Two Years Experience of the BioDME ProjectTwo Years Experience of the BioDME Project-- A complete Wood to Wheel ConceptA complete Wood to Wheel Concept
tcbiomass 2013Chicago, September 4, 2013
Ingvar Landälv,Luleå University of Technology
Sweden
Agenda
• Why was the BioDME project initiated?
• The project at a glance in 3.5 minutes
• How does the process work ?
• How was the Start-Up?
• How has the availability been?
• Did we meet BioDME Production goals?
• Is BioDME distribution difficult?
• Do the trucks function according to expectation?
• Where do we go from here?
European Project BioDME7th Framework Programme2
Volvo Group Trucks Technology3 European Project BioDME
7th Framework Programme
From VOLVO’s ”Climate Issues in Focus”Summary of results for different criteria and fuels
7 Trucks on show
Source: http://www.volvogroup.com/SiteCollectionDocuments/V olvo%20AB/values/environment/climate_issues_in_focu s_eng.pdf
Why
was
the
Bio
DM
E p
roje
ct in
itiat
ed?
CO2 emissions and primary energy usage per km of dr iving differs a lot depending on selected well-to wheel p athway
26 February 2013
4
Fuels 2010
-200
-100
0
100
200
300
400
0 100 200 300 400 500 600
Total WTW energy (MJ / 100 km)
WT
W G
HG
em
issi
ons
(g C
O2
eqv
/ km
)
Conventional gasoline
Conventional diesel
RME: Gly as chemical
RME: Gly as animal feed
Syn-diesel: CTL
Syn-diesel: GTL
Syn-diesel: Farmed wood
Syn -diesel: Waste wood, Black liqour
DME: CTL
DME: GTL
DME: Farmed wood
DME: Waste wood, Black liqour
EtOH: Wheat, Straw CHP, DDGS as AF
EtOH: Sugar cane (Brazil)
EtOH: Wheat, Straw CHP, DDGS as fuel
EtOH: Farmed wood
EtOH: Wheat straw
EtOH, Wheat, Lignite CHP, DDGS as AF
EtOH, Wheat, Lignite CHP, DDGS as fuel
EtOH, Wheat, NG GT+CHP, DDGS as AF
EtOH, Wheat, NG GT+CHP, DDGS as fuel
Biogas, municipal waste
Biogas, liquid manure
Biogas, dry manure
CTL
GTL-DME
GTL-syndiesel
Ethanol
Biogas, liquid manure
Gasoline and diesel
Source: WtW study Eucar/Concawe/JRC 2005, 2010 Vehicles(basis for EU RED/FQD default values)
RME
DME & FT
Biogas
Why
was
the
Bio
DM
E p
roje
ct in
itiat
ed?
The BioDMEconcept
Production of DME from Biomass and utilisation as fuel for transport and for industrial use
Starting date: 1 September 2008Duration 52 monthsContact: [email protected]
Total budget 28.4 M€EU funding: 8.2 M€Energimyndigheten: 9.6 M€
EUROPEAN PROJECTGrant agreement No:TREN/FP7EN/218923
BioDME Project Partners
- BioDME Plant engineering, construction and operation
- BioDME Plant owner
BioDME Project Coordinator- Engine development- Vehicle manufacturing- Field test responsible
- DME injection systemdevelopment
- Laboratory support toplant operation
- DME production technology provider
- BioDME distribution- BioDME filling stations
- DME fuel specification- Fuel Additive development
The Project at a Glance
In June 2012 Volvo together with Project Partners p roduced a film which in 3 ½ minute summarizes the BioDME pr oject covering e.g.
• Location
• Principle of the DME production concept utilizing B lack Liquor
• Potential for a Pulp Mill and for Sweden
• Truck performance
• Etc
European Project BioDME7th Framework Programme7
FILM
Pre-commissioning, Commissioning & Start-Up 2011
European Project BioDME7th Framework Programme8
June 2011
European Project BioDME7th Framework Programme9
Aminewash
H2S / CO2 to pulp mill incinerator
COshift
Carbonfilter
MeOHSynthesis 1
MeOHSynthesis 2
First single-pass MeOH synthesis featuring > 95% yie ld
Sulphurguard
MeOH (recycled)DME Product
DMEsynthesis
Water
DP-1unit
SyngasCompressor
Gas conditioning & Cleaning
DME synthesis &product purification
Off gases
Black LiquorOxygen
Gasification
Raw Methanol
DME storage
Block Flow Diagram
DME day tanks
How does the process work ?
