integrated home energy from waste & biomass tom horgan and noa simons february 6, 2009

Integrated Home Energy from Waste & Biomass

Tom Horgan and Noa Simons

February 6, 2009

Outline• Executive Summary

• Introduction

• Research Summary

• Integrated Home Energy System (IHES)

• Wrap Up

Executive Summary• We propose to build and market an integrated

home energy system.– Multi-fuel (Biomass, MSW, Sewage), “Clean Gasification” based– Multiple energy conversion options (CHP, Gas Gen, LF, FC) with

ability to run from NG/LPG if available

• Rationale:– Lean (saves $), Green (recycle), Mean (self sufficiency)– Clean Gasification - Enabling Technology for BTLTF

(Biomass To Liquid Transportation Fuel)– Direct competition with crude products unrealistic

Introduction• Preconception

– Alternative energy field was exploding with oil prices reaching $150/barrel in 2008

– Modern science applied to BLTTF has yielded many new concepts ready for advancement & commercialization

– New technologies could make old concepts more viable

• Expectation– Research literature, talk to scientists, down-select

concepts, develop business plan and commercialize

Introduction• Reality

– Majority of research dollars to bioethanol and bio“diesel”– Liquefaction, pyrolysis - low grade fuels for heating

• Low fraction of alkanes, upgrading methods in research phase

– FT synthesis only proven route to diesel• Highly Capital Intensive (pure syngas), nonselective

– Methanol is doable – trouble as a transportation fuel– MTG considered failed technology (durene)– Gasification technology major obstacle for all three

• Inefficient (drying), expensive (multistep cleaning)

– Energy density of green biomass ¼ of crude (out of the ground)

– Electricity is more valuable than liquid fuels

Introduction• Distributed Generation

– Electricity is the most valuable form of energy– Electricity generation only ~33% efficient nationwide

(line losses)– Household waste contains 30% of total energy used– On site generation saves money, is green and enables

sense of self sufficiency

• Critical Technology– Core technology development for distributed generation

is same for all biomass conversion processes (gasification, cleaning, drying)

• Integrated Home Energy from Biomass & Waste

• Market Opportunity (2008 Data)

http://www.eia.doe.gov/

The State of Energy

The State of Energy• Usage & Losses

https://eed.llnl.gov/flow/images/LLNL_Energy_Chart300.jpg

• World Oil Reserves

http://en.wikipedia.org/wiki/Oil_reserves

The State of Energy

• Estimates on proven reserves are historically low (reserve growth) and have been “running out” since the 30’s

• Unproven (P50) and untapped reserves available (arctic)

• Prices may not rise a quickly as predicted

The State of Energy

http://spectrum.ieee.org/jan07/4820

1% of All BiomassOn Earth

(~ 50 cubic miles proven reserves as

of 2008)

Note: All of the dewatered sludge in NYS contains enough energy for ~ 30 gas stations

=

• Comparing Fossil & Biomass Fuel Conversion

– Fossil Fuel: Millions of years worth of algae (crude) & biomass (coal) cooked and condensed by the earth

– Biofuels: Wood, sludge, farm waste, etc that needs to be dried and converted

• Crude Oil (raw) – 42.7 MJ/kg– Gasoline - 43.5 MJ/kg (~80%)– Diesel - 42.8 MJ/kg (~85%)

• Biomass/Solids – 6 to 20 MJ/kg– MTG Gasoline - 43.5 MJ/kg (< 50%)– FT Diesel - 42.8 MJ/kg (< 60%)

• 5 to 15x more input energy for BTLTF


The State of Energy

• Market Volatility


The State of Energy

Research Summary• Research efforts…

– Focused on evaluation of BTLTF technologies such as Fischer Tropsch, Methanol, MTG

– Uncovered issues with gasification that prohibited commercialization

– Shifted to catalytic gasification and ionic liquids as means of addressing issues

– Settled on distributed generation as the most promising route to profitability in biomass conversion

