Integrated Home Energy from Waste Biomass Tom Horgan

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

Outline • Executive Summary • Introduction – Preconception, Expectations, Distributed Generation • Research Summary – – – The State of Energy: Crude vs BTLTF Conversion Route Energy & Economic Comparisons Pyrolysis, Liquefaction, MTG, FT Synthesis Gasification: Analysis & Modeling Catalytic gasification, ionic liquids Integrated Home Energy System

Outline • Integrated Home Energy System (IHES) – – Concept Description Component Functions/technologies Phased Development Plan Estimated timeline/cost • Additional Topics – How do we find the “google in a haystack” • Wrap Up

Executive Summary • We propose to build and market an integrated home energy system. – Multifeed – Biomass, MSW, Sewage – “Clean Gasification” based – Multiple energy conversion options (CHP fuel cell, Gas Gen, LF) • Rationale: – Lean (saves $), Green (recycle), Mean (self sufficiency) – Clean Gasification - Enabling Technology for BTLTF – Direct competition with crude products unrealistic • Additional Discussion – Biomass Research database is massive. How do we find the “Google in a haystack”?

Introduction • Preconception – Alternative energy field was exploding with oil prices reaching $150/barrel in 2008 – Modern science applied to BLTTF (Biomass To Liquid Transportation Fuel) has yielded research databases full of new concepts ready for advancement & commercialization • Expectation – Search databases, talk to scientists, down-select concepts, develop business plan and commercialize

Introduction • 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)

Introduction • Distributed Generation – Electricity generation ~33% efficient nationwide – Household waste contains 30% of total energy used • 50 kg/day can supply remaining electricity with heat in excess – Core gasification technology development required for all biomass conversion processes – Homeowner saves money, goes green and increases sense of self sufficiency

The State of Energy • Usage & Losses https: //eed. llnl. gov/flow/images/LLNL_Energy_Chart 300. jpg

The State of Energy • World Oil Reserves – “Proven” vs “Unproven” http: //en. wikipedia. org/wiki/Oil_reserves

The State of Energy • Market Opportunity http: //www. eia. doe. gov/

The State of Energy • 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 – Diesel - 43. 5 MJ/kg (~80%) 42. 8 MJ/kg (~85%) • Biomass/Solids – 6/20 MJ/kg – MTG Gasoline – FT Diesel - 43. 5 MJ/kg (< 50%) 42. 8 MJ/kg (< 60%) • 5 to 15 x more input energy http: //www. eia. doe. gov/

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

Research Summary • Fischer Tropsch Synthesis – Gasification – Synthesis – Upgrading

Research Summary • 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 CO 2 and N 2) – Dilute syngas leads to large reactors (higher cost)

Research Summary • Methanol Synthesis Natural Gas Desulph Coal or Biomass SMR Gasifier Cleaning Steam O 2, Air 2 H 2 + CO CH 3 OH 50 Atm, 270 C Copper Oxide Catalyst H = -92 k. J/mol Syngas (H 2, CO (CO 2, N 2)) Compressor Purge Gas Methanol Convertor Syngas Recycle Loop Cooling/ Distillation MTG Process Methanol

Research Summary • 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 • Methanol to Gasoline 2 CH 3 OH CH 3 OCH 3 + H 2 O 320 C Alumina CH 3 OCH 3 H 2 O + C 2 – C 5, alkenes, cycloalkanes, aromatics 400/420 C Zeolite Light HC, CO 2, H 2

Research Summary • 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 • Gasification – First step in FT, methanol, MTG, FC, generator – Biomass is heated under low oxygen conditions (Atmospheric, > 600 C) – Steam sometimes added – Volatile material driven of leaving char, steam and tars – Char reacts with air and steam to form syngas (H 2, CO, others)

Research Summary • Gasification Reactors – Small Scale – Downdraft Gasifier • • Outside dimensions (w/ hopper): 4 ft h x 1. 5 ft d Syngas production rate: ~ 35 ft 3/lb of 15% wood Max Capacity: ~700 lbs wood/day - 1000 ft 3/h (320 MJ/h) Outlet Temp: 50/75 C after cyclone/filter $2300 Assembled $1400 Not Assembled http: //www. allpowerlabs. org

Research Summary • Gasification - Issues – Gasification rated primary barrier to commercialization of BTLTF System • Very pure syngas required (essentially H 2/CO) – Systems diluted with N 2, CO 2 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 H 2/CO ratio.

