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Biomass Energy Delivery through Pyrolysis Oil

Biomass Energy Delivery through Pyrolysis Oil. Anjan Ray UOP India Pvt Ltd. Indian Institute of Chemical Engineers December 18, 2010 Gurgaon, India. © 2010 UOP LLC. All rights reserved. UOP 5363-01. UOP Overview.

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Biomass Energy Delivery through Pyrolysis Oil

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  1. Biomass Energy Delivery through Pyrolysis Oil Anjan RayUOP India Pvt Ltd Indian Institute of Chemical EngineersDecember 18, 2010Gurgaon, India © 2010 UOP LLC. All rights reserved. UOP 5363-01

  2. UOP Overview • Leading supplier and licensor of processing technology, catalysts, adsorbents, process plants, and technical services to the petroleum refining, petrochemical, and gas processing industries. • UOP Technology Furnishes: 60% of the world’s gasoline; 85% of the world’s biodegradable detergents; 60% of the world’s para-xylene. • 3400 employees worldwide. • Strong relationships with leading refining and petrochemical customers worldwide. • UOP’s innovations enabled lead removal from gasoline, the production of biodegradable detergents, the first commercial catalytic converter for automobiles. 2003 National Medal of Technology Recipient Biofuels: Next in a Series of Sustainable Solutions

  3. Macromarket Summary: Through 2020 • Global energy demand is expected to grow at CAGR 1.6%. • Primary Energy diversity will become increasingly important over this period with coal, natural gas & renewables playing bigger roles • Fossil fuels will continue to supply ~80% of primary energy and 90 to 95% of liquid transportation needs • Biofuels are expected to grow at 8-12%/year to ~3.0 MBPD Source: IEA, 2008 Can bio-based productsreplace petroleum’s… Physical properties?Versatile and high-performance Cost?$12/GJ (@$75/bbl) Scale?31,000,000,000 bbl/yr • Is there sufficient land area? • Is the land area productive enough? • For which petroleum-based products can bio-based ones directly substitute? • Can modifications of process or product improve indirect substitution? • Can technological innovation lower the cost of individual steps? • Can economies of scale lower the end cost to a competitive level? Source: Lux Research, Inc. 2010 Energy Security, GHG Abatement & Economics will Drive Investment UOP 5363-03

  4. Biofuels: Regional Drivers • SE ASIA/ S. AMERICA • Agro sector focus DriversChange Priority for Different Economies/Geographies • EUROPE • Energy Security: RED • Global warming: RED/FQD • AFRICA • Rural development • CHINA/INDIA • Energy Security • Rural development • Employment • N. America • Energy Security: RFS • Environment • Agro sector subsidies

  5. Biofuels Overview: Technology Pathways Feedstocks Products = UOP Areas Ethanol Sugars Dehydration Fermentation C6 Sugars Distiller’s Grain Renewable Energy CO2 C5 / C6 Sugars Starches Enzyme Conversion Acid or Enzyme Hydrolysis Green Gasoline Direct Conversion Hydrotreating Lignin, Cellulose & Hemicellulose Pyrolysis/Thermal Depolymerization Bio-oil - Fischer Tropsch Lights H2O Syngas Gasification Green Diesel/Jet Alcohol Synthesis FCC Natural Oils Hydrotreating Glycerine Co-Feed 2nd Gen Feeds (Jatropha, Camelina & Algal) Transesterification FAME or FAEE Current biofuel market based on sugars & oils. Use bridging feedstocks to get to 2nd Generation Feeds:Algae & Lignocellulosics

  6. Butane Sulfur Light Ends Sulfur Plant Gas ProcessingUnit Butane-Butylene Isobutane Alcohol H2 Iso-octane Iso-octaneProduction Alkylation Etherification Fuel Gas Isomerate LPG Light Naphtha Gasoline Isomerization Alkylate Jet Fuels Crude Oil Flue Gas H2 H2 Reformate LPG Solvents CatalyticReforming Diesels Naphtha NaphthaHydrotreating Crude Treating& Desalting H2 AromaticsProduction BTX Light Distillates Crude Oil Distillation(Topping) HeatingOils Distillates Light DistillateHydrotreating H2 Latest RefiningTechnologyDevelopment & Licensing Heavy Distillate Diesel and Heating Oil Geases Heavy DistillateHydrotreating Light OlefinsProduction Fuel Oil Gasoline H2 Fluid CatalyticCracking Product Treating Blending AtmosphericGas Oil Gasoline, Naphtha, Middle Distillates, Gasoline Gas OilHydrotreating H2 Kerosene and Jet Fuels Gas Oil Vacuum Distillation Hydrocracking Diesel and Heating Oils Lube Oils Lube Oils Lube OilProduction SolventExtraction &Deasphalting Heavy Fuel Oil Vacuum Resid Visbreaking Asphalts Asphalt Syngas/Steam Gasification Diesel Coking ElectricityCoke Natural Gas Natural Gas, Fuel Oil EnergyConservation &Management(PowerProduction) Plant Maintenance/Reliability/Safety EnvironmentalControls Plant Upgrades& Revamps Hydrogen Production/Purification/Recovery Gas-to-Liquids Fuel, Wax H2 Petroleum Refining Context • Refining: ~100 years • ~750 refineries • ~85M BBL of crude refined daily • ~50M BBL transport fuels • Complex but efficient conversion processes • High quality transport fuels Massive Scale Technology Evolution Expected UOP 5363-04

