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Dr. Eckart Heinl Group Research

The BtL-Project RENEW of the European Union Managed by VW. Dr. Eckart Heinl Group Research. VOLKSWAGEN AG. Key Data. renew able fuels for advanced powertrains. finance: budget 20 M€ funding 10 M€ duration: 4 years start: 01 / 2004

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Dr. Eckart Heinl Group Research

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  1. The BtL-Project RENEW of the European Union Managed by VW Dr. Eckart Heinl Group Research VOLKSWAGEN AG

  2. Key Data renewable fuels for advanced powertrains finance: budget 20 M€ funding 10 M€ duration: 4 years start: 01 / 2004 partners: 31 from 8 countries core group: VW, DC, Renault, Volvo, Choren, Cutec, Chemrec, Abengoa, EC renewable energy coordinator: Dr. Frank Seyfried, Volkswagen AG

  3. CO2-emissions [g/km] Gasoline + Diesel new passenger car fleet A C E A Diesel 180 target 140 g/km 160 - 25% 140 2000 2005 1995 year Motivation voluntary commitment of European car manufacturers (ACEA)

  4. 2010 2015 2020 new proposal 2020 5,75% 7% 8% biofuels 15 % 2% 5% 10% natural gas 10 % LPG 5 % H2 - 2% 5% a few % 7,75% 14% 23% > 30 % Total • increasing support of renewable energies by the EU • mid term: blends of conventional fuels with biofuels and “Gas to Liquids”; natural gas partly supported by EU and energy industry • long term: priority of hydrogen as sustainable fuel by policy and industry Motivation

  5. Motivation/Objectives • Integrated approach ACEA / EC fuel directive • current biofuels have not the potential to substitute fossil fuels in significant amounts • the full plant usage has best biofuel potential • Objectives • evaluation of most efficient conversion technology - ecological (LCA) and economical • substitution potential for biofuels • biofuel specification for current and future ICEs • commonly agreed strategic recommendations

  6. Biomass Gasification Life Cycle Assessment bench mark of known routes SynGas: CO + H2 Fuel Synthesis SunDiesel HCCI-fuel DME Ethanol Scope

  7. Structure SP 5 SP 1 SP 2 SP 3 SP 4 Biomass and process assessment - biomass potential - life-cycle assessment - economical impact - suitability for ICEs - production assessment Optimised fuels for new drive trains Optimisation of bioethanol production Optimised processes for FT- fuel DME production - from black liquor - Training 2 summer schools SP 6

  8. SP 1 Fuel Optimisation • Objectives • production of optimised BtL fuel for conventional diesel engines and new combustion processes • Partner and responsibilities • UET fuel production • DC common rail engine tests • VW unit injection (PD) engine tests • Renault tests on a HCCI engine test bench • CERTH upgrading the product • ITN analysing the fuels

  9. Commonly agreed fuel specifications: SP 1 Fuel Optimisation • 300 l of kerosene high and 600l of diesel have just been delivered to DC • 600 l of kerosene high have just been delivered to VW • 150 l of naphtha (FBP < 150°C) have just been delivered to Renault

  10. Usual Diesel Item Unit GTL 10 “Naphta” GTL 20 “Kerosine” ( 124 A ) Density 15°C kg/m3 672,6 736,1 834 Distillation : IBP °C 43 152,5 162 10% °C 61 159,5 196 50% °C 95 167,0 272 90% °C 126 185,5 337 95% °C - - 348 FBP °C 166 208 359 Cetane number - 45-55 64,5 54 Results SP 1 • overview:GTL fuels vs conventional fuel • synthetic GTL fuels / main characteristics : • -GTL10 : cetane equivalent to conventional / usual Diesel, but highly volatile • - GTL 20 : “intermediate” volatility, but with noticeably higher cetane

  11. Results SP 1 preliminary results about fuel effects in a HCCI-engine influence of GTL fuels on soot emissions power (BMIP) increase at constant 3700 r.p.m. with 3 different intake manifold pressures 2,0 bar 2,4 bar 2,7 bar 3700 rpm 3700 rpm 3700 rpm Power (J/m3) Power (J/m3) Power (J/m3)

  12. SP 2 Process Optimisation • Objectives • optimised process for Fischer-Tropsch fuel production • Partner and responsibilities • CUTEC fluidised bed gasification, FT-fixed bed reactor • FZK pyrolysis and entrained flow gasification • BKG, TUV gas treatment and FT-synthesis • IGNG exergetic analysis • ITN analysis of the fuels • EdF process integration and upscaling • CERTH catalyst development • VW suitability of fuel from engine tests

  13. assessment of different process routes for Fischer-Tropsch BtL-fuels SP 2 Process Optimisation comparison of: - entrained flow and fluidised bed gasification - different FT reactor concepts biomass conditioning gasification gas cleaning Fischer Tropsch reactor *) *)Source: FUTURE Energy GmbH

  14. SP 2 Process Optimisation gasification and gas cleaning gas engine and generator additional gas cleaning Fischer Tropsch reactor off gas compressor raw product cloride and sulphur removal Güssing power plant 8 MW th. ;2.5 MW el. Fischer Tropsch synthesis in side stream • development of flow chart and interaction with biomass CHP • gas cleaning • design of slurry reactor

  15. SP 3 Black Liquor Gasification • Objectives • detail engineering of DME production from black liquor • Partner and responsibilities • Chemrec & STFI evaluation of pilot plant data and simulation - full scale (250-300 MWth) and - demonstration scale (45 MWth ) plant • Södra Cell evaluating the impact of the unit in a pulp mill host plant • VTEC performing heavy duty engine tests • Ecotraffic developing a distribution strategy for the products

  16. forest forest residual pulp wood pulp mill biomass transformer combined recovery and fuel synthesis fuel (DME) pulp SP 3 Black Liquor Gasification smart issue: present high value biomass (black liquor) is replaced by minor value biomass (forest residues) for energy purposes in the pulp mill • basic engineering finished • 2 alternatives in DME production are assessed at the moment: two steps or one step by Haldor Topsoe • start of construction: mid 2005

  17. SP 4 Bioethanol Production • Objectives • optimisation of bioethanol production • Partner and responsibilities • Abengoa assessment of the common enzymatic pathway as a benchmark • AICIA consideration of the thermochemical pathway, including gasification-, and catalyst tests as well as final process simulation and optimisation

  18. SP 5 Biofuel Assessment • Objectives • biofuel assessment • Partner and responsibilities • EC BREC assessment of biomass resource and potentials • ESU-services Life Cycle Analysis • IEE assessment of micro- and socio-economics • EEE technical assessment • PSI thermochemical gaseous fuel production

  19. potential of straw, wood and energy crops has been evaluated for the EU 25 using literature and statistical data Results SP 5 e.g.: straw: cereal straw 771 PJ permanent crops residues 74 PJ maize 61 PJ total 906 PJ 22 Mtoe 20…60% are available for energy/~ local conditions

  20. Results SP 5 alpine (CH + AT) south: GR,SP,IT,PR,BG, RO UK + IR west: GE,FR,BE,Lux,NL north: FIN,SE,DK CEE-8 0 200 400 600 800 1000 1200 1400 1600 total: 3632 PJ (86 Mtoe)

  21. process parameters assess- ment recommen- dations provision and costs first fuel tests 2004 2005 2007 2008 2006 Conclusion commonly agreed strategic recommendations process evaluation - costs - efficiency - ecology optimised fuel biomass potential Europe

  22. For further informations: www.renew-fuel.com Thank you for your attention!

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