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Advanced Biofuels
World Future Fuels Summit New Delhi, India, 15 February 2020
Anjan Ray CSIR‐Indian Institute of Petroleum, Dehradun
Key Success Factors of Alternate Fuels
• Performance / Acceptability ‐ Does it work? • Scale and supplies – Can we get enough whenever and wherever needed?
• Cost – is it affordable relative to incumbent? If not, who bears the difference?
• Adaptability to existing infrastructure – Does money have to be spent to make it work?
• Sustainability – Does it mitigate environmental impact? Is the Net Energy Ratio favourable?
Alternate Fuel: Generations Generation Conflict with
Food? Drop‐in? Carbon
Neutral? Example
1 Yes No No FAME Biodiesel 1G ethanol
2 Yes (if from edible oils) No (if from non‐edible lipids AND no Land Use Change)
Yes No HVO “Green Diesel” and Bio‐jet from soya/rapeseed
2 No No No Lignocellulosic (2G) ethanol
3 No Yes No HVO/Jet from algal lipids and waste oils
4 No Yes Almost Gas fermentation
India – Gross Carbon Imports (approx) Commodity Import, MMT/yr % C Imported C, MMT/yr
Crude Oil 220 85% 190
Coal 200 75% 150
Natural Gas 15 77% 11.6
Demand Side Response • Reduce energy requirement (enhance efficiency) • Reduce carbon requirement (non-carbon energy e.g. solar,
wind, geothermal) Supply Side Response
Find about 350 MMT of domestic carbon (on current basis) to replace our fuel carbon imports
Need energy security solutions that ALSO reduce GHG Emissions
A BASKET OF POSSIBILITIES INCUMBENT REPLACEMENT TECHNOLOGY CHALLENGES
Diesel Biodiesel, Green Diesel, Bio‐based alcohols and Ethers
Esterification, Hydroprocessing, Fermentation, Syngas‐derived
Scalable Feedstock Supply
Gasoline Bio‐based alcohols and ethers, green gasoline
F‐T, Fermentation, Alcohol‐to‐gasoline, Hydroprocessing, Pyrolysis/FCC, Catalytic Pyrolysis Bio‐coking
Handling and blending infrastructure, feedstock variation
Aviation Fuel Drop‐in Bio‐jet Hydroprocessing, Sugar conversion, alcohol‐to‐jet, F‐T
Scalable Feedstock Supply
CNG / PNG Bio‐CNG/Bio‐PNG, HCNG, Bio‐H2
Fermentation Purification, Supply chains
Low‐sulfur Bunker Fuel
Green heavy distillate, biomass‐derived oils
Hydroprocessing, Pyrolysis/FCC, HTL, MSW‐thermochemical processing
Economic value relative to alternatives
Scope to Use Existing Refining Infrastructure or Hub‐and‐Spoke Models
Policy Support • Overarching National Biofuels Policy in place • Bio‐ethanol 1G accelerated by favourable pricing and option to use cane juice and spoiled grain
• 2G ethanol scale‐level and demo plants under PM Ji‐VAN Yojana
• SATAT scheme for CBG launched • Biofuels and Bio‐energy projects being emphasized by user ministries and departments like Railways, Civil Aviation, IAF etc
Progress and Outcomes – Ethanol blending program close to achieving 10% levels – Biodiesel feedstock supply accelerated through RUCO – UCO biodiesel procurement price announced – SATAT has received enthusiastic response – Opportunities to combine SATAT with City Gas Distribution emerging
– Up to 12 2G ethanol projects on the anvil; evident commitment from state sector refineries
– BIS standards issued for several neat biofuels and blends – Advanced Biofuels projects still largely at pilot scales – but focus on waste utilization helping shape new technologies
– IOCL‐Lanzatech demo project on refinery gaseous emissions to ethanol and to acetic acid moving towards implementation
Where must we focus? • Supply Chains – Identify, collect and segregate domestic carbon
• Scalable conversion – Field‐implemented solutions at >1000 tons of carbon atoms per day (centralized) or 1000+ installations of 1 ton of carbon atoms per day (decentralized)
• Sustainability – Critically examine Net Energy Ratio, carry out LCA studies and develop the techno‐economic model at an early stage Now is the time to prioritize demonstrations and deployment