Research Summary • Ionic Liquids – Dissolution of wood – Argyropoulos to Write Proposal on… • Dissolution of Sludge • Catalytic Cracking of Pyrolysis Products • Catalytic Gasification – To be included in future discussions with NREL

Research Summary • Economic/Energy Comparison

Research Summary • 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

Integrated Home Energy • Household Mass Balance (Family of 4) Food Water Paper Plastics MSW Water Sewage Average Usage: ~320 MJ/day Waste: ~ 100 MJ/day (~30%) 290 GPD 0. 1% Solids ~ 7 MJ/day 8 Kg/day ~91 MJ/day

Integrated Home Energy • Quick Energy Calcs (Avg Household, 4 people) – – Usage: 320 MJ/day 60% Electric, 40% Thermal Annual Cost: $1800 (~ $5/day) Waste = 30% of Total Usage (92% MSW, 8% Sewage) Fuel Value Comparison ($/1000 MJ, Trillion MJ) – Conclusion: Make Electricity from MSW, Wood, Coal or NG http: //www. eia. doe. gov/

Integrated Home Energy • Concept Wood Chips Syngas MSW Mechanical Grinder/Mixer Water Sewage Air Slag Dewater WGS Dryer/ Pellitizer N 2/CO 2 Removal Gasifier Cleaning/ Scrubbing

Integrated Home Energy • Concept 2 k. W Syngas Generator Wood Chips, MSW, Sewage Mechanical Grinder/Mixer Dewater Dryer/ Pellitizer Air Slag Gasifier Energy Storage Syngas WGS N 2/CO 2 Removal Cleaning/ Scrubbing Start Up

Integrated Home Energy • IHES Component Functions – Feed preparation/pretreatment • Wood (20%): Chipped/dried • MSW (50%): Ground/dried (pellitized? ) • Sewage (99%): Dewatered, dried, ground – Gasification • Supply Heat & Syngas – Generator: Particulate & tar free – FC: Particulate & tar free w/ CO < 1% – BTLTF: Particulate & tar free, H 2/CO tunable, N 2/CO 2 free

Integrated Home Energy • IHES Component Functions – Combined Heat & Power • Gasifier: Heat for drying & residence • Generator: Electricity to residence & storage • FC: Electricity to residence and storage. Heat to residence and drying – Energy Storage • Battery Pack: – Provide start up power – Provide power when no fuel available

Integrated Home Energy • Component Technologies – Mechanical grinding/mixing/shredding • • Wide availability at industrial scale Biomass Shredders may also work for MSW Residential Scale Shredder ~ $600 (Home Depot) Continued research on integrated designs – Feed Drying • Feed drying improves efficiency but not required for biomass (probably required for MSW) • Heat produced exceeds household demands • Integrated heat exchanger to provide drying energy

Integrated Home Energy • Component Technologies – Pelitizing • Cost of Pellitizing shredded MSW may be offset by efficiency & gas quality improvements • More research – implement in later phases • Manure Briquettes – http: //www. aesenergy. net/news/cow-manure-toenergy. html – Dewatering • Required if sewage is used but energy content does not justify expenditure

Integrated Home Energy • Component Technologies – Gasification • Specs: Atmospheric, air blown, direct heated, 5 k. W • Numerous technologies available. Requires full scale evaluation process for down selection – – – http: //noest. ecoundco. at/news/docs/1277_Biomass_Engineering_UK. pdf http: //www. croreyrenewable. com/index. html http: //www. associatedphysics. com/Prod. Services/Gasification. html http: //www. phoenixenergy. net/ http: //gasbiopower. com/home http: //www. primenergy. com/Gasification_idx. htm • Many more…

Integrated Home Energy • Component Technologies – Gas Cleaning/Scrubbing • Initial: Cyclone (particulate), cold water quench followed by sand filter • Research more advanced cleaning technologies for later phases – N 2/CO 2 Removal • Enabling technology for residential scale (microchannel) Fischer Tropsch process • Membrane filter technology: – http: //www. mtrinc. com/co 2_removal_from_syngas. html