Research Summary• Conclusions

– Competing with crude on transportation fuels is a very tall order

– Electricity has higher value and is easier to achieve w/ biomass

– Gasification is core technology for both BTLTF and electricity generation

– Distributed generation competes with electricity on site using waste & wood (or NG)

– Integrated Home Energy System (IHES)

Research Summary• Future & Concurrent Research

– Robust Gasification• Gasification drawbacks are major impediment to

commercialization• Conversion processes all require clean syngas

(particulate and tar)• Conversion processes require different H2/CO ratio• Microchannel FT synthesis requires pure H2/CO

(free of N2 and CO)• Robust gasifier concept incorporates advanced

cleaning, CO2/N2 filtration and shift catalyst for control of H2/CO ratio

• Solution for all gasification processes

Integrated Home Energy

• Household Mass Balance (Family of 4)

FoodWaterPaperPlastics

WaterSewage

MSW

290 GPD0.1% Solids~ 7 MJ/day

8 Kg/day~91 MJ/day

Average Usage: ~320 MJ/dayWaste: ~ 100 MJ/day (~30%)Average Usage: ~320 MJ/dayWaste: ~ 100 MJ/day (~30%)

• Concept (micro CHP)

WaterSewage

SyngasSyngas

Slag

Gasifier

Feed Prep

Dewater WGS

Dryer

Cleaning/ Scrubbing

N2/CO2 Removal

MSW


WoodChips

Air


• IHES Concept– IHES is micro CHP Unit that supplies heat and

power to residence

– Gasifier accepts MSW and Biomass feedstocks

– NG/LPG can also fuel generator and be used for start up energy/emergency back up

– Net metering provides opportunity for net positive gain

Integrated Home Energy• Business Case (Avg Household, 4 people)

– Usage: 320 MJ/day 60% Electric, 40% Thermal– Annual Cost: $1800– Waste = 30% of Total Usage (92% MSW, 8% Sewage)– Assume 60% gasifier efficiency, 30% electric and 70%

thermal recovery• Gasify all MSW and 50kg wood per day • All electricity supplied with heat in excess• Wood cost = ~ $330 annually

– Annual Savings = $1800 - $330 = $1470– NG could supplement in absence of wood



• IHES Component Development– Feed preparation/pretreatment

• Chipper/shredder must be able to prepare both wood and MSW

• Grind/mixing for uniform gasification

– Dewatering• Advanced dewatering for on site sewage

treatment (much later development)

– Drying• Recover internal heat to pre-dry feed for

improved efficiency


• IHES Component Development– Gasifier

• Must supply heat & syngas from a variety of waste and biomass feedstocks

– Gas Cleaning• Cyclone, cold water quench followed by sand filter.

Research advanced methods.• CO2/N2 membrane filtration (much later

development for microchannel FT)

– Water Gas Shift• Design and implement WGS for H2/CO control


• IHES Component Development– Energy Storage

• Battery module for start up.• NG functionality can also support start up and back

up capability

– Controls & Software• Control methods for WGS (control steam on outlet

temp)• Control methods for heat rejection• Control methods for load following (much later

development)

Integrated Home Energy• Phased Development Plan

– Phase 1: Proof of Concept with Advanced Gasification Development (6 months)

• Assemble and test a simple downdraft gasifier/gas generator system on wood (Zanoni)– Downselect and purchase gasifier, gas generator, chipper, etc

– Research/validate wood gasification (mc, wood type, etc).

– Assemble/test and develop heat rejection, gas cleaning

• Advanced Gasifier Development (Horgan)– Test & Development, MSW gasification methods

– Evaluate methods of feed prep, required temperatures, etc

– Research/development/test CHP functionality


– Phase 1: Cost Estimates*• Hardware

– Purchase 2 gasifiers, NG generator (~ $10 to 15K)

– Misc tools/test equipment ($1 to $3K)

– One Computer - Zanoni ($1K)

– Additional Hardware for BOP ($3 to 5K)

• Salaries: 2 x $90K * 0.5 = $90K

• Rental: $1 to $1.5K /per month = $6 to $9K

• Total: ~ $120,000

* Should have Zanoni do this right


– Phase 2: Prototype Demonstration with More Gasification Development (6 months)