Fuel Supply Security for India
• India depends significantly (>80%) on crude oil imports • This dependence is becoming more acute with increasing economic growth
• Strategic reserves of fuel for Indian Defence Forces are a matter of concern
• Recent geopolitical events (e.g. fresh Iran sanctions) adversely impact supply security as well as pricing
• Unlike the US, India had not previously actively explored the possibility of 100% fuel supply security for Armed Forces using domestic carbon sources
Domestic Carbon Sources
• Used Cooking oil – Estimated ~2 million tons annually @ 10% of total edible oil consumed in
India – As of today, simply goes “down the drain” and adds to environmental
burden – China collects and trades over 1 MM TPA already of its domestic UCO – Easy to access from cantonments, canteens, community kitchens
• Tree borne oils – Over 400 species identified in India, growing wild – Lack of demand and no incentives for collection of seeds limits supply side
• Short rotation crops – Non‐edible oilseeds like niger, carinata, camelina etc (mustard family) – Can be planted and grown between staples as a second or third crop – Need organized long term demand to stimulate farmer interest
“Annually, about 23 MMT cooking oil is consumed in India. There is potential to recover and use about 3 MMT of this after cooking” – Food Safety and Standards Authority of India
As of now, used cooking oil is either disposed in an environmentally insenstive manner or finds it way to smaller restaurants, roadside eateries and street‐vendors
Why 1G ethanol succeeded up to a point
• Joined at the hip to the sugar economy – But prone to crop planting cycle – Crop water demand questionable
• Relatively low user impact at 5% blend level – But tougher at 10% and more, especially for 2‐wheelers
• Alcohol production already available for potable and industrial purposes – But competition of production for these uses; fuel pricing had to be made attractive
• Robust supply chains evolved quickly Beyond 10% blending level, 2G became imperative
(1) Region specific biomass availability (2) Sustainable supply (3) Supply window (4) Cost of the raw materials and logistics
(1) Proximate and ultimate characteristics (2) Milling size (3) Choice of Pretreatment (4) Mixed sugar streams / separate C5 and C6 streams (5) Costing of the Pretreatment process (process and input chemical cost)
Choice of Pretreatment
Choice of 2G starting material
(1) Cost of the enzyme (2) Enzyme activity (3) Enzyme and substrate loading and hydrolysis efficiency (4) Hydrolysis time (5) Enzyme recycling
Enzymatic hydrolysis
Why 2G ethanol is challenging
A very large number of variables to be managed; feedstock complexity
(1) Choice of organism (2) Use of C5 sugar (3) C5/C6 Co‐fermentation (4) Separate fermentation of C5 and C6 (5) Ethanol productivity and tolerance (6) Yeast recyclability (7) Choice of fermentation (SHF / SSF / SHCF)
Fermentation
(1) Choice of dehydration method including distillation (2) Post distillation treatment of fermentation broth
(1) Real‐time LCA (2) By‐product valorization (lignin, CO2…) (3) Calculation of end to end process economics
Dehydration
LCA and economics
Why 2G ethanol is challenging
High sensitivity to supply chain uncertainties and asset utilization
Scaling Up Biofuels
• Lipids to bio‐diesel and bio‐jet fuel • Sugars/starches to alcohols • Bio‐gas to CBG / Bio‐PNG • Agro/forestry residues to fuels/chemicals • Community wastes (MSW / Septage) to fuels • Waste plastic to fuels and petrochemicals • Industrial emissions (CO/CO2/CH4) to fuels/chemicals
Lipids are among the cleanest naturally occurring feedstocks for biofuels
First Developing Country to Fly First Biofuels Flight with Indigenous Fuel
