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GTI Biorenewables
Vision, Challenges, Programs,and Status
Terry Marker, Vann Bush, Eddie Johnston, Bill Liss, Jack Lewnard
Chicago Chapter AIChE September 15, 2009
August 2009
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Business Confidential 2
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Biofuels Turning Up The Heat
>Introduction to GTI
>Biogas
>Biomass pre-treatment
>Thermochemical conversion optionsHydropyrolysis
Gasification
> Gas clean-up> Syngas, fuel, and/or power
>tcBiomass Conference
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What We Do
>GTI solves important energy challenges, turningraw technology into practical solutions that
create exceptional value for our customers in theglobal marketplace.
Energy Solutions Delivered
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> Not-for-profit research,with 65+ year history
> Facilities
18 acre campus near Chicago
200,000 ft2,28 specialized labs
> $60 million in revenue
> Staff of 250
> A growing business> 1000 patents; 500 products
> Commercial partners take ourtechnologies to market
Energy & Environmental Technology Center
Flex-FuelTest
FacilityOffices& Labs
Our Company at a Glance
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Reducing carbon emissions to the environment
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> Fastest growing area in energy R&D Global R&D spending up 20% in 2006 Corporate $9.1B; Govt $7.2B
> Increased domestic (and continuinginternational) concerns about energyindependence, sustainability, globalwarming, and need to hedge fossil prices
Renewable Energy - Premises
Biofuels required to meet mandated RPS, renewable fuel targets in
many states and countries, with increasing interest from suppliersand users for green natural gas
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Biogas- Natures Oldest Renewable
> Manure or waste to methane via anaerobicdigestion ideal for low-solids streams
> First recorded us in Assyria ca 10 BC to heatbath water
> Millions of small systems in China and India
> US and Europe primarily using biogas for power
generation; missed opportunity for higher-valueuses
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Biogas Composition and Potential
> Biogas basics Produced from anaerobic digestion of
biomass, typically dilute organicwaste stream
Digesters for manure, mixed agwaste, wastewater treatment, and
landfills Composition 30-60% methane;
water-saturated with CO2 as primarycontaminant
Other contaminants specific to feed
> 1-2 TCF biogas total US recoverableresource
> EU comparable or higher, butmarket further developed
Human Related U.S. Methane Emissions
(in TgCO2 equivalent)
Coal Mining
Landfills
Natural Gas
Systems
Enteric
Fermentation
Other
Manure
Management
Wastewater
Treatment
Source: US Emis sions Inventory 2005
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AIChE September 15 2009 9Business Confidential 9AIChE September 15 2009
GTI Biogas Projects
> Altamont Landfill to LNG for Garbage Truck Fleet
Livermore CA, Waste Management and Linde
> Gills Onion to Fuel Cell
Digester Gas, FuelCell Energy Fuel Cells
> Landfill Gas to Hydrogen
> Pipeline Quality Renewable Gas from Dairy Waste Conversion
Utilities Participating (PG&E)
Guidance Paper on Gas Quality Issues
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Biogas Challenges
> Push EU mandates to redirect organic waste from landfill, ban sludge and manure spreading, and
required access to gas and electric grid for renewable energy
US mandated biogas recovery from landfills and wastewater treatment plants
US emerging regulations on manure
> Pull Renewable Portfolio Standards and favorable incentives (currently only when used for electricity)
Project developers and gas industry interested in pipeline quality gas
> Gas contract higher value than power contract, albeit with higher capital cost
> Creates transportable low-carbon fuel so electric utilities can reposition fossil NGCCpower plants as green facilities, meet RPS requirements, and access renewable credits
> CO2 credits from GHG abatement add 10% to product value
> Addressing the higher-value pipeline gas market requires a newapproach to gas processing and harmonized gas quality specifications
> Selling gas into the gas grid requires robust, fully-qualified, packagedsolution encompassing compression, clean-up, and instrumented custodytransfer
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Biomass Pretreatment Project
Develop a process to render any ligno-cellulosic biomass intomaterial amenable to efficient gasification or pyrolysis.