Integrated Home Energy • Syngas Conversion Comparison – Gas Generator • Efficiency: Unknown on Syngas • CHP: Gasifier yes, Generator no • Other: Use NG generator, off-the-shelf gasifier – Fuel Cell • Efficiency: > 30% Electric, > 80% Overall, ~ 60% w/ Gasifier • CHP: yes • Other: built in desulph, tar cracking – Liquid Fuels • Efficiency: ~ 50% overall with significant development • CHP: yes • Other: Microchannel, N 2/CO 2 removal

Integrated Home Energy • Overall Approach – Contact NREL for Concept Evaluation – Visit Community Power & NREL 2/15 – Evaluate additional gasification technologies for residential scale and down select

Integrated Home Energy • Phased Development Plan – Phase 1: Proof of Concept • Simple DD Gasifier/Gas Generator – Downselect gasifier & gas generator technology – Purchase chipper/gasifier/generator & test in Saratoga – 3 to 6 months, < $15, 000 – Phase 2: Prototype Development • MSW Gasification/Gas Generator – – – Develop/test methods of MSW prep for gasification Assess need for pellitizer/additional drying/advanced cleaning Develop prototype skins/frame/etc Purchase additional gasifier 2 to 4 months, < $10, 000

Integrated Home Energy • Phased Development Plan – Phase 3: Advanced Concept Development • Advanced Gasification – – Purchase H 2, CO sensor or GC Integrate shift catalyst/steam and controls Test on fuel cell in cooperation with Plug Power 1 to 2 years, < $100, 000 – Phase 4 – Advanced Concept Development • Transportation Fuel Synthesis – Evaluate CO 2 and N 2 removal technology – Evaluate microchannel technology – 3 to 5 years , < $1 million

Additional Discussion • How do we find the “google in a haystack”? • How do we get people to come to us with ideas? • Rapid Concept Evaluation • Berkshire Energy Laboratory

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

Backup Slides

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

The State of Energy 1% of All Biomass On Earth = (~ 50 cubic miles proven reserves as of 2008) http: //spectrum. ieee. org/jan 07/4820

Research Summary • Fischer Tropsch Synthesis– Gasification – covered as a separate topic – FT Synthesis Reaction Chemistry

Research Summary • Fischer Tropsch Synthesis– Product Distribution • Low Temp FT ü 200/240 C üCobalt ü waxes • Hi Temp FT ü 300/350 C üIron ü liquids

Research Summary • Fischer Tropsch Synthesis– Reactor Design Types

Research Summary References: “Bio-syngas production with low concentrations of CO 2 and CH 4 from microwave-induced pyrolysis of wet and dried sewage sludge” by Diminguez et al (2007) http: //www. adktroutguide. com/files/Weekly_Update_11_7_08. do c

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

Research Summary • Gasification Reactors - Industrial

Research Summary • Residential Systems – Develop commercially viable residential scale product for conversion of wood/biomass to electricity – System Concepts • Gasifier/Syn. Gas Generator • Gasifier/Methanol Convertor/Generator • Gasifier/Fuel Cell

Research Summary • Residential Systems - System Concepts – Gasifier/Syn. Gas Generator • Advantages: – Simple concept – Relatively easy to implement on a small scale – Been tried and implemented • Disadvantages – – Low efficiency Low heating value of syngas Long term operational issues due to tars and particulates Attempted by Community Power Corp & rejected on cost – XX Kwh/chord of wood

Research Summary • Residential Systems - System Concepts – Gasifier/Methanol Convertor/Generator • Advantages: – Liquid Fuel – Clean Burning Methanol • Disadvantages – Complex concept – Undeveloped – Estimate XX Kwh/chord of wood

Research Summary • Residential Systems - System Concepts – Gasifier/Fuel Cell • Advantages: – High efficiency CHP – Easy implementation • Disadvantages – FC Reliability – Syngas Quality – Estimate XX Kwh/chord of wood

Research Summary • Residential Systems - System Concepts – Gasifier/Fuel Cell • Modeling Results

Research Summary • 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 2 mm, < 150 C, < 30 min) – Safety: Low vapor pressure and highly recyclable. Some are combustible. Many are toxic if released to the environment.

