ThermochemicalThermochemical Platform OverviewPlatform Overview

Kevin CraigSecond Meeting of S-1007

November 7, 2003Washington, D.C.

Operated for the U.S. Department of Energy by Midwest Research Institute • Battelle • Bechtel

3.0 Thermochemical Platform

Breakout of FY04 Thermochemical Platform BudgetTotal Budget Request: $78.56M

4%

22%10%

32%

13%

13%

6%

Thermal Processing

2%

Cleanup and Conditioning

3%

Thermochemical Platform Analysis

1%Feedstocks Sugar Platform Products

Integrated Biorefineries Program Management Reserve and New Solicitaions

PyrolysisPyrolysis• Thermal conversion (destruction) of organics in the absence of oxygen • In the biomass community, this commonly refers to lower temperature

thermal processes producing liquids as the primary product• Possibility of chemical and food byproducts

GasificationGasification• Thermal conversion of organic materials at elevated temperature and

reducing conditions to produce primarily permanent gases, with char, water, and condensibles as minor products

• Primary categories are partial oxidation and indirect heating

Basic DefinitionsBasic Definitions

Fuels,Chemicals &

Materials

SyngasPlatform

Sugar Platform

BiomassCombined

Heat & Power

Residues

Clean Gas

Conditioned Gas

CellulosicFeedstocks

Advanced Biomass R&D

Systems Integration

Draft MYPP milestones

2005: Demonstrate an integrated process for fuels production from biomass

2007: Complete technology development needed to enable start-up demonstration of a biorefinery producing fuels, chemicals and power

2010: Help U.S. industry to establish the first large-scale biorefinery based on agricultural residues

OBP Program ObjectivesOBP Program Objectives

Strategic FitStrategic Fit

To produce an inexpensive, clean syngas from biomass that is compatible with

existing and advanced processes for the production of fuels, chemicals, and power

Objective Objective –– Syngas PlatformSyngas Platform

MeOH

BIOMASSBIOMASS

Cofiring/Reburn

CombinedCycle

Cat: Ni/Mg

Cat: Mixed BasesNa, Ca

CaCN

Cat: Cu-ZnO Cat: Zeolite

HYDROGEN

ETHANOL,MIXED ALCOHOLS

METHANOL, DME

OLEFINS

FTL

LPG

NAPHTHA

KEROSENE/DIESEL

LUBES

WAXES

GASOLINE

OXOCHEMICALSe.g., KETONES

AMMONIA

SNG

CHP

CHP

SYNGAS

FEED PREP

GASIFICATION

CLEANUP

Cat = Catalytic Conversion Process

Cat: Ni, Fe, Cu-Zn

Cat: Ni

Cat: Cu-Zn,Cu-Co

Cat: Cu-ZnO

Cat: H3PO4, Cr2O3

Cat: Fe

Cat: Co/K

UPGRADING

Syngas ProductsSyngas Products

Strategic FitStrategic Fit

Acid GasRemoval

Feed Preparation& Handling

Synthesis

ProductCO2

CatalyticConditioning& Reforming

CompressionLP IndirectGasification

BiomassShift

Conversion CompressionLow PressureGasification

LP IndirectGasification

Compression& Reforming

Cold GasCleanup

Representative Gasification PathwaysRepresentative Gasification Pathways

Hot GasCleanup

High PressureGasification

Oxygen

CompressionReforming

CompressionCooling

and DistillationMethanol

Production

Sulfur Removal Steam ReformingNaturalGas

Steam, Oxygen

Methanol

RecyclePurge

CO, CO2, H2

Syngas

Syngas

Case 1: GTI, HGCU, ATR, shift, conv MeOH, stm turbine

Case 2: BCL, scrubbing, stm reformer, shift, conv MeOH, stm turbine

Feed prep, gasification, O2, & syngas compression = 34-38% of total capital

Clean syngas generation = 60-64% of total capital

feed prepgasificationO2 plant (Case 1 only)clean up & coolingsyngas compression (Case 2 only)reformingC O2 removalMeOH synthesis & compressionpower generation

7%

14%

15%

9%15%

9%

22%

9%

8%6%

19%

9%

22%

5%

27%

4%

Case 1: GTI, HGCU, ATR, shift, conv MeOH, stm turbine

Case 2: BCL, scrubbing, stm reformer, shift, conv MeOH, stm turbine

Feed prep, gasification, O2, & syngas compression = 34-38% of total capital

Clean syngas generation = 60-64% of total capital

feed prepgasificationO2 plant (Case 1 only)clean up & coolingsyngas compression (Case 2 only)reformingC O2 removalMeOH synthesis & compressionpower generation

