norm olson beconpp 2 2013 v2
TRANSCRIPT
Chemicals and Fuels from Biomass
Norm Olson P.E.Biomass Energy Conversion (BECON) Facility
Iowaenergycenter.org
The Iowa Energy Center’s Mission• Broad Scope
– complex connections to many issues
– focusing on Iowa– energy efficiency– renewable energy– education
• all groups• all ages• all sectors of the economy
Demonstration/Training/Research Facilities
BECON (Biomass Energy CONversion)
renewable energy/ biomass to fuels and chemicals
• demonstration and research • tours• meeting/class space
Outreach
•Nearly 14,000 people have either toured BECON or heard the BECON presentation since 1999•BECON has had visitors from most states and over 76 foreign countries•Numerous state and Federal legislators, Presidential candidates and former U.S. President George Bush have visited BECON
EIA Outlook
U.S. 2012 Production – 8.9 million barrels per day Source: BP SR
British Petroleum R/P Ratio
Proved reserves of oil – Generally taken to be those quantities that geological and engineering information indicates with reasonable certainty can be recovered in the future from known reservoirs under existing economic and operating conditions.
U.S. R/P Ratio China R/P Ratio
2012 2013 2012 2013Oil 10.8 10.7
9.9 11.4Natural Gas 13.0 12.5 29.8 28.9Coal 239 257 33.0 31.0
Reserves-to-production (R/P) ratio – If the reserves remaining at the end of any year are divided by the production in that year, the result is the length of time that those remaining reserves would last if production were to continue at that rate.
Source: BP statistical Review of World Energy, June 2012, 2013
The Ideal Alternative Fuel• Can be produced from any raw energy source (i.e. wind, solar,
biomass, coal, nuclear, hydro etc.)• Is cost effective• Has significant storage and delivery systems already in place• Is environmentally friendly• Can be used in any prime mover (i.e. diesel engines, fuel cells,
SI engines, gas turbines, etc.)• Has a proven, acceptable safety record • Produced in the U.S.
Ammonia Basics 1
• Ammonia (NH3) can be produced from any raw energy source, including all fossil, renewable and nuclear sources.
• Ammonia is cost competitive with gasoline as a transportation fuel
• Ammonia has extensive, worldwide transportation and storage infrastructure already in place
• Ammonia is very environmentally friendly when used as a transportation fuel and produces only N2 and H20 at the tailpipe with low-cost emissions controls.
• Ammonia has been successfully demonstrated in SI engines, CI engines, and fuel cells.
Conversion Systems
Biomass Conversion Systems
Feedstock Processing
Thermochemical ConversionBiological Conversion
Anaerobic Digestion/Composting
Feedstock Processing
High Solids Unit(Composting)
Low Solids UnitScrubber
Methane to Engine
Generator
Distillation
Ethanol
Residue
SaleableBy-product
Drying/Vapor Recovery
Multi-farm Storage &
Fermentation
Harvest, acidification, &
inoculation
High-sugar energy crop
Local Processing Center
Alcohol Production II
C6H1206yeast
enzymes2C2H50H + 2CO2
Gasification
Feedstock Processing To Engine Generator
To Ash Disposal
Gasifier
Scrubber Syn-gas
Pyrolysis
Feedstock Processing
Waste Disposal
Pyrolysis Refining
Syn-oilBio-Chemicals
Biodiesel Production
Chemical Reactor
Vegetable Oils
Alcohol
Glycerin
Biodiesel
Vegetable Oils + Alcohol Biodiesel + Glycerincatalyst
Supercritical Fluids
High Pressure Reactor
Biomass
High Pressure Fluid
Product
Combined Systems
Greenhouse
Anaerobic Digestion Unit
Fermentation Unit
Fuel Cell Unit
Electricity
Heat
CO2
Dairy Facility
Iowa Bio-Refinery
Bio-Refinery Model
MGP - Lakota
The Ideal Biomass System• Soil tilth improved – no erosion loss, increased soil organic carbon
content • Nutrients and micronutrients returned to soil• Fertilizer made from plant residue in same field• Use of currently available planting, harvesting storage techniques• No fossil fuel use• Cost effective• Local economic development• Biorefinery concept – multiple products (food, chemicals, fuel
additives) energy efficient, low air/water emissions, low water use
Ideal Annual Crop System – Silage Harvest
Ideal Annual Crop System – Silage Storage
Wisconsin
Ideal Annual Crop System – Cover Crop
www.leopold.iastate.edu/.../cover.htm
Local Processing – All nutrients (PKN, micronutrients) returned to soil. Closed loop.
