Integrated Home Energy from Waste & Biomass

1. Integrated Home Energy from Waste & Biomass Tom Horgan and Noa Simons February 6, 2009

2. Executive Summary Introduction Research Summary Integrated Home Energy System (IHES) Wrap Up Outline

3. We propose to build and market an integrated home energy system. Multi-fuel (Biomass, MSW, Sewage), “Clean Gasification” based Multiple energy conversion options (CHP, Gas Gen, LF, FC) with ability to run from NG/LPG if available Rationale: Lean (saves $), Green (recycle), Mean (self sufficiency) Clean Gasification - Enabling Technology for BTLTF (Biomass To Liquid Transportation Fuel) Direct competition with crude products unrealistic Executive Summary

4. Preconception Alternative energy field was exploding with oil prices reaching $150/barrel in 2008 Modern science applied to BLTTF has yielded many new concepts ready for advancement & commercialization New technologies could make old concepts more viable Expectation Research literature, talk to scientists, down-select concepts, develop business plan and commercialize Introduction

5. Reality Majority of research dollars to bioethanol and bio“diesel” Liquefaction, pyrolysis - low grade fuels for heating Low fraction of alkanes, upgrading methods in research phase FT synthesis only proven route to diesel Highly Capital Intensive (pure syngas), nonselective Methanol is doable – trouble as a transportation fuel MTG considered failed technology (durene) Gasification technology major obstacle for all three Inefficient (drying), expensive (multistep cleaning) Energy density of green biomass ¼ of crude (out of the ground) Electricity is more valuable than liquid fuels Introduction

6. Distributed Generation Electricity is the most valuable form of energy Electricity generation only ~33% efficient nationwide (line losses) Household waste contains 30% of total energy used On site generation saves money, is green and enables sense of self sufficiency Critical Technology Core technology development for distributed generation is same for all biomass conversion processes (gasification, cleaning, drying) Integrated Home Energy from Biomass & Waste Introduction

7. Market Opportunity (2008 Data) The State of Energy http://www.eia.doe.gov/

8. Usage & Losses The State of Energy https://eed.llnl.gov/flow/images/LLNL_Energy_Chart300.jpg

9. World Oil Reserves The State of Energy • Estimates on proven reserves are historically low (reserve growth) and have been “running out” since the 30’s • Unproven (P50) and untapped reserves available (arctic) • Prices may not rise a quickly as predicted http://en.wikipedia.org/wiki/Oil_reserves

10. The State of Energy 1% of All Biomass On Earth (~ 50 cubic miles proven reserves as of 2008) Note: All of the dewatered sludge in NYS contains enough energy for ~ 30 gas stations = http://spectrum.ieee.org/jan07/4820

11. Comparing Fossil & Biomass Fuel Conversion Fossil Fuel: Millions of years worth of algae (crude) & biomass (coal) cooked and condensed by the earth Biofuels: Wood, sludge, farm waste, etc that needs to be dried and converted Crude Oil (raw) – 42.7 MJ/kg Gasoline - 43.5 MJ/kg (~80%) Diesel - 42.8 MJ/kg (~85%) Biomass/Solids – 6 to 20 MJ/kg MTG Gasoline - 43.5 MJ/kg (< 50%) FT Diesel - 42.8 MJ/kg (< 60%) 5 to 15x more input energy for BTLTF The State of Energy http://www.eia.doe.gov/

12. Market Volatility The State of Energy http://www.eia.doe.gov/

13. Research efforts… Focused on evaluation of BTLTF technologies such as Fischer Tropsch, Methanol, MTG Uncovered issues with gasification that prohibited commercialization Shifted to catalytic gasification and ionic liquids as means of addressing issues Settled on distributed generation as the most promising route to profitability in biomass conversion Research Summary

14. Conclusions Competing with crude on transportation fuels is a very tall order Electricity has higher value and is easier to achieve w/ biomass Gasification is core technology for both BTLTF and electricity generation Distributed generation competes with electricity on site using waste & wood (or NG) Integrated Home Energy System (IHES) Research Summary

15. Future & Concurrent Research Robust Gasification Gasification drawbacks are major impediment to commercialization Conversion processes all require clean syngas (particulate and tar) Conversion processes require different H2/CO ratio Microchannel FT synthesis requires pure H2/CO (free of N2 and CO) Robust gasifier concept incorporates advanced cleaning, CO2/N2 filtration and shift catalyst for control of H2/CO ratio Solution for all gasification processes Research Summary

16. Household Mass Balance (Family of 4) Integrated Home Energy Food Water Paper Plastics MSW 8 Kg/day ~91 MJ/day Water Sewage 290 GPD 0.1% Solids ~ 7 MJ/day Average Usage: ~320 MJ/day Waste: ~ 100 MJ/day (~30%)