• Integrate advanced gasification, generator and CHP loop into homogeneous unit (Zanoni)– Validate CHP functionality/software & controls

– Develop detail drawings, design system layout & enclosure

– Assemble and test prototypes

• Advanced Gasifier Development (Horgan)– Test & Development of integrated shift for H2/CO control

– Research/development of membrane CO2/N2 removal


– Phase 2: Cost Estimate• Hardware:

– Custom designed gasifier & system components ($100 to $150K)

– NG Generator ($3K)– Shift reactor, software & controls ($15K)

• Software: Solid Works ($10K)

• Salaries: 2 x $90K * 0.5 = $90K

• Rental: $1 to $1.5K /per month = $6 to $9K

• Total: ~ $235/285K


• Intellectual Property– Multifuel, gasification based CHP system for

residential use– Robust Gasifier: multi-fuel, with H2/CO control and

advanced cleaning technology

• Patents– Multiple patents for multi-fuel gasifier with specific

processing methods– None found for IHES system as conceived

Integrated Home Energy• Competition

– No direct competition in Multi-fuel, gasification based residential scale systems

– Community Power Corp – Wood fueled systems for farms/light industrial

– Main competition Micro CHP NG Systems• Marathon Engine Systems: NG Micro CHP for hot

water systems• Freewatt: Forced hot air w/ 1.2 kW Honda

Generator – heat following http://www.marathonengine.com

Conclusions• Integrated home energy system is

marketable technology (< $10K in 5 years)

• Gasification development supports future, large scale work

• Need a lab and team to search the biomass research database

Backup Slides

• Fuel Value


The State of Energy

Research Summary• Liquefaction & Pyrolysis

– Do not synthesize transportation grade fuel without upgrading (undeveloped)

– Pyrolysis oils are corrosive– Biopetrol model is liquefaction of sludge to fuel

oil/burn on site – business plan claims 1yr ROI– Dynamotive works with multiple customers on

retrofitted applications (bigger/stainless steel pumps, motors etc)

– Storrs process (describe & why shut down)

Research Summary

• Fischer Tropsch Synthesis– Gasification – Synthesis– Upgrading

Research Summary• Fischer Tropsch Synthesis-

– Gasification – covered as a separate topic

– FT Synthesis Reaction Chemistry


– Product Distribution

•Low Temp FT200/240CCobaltwaxes

•Hi Temp FT300/350CIronliquids


– Reactor Design Types


– Chain growth a function of temp, pressure, catalyst type & condition, reactor design

– Exothermic reactions lead to poor temp control and wide distributions

– Slurry reactors are best but suboptimal– Microchannel reactors may play but still new (Velocys)– The more pure the syngas the better (even for CO2

and N2)– Dilute syngas leads to large reactors (higher cost)

Research Summary

• Methanol Synthesis

CompressorMethanolConvertor

Syngas Recycle Loop

Cooling/Distillation

Syngas (H2, CO (CO2, N2))

PurgeGas

Desulph SMR

Gasifier Cleaning

Natural Gas

Coal or Biomass

Methanol

Steam

O2, Air

2H2 + CO CH3OH 50 Atm, 270CCopper Oxide CatalystH = -92 kJ/mol

MTG Process

Research Summary• Methanol Synthesis

– Commercial Production mainly from NG (coal)– Max Thermal Efficiency ~65%

• Single pass 25%, Exothermic, Thermo constraints

http://bioweb.sungrant.org/Technical/Bioproducts/Bioproducts+from+Syngas/Methanol/Default.htm

Research Summary• Methanol Synthesis

– Methanol Demand• 37% formaldehyde (resins/glues for particle board and ply wood) • 21% MTBE (gasoline additive that reduces exhaust emissions) • 14% acetic acid (chemicals for adhesives, coatings and textiles)

– Used directly as a fuel…• Burns cleaner than gasoline (Higher Octane)• Corrosive to engine parts, gaskets, etc• Slower burning (advance ignition time)• Cold starting an issue (lower vapor pressure)• Absorbs water

Research Summary• Methanol to Gasoline

320C Alumina

400/420C Zeolite

Light HC, CO2, H2

2CH3OH CH3OCH3 + H2O

CH3OCH3 H2O + C2 – C5, alkenes,cycloalkanes, aromatics

Research Summary• Methanol to Gasoline

– Product Composition

– The aromatic portion is at the high end of the gasoline spec (6/29%)

– Aromatics are about 20% Durene – low melting point (icing). Separation is expensive.