  7. Biofuels in Modern RefineryContext: Key Attributes • Supplement crude diet with locally sourced feeds • Provides some insulation against price shock • More secure supply chain • Critical issue is creating a truly fungible product • Use the same infrastructure as oil refining today • Does not require modifications to transport platform • Address the environmental pressures of fossil fuel combustion • Life Cycle Analysis of biofuels shows dramatic benefits • Sustainable feed and product chain to insure long term success • Cost competitive technology offerings UOP 5363-05

  8. Oxygenated Biofuels Ethanol Biodiesel Inedible Oils: Camelina, Jatropha FirstGeneration Second Generation Lignocellulosic biomass, algal oils Natural oils fromvegetables and greases UOP Renewables Vision • Building on UOP technology and expertise • Produce real fuels instead of fuel additives/blends • Leverage existing refining/ transportation infrastructure to lower capital costs, minimize value chain disruptions, and reduce investment risk. • Focus on path toward second generation feedstocks & chemicals Hydrocarbon Biofuels Gasoline Diesel Jet UOP 5149-08

  9. Transition Option

  10. UOP/ENI Ecofining™ Process Comparison vs. Biodiesel • Superior technology that produces a drop-in diesel • Uses existing refining infrastructure, can be transported via pipeline, and can be used in existing automotive fleet • CFPP and Cloud Point can be controlled • Excellent blending component, allowing refiners to expand diesel pool by mixing in “bottoms” • Can be used as an approach to increase refinery diesel output Natural Oil/ Grease + Methanol Biodiesel (FAME) + Glycerol Natural Oil/ Grease+Hydrogen Green Diesel + Propane Performance Comparison

  11. Ecofining: Implementation Options 4. Stand-alone Hydroprocessing/ Isomerization (Ecofining Unit) • Feedstocks • Rapeseed • Tallow • Jatropha • Soybean • Algal Oils • Palm Oil 3. Integrate with new or existing DHT 2. Revamp existing DHT 1. Co-Processed Hydroprocessing UOP 5149-12

  12. Green Diesel vs. Biodiesel (FAME) Natural Oil/ Grease Methanol Hydrogen Green Diesel Biodiesel (FAME) + Glycerol + Propane UOP/ENI EcofiningTM Process to Produce Green Diesel Preferred Bio Derived Diesel of ACEA UOP 5149-13

  13. Breakeven Analysis: Sensitivity to Feed Oil Prices Sensitivity to Vegetable Oil Price $400 $200 $0 $60 $65 $25 $30 $35 $70 $100 $105 $40 $45 $50 $55 $75 $80 $85 $90 $95 $110 $115 $120 $125 -$200 -$400 NPV, $M -$600 -$800 $400/MT ($59/bbl) $600/MT ($88/bbl) $800/MT ($118/bbl) $1000/MT ($146/bbl) -$1,000 -$1,200 -$1,400 Crude Price, $/bbl Economics Driven by Relative Cost of Feedstocks

  14. Economics of Oil Upgrading • Strongly dependent on price of starting oil • Requires source of hydrogen to modify oil – expense • Upgrading steps complimentary with traditional refinery operations • Capital charge dependent on access to existing facilities

  15. Second Generation Option

  16. Lignocellulosic Biomass Processing Options Fermentation/ Catalysis Direct Combustion Heat & Power Fast Pyrolysis Pyrolysis Oil Transport Fuels Upgrading Solid Biomass SynGas Hydro-cracking/Dewaxing Fischer Tropsch Gasification Envergent Route to Energy Bioethanol/ Biobutanol UOP 5363-08

  17. Pyrolysis Oil to Energy & Fuels Vision P P Energy/ Fuels P P Electricity Production Forest Fiber Available for Sale Fuel Oil Substitution Fast Pyrolysis Pyrolysis Oil Biomass Transport Fuels (Gasoline, Jet, Diesel) Commercially available in 2012 Ag Residue Phased Commercialization

