two years experience of the biodme project -- a … a complete wood to wheel concepta complete wood...
TRANSCRIPT
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Two Years Experience of the BioDME ProjectTwo Years Experience of the BioDME Project-- A complete Wood to Wheel ConceptA complete Wood to Wheel Concept
tcbiomass 2013Chicago, September 4, 2013
Ingvar Landälv,Luleå University of Technology
Sweden
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Agenda
• Why was the BioDME project initiated?
• The project at a glance in 3.5 minutes
• How does the process work ?
• How was the Start-Up?
• How has the availability been?
• Did we meet BioDME Production goals?
• Is BioDME distribution difficult?
• Do the trucks function according to expectation?
• Where do we go from here?
European Project BioDME7th Framework Programme2
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Volvo Group Trucks Technology3 European Project BioDME
7th Framework Programme
From VOLVO’s ”Climate Issues in Focus”Summary of results for different criteria and fuels
7 Trucks on show
Source: http://www.volvogroup.com/SiteCollectionDocuments/V olvo%20AB/values/environment/climate_issues_in_focu s_eng.pdf
Why
was
the
Bio
DM
E p
roje
ct in
itiat
ed?
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CO2 emissions and primary energy usage per km of dr iving differs a lot depending on selected well-to wheel p athway
26 February 2013
4
Fuels 2010
-200
-100
0
100
200
300
400
0 100 200 300 400 500 600
Total WTW energy (MJ / 100 km)
WT
W G
HG
em
issi
ons
(g C
O2
eqv
/ km
)
Conventional gasoline
Conventional diesel
RME: Gly as chemical
RME: Gly as animal feed
Syn-diesel: CTL
Syn-diesel: GTL
Syn-diesel: Farmed wood
Syn -diesel: Waste wood, Black liqour
DME: CTL
DME: GTL
DME: Farmed wood
DME: Waste wood, Black liqour
EtOH: Wheat, Straw CHP, DDGS as AF
EtOH: Sugar cane (Brazil)
EtOH: Wheat, Straw CHP, DDGS as fuel
EtOH: Farmed wood
EtOH: Wheat straw
EtOH, Wheat, Lignite CHP, DDGS as AF
EtOH, Wheat, Lignite CHP, DDGS as fuel
EtOH, Wheat, NG GT+CHP, DDGS as AF
EtOH, Wheat, NG GT+CHP, DDGS as fuel
Biogas, municipal waste
Biogas, liquid manure
Biogas, dry manure
CTL
GTL-DME
GTL-syndiesel
Ethanol
Biogas, liquid manure
Gasoline and diesel
Source: WtW study Eucar/Concawe/JRC 2005, 2010 Vehicles(basis for EU RED/FQD default values)
RME
DME & FT
Biogas
Why
was
the
Bio
DM
E p
roje
ct in
itiat
ed?
The BioDMEconcept
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Production of DME from Biomass and utilisation as fuel for transport and for industrial use
Starting date: 1 September 2008Duration 52 monthsContact: [email protected]
Total budget 28.4 M€EU funding: 8.2 M€Energimyndigheten: 9.6 M€
EUROPEAN PROJECTGrant agreement No:TREN/FP7EN/218923
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BioDME Project Partners
- BioDME Plant engineering, construction and operation
- BioDME Plant owner
BioDME Project Coordinator- Engine development- Vehicle manufacturing- Field test responsible
- DME injection systemdevelopment
- Laboratory support toplant operation
- DME production technology provider
- BioDME distribution- BioDME filling stations
- DME fuel specification- Fuel Additive development
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The Project at a Glance
In June 2012 Volvo together with Project Partners p roduced a film which in 3 ½ minute summarizes the BioDME pr oject covering e.g.