– Actual efficiency 44% (Hamiton).

Research Summary• Gasification

– First step in FT, methanol, MTG, FC, generator– Biomass is heated under low oxygen

conditions (Atmospheric, > 600C)– Steam sometimes added– Volatile material driven of leaving char, steam

and tars– Char reacts with air and steam to form syngas

(H2, CO, others)

Research Summary• Gasification Reactions

Research Summary• Gasification Reactors – Small Scale

– Downdraft Gasifier• Outside dimensions (w/ hopper): 4ft h x 1.5ft d• Syngas production rate: ~ 35 ft3/lb of 15% wood• Max Capacity: ~700 lbs wood/day - 1000 ft3/h (320 MJ/h)• Outlet Temp: 50/75C after cyclone/filter

$2300 Assembled

$1400 Not Assembled

http://www.allpowerlabs.org

Research Summary• Gasification - Issues

– Gasification rated primary barrier to commercialization of BTLTF System

• Very pure syngas required (essentially H2/CO)– Systems diluted with N2, CO2 lead to large reactors– Substantial Cleaning & Scrubbing required– Biomass variability leads to syngas variability

• Holy Grail: Robust GasificationRobust Gasification– Gasification System that receives ANY carbonaceous

feedstock and returns pure syngas with tunable H2/CO ratio.

Research Summary• Gasification Reactors - Industrial

Research Summary• Economic/Energy Comparison

Research Summary• Ionic Liquids

– Air and moisture stable salts – electrically conductive, low vapor pressure, liquid at room temp

– Composed of 100% ions - large organic cat ions (~1018), small inorganic anions (much less)

– Applications: Stable solvents, acid scavenging, cellulose processing, petrochemical synthesis, transport medium, many others

– Dissolve wood & other organics (0.2 to 2mm, < 150C, < 30min)

– Safety: Low vapor pressure and highly recyclable. Some are combustible. Many are toxic if released to the environment.

Research Summary• Argyropoulos Patents

– Low Energy Pyrolysis of Wood – WO 2008/098036 A1

• IL Pyrolysis: Wood dissolved in IL, 190/200C (20 min), 10% more tar, 12% less char , 10% higher/more selective yield of distillates than Fast Pyrolysis

– Fast Pyrolysis: Pretreated w/ organic solvents, 425/500C (2s), tar, char, liquids (200+ intermediates)

– Low Energy Glucose from Wood for BioEthanol– US 2008/053139

• IL dissolved wood is easily hydrolyzed by enzymes to release Glucose for production of bioethanol

– Polymers and Composites from Dissolved Wood – US 2008/053151

• IL dissolved wood can be blended with co-polymers, polymers and functional additives to form eco-friendly (degradable) composites

Research Summary• Ionic Liquids

• Potential for Transportation Fuel Synthesis– IL Pyrolysis produces a much narrower range of hydrocarbons

with higher potential for catalytic cracking to trans fuels

– Sludge dissolution and homogenous processing to fuels

– Catalytic Gasification of Dissolved Wood (Syngas)

– Other undiscovered routes to aliphatics/aromatics

• Petrochina – Gasoline by alkylation of C4 olefins with iso-butane in ionic liquids

Research Summary• Catalytic Gasification

– Project Concepts

• Low Energy Catalytic Biomass Syngas Gasification

– Investigate routes with lower temps and pressures. Preprocessing.

• Low Energy Catalytic Sludge Syngas Gasification

– Investigate routes with lower temps and pressures. Preprocessing.

