jaap Koppejan
EMIMENT workshop, 8-9 03 2004, Riga
8 March 2004EMINENT 2t
HTU = crude oil from biomass
8 March 2004EMINENT 3t
What is HTU ?Conditions: 300 – 350°C; 120 - 180 bar
reaction time 5 - 20 minutesliquid water
Feedstocks: All types of biomass, domestic, agricultural and industrial residues, woodAlso wet feedstocks, no drying required
Chemistry: Oxygen removed as Carbon Dioxide
Products 45% Biocrude (%w on feedstock, dry basis)25% Gas (> 90% CO2)20% H2O10% dissolved organics (e.g., acetic acid, methanol)
Thermal efficiency: 70 - 90 %
8 March 2004EMINENT 4t
HTU® Product characteristics
Biocrude - Heavy organic liquid- Solidifies at 80 °C- Not miscible with water- Oxygen content 10 - 18 %w- H/C ratio = 1.1- LHV 30 -35 MJ/kg
Applications
Biocrude: (co)combustion in coal- and oil- fired power stations
After hydrogenation: - premium diesel fuel; kerosene- lubrication oils - chemicals feedstock (cracker)
8 March 2004EMINENT 5t
Perspectives for energy from biomass
1990 2040
Energy demand 350 1000
Delivered by:
Fossil fuels 255 480
Renewables 80 >400
Hydropower 20 50
Wind - 70
Solar - 130
BiomassBiomass 6060 >200>200
(Shell scenario)
8 March 2004EMINENT 6t
Global potential for energy from biomass
Energy farming on 109 ha land area @ 15 ton(db)/ha.year
250 EJ/yr
Biomass residues (Forestry, wheat, rice, sugar cane, corn,etc.
70 EJ/yr
8 March 2004EMINENT 7t
Suitable feedstocks for HTU in Europe
• Agricultural / Industrial Residues 200 Million tons/a (db)
(Source: Eurec agency, 1996)
• Short-term niches for HTU:- Olive Oil Industry 3 - 5 Million tons/a
(db)- Organic household waste 26 ktons/a
(db) per (from centralized waste separation) 250,000
inhabitants- Residues from sugar and beer production.
8 March 2004EMINENT 8t
• Agricultural and industrial residues 4,000 Mt/a (db)
(Source: “Renewable Energy; sources for (approx. 70 EJ/a)
fuels and electricity”, 1993)
• Future organic household waste 800 Mt/a (db)
(own tentative estimate)
• Short-term niches for HTU:- Organic household waste- Bagasse (> 100 Mtons/a)- Forestry residues from existing plantations- Coir dust
Suitable feedstocks for HTU worldwide
8 March 2004EMINENT 9t
Development of HTU
1982 – 1988 Process R&D, Shell Laboratory, Amsterdam
1994 – 1997 Technical-Economic evaluation of HTU technology
1997 – 2000 Process development project
2002 – 2004 Final process development
2006 – 2007 First commercial demonstration
2009 HTU diesel commercially available
8 March 2004EMINENT 10t
Technology Development Path( S - curve)
Scientific Base/ Explanatory
ProcessScouting
Techn./Econ.Feasibility
ProcessDevelopment
CommercialPrototype
HTU diesel commercially available
Next S- curve
Improvedscientific base
2006-2007
2004-2005
2000-2002
1983
2008-2009
8 March 2004EMINENT 11t
HTU pilot plant at TNO• Feed 100 kg/h (wet)• Biocrude product 8 kg/h
8 March 2004EMINENT 12t
Block scheme of HTU pilot plant
Biomass
10-20 kg/hr (db)
High pressure pump
Preheater/Reactor 1
Reactor 2 Cooler
Gas /liquid
separator
CO2
Condensor
Pressure reducer
1 barbiocrude/water collection
storage
gases
330 °C
180 bar
storage
Cooler
CO2
8 March 2004EMINENT 13t
Thermal efficiencyDefinition:
th = (HHV of biocrude output) * 100 %
(HHV of feed) + (HHV from external fuel)
For present process design:
th = 55.62 * 100% = 74.9 % 72.98 + 1.3
(Theoretical maximum for this case is 78.6 %)
8 March 2004EMINENT 14t
Upgrading of biocrude by HDO
• Principle of catalytic Hydrodeoxygenation
has been demonstrated
• Upgrading cost compensated by higher
product value
• Diesel fraction has excellent ignition
properties
• Potential applications:• Transport fuel
• Kerosine
• Fuel in high-efficient gas turbine
• Feedstock for chemicals (via ethylene cracker)
• Etc.
8 March 2004EMINENT 15t
HDO process scheme
Biocrude
Hydrogen
HDOreactorsystem
Fractionator
(from HTU)
electricity
NH3, H2S
C1-C4 gas
H2O
Kerosine
Gas oil
>370°C residue
To refininery pool
Air transport
Diesel fuel forRoad transport
Lubricating oil;chemical feedstock
Naphtha
Separatorsection
Recycle gascompressor
8 March 2004EMINENTt
0
1
2
3
4
5
6
7
8
-1 0 1 2 3
Feedstock price, $/GJ
Bio
cru
de
cost
, $/
GJ
First Plant
Coal (2 $/GJ) / Crude Oil (12 $/bbl) Replacement
Future plant
0
+ 40 $ pe
r ton
CO
2 avoid
ed
energy farmingBiomass residues
- 20
+ 20
+ 60
Production costs of biocrude and costs of avoiding one ton of CO2
8 March 2004EMINENT 17t
0
2
4
6
8
10
-2 -1 0 1 2 3
Biomass HTU Feedstock Price, $/GJ
To
tal P
rod
uct C
ost,
$/G
J
First Plant
Premium Diesel, assumed crude oil =25 $/bbl
Future plant
Biomass residues energy farming
Production costs of HTU diesel
8 March 2004EMINENT 18t
HTU® R&D topics
Most essential items:• Pressurizing feedstock• Continuous integrated operation of pilot plant
Important items• Heating – up feedstock• Oil/water separation• Product properties / applications• Effluent treatment
Design data:• Phase equilibria• Physical properties, esp. at reactor/separator
conditions
8 March 2004EMINENT 19t
Process Development
Work in autoclaves, • 10 ml, 1 liter, 2 liter• Testing of feedstocks and process conditions
Continuous pilot plant• capacity 20 kg/hour (dry basis)• commissioning 1 July 1999• first product prepared: 24 November 1999• 24 h run with verge grass feb 2004• 3 weeks run planned march 2004
8 March 2004EMINENT 20t
Results of first development phase
• Pilot plant construction completed• Pilot plant operation: - process principles verified
- most initial problems solved- 200 kg biocrude produced
• Pressurizing of feedstock successfully proven with commercial prototype pump
• Data on thermodynamics and phase equilibria obtained; model operational
• Waste water treatment routes defined• Product: various applications explored• Process design and cost estimation completed• Fundamental research to start: NWO – Japan project.
8 March 2004EMINENT 21t
Commercial HTU demonstration plant
Location: Large new waste incinerator in Amsterdam, synergy for O&M, wastewater treatment, etc.
Input: Roadside grass7 ton/h of feedstock, 3 t/h on dry basis
Output: 1,4 t/h biocrude (incl ash)
Capital investment 17 M€, startup 2006-2007
8 March 2004EMINENT 22t
Commercial HTU plant