• Location
• Principle of the DME production concept utilizing B lack Liquor
• Potential for a Pulp Mill and for Sweden
• Truck performance
• Etc
European Project BioDME7th Framework Programme7
FILM
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Pre-commissioning, Commissioning & Start-Up 2011
European Project BioDME7th Framework Programme8
June 2011
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European Project BioDME7th Framework Programme9
Aminewash
H2S / CO2 to pulp mill incinerator
COshift
Carbonfilter
MeOHSynthesis 1
MeOHSynthesis 2
First single-pass MeOH synthesis featuring > 95% yie ld
Sulphurguard
MeOH (recycled)DME Product
DMEsynthesis
Water
DP-1unit
SyngasCompressor
Gas conditioning & Cleaning
DME synthesis &product purification
Off gases
Black LiquorOxygen
Gasification
Raw Methanol
DME storage
Block Flow Diagram
DME day tanks
How does the process work ?
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Black Liquor Gasification
European Project BioDME7th Framework Programme10
Syngas
Carbonfilters
Filtercloggingresolved
Black Liq.
Changed qualitydue to alteredash recyclein mill fr 2009
Operate with lower syngas ratethan design
Installedon-stream
steam regene-ration
20 ton bls/d but withlower LHV than design
How was the Start-Up?
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Synthesis Gas Preparation
Feed Gas
Steam
Water
Synthesis Gas
MDEA
WGS
AGRSGS-cat CO2, H2S
• Demonstration of Sulphur-rich synthesis gas water s hift
Added superheat via extra heater
MoreS componentsthan design
How was the Start-Up?
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Single-pass Methanol synthesis– breaking the equilibrium limitation
Guard-reacto r
MPS
Raw MeOH
Synthesis GasLPS
S-guard
MeOH-cat
Carbonyl-guard MeOH reactors
• Stoichiometric syngas at P > 130 bar in synthesis
• Sulphur & Carbonyl Guards demonstrated
Membranefailure
Shorterlife thanPlanned*
How was the Start-Up?
*) due to higher S load than design
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DME Synthesis & Distillation
• 99.5% DME directly from raw methanol
• Reduced wax production and wax removal demonstrated
DME reactor DME Purification
Light byproduct
Wax
MeOHDME
MeOH
DME-cat
Water
Minorredesign
How was the Start-Up?
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BioDME Production
European Project BioDME7th Framework Programme14
Over 4 ton DME/dwas reached in Sep -12
The plant incl. gasification isoperated by 2 operators per shift
Key operation data:Gasification at 30bar/1050˚CMethanol synthesis at 130 barDME synthesis at 15 bar
BioDME toStorage
Black Liquorto gasification
Gasification
GasCleaningGas Shift,
Synthesis&
Distillation
SmurfitKappaKraftlinerPulp Mill
Did we meet BioDME Production goals?
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BioDME Plant Non-availability 1H, 2012
European Project BioDME7th Framework Programme15
How has the availability been?
On stream factor, PLANNED: 50% of calendar timeOn stream factor, ACHIEVED: approx. 65% of calendar timeOn stream factor, ACHIEVED: approx. 78% of planned operation timeLongest run: 26 days followed by a planned stop
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BioDME Quality Control
• Quality control of BioDME and participating in DME ISO standardization process
– Development of analysis methods for BioDME from storage tank, from the trailer and from filling stations
– LPG residues observed in filling stations, originating from trailer [1].
European Project BioDME7th Framework Programme16
Typical analysis of produced BioDME ISO draft [2]
C2 ppm wt 15
10000C3 ppm wt 160
C4 ppm wt 600
Methanol ppm wt 120 500
Water ppm wt 40 300
CO2 ppm wt 100 1000
DME (by difference)
% wt > 99.8 > 98.5
First unloading Dec. 201113 000 kg BioDME
[2]. Bollon, F. 7th Asian DME Conference, Niigata, Nov 16-18, 2011
[1]. Öhrman, O. et al. Quality control of BioDME produced via black liquor gasification. 7th Asian DME Conference, Niigata, Nov. 16-18, 2011.
Did we meet BioDME Production goals?
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BioDME Production 390 tons by end of Project
European Project BioDME7th Framework Programme17
0
50
100
150
200
250
300
350
400
450
dec-11
jan-12
feb-12
mar-12
apr-12
maj-12
jun-12
jul-12
aug-12
sep-12
okt-12
nov-12
dec-12
jan-13
feb-13
mar-13
apr-13
maj-13
Pro
du
ced
Bio
DM
E,
ton
B
C
D
E
A
F 500 tons April 20, 2013
A. Authority inspectionB. Change of ceramics and catalystsC. HolidaysD. Main DME storage full + ceramic repairE. Rebuild for steam supported atomizationF. No operation during change of ownership
Did we meet BioDME Production goals?