• Catalytic Fuel Gas Gasification w/ Reforming

– Steam vs. Autothermal, Modeling for feasibility (efficiency/cost)

Research Summary• Catalytic Gasification

– Syngas Methods• Noncatalytic Supercritical: (450/600C, 4000/6000 PSIG)

– Hi Cap Cost, Limited Biomass testing

• Low Temp Catalytic (225/265C, 400/800 PSIG, Pt or Ni)

– Simple organics, not tried on biomass

– Fuel Gas Methods• Catalytic Hydrothermal (350C, 3000PSIG, Ru or Ni)

– Good carbon conversion, biomass & sludge

• Supercritical Carbon Catalyzed (600C, 3700PSIG)

– Good carbon conversion, coke, ash, plugging

Berkshire Energy Lab• Robust Gasification

– No suitable biomass gasification technology exists for FT

– Require feedstock drying– Syngas must be cleaned of particulates/tars– H2/CO ratio must be fixed at 2– Feedstock variability significantly impacts gas quality.– Ability to gasify any carbonaceous feed is highly

beneficial (residential)– May be a commercial product in itself

Berkshire Energy Lab

• Robust Gasifier - Concept 1

Mechanical Grinder/Mixer

Dryer/ Pellitizer

Gasifier

Cyclone/Scrubber

Shift SyngasSyngas

Steam ControlTemp Control

BiomassRes Solid WasteSewageSludge Solvent? Char/Slag

H2 Sensor

Distributed Energy Systems

• Residential scale gasification as part of fundamental research

• Potential integration with Plug Power fuel cells when 5 KW system reaches $15k capex (~3 years)

• Methanol synthesis research - though limited applications given conversions needed

• OTHER?

Distributed Energy Systems

• Slide on Plug Power (Saratoga Energy) financials – partner?

• Slide comparing liquid fuels to electricity – why methanol won’t work

• Picture of unit

Lab Start-Up Costs

• Equipment needed (go to Fischer Scientific)• Site selection (NY, Lenox?)• New hires - skills needed (funding)• Partnerships to build

Integrated Home Energy• Notes

– Compare w/ Community Power– Need to do gasification road show– Research Co2/N2 removal– Need to talk about CHP in gasifier vs FC– Energy storage? Charge batteries? What is efficiency

of battery charging and usage?– “Microchannel Gasifier” – Gasify smaller amounts of

feed with faster throughput???


Integrated Home Energy• Syngas Conversion Comparison

– Gas Generator• Efficiency: Unknown on Syngas• CHP: Gasifier yes, Generator no• Other: Use NG generator, off-the-shelf gasifier

– Fuel Cell• Efficiency: > 30% Electric, > 80% Overall, ~ 60% w/ Gasifier• CHP: yes• Other: built in desulph, tar cracking

– Liquid Fuels• Efficiency: ~ 50% overall with significant development• CHP: yes• Other: Microchannel, N2/CO2 removal


• Component Technologies– Gasification

• Specs: Atmospheric, air blown, direct heated, 5kW• Numerous technologies available. Requires full

scale evaluation process for down selection

– http://noest.ecoundco.at/news/docs/1277_Biomass_Engineering_UK.pdf– http://www.croreyrenewable.com/index.html– http://www.associatedphysics.com/ProdServices/Gasification.html– http://www.phoenixenergy.net/– http://gasbiopower.com/home– http://www.primenergy.com/Gasification_idx.htm

• Many more…


• Component Technologies– Gas Cleaning/Scrubbing

• Initial: Cyclone (particulate), cold water quench followed by sand filter

• Research more advanced cleaning technologies for later phases

– N2/CO2 Removal• Enabling technology for residential scale

(microchannel) Fischer Tropsch process• Membrane filter technology:

– http://www.mtrinc.com/co2_removal_from_syngas.html

integrated home energy from waste & biomass tom horgan and noa simons february 6, 2009

Documents

state of energy slide

biomass waste slide

total energy

input energy

state of energy http

state of energy estimates

predicted slide

btltf biomass