Military Flights Antonov‐32 Indian Air Force Republic Day Parade 26 January 2019
Civilian Flight Bombardier Q400 Operated by SpiceJet Dehradun‐Delhi 27 August 2018
Acid Gas Removal
Vegetable Oil
Reactor
Separator
H20
CO2
+ Gas OilMake up Hydrogen
Propane &Light Ends
Naptha or Jet
Diesel Product
Deoxygenation/Isomerization
Deoxygenation/Selective Cracking/Isomerization/ aromatization
Useful products
Light Gases(<C5) Naphtha (C5-C9) Bio-Jet Fuel (C9-C15) Diesel Range(C18+)
Undesired products CO, CO2 and Water
Pretreater
Pretreater
+H2
Na, P, K, Ca, Fe
Na, P, K, Ca, Fe
Useful products Light Gases(<C5) Diesel
Range(C18+) Undesired products
CO, CO2 and Water
CSIR‐IIP Bio‐jet Fuel Process
Continuous Pilot Production of 30L/day of HEFA Bio-Jet Fuel Technology Package Ready at 1000x scale
Scalable options for lipids • Today: ONLY Food value chain by‐products
– Used Cooking Oil – Palm Stearin; other edible oil refining co‐products – Fats/oils from slaughterhouses, poultry, fisheries
• EMERGING – Tree borne oils (regional TBOs, not just jatropha) – Rotation crops (carinata; early success in Punjab)
• FUTURISTIC – Microbial oils – Dairy and sewage fats
Food Value Chain By‐Products
• Used Cooking Oil – ~27 MMTPA edible oil consumed in India – The used oil is re‐used or dumped
• Palm stearin – ~25% of palm oil refining ends up as stearin
• Animal fat / poultry fat / fish oils – Exported from India – Also used locally in animal feed formulations
Tree Borne Oils A collection‐cum‐plantation approach
Combine collection & plantation models; common end-use mechanism
Major TBO varieties • Sal (Shorea robusta) • Neem (Azadirachta indica) • Mahua (Madhuca longifolia) • Karanj (Pongamia pinnata) • Kokum (Garcinia indica) • Lakshmi Taru (Simarouba Glauca) • Chinese Tallow (Sapium Sebiferum)
“We collect just 0.5 million tonnes of TBOs a year, while there is a potential to collect 3.5 million tonnes,” ‐ Solvent Extractors’ Association of India “In the absence of mandis, TBOs gatherers are forced to sell at prices dictated by brokers which often leads to further exploitation” – www.downtoearth.org
Biofuels
Valuable Wax
CSIR ‐ Institute of Himalayan Bioresource Technology, Palampur
Beyond Jatropha: 100+ regional alternatives e.g. sapium
Short rotation crops
Between rotation crops and TBOs, opportunities in every state
Is land availability really an issue in India? • Total Arable ~ 160M ha • Irrigated ~ 70M ha • Mono‐cropped ~ 40M ha
Brassica Carinata – Punjab Camelina Sativa (False flax) – Northeast Guizotia Abyssinica (Niger / Thistle seed) ‐ MP Tobacco Castor Non‐edible safflower
Crop residues: Fodder, bio‐fertilizer and/or biofuels
Oleaginous Yeast Lipids
# Fatty acid Short-hand designation %(w/w)
1 Capric Acid C10:0 4.76
2 Lauric Acid C12:0 6.31
3 Myristic Acid C14:0 5.76
4 Palmitic Acid C16:0 19.75
5 Stearic Acid C18:0 2.76
6 Oleic Acid C18:1 48.69
7 Linoleic Acid C18:2 4.74
Total Saturated fat 40.88
Total Mono unsaturated fat 48.92
Total Polyunsaturated fat 4.99
Fatty acid composition of SCO from RMIIPL32
Microbial Lipids could Alter India’s Lipid Supply Chain for Biofuels
In Conclusion... • Aviation Biofuels have taken longer than anticipated to fulfill their promise
• Scalability has been the primary constraint – but solutions to feedstock supply are emerging
• Increased focus on deployment has been enabled by a demonstration plant, operational since early 2018
• A concerted effort along the value chain, with deep engagement of stakeholders, supported by conducive policies, is making a visible difference
• The first commercial scale plant using the CSIR‐IIP One‐Step HEFA Process likely to be announced in 2020
Thank You
World Environment Day, 2017 90+ butterfly and moth species
Great Backyard Bird Count, 2018
64 bird species
We Have Only One Planet