ideas with power and energy - p2 infohouse · cryofuels’ lpmrc prototype • 85 gpd • 5...
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IDEAS WITH POWER AND ENERGY
www.cryofuelsystems.com
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Near Term Availability of
Cost- Effective Liquid Natural Gas
CryoFuel Systems, Inc. John A. Barclay
July 25, 2001
www.cryofuelsystems.com
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Global Energy Systems are in TransitionPE
RC
ENTA
GE
OF
TOTA
L M
AR
KET
100
80
60
40
20
0 1850 1900 1950 2000 2050 2100
Oil and Nautural Gas Liquids
Methane
Sustainable economic Growth
Hydrogen
Gases Liquids
Solids
Petroleum oil
Methane
"City Gas" hydrogenWhale oil
Non-sustainable economic Growth Coal
Wood
YEAR From Hefner (1993)
www.cryofuelsystems.com
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The Transportation Sector
• ~650 million vehicles worldwide; steady growth
• US has ~190 million vehicles now; ~3% growth
• In the US only ~0.05% of transportation sector fuel is Natural Gas (CNG or LNG) –Yet ~28% of overall energy supply in US from NG
– A key barrier to change is lack of established fueling infrastructure – catch 22 with fleets
– Distributed LNG/LCNG stations dispensing competitively priced fuel are essential
www.cryofuelsystems.com
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NGVs are on the move
• Economic drivers
• Air Quality Emissions
• Greenhouse gas-global 0 100 200 300
Thousands
400 500
warming is serious
• Energy security issues
• >1 MM NGVs Worldwide
A rg e n t in a
It a ly
US A
B ra z il
R u s s ia
Ve n e z u e la
N e w Z e a la n d
C a n a d a
Eg yp t
P a k is t a n
T rin id a d
In d o n e s ia
M a la ys ia
Tha ila n d
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CryoFuel Systems, Inc. designs, manufactures, and operates innovative distributed cryogenic gas purification and liquefaction systems for waste gas recovery and for producing transportable clean fuels.
www.cryofuelsystems.com
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CryoFuel’s Technology Development
• Cryogenic engineering capabilities • Conventional Liquefier Development
– 8 years and several million dollars – Analysis of best cycles for small scale applications.– Improvements to reduce costs in small applications:
• Cycle selection and optimization; • Component design (heat exchangers); • System integration for energy regeneration and recuperation.
• Gas separation technology development • Advanced Liquefier Development
– Magnetic and other refrigeration cycles—breakthrough technology.
www.cryofuelsystems.com
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CryoFuel’s LNG/LCNG Fueling StationNatural Gas Boil-off Vapor Return
Supply Line
LNG
LNG Withdrawal Line
Hig
h Pr
essu
re N
atur
al G
as
W in
Liquefier Cold Box
CNG Line
Vap
oriz
ing
HEX NG
Liquefier
Cryogenic Pump
CNG Buffer Volume Storage Tank
NG-Driven Motor
Regenerative
Purifier System Compressor
CNG
LNG
Withdraw
al Line
LNG Storage Reservoir LNG
LNG Transfer Vapor Return
LNG Line
www.cryofuelsystems.com
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CryoFuels’ LPMRC Prototype
• 85 gpd • 5 refrigerant system
• 300 psig max refrigerant pressure
• 50 psig process gas pressure
• Scaling to 5,000 gpd is no problem – many larger LNG liquefiers use MRC technology
www.cryofuelsystems.com
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Proprietary Cryogenic Bulk Purification:The Key to Open the Waste Gas Niche
INPUT 50% CH4 and 50% CO2 as input
OUTPUT CH4 had <0.5% CO2 CO2 had <0.1% CH4
SUPERIOR TO COMPETING TECHNOLOGIES
Energy efficiency Separation factor Saleable byproduct
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a ay From EPA "Candidate" Landfill Projects Only
Landfill Gas Potential in the West LNG G llons/d
LNG gallons/day
AZ 783,714
226,135
Note: Some of these may not have collection systems installed, tax credits available, yet those may be required to 137,331 install collection systems and there are efforts65,034 93,095 ID underway to renew the tax credit program.
AZ CA ID MT NV OR UT WA
More than enough waste gas to supply the market demand!
Data derived from EPA Candidate Site data base www.cryofuelsystems.com
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Unique Competitive AdvantageEquipment Sized to Match the Niche
Distribution of Landfills
250
200
150# of Landfills
100
50
0
0-5 5-10
10-15
15-20
20-25
25-30
30-35
35-40
40-45
45-50
LNG (Thousand gallons/day)
www.cryofuelsystems.com
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Fuel Processing & Distribution
Landfill Flare
Liquefier
Trash Truck
Li i
LNG
CryoFuels Storage & Wholesale Dispenser
Heavy Duty LNG Truck
ght Duty CNG Veh cle
www.cryofuelsystems.com
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Post Purification Module
ProcessStream
Pre-Purification Module
Bulk Purification Module
Liquefier
Refrigeration Module
CryoFuel’s Modular Processing Equipment
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Post Purification Module
ProcessStream
Pre-Purification Module
Bulk Purification Module
Liquefier
Refrigeration Module
(1) Power, eg. Genset
GENSET
(2) CO2 Recovery
CO2
(3) Oxygen Removal(4) LNG Storage LNG
O2
(5) Dispensing(6) LCNG or Pipeline Production
(1)
(2)(3)
(4)
(5)
(6)
Options extend System capabilities
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1. Gas from the landfill flare station enters the purifier.