  18. Rapid Thermal Processing (RTPTM) Technology Pyrolysis Oil Solid Biomass Commercially Proven Patented Technology UOP 5363-10

  19. RTP Operating History & Commercial Experience Commercialized in the 1980’s 7 units designed and operated in the US & Canada Continuous process with >90% availability Note: design basis for wood based plants assumes feedstocks with 6 wt% moisture content. Significant Commercial Experience

  20. UOP FCC Background • FCC technology is key process in gasoline production • UOP has been designing FCC units since the early 1940’s – one of the co-inventors • Licensed over 250 units – more than 50% of world-wide capacity • Unit sizes from 1,500 to 200,000 BPD capacity RTPTM UOP FCC FCC Experience Enables Scale-up UOP 5121-03

  21. RTPTM Unit Process Diagram Quench & Separation Conversion FeedSystem Surge Bin Feed Bin Heat forMoistureReduction Minimal Net Utilities – RTP Is Self sustaining Process With Reduced Carbon Footprint UOP 5363-11

  22. Feedstock Sources • Forestry and Pulp and Paper • Wood chips, sawdust, bark • Lignin • Agricultural • Residues - straw, expended fruit bunches from palm (EFB), other • Purpose-grown energy crops – miscanthus, elephant grass • Post-consumer • Construction and Demolition Waste, Categories 1 & 2 • Municipal solid waste (future) • USDA study 2005 - > 1 billion ton per year available in United States alone Regional Technical Biomass Potentials in 2050(Mtoe/yr) Source: VTT, 2007a Cellulosic Feedstocks Widely Available UOP 5363-12

  23. Feed Handling / Preparation • Water is a heat sink • Dried to 5-6 wt% moisture content for efficient RTPTM reactor operation • Size impacts heat transfer • Biomass sized to 0.125-0.25 inch (3-6 mm) • Capacity of unit expressed on bone dry feed basis • BDMTPD • Zero water content RTP is Self-Sustaining – Excess Heat Dries Raw Biomass

  24. RTPTM Product Yields 400 TPD of Hardwood Yields For Various Feeds Cellulosic Feedstock Flexible with High Yields of Pyrolysis Oil UOP 5363-13

  25. RTPTM Pyrolysis Oil Properties • Pourable, storable and transportable liquid fuel • Energy densification relative to biomass • Contains approximately 50-55% energy content of fossil fuel • Stainless steel piping, tankage and equipment required due to acidity • Requires separate storage from fossil fuels Comparison of Heating Value of Pyrolysis Oil and Typical Fuels Suitable for Energy Applications

  26. Pyrolysis Oil: Alternate Revenue Stream • Development of pyrolysis oil as a well-defined commodity critical to success • Producer and consumer confidence • ASTM standard specification foruse of pyrolysis oil inindustrial burners is a key first step ASTM D7544, Standard Specification for Pyrolysis Liquid Biofuel Comparison of Cost of Selling PyOil vs. Making PyOil

  27. Pyrolysis Oil Energy Applications • Compatible with specialized turbines • Specialized burner tips improve flame/burning • Convert to steam to use existing infrastructure • Use as a blend in diesel engines • Upgradable to hydrocarbon fuels FuelBurner Heat Gas Turbine RTPUnit ElectricityCHP DieselEngine GreenGasoline,GreenDiesel &Green Jet OptimizedUOPUpgradingTechnology Hydro-cracking/Dewaxing Syngas Fischer-Tropsch Gasification Multiple Applications for Pyrolysis Oil, a Renewable Fuel Available Today UOP 5363-14

  28. Pyrolysis Oil: Replacement of Fossil Fuels to Generate Heat Specialized burner tips improve flame/burning Low emissions (NOx, SOx) Fuel consistency - ASTM D7544 Flexibility to decouple pyrolysis oil production from energy generation (location and time) GHG emission reduction of 70-90% Low cost liquid biofuel ~40% cheaper to make and use pyrolysis oil than to purchase #2 fuel oil on an equivalent energy basis 400 BDMTPD RTP Unit Assumes 60 $US/bbl crude Includes RTP operating cost and 15-yr straight line depreciation of CAPEX 330 Days per Year Comparison of Cost of Buying #2 Fuel Oil vs. Making Pyrolysis Oil ~ 8 $US Million per Year Savings