17. Concept (micro CHP) Integrated Home Energy Heat & Power Feed Prep Wood Chips Syngas Dewater WGS MSW N2/CO2 Removal Dryer Water Sewage Gasifier Cleaning/ Scrubbing Air Slag

18. IHES Concept IHES is micro CHP Unit that supplies heat and power to residence Gasifier accepts MSW and Biomass feedstocks NG/LPG can also fuel generator and be used for start up energy/emergency back up Net metering provides opportunity for net positive gain Integrated Home Energy

19. Business Case (Avg Household, 4 people) Usage: 320 MJ/day 60% Electric, 40% Thermal Annual Cost: $1800 Waste = 30% of Total Usage (92% MSW, 8% Sewage) Assume 60% gasifier efficiency, 30% electric and 70% thermal recovery Gasify all MSW and 50kg wood per day All electricity supplied with heat in excess Wood cost = ~ $330 annually Annual Savings = $1800 - $330 = $1470 NG could supplement in absence of wood Integrated Home Energy http://www.eia.doe.gov/

20. IHES Component Development Feed preparation/pretreatment Chipper/shredder must be able to prepare both wood and MSW Grind/mixing for uniform gasification Dewatering Advanced dewatering for on site sewage treatment (much later development) Drying Recover internal heat to pre-dry feed for improved efficiency Integrated Home Energy

21. IHES Component Development Gasifier Must supply heat & syngas from a variety of waste and biomass feedstocks Gas Cleaning Cyclone, cold water quench followed by sand filter. Research advanced methods. CO2/N2 membrane filtration (much later development for microchannel FT) Water Gas Shift Design and implement WGS for H2/CO control Integrated Home Energy

22. IHES Component Development Energy Storage Battery module for start up. NG functionality can also support start up and back up capability Controls & Software Control methods for WGS (control steam on outlet temp) Control methods for heat rejection Control methods for load following (much later development) Integrated Home Energy

23. Phased Development Plan Phase 1: Proof of Concept with Advanced Gasification Development (6 months) Assemble and test a simple downdraft gasifier/gas generator system on wood (Zanoni) Downselect and purchase gasifier, gas generator, chipper, etc Research/validate wood gasification (mc, wood type, etc). Assemble/test and develop heat rejection, gas cleaning Advanced Gasifier Development (Horgan) Test & Development, MSW gasification methods Evaluate methods of feed prep, required temperatures, etc Research/development/test CHP functionality Integrated Home Energy

24. Phased Development Plan Phase 1: Cost Estimates* Hardware Purchase 2 gasifiers, NG generator (~ $10 to 15K) Misc tools/test equipment ($1 to $3K) One Computer - Zanoni ($1K) Additional Hardware for BOP ($3 to 5K) Salaries: 2 x $90K * 0.5 = $90K Rental: $1 to $1.5K /per month = $6 to $9K Total: ~ $120,000 * Should have Zanoni do this right Integrated Home Energy

25. Phased Development Plan Phase 2: Prototype Demonstration with More Gasification Development (6 months) Integrate advanced gasification, generator and CHP loop into homogeneous unit (Zanoni) Validate CHP functionality/software & controls Develop detail drawings, design system layout & enclosure Assemble and test prototypes Advanced Gasifier Development (Horgan) Test & Development of integrated shift for H2/CO control Research/development of membrane CO2/N2 removal Integrated Home Energy

26. Phased Development Plan Phase 2: Cost Estimate Hardware: Custom designed gasifier & system components ($100 to $150K) NG Generator ($3K) Shift reactor, software & controls ($15K) Software: Solid Works ($10K) Salaries: 2 x $90K * 0.5 = $90K Rental: $1 to $1.5K /per month = $6 to $9K Total: ~ $235/285K Integrated Home Energy

27. Intellectual Property Multifuel, gasification based CHP system for residential use Robust Gasifier: multi-fuel, with H2/CO control and advanced cleaning technology Patents Multiple patents for multi-fuel gasifier with specific processing methods None found for IHES system as conceived Integrated Home Energy

28. Competition No direct competition in Multi-fuel, gasification based residential scale systems Community Power Corp – Wood fueled systems for farms/light industrial Main competition Micro CHP NG Systems Marathon Engine Systems: NG Micro CHP for hot water systems Freewatt: Forced hot air w/ 1.2 kW Honda Generator – heat following http://www.marathonengine.com Integrated Home Energy

29. Integrated home energy system is marketable technology (< $10K in 5 years) Gasification development supports future, large scale work Need a lab and team to search the biomass research database Conclusions