Gasification
Pyrolysis
Fuel gas Power Liquid fuels Chemicals
Versatile PretreatmentTechnology
We must use forestry and agriculturalbiomass sources to reach biofuel goals.
Logistics of biomass supply is a major
economic and carbon intensity hurdle.
Higher energy density bio-feedstock wouldallow larger, more economic process scale.
Gasification and pyrolysis both benefit fromfeedstock consistency.
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Treatment of Pine Chips
Before After
C, % 51.4 68.3
H, % 5.9 5.1
O, % 42.1 25.9
Ash, % 0.39 0.27
HHV (dry),
Btu/lb
8,500 11,800
Treated material is friable and easily pulverized.
Preliminary energy balance shows 86% recovery
of energy as treated solids.
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Chemistry Issues for BiomassPyrolysis
High temperature uncontrolled thermal reaction, makes free radicals,
causes condensation reactions making condensed ring polynuclear
aromatics and olefins and polymerization retrograde reactions make
compounds harder to upgrade with hydroconversion
No significant reduction in oxygen in pyrolysis step, pyrolysis oil and wood
have the same % oxygen and same heating content on BTU/lb basis
Structure needs hydrogen to reduce olefins, avoid condensation reactions
and avoid retrograde reaction
Biomass does not have polynuclear aromatics to start with but we create
them in pyrolysis step
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Typical Structure of Lignin
Perfect structure for conversion to
gasoline and aromatics
Carbon= 64%Hydrogen =6%
Oxygen= 30%
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Integrated Hydropyrolysis andHydroconversion (IH2 )
Fast biomass heat up maximizes liquid yield Hydroconversion with catalysts produces low-oxygen, low-acidity liquids Polynuclear aromatic components are not formed Self-sufficient process requires no supplemental water or hydrogen High-quality renewable gasoline and diesel products are produced
0
10
20
30
40
50
60
70
80
90
100
Petroleum Diesel GTI RG Petroleum Gasoline
gCO2eq.
/MJ Fuel Combustion
Fuel Transportation
Fuel ProductionTransportation of Feedstocks
Feedstock Production, RMA
Feedstock Chemicals
CONVERSION OF BIOMASS DIRECTLY INTO GASOLINE AND DIESEL
Over 90% lowergreenhouse gases inrenewable gasoline
from IH2
processcompared topetroleum-basedfuels
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Product Property Comparison
Fast Pyrolysis Oil IH2 product
% Oxygen 50
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Gasification: High Temperature Option
SNG
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GTI-Carbona Fluidized-BedBiomass Gasifier
High carbon conversion, 95-98%+
Capability to gasify a wide variety of
fuels, including coal/biomass mixtures
Simple design with safe, reliable
operation
Air-blown, enriched-air or oxygen-blown
operation
Atmospheric to 30+ bara
Operates at a lower temperature than a
slagging gasifier (to 1000 C)
Longer metal component and refractory
life Good turndown capability, 30 50%
Demonstrated at commercial scale by
Carbona
OXYGEN or
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GTI/Carbona Biomass Feedstocks
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Capacity,
Tons
/day
1
10
100
1000
1970 1975 1980 1985 1990 1995 2000 2005
24
80
30
100
8x150
40
HP Biomass
HP Coal
LP Coal
10
8
40
20
Flex-FuelShanghaiMaui
FinlandRENUGASChicago
UGAS Pilot and PDU - Chicago
2010
165
DenmarkChina
2x300
Scale-up History ofGTI Gasification Technology
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Flex-Fuel Test Facility:Pilot-Scale Fluidized Bed Gasifier
Pilot-scale process R&D
Periodic test campaigns
~30 testing staff
Biomass 20 tpd w/air; 40 tpd w/oxygen
Gasification Pressure to 27 bara
Extensive On-line Syngas Analysis Systems