Research Summary • 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 2 mm, < 150 C, < 30 min) – Safety: Low vapor pressure and highly recyclable. Some are combustible. Many are toxic if released to the environment.

Research Summary • Argyropoulos Patents – Low Energy Pyrolysis of Wood – WO 2008/098036 A 1 • IL Pyrolysis: Wood dissolved in IL, 190/200 C (20 min), 10% more tar, 12% less char , 10% higher/more selective yield of distillates than Fast Pyrolysis – Fast Pyrolysis: Pretreated w/ organic solvents, 425/500 C (2 s), tar, char, liquids (200+ intermediates) – Low Energy Glucose from Wood for Bio. Ethanol– US 2008/053139 • IL dissolved wood is easily hydrolyzed by enzymes to release Glucose for production of bioethanol – Polymers and Composites from Dissolved Wood – US 2008/053151 • IL dissolved wood can be blended with co-polymers, polymers and functional additives to form eco-friendly (degradable) composites

Research Summary • Ionic Liquids • Potential for Transportation Fuel Synthesis – IL Pyrolysis produces a much narrower range of hydrocarbons with higher potential for catalytic cracking to trans fuels – Sludge dissolution and homogenous processing to fuels – Catalytic Gasification of Dissolved Wood (Syngas) – Other undiscovered routes to aliphatics/aromatics • Petrochina – Gasoline by alkylation of C 4 olefins with iso-butane in ionic liquids

Research Summary • Catalytic Gasification – Project Concepts • Low Energy Catalytic Biomass Syngas Gasification – Investigate routes with lower temps and pressures. Preprocessing. • Low Energy Catalytic Sludge Syngas Gasification – Investigate routes with lower temps and pressures. Preprocessing. • Catalytic Fuel Gasification w/ Reforming – Steam vs. Autothermal, Modeling for feasibility (efficiency/cost)

Research Summary • Economic/Energy Comparison

Research Summary • Gasification Reactions

Research Summary • Catalytic Gasification – Syngas Methods • Noncatalytic Supercritical: (450/600 C, 4000/6000 PSIG) – Hi Cap Cost, Limited Biomass testing • Low Temp Catalytic (225/265 C, 400/800 PSIG, Pt or Ni) – Simple organics, not tried on biomass – Fuel Gas Methods • Catalytic Hydrothermal (350 C, 3000 PSIG, Ru or Ni) – Good carbon conversion, biomass & sludge • Supercritical Carbon Catalyzed (600 C, 3700 PSIG) – Good carbon conversion, coke, ash, plugging

Berkshire Energy Lab • Robust Gasification – No suitable biomass gasification technology exists for FT – Require feedstock drying – Syngas must be cleaned of particulates/tars – H 2/CO ratio must be fixed at 2 – Feedstock variability significantly impacts gas quality. – Ability to gasify any carbonaceous feed is highly beneficial (residential) – May be a commercial product in itself

Berkshire Energy Lab • Robust Gasifier - Concept 1 Biomass Res Solid Waste Sewage Sludge Mechanical Grinder/Mixer Dryer/ Pellitizer Solvent? Cyclone/ Scrubber Gasifier Char/Slag Shift H 2 Sensor Steam Control Temp Control Syngas

Distributed Energy Systems • Residential scale gasification as part of fundamental research • Potential integration with Plug Power fuel cells when 5 KW system reaches $15 k capex (~3 years) • Methanol synthesis research - though limited applications given conversions needed • OTHER?

Distributed Energy Systems • Slide on Plug Power (Saratoga Energy) financials – partner? • Slide comparing liquid fuels to electricity – why methanol won’t work • Picture of unit

Lab Start-Up Costs • • Equipment needed (go to Fischer Scientific) Site selection (NY, Lenox? ) New hires - skills needed (funding) Partnerships to build

Integrated Home Energy • Notes – – – Compare w/ Community Power Need to do gasification road show Research Co 2/N 2 removal Need to talk about CHP in gasifier vs FC Energy storage? Charge batteries? What is efficiency of battery charging and usage? – “Microchannel Gasifier” – Gasify smaller amounts of feed with faster throughput? ? ? http: //www. eia. doe. gov/