2. The gas is compressed and chilled to remove water and heavy organic materials
3. Water and heavy organic chemicals are vaporized and burned in the flare.
4. Purified gas enters the adsorption beds to filter any remaining trace chemicals.
5. Last impurities are removed and incinerated in the flare.
6. Clean landfill gases, which are now methane (CH4), nitrogen (N2), and carbon dioxide (CO2), enter the vacuum cold box.
7. A cryogenic refrigerator drives the purification and liquefaction process.
8. Pure CO2 is cryogenically separated for resale.
9. N2 & CH4 are separated from the product stream.
10. N2 & CH4 is used to drive the engine for the plant. N2 is released back into the atmosphere.
11. High purity CH4 is now LNG fuel ready for distribution.
CONDENSATESUMP
CHILLER TSA REGENERATION WASTE
CO2 - LNGSEPARATION
CO2
COLD BOX
N2,
CH4
CH4
AMBIENTFLARE
CLEAN LFG
ENGINE
WASTE HEAT
FUELGAS
LNG
CO2
FLARE
LEACHATE
LFG1
2
3
4
56 8
9
10
117
Landfill Gas Purification and LNG Production
T 360.794.3755
F 30.794-4636
www.cryofuelsystems.com
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CryoFuel Sets an Industry Milestone
• Hartland Landfill, Victoria, B.C.
• Funded by CryoFuel, CAFI, and NR Can
• First LNG 17 November 2000 – 96% CH4 in LNG
• First landfill gas to LNG system with CO2 product– 99% pure CO2
• All major subsystems proven in pilot unit
www.cryofuelsystems.com
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Hartland Pilot Project Achieved All Key Objectives
• Produces LNG with ~96% CH4 from poor LFG – 38-46% CH4; 23-33% CO2; 38-14% N2; 0.4-1.1% O2 (generally first case)
• Produces 99% pure CO2 • All four process modules validated our design calculations
– Pre-purification module works • Addition of O2 removal; regeneration of adsorption beds, and other features
into the first 5,000 LNG gallon/day unit. – Bulk purification module works
• CO2 freezing heat exchanger improvements identified • Zeolite TSA polishing bed improvements identified • Operational changes to obtain continuous operation
– Liquefaction module works • Operational changes to enable smooth transition among HEXs
– Post-purification module works
www.cryofuelsystems.com
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Hartland Pilot Project Results
• Overall energy efficiency depends upon N2 concentration in LFG – Genset is a CAT engine converted to run on NG with diesel ignition – 90% generator and 32% engine gives ~28% overall conversion efficiency – Total o/p ~142 kW; therefore chemical energy input required ~500 kW – LFG flow rate required at 46% CH4 and 14% N2 is ~170 scfm @ 850 LNG – Overall system efficiency is ~64% – As N2% increases the LFG requirement decreases due to N2 rejection
• LFG demand decreases as engine fed by N2/CH4 mixture as LNG o/p drops • At ~38% N2 there is excess N2/CH4 that is returned to flare
– Overall system efficiency with ~29% N2 is ~30%. • System is very robust with regard to composition
– The same unit can produce from ~6000 LNG gal/day to ~3000 LNG gal/day as the N2 concentration varies.
– Strong incentive for LFG owner to manage landfill well to increase capital utilization and increase project ROI
www.cryofuelsystems.com
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Multiple Sources…Multiple Products
Sources Price @ Source Wholesale Price Price at End User Value Added
~$0.25/MMBtu
$0.40/LNG Gallon $5.25/MMBtu $0.72/LNG Gallon
LNG in Vehicle ~$0.40/MMBtu
$1.20/DEG Taxes
Storage $9.25/MMBtu
Distribution ~$1.00/MMBtu Dispensing
$0.48/LNG Gallon $ Margin$5.59/MMBtu
~$3.50/MMBtu $0.69/LNG Gallon
$8.04/MMBtu www.cryofuelsystems.com
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LNG Cost Components($0.25/MMBTU Feedstock)
$/G
allo
n
Return on Capital Feedstock for
$0.60
$0.80
LNG Feedstock for
$0.40 SystemMaintenance:
$0.20 Parts Maintenance:
$0.00 Materials Maintenance:5000 3000 1500 Labor Operator LaborGallons/Day
CO2 Sales Revenue Potentially Worth $0.02-0.10/gallon. Not Shown www.cryofuelsystems.com
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Economic Advantage of LNG
Diesel LNG Wholesale from waste gas site $0.40 Transportation/Distribution .10 Delivered to Station $1.158 .50 Federal Tax .243 .119 State & Local Tax .299 .111 Energy Content Adjustment 0 .511 Delivered to Tank 1.70 1.241 Fuel Savings per diesel gal $0.459
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5,000 GPD Plant
• Spec Gas: (to produce 5,000 gpd) – CH4-45% CO2-39% N2-10% O2<2% H2O saturated – 1.2 MMscf/day
• Production rate function of gas composition (eg 2% N2 yields > 5,500 gpd from same inlet flow)
• LNG quality: >97% CH4 (Note: if higher N2 tolerable, production increases significantly)
• CO2: ~20 tons/day. Hartland is 99+% pure • Price: ~$1.3 MM excluding genset. Progress payments
assumed. • O&M: ~$100,000 per year assuming operator involvement
spread over multiple projects.
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LNG from Landfill Gas: The Business Requirement
• Gas resource owner • Gas field operator • Equipment design/build/installer • Project owner/financier • Project operator • Products marketer • Products offtaker (wholesale? retail?) • LNG consumption technology supplier • LNG consumer
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