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100 ton per day Bioenergy Demo Plantin Maui, Hawaii using bagasse80 ton per day Gasification Pilot Plant in
Tampere, Finland using biomass & coal
Biomass Gasifier Projects
165 ton per day CHP Plant inSkive, Denmark using wood
40 ton per day Flex-Fuel Test Facilityin Des Plaines, IL for biomass & coal
1992 1994
2006 2003
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Synthesis Gas Process
FuelTreatment Gasification
HydrocarbonReforming
Particle,Alkali
Removal
Shift
HydrogenSeparation
Hydrolysis,Acid GasRemoval
TraceRemoval
Synthesis,Upgrading
PowerCHP
Methanol
DMEAlcoholsFT DieselGasoline
H2
SNG
GTI R&D
Biomass
pretreatment,
pyrolysis
GTI U-GAS,
RENUGAS,
GPE bluegas,
PWR Compact
Gasifier
Ultra-Clean
GTI Catalysts,
Tar Reforming
Morphysorb,
UCSRP,
CrystaSulf (+DO)
Ultra-Clean
Membranes
UCSRP,
CrystaSulf-DO
Ultra-Clean Catalyst
Coal
Biomass
Coal and Biomass
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Engineering New Catalysts For In-Process Elimination Of Tars
Scope: Engineer new catalyst forms, use GTI submerged combustion melter to economicallyproduce optimized catalysts for the reduction or elimination of tars in biomass gasification,evaluate catalysts for in-bed tar reduction in Flex-Fuel Test Facility (FFTF)
Status: Created new technologies for producing catalysts. Successfully demonstrated catalystperformance in lab trials with steam reforming of methane and with naphthalene as a
surrogate biomass tar. Conducted baseline tests in FFTF. Proceeding to second phase for
manufacture and testing of catalyst formulations.
Value: Create lower-cost, high-performing catalysts for tar
reduction in biomass gasifiers
founded1836
AlfredUniversity
0 5 10 15 20 25 30 35 40 45 50Elapsed Time, h
70
75
80
85
90
95
100
NaphthaleneRedu
ction,
%
Reactor Temperature900C
850C
800C
750C
NAPHTHALENE DECOMPOSITION
50
60
70
80
90
100
0 20 40 60 80 100
Elapsed Time, h
STEAM REFORMING OF METHANE (800C)
MethaneConvers
ion(%)
Ni Metal
Olivine
Ni-olivine Catalyst
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> Laboratory Screening of H2 MembranesCeramic membranes
Metallic membranes
> Field Prototype Tests
Biomass gasifier Integrated system
> guard-shift-membrane
H2 flux, purity targets
Hydrogen Production from Biomass
hydrogen
feed
Porous supportmembraneCopper seal coated by carbon
SCHOTT
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Pilot Testing Program at GTI
2nd Generation Biofuel Production from Woodby Fluidized Bed Gasification and F-T
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Skive, DenmarkCombined Heat & Power Project
Fuel storage
Heat accumulator
Fuel receiving and storage
Gasification plant
GASIFIER
GAS FILTER
GASCOOLER
GAS ENGINES
TARREFORMER
BIOMASS
AIR & STEAM
ASH
FLY ASH
BOILER
TO STACK
WATER
GAS SCRUBBING GAS BUFFERTANK
POWER
6 MWe
DISTRICT HEATING12 MWth
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tcbiomass International Conference
>AIChE Special Rate:
$450 one day pass
$900 three day conference registration
Brochures/information at registration desk
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AIChE September 15 2009 32Business Confidential 32AIChE September 15 2009
Summary
Many renewable bio-energy options; producing fungible productsthat integrate with existing energy infrastructure is key
Anaerobic digestion of low-solids wastes is energeticallyfavorable; biogas applications active area of RD&D
Biomass pre-conditioning likely required for large-scaleaggregation for renewable fuels
Gasification of high-solids biomass is energetically favorableroute to syngas, fuels, and CHP
GTI is developing integrated hydropyrolysis route to address low-temperature liquid fuels production
tcbiomass is a great opportunity to learn more