Ideal Annual Crop System – Processing
Biomass Feedstocks
• Agricultural Residues• Food Processing Waste• Livestock Production Waste• Municipal Solid Waste• Obsolete Seed Corn• Wood Waste
Feedstock Costs• Cost of corn stover ~ 3 cents/lb. ($60/ton)
Corn @ $3.50/bushel ~ 7 cents/lb
• Consists mainly of C, H and O
• Cost of petroleum ~ 8 cents/lb ($25/barrel)
16 cents/lb ($50/barrel)
24 cents/lb ($75/barrel)
32 cents/lb ($100/barrel) 40 cents/lb
($125/barrel)48 cents/lb
($150/barrel)• Consists mainly of C and H • Organic chemicals are mainly C, H
A Little History
• Oil came in at $1.50/barrel in the mid-1940’s ($0.0045/pound)
• Corn was approximately $1.50/bushel in 1950 (approx. $0.03/pound)
Forward to the Past
• Prior to the 1940’s most chemicals were plant derived
• Celluloid, Cellophane, Bakelite, rayon, paints, adhesives
• Henry Ford Vegetable Mobile• Fermentations to ethanol, butanol, propanol and
other alcohols was common prior to the 1940’s.
Getting There from Here
• Corn stalks - C,H,O• Sugars - C,H,O• Ethanol - C2H6O
• Ethylene - C2H4
• Ethylene Dichloride - C2H4Cl2
• Vinyl Chloride - C2H3Cl• PVC
• Corn stalks - C,H,O• Sugars• Propanol• Propylene• Acrylonitrile• Polyacrylonitrile• Carbon Fiber
Getting There from Here
Some Big-time Players
• Dow/Cargill – polylactic acid – Blair, NE• Dupont/Pioneer• Monsanto/Dekalb• Shell
Rural Economic Potential
1999 2004
Iowa Ag. and Food Exports $3.5 Billion $4.7 Billion 24 MT Stover @ $0.03/lb.$1.4 Billion
Iowa Gross State Product $86 Billion $111 Billion24 MT Stover @ $2.50/lb.$120 Billion
Breakfast Cereal $1-$3/Pound
Clothing - $10-$100’s/Pound
Plastic Tanks - $2.00/pound
RMI Hypercar $5-$10/ pound
Auto-making and associated businesses employ one-seventh of U.S. workers (approaching two-fifths in some European countries) and represent one-tenth of America's consumer spending.
Henry Ford’s Soybean Plastic
Selected BECON Commercialization and Educational Highlights
• National Biodiesel Training Center – Jon Van Gerpen – USDA Grant• Frontline – Thermal Gasification – Commercial installation of thermal gasifier at
Chippewa Valley Ethanol in Benson, Minnesota. BECON thermal gasifier developed under an IEC grant to Robert Brown.
• Cellencor – microwave drying – numerous commercial installations. Outgrew BECON and moved/expanded into the Ankeny, Iowa Industrial Park.
• Albemarle/Catilin – heterogeneous catalyst licensed from ISU (Victor Linn). Multi-year process development currently (2013) in process using BECON’s pre-commercial biodiesel production unit.
• Conoco Phillips and Avello – pyrolysis – license obtained based on Robert Brown’s IEC-funded pyrolysis work at BECON.
• Drying Solutions – energy efficient steam heat recovery dryer – several commercial installations.
• Myco Max – fungal thin stillage treatment - Hans Van Leeuwen. R&D 100 Awards. Innovator of the Year. “Graduated” to Lincolnway Energy
Key Benefits
• Developing systems to economically produce chemicals and fuels from biomass will spur rural economic development.
• Adding value to agricultural products will enhance the profitability of many Iowa industries.
• Demonstrating full-scale biomass conversion systems promotes increased adoption of these technologies.
• Developing new products and technologies with export potential will strengthen Iowa’s economy (consulting).
• Producing and using biochemicals is more environmentally sound than producing and using petrochemicals.
• Combining biomass research, demonstration, education and training at one facility helps focus this work and enhances exposure.
What’s it Going to Take?
• Pre-Commercial Demonstration• Research and Development• Pioneer Spirit• Fortitude• Foresight• Wisdom• Integrated Systems• Political Support
Agriculture Looks Good