Black Liquor Gasification
European Project BioDME7th Framework Programme10
Syngas
Carbonfilters
Filtercloggingresolved
Black Liq.
Changed qualitydue to alteredash recyclein mill fr 2009
Operate with lower syngas ratethan design
Installedon-stream
steam regene-ration
20 ton bls/d but withlower LHV than design
How was the Start-Up?
Synthesis Gas Preparation
Feed Gas
Steam
Water
Synthesis Gas
MDEA
WGS
AGRSGS-cat CO2, H2S
• Demonstration of Sulphur-rich synthesis gas water s hift
Added superheat via extra heater
MoreS componentsthan design
How was the Start-Up?
Single-pass Methanol synthesis– breaking the equilibrium limitation
Guard-reacto r
MPS
Raw MeOH
Synthesis GasLPS
S-guard
MeOH-cat
Carbonyl-guard MeOH reactors
• Stoichiometric syngas at P > 130 bar in synthesis
• Sulphur & Carbonyl Guards demonstrated
Membranefailure
Shorterlife thanPlanned*
How was the Start-Up?
*) due to higher S load than design
DME Synthesis & Distillation
• 99.5% DME directly from raw methanol
• Reduced wax production and wax removal demonstrated
DME reactor DME Purification
Light byproduct
Wax
MeOHDME
MeOH
DME-cat
Water
Minorredesign
How was the Start-Up?
BioDME Production
European Project BioDME7th Framework Programme14
Over 4 ton DME/dwas reached in Sep -12
The plant incl. gasification isoperated by 2 operators per shift
Key operation data:Gasification at 30bar/1050˚CMethanol synthesis at 130 barDME synthesis at 15 bar
BioDME toStorage
Black Liquorto gasification
Gasification
GasCleaningGas Shift,
Synthesis&
Distillation
SmurfitKappaKraftlinerPulp Mill
Did we meet BioDME Production goals?
BioDME Plant Non-availability 1H, 2012
European Project BioDME7th Framework Programme15
How has the availability been?
On stream factor, PLANNED: 50% of calendar timeOn stream factor, ACHIEVED: approx. 65% of calendar timeOn stream factor, ACHIEVED: approx. 78% of planned operation timeLongest run: 26 days followed by a planned stop
BioDME Quality Control
• Quality control of BioDME and participating in DME ISO standardization process
– Development of analysis methods for BioDME from storage tank, from the trailer and from filling stations
– LPG residues observed in filling stations, originating from trailer [1].
European Project BioDME7th Framework Programme16
Typical analysis of produced BioDME ISO draft [2]
C2 ppm wt 15
10000C3 ppm wt 160
C4 ppm wt 600
Methanol ppm wt 120 500
Water ppm wt 40 300
CO2 ppm wt 100 1000
DME (by difference)
% wt > 99.8 > 98.5
First unloading Dec. 201113 000 kg BioDME
[2]. Bollon, F. 7th Asian DME Conference, Niigata, Nov 16-18, 2011
[1]. Öhrman, O. et al. Quality control of BioDME produced via black liquor gasification. 7th Asian DME Conference, Niigata, Nov. 16-18, 2011.
Did we meet BioDME Production goals?
BioDME Production 390 tons by end of Project
European Project BioDME7th Framework Programme17
0
50
100
150
200
250
300
350
400
450
dec-11
jan-12
feb-12
mar-12
apr-12
maj-12
jun-12
jul-12
aug-12
sep-12
okt-12
nov-12
dec-12
jan-13
feb-13
mar-13
apr-13
maj-13
Pro
du
ced
Bio
DM
E,
ton
B
C
D
E
A
F 500 tons April 20, 2013
A. Authority inspectionB. Change of ceramics and catalystsC. HolidaysD. Main DME storage full + ceramic repairE. Rebuild for steam supported atomizationF. No operation during change of ownership
Did we meet BioDME Production goals?