  29. RTPTM Economics – Fuel Oil Substitute 15.0 14.0 13.0 50 12.0 Cost of Buying Equivalent Amount of #2 Fuel Oil 11.0 40 Delivered &Dry Feedstock Cost, $US/Metric Tonne Million $US/year 10.0 30 9.0 40 $US/MT Feedstock Breaks even @ ~28 $US/barrel 8.0 7.0 6.0 5.0 15 20 25 30 35 40 45 Crude Oil Price, $US/barrel Comparison of Cost of RTP Operation to Purchasing Equivalent Amount of Fuel Oil • 400 BDMTPD RTP, hardwood whitewood feed; 330 days per year • #2 Fuel Oil scaled from 28 Nov 08 WTI Spot, 55 $US/bbl, & 1.67 $US/USGal for #2 Fuel Oil, Source EIA • Pyrolysis oil contains 55% of energy content of fuel oil, by volume. • 15 year straight line depreciation included in cost of operation; $US 30 million RTP ISBL CAPEX Economic Solution for Fuel Oil Substitution

  30. Pyrolysis Oil: Production of Green Electricity • Compatible with specialized turbines • Green electricity production cost is 0.12 $US/kW-h • Includes RTP operating cost and 15-yr straightline depreciation of CAPEX (including gas turbine) • Experience in stationary diesel engine as blend with fossil fuel • Operation with 100% pyrolysis oil under development • Commercial application expected by 2Q2011

  31. Pyrolysis Oil Upgrading • Objectives • Remove oxygen molecules • Reduce acidity and viscosity • Break up molecules to make high octane gasoline or diesel/jet precursors • Commercialization expected in 2012 • Solution • Thermochemical upgrading; leverage existing hydroprocessing technologies • Preliminary Results • 30 Wt% hydrocarbon yield from dry biomass Preliminary Yields from Hydrocarbon Achieved in Lab, Working on Stability and Scale UOP 5363-18

  32. Integration into Commercial Refinery Light acids/ oxygenates may be used to supplement H2 generation Partial Deox PY Oil Stabilizer Integration at the commercial plant level: • A number of options exist for integration of py oil into refinery processes: • As stabilized py oil • As partially or fully deoxygenated py oil • For by-products (light acids, oxygenates) as H2 generation UOP 5363-19

  33. Integrated Biorefinery Demonstration • UOP has received a DOE grant to demonstrate fuels technology from conversion of second generation feedstocks • Demonstration to be done at a refinery location, with commercial partners • Fuel sourced from pyrolysis technology is based on renewable feedstocks • Waste biomass • On purpose energy crops • C&D wastes • Completely fungible fuels is the objective of the project • Technology development that complements traditional refinery technology Demonstration Plant to Start up by 2014 UOP 5363-20

  34. Pyrolysis Oil vs. Fossil Fuel LCA Carbon Dioxide Impact Canadian Scenario Sawmill Residues RTP unit located at sawmill site Feed Transportation Distance = 0 PyOil 88% lower GHG than Petroleum-derived heating oil LCA Result courtesy of Don O’Connor (S&T)2 Consultants Inc. 11657 Summit Crescent Delta, BCCanada, V4E 2Z2 Significant GHG Benefits With Biofuels UOP 5363-21

  35. Pyrolysis Oil vs. Fossil Fuel LCA • Pyrolysis Oil Production foot printsimilar to fossil energy alternatives • Assumed biomass transport distances • 200 km for logging residues • 25 km for short rotation forest crops • Pyrolysis Oil Life Cycle foot printGreener than other alternatives • Carbon neutral combustion emission • 70-88% lower GHG emissions • SOx emissions similar to Natural Gas

  36. RTPTM Project Benefits Economics • Economic solutionfor renewable energy • Competitive relative to fossil fuels • Leverages existing assets • Provides alternate revenue stream Technical • Proven application • Feedstock flexibility • Minimal net utilities • Storable product allows decoupling from end user Environment & Social • Reduction of greenhouse gases and emissions • Waste disposal • Minimum environmental Impact • Agriculture development • Employment Energy Security • Energy diversification • Reduction of fossil energy requirements Pyrolysis to Energy Now – Transport Fuels in 2012 UOP 5363-22

  37. Biofuels and RefiningA Compatible Future • Several options exist to address the growing demand for renewable fuels • Choice of option depends strongly on available feed • Economics tied to feed supply and alternate feed uses • Triglyceride oil starting points give immediate transport fuels solution • Cellulosic materials provide an energy substitute • Longer term transport solution • RTP technology for conversion of biomass to an energy delivery intermediate • Commercially proven technology: 8 units designed and operated • Reliable operation with 90% on-line availability similar to refining operations • Cost competitive with fossil fuel oil (depending on crude price and feedstock cost) • 25-30% cheaper than #2 Fuel Oil on energy basis • Transport fuels technology available soon • DOE demo in progress • Alternate fuel with secure supply chain • Tangible environmental benefits UOP 5363-23

  38. UOP 5363-24

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