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Piteå
Stockholm
Jönköping
Göteborg
Fuel distribution as for LPG
European Project BioDME7th Framework Programme18
• Available technology modified for DME
• Safety regulations based on LPG
• ~200 k€ per filling station (+33% vs diesel)
• Easy to achieve
Four filling stations
200 m3 storage tank in Piteå
34 m3 trailer
Is BioDME distribution difficult?
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Field test status 2012-12-31
• 10 field test trucks
• Accumulated mileage: 824 798 km / 512 600 mi
• Max truck mileage : 183 588 km / 115 000 mi
European Project BioDME 7th Framework Programme
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
km
Date
Total Field test mileage
Do the trucks function according to expectation?
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Emission verificationPEMS – Portable Emission Measurement System
European Project BioDME7th Framework Programme20
Cycle NOx(g/kWh)
PM(g/kWh)
HC (g/kWh)
CO (g/kWh)
EU-V EEV limits (ETC)
2.0 0.02 0.40 3.0
PEMS 20ton
1.66 0.00* 0.25 2.34
PEMS 60ton
1.72 0.00* 0.31 1.82
* Measured with AVL 483 Micro Soot Sensor
• Independent (AVL) verification after 183 000 km (11 5 000 mi) • EU-V Emissions still fulfilled
Do the trucks function according to expectation?
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CHEMRECEnergy to Succeed
Chemrec Status January 2013
21
� Dec 31, 2012: Chemrec Piteå companies including pilot plants sold by
Chemrec AB to LTU Holding AB,
� Jan 1, 2013: 17 pilot plant staff employed by LTU.
� Dec 31, 2012: License agreement between licensor Chemrec AB &
HaldorTopsøe with LTU and LTU Holding. Technology rights stay with
licensors.
� Jan 30, 2013: Consortium Agreement between parties involved in
continued R&D.
� Chemrec has reduced staff awaiting long term stable regulations for
advanced biofuels. Two Chemrec Stockholm staff temporarily on leave
assigned to LTU
� Continued operation of the plants as part of LTU Biosyngas Program
10/18/2009 16
FLARE
Raw Syngas
GREENLIQUOR
Black Liquor
GAS COOLER
Oxygen
Atomizing medium
GASIFIER
QUENCH
C.W
BFW
MP-Steam
Weak Wash
CLEANSYNGAS
BFW
SULPHUR ABSORPTION
Condensate
White/Green Liquor
LP-St.
Whe
re d
o w
e go
from
her
e?
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Volvo Group Trucks Technology
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
km
Date
Total Field test mileage
Extended Volvo field test8 trucks, 2013-01-01 to 2014-06-30
(1000 Km / 1000 mi) Status2013-04-08
TargetJune 2014
Total mileage 970 / 603 1 475 / 917
1 truck 200 / 124 300 / 186
Extended field test
1 million kmMay, 2013
Whe
re d
o w
e go
from
her
e?
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Fuel consumption
European Project BioDME7th Framework Programme23
TruckApplication
Gross weight(Min/Max/Avg)
Typical FC Diesel Equivalent(l /10 km & mi/gal))
FH-787Regional and local haul
14/26/21 ton 2.3 / 10.2
FH-711long haul
25/50/ ton 4.1 / 5.7
FH-842local start/stop
21/57/53 ton 6.1 / 3.8
Volvo through their US branch on June 6, 2013 decided to start commercial production of
DME fuelled vehicles in the US in 2015.See:
http://www.volvotrucks.com/TRUCKS/NA/EN-US/PRODUCTS/ALTERNATIVEFUELS/
CNG/Pages/DME.aspxThe link includes:
Volvo introduction, a YouTube filmDME – “The future is here”, a YouTube filmDME – “It is all around us”, a YouTube film
and other material.
See also:www.biome.euBioDME Video
http://www.youtube.com/watch?v=cF1F7luFpnc
ThankYou!
Volvo US DME truck