7%

14%

15%

9%15%

9%

22%

9%

9%

22%

9%

9%

22%

9%

8%6%

19%

9%

22%

5%

27%

4%

5%

27%

4%

Potential ImpactPotential Impactof Overcoming Barriersof Overcoming Barriers

Critical IssuesCritical Issues

Barrier PriorityPotential CostReduction, %

Cleanup& Conditioning High 15 - 25

Syngas Utilization(Products) High 10 - 15

ProcessIntegration High 5 - 10

Thermal Processing Medium 5 - 10

Feed Processing& Handling Low 5 - 10

Sensors& Controls

Low 5 - 10

Syngas Platform Cost Curve for Fischer Tropsch Liquids

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

BaseNth Plant

Feed Handling

Gasification Gas Conditioning

SyngasUtilization

Process Integration

Co

st o

f P

rod

uct

ion

($/

GJ)

0.00

0.80

1.60

2.40

3.20

4.00

4.80

5.60

6.40

Co

st o

f Pro

du

ctio

n ($

/gal

EtO

H E

qu

iv)

550 tpd

2200 tpd

$0.16 $0.16 $0.16$0.64$0.32

Pioneer Plant Costs

Without Integrated Demonstrations

With Integrated Demonstrations

Ref: Hamelinck, et.al. (2003)

CostReduction

$/gal EtOH equiv

$0.085 $0.085 $0.085$0.17 $0.34

Strategic FitStrategic Fit

Renewable Fuels: Estimated Cost of Production and Impact of Renewable Fuels Excise Tax Credit

0 5 10 15 20 25 30 35

Natural Gas

Syngas/NG

Syngas/Biomass

Gasoline

Diesel

FT/NG

FT/Coal

FT/Biomass

FT/Biomass w Credit

Corn Ethanol

Corn Ethanol w Excise Tax

Excise Tax Credit

EtOH/Biomass ferm.

EtOH/Biomass ferm. W Credit

Methanol

MeOH/Coal

MeOH/Biomass

MeOH/Biomass w Credit

Hydrogen

H2/Coal

H2/Biomass

H2/Biomass w Credit

$/GJ (LHV)

Market Price

Cost of Production

Excise tax credit estimated using $0.052/gallon gasoline at 10% ethanol

Feed Processing & Handling: Improve feeder reliabilityImprove biomass properties

Gasification / Conversion:Investigate gasification and tar formation/destruction fundamentalsGasify biorefinery lignin residuesPilot test high-efficiency and novel gasifiersDevelop wet gasification

Syngas Cleanup & Conditioning: Develop tar cracking and methane reforming catalysisDevelop improved particulate removal techniquesTest improved pilot scale non-condensing & condensing gas cleanup

Objectives By Barrier AreasObjectives By Barrier Areas

Critical IssuesCritical Issues

Syngas Utilization: Demonstrate viability of syngas as a feed for C1 synthesisDemonstrate syngas utilization for biorefinery utilitiesInvestigate the catalytic upgrading of pyrolysis oilsComplete an assessment of distributed systems

Process Integration: Demonstrate at precommercial scale integrated syngas-based hydrogen,

fuels, and chemicals synthesis processes

Sensors and Controls:Develop on-line cost-effective sensors for process control applications.

Sensors will be developed or adapted for feed, tars, alkalis, heteroatoms, and nitrogen compounds

Objectives By Barrier AreasObjectives By Barrier Areas

Critical IssuesCritical Issues

Proposed Biomass Syngas Platform FundingFY2004 - 2015

Management6%

Analysis5%

Feed Processing & Handling

3%

Gasification /Pyrolysis

7%

Cleanup & Conditioning

6%Sensors and Controls

2%

Products (Utilization)5%

Integrated Biorefineries

66%

Core Research23%

Total Proposed Funding, $300 million

Proposed SynGas PathwayProposed SynGas Pathway

End Result and Projected Completion DateEnd Result and Projected Completion Date• The end result for the SynGas Platform is to have completed the RD&D necessary

to begin 1st generation commercial projects• Development will draw on experience of coal gasification (e.g. Clean Coal) and

commercial syngas conversion processes• The Platform plan does not include new-generation technologies that may come

into the pipeline

2005 2010 20152000

Initiate Industry & UniversityCore Research

Start the First BiorefineryApplication Project

Complete Industry, Universityand Nat’l Lab Core Research

Complete Integrated Biorefinery DemonstrationsInitiate National Laboratory

Syngas Platform Research