30. Backup Slides

31. Fuel Value The State of Energy http://www.eia.doe.gov/

32. Liquefaction & Pyrolysis Do not synthesize transportation grade fuel without upgrading (undeveloped) Pyrolysis oils are corrosive Biopetrol model is liquefaction of sludge to fuel oil/burn on site – business plan claims 1yr ROI Dynamotive works with multiple customers on retrofitted applications (bigger/stainless steel pumps, motors etc) Storrs process (describe & why shut down) Research Summary

33. Fischer Tropsch Synthesis Gasification Synthesis Upgrading Research Summary

34. Fischer Tropsch Synthesis- Gasification – covered as a separate topic FT Synthesis Reaction Chemistry Research Summary

35. Fischer Tropsch Synthesis- Product Distribution Research Summary • Low Temp FT • 200/240C • Cobalt • waxes • Hi Temp FT • 300/350C • Iron • liquids

36. Fischer Tropsch Synthesis- Reactor Design Types Research Summary

37. Fischer Tropsch Synthesis- Chain growth a function of temp, pressure, catalyst type & condition, reactor design Exothermic reactions lead to poor temp control and wide distributions Slurry reactors are best but suboptimal Microchannel reactors may play but still new (Velocys) The more pure the syngas the better (even for CO2 and N2) Dilute syngas leads to large reactors (higher cost) Research Summary

38. Methanol Synthesis Research Summary Natural Gas Desulph SMR 2H2 + CO CH3OH 50 Atm, 270C Copper Oxide Catalyst H = -92 kJ/mol Gasifier Cleaning Coal or Biomass Steam O2, Air Syngas (H2, CO (CO2, N2)) Compressor Methanol Convertor Cooling/ Distillation Methanol Syngas Recycle Loop Purge Gas MTG Process

39. Methanol Synthesis Commercial Production mainly from NG (coal) Max Thermal Efficiency ~65% Single pass 25%, Exothermic, Thermo constraints Research Summary http://bioweb.sungrant.org/Technical/Bioproducts/Bioproducts+from+Syngas/Methanol/Default.htm

40. Methanol Synthesis Methanol Demand 37%  formaldehyde (resins/glues for particle board and ply wood) 21%  MTBE (gasoline additive that reduces exhaust emissions) 14%  acetic acid (chemicals for adhesives, coatings and textiles) Used directly as a fuel… Burns cleaner than gasoline (Higher Octane) Corrosive to engine parts, gaskets, etc Slower burning (advance ignition time) Cold starting an issue (lower vapor pressure) Absorbs water Research Summary

41. Methanol to Gasoline Research Summary 2CH3OH CH3OCH3 + H2O 320C Alumina CH3OCH3  H2O + C2 – C5, alkenes, cycloalkanes, aromatics 400/420C Zeolite Light HC, CO2, H2

42. Methanol to Gasoline Product Composition The aromatic portion is at the high end of the gasoline spec (6/29%) Aromatics are about 20% Durene – low melting point (icing). Separation is expensive. Actual efficiency 44% (Hamiton). Research Summary

43. Gasification First step in FT, methanol, MTG, FC, generator Biomass is heated under low oxygen conditions (Atmospheric, > 600C) Steam sometimes added Volatile material driven of leaving char, steam and tars Char reacts with air and steam to form syngas (H2, CO, others) Research Summary

44. Gasification Reactions Research Summary

45. Gasification Reactors – Small Scale Downdraft Gasifier Outside dimensions (w/ hopper): 4ft h x 1.5ft d Syngas production rate: ~ 35 ft3/lb of 15% wood Max Capacity: ~700 lbs wood/day - 1000 ft3/h (320 MJ/h) Outlet Temp: 50/75C after cyclone/filter $2300 Assembled $1400 Not Assembled Research Summary http://www.allpowerlabs.org

46. Gasification - Issues Gasification rated primary barrier to commercialization of BTLTF System Very pure syngas required (essentially H2/CO) Systems diluted with N2, CO2 lead to large reactors Substantial Cleaning & Scrubbing required Biomass variability leads to syngas variability Holy Grail: Robust Gasification Gasification System that receives ANY carbonaceous feedstock and returns pure syngas with tunable H2/CO ratio. Research Summary

47. Gasification Reactors - Industrial Research Summary

48. Economic/Energy Comparison Research Summary

49. Economic/Energy Comparison Research Summary

50. Ionic Liquids Air and moisture stable salts – electrically conductive, low vapor pressure, liquid at room temp Composed of 100% ions - large organic cat ions (~1018), small inorganic anions (much less) Applications: Stable solvents, acid scavenging, cellulose processing, petrochemical synthesis, transport medium, many others Dissolve wood & other organics (0.2 to 2mm, < 150C, < 30min) Safety: Low vapor pressure and highly recyclable. Some are combustible. Many are toxic if released to the environment. Research Summary