Piteå
Stockholm
Jönköping
Göteborg
Fuel distribution as for LPG
European Project BioDME7th Framework Programme18
• Available technology modified for DME
• Safety regulations based on LPG
• ~200 k€ per filling station (+33% vs diesel)
• Easy to achieve
Four filling stations
200 m3 storage tank in Piteå
34 m3 trailer
Is BioDME distribution difficult?
Field test status 2012-12-31
• 10 field test trucks
• Accumulated mileage: 824 798 km / 512 600 mi
• Max truck mileage : 183 588 km / 115 000 mi
European Project BioDME 7th Framework Programme
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
km
Date
Total Field test mileage
Do the trucks function according to expectation?
Emission verificationPEMS – Portable Emission Measurement System
European Project BioDME7th Framework Programme20
Cycle NOx(g/kWh)
PM(g/kWh)
HC (g/kWh)
CO (g/kWh)
EU-V EEV limits (ETC)
2.0 0.02 0.40 3.0
PEMS 20ton
1.66 0.00* 0.25 2.34
PEMS 60ton
1.72 0.00* 0.31 1.82
* Measured with AVL 483 Micro Soot Sensor
• Independent (AVL) verification after 183 000 km (11 5 000 mi) • EU-V Emissions still fulfilled
Do the trucks function according to expectation?
CHEMRECEnergy to Succeed
Chemrec Status January 2013
21
� Dec 31, 2012: Chemrec Piteå companies including pilot plants sold by
Chemrec AB to LTU Holding AB,
� Jan 1, 2013: 17 pilot plant staff employed by LTU.
� Dec 31, 2012: License agreement between licensor Chemrec AB &
HaldorTopsøe with LTU and LTU Holding. Technology rights stay with
licensors.
� Jan 30, 2013: Consortium Agreement between parties involved in
continued R&D.
� Chemrec has reduced staff awaiting long term stable regulations for
advanced biofuels. Two Chemrec Stockholm staff temporarily on leave
assigned to LTU
� Continued operation of the plants as part of LTU Biosyngas Program
10/18/2009 16
FLARE
Raw Syngas
GREENLIQUOR
Black Liquor
GAS COOLER
Oxygen
Atomizing medium
GASIFIER
QUENCH
C.W
BFW
MP-Steam
Weak Wash
CLEANSYNGAS
BFW
SULPHUR ABSORPTION
Condensate
White/Green Liquor
LP-St.
Whe
re d
o w
e go
from
her
e?
Volvo Group Trucks Technology
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
km
Date
Total Field test mileage
Extended Volvo field test8 trucks, 2013-01-01 to 2014-06-30
(1000 Km / 1000 mi) Status2013-04-08
TargetJune 2014
Total mileage 970 / 603 1 475 / 917
1 truck 200 / 124 300 / 186
Extended field test
1 million kmMay, 2013
Whe
re d
o w
e go
from
her
e?
Fuel consumption
European Project BioDME7th Framework Programme23
TruckApplication
Gross weight(Min/Max/Avg)
Typical FC Diesel Equivalent(l /10 km & mi/gal))
FH-787Regional and local haul
14/26/21 ton 2.3 / 10.2
FH-711long haul
25/50/ ton 4.1 / 5.7
FH-842local start/stop
21/57/53 ton 6.1 / 3.8
Volvo through their US branch on June 6, 2013 decided to start commercial production of
DME fuelled vehicles in the US in 2015.See:
http://www.volvotrucks.com/TRUCKS/NA/EN-US/PRODUCTS/ALTERNATIVEFUELS/
CNG/Pages/DME.aspxThe link includes:
Volvo introduction, a YouTube filmDME – “The future is here”, a YouTube filmDME – “It is all around us”, a YouTube film
and other material.
See also:www.biome.euBioDME Video
http://www.youtube.com/watch?v=cF1F7luFpnc
ThankYou!
Volvo US DME truck
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