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Uwe Zwiefelhofer Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur PowerPoint PPT Presentation


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EU-Malaysia Biomass Stakeholders Knowledge Exchange Session. Conversion of Biomass Using Proprietary Technologies – Lurgi‘s Experiences. Uwe Zwiefelhofer Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur

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Uwe Zwiefelhofer Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur

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EU-Malaysia Biomass Stakeholders Knowledge Exchange Session

Conversion of Biomass Using

Proprietary Technologies

– Lurgi‘s Experiences

Uwe Zwiefelhofer

Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur

Tel: +6 03 2164 6446 Fax: +6 03 2164 5448 Email: [email protected]


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Biomass to Fuels in 1950’s ….

… the direct approach….


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This Presentation

  • Lurgi at a Glance

  • Biomass Availability

  • Conversion of Biomass: Challenges, Concepts

  • Technology Overview and Status

  • Economics


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This Presentation

  • Lurgi at a Glance

  • Biomass Availability

  • Conversion of Biomass: Challenges, Concepts

  • Technology Overview and Status

  • Economics


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Member of

Lurgi at a Glance Lurgi Portrait

1500 Engineers, that deliver Innovative Technologies and Plants from One Hand for Oil, Coal and Gas Industry

Studies, Basic -, Detail Engineering, Licence, Procurement

Proprietary Technologies

Market Leader CTC, GTC, Biofuels

Project Management, Turn Key Execution

d

Technical Services

  • Technology and

  • EPC Expertise

  • Total Customer Focus

  • Innovative Solutions

  • Single Line Responsibility

Research and Development


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E&C Cryogenics

E&C Lurgi

1 500 Employees in 6 Engineering Centers

1 300 Employees in 8 Engineering Centers

Champigny

Frankfurt

Krakow

Vitry

Beijing

Houston

Harima

Shanghai

Hangzhou

Houston

Delhi

Hyderabad

Johannesburg

Lurgi at a Glance E&C : Engineering and Construction

  • Air Liquide : Relies on > 100 years of in-house Engineering and Technologies Engineering Capabilities: Doubled with Acquisition of Lurgi Strong Force: 2800 Engineers in the E & C Activities


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  • Sel. Refinery technologies

  • Hydrocracker

  • FCC

  • HDS

  • Aromatics

  • Polymers

  • Petchems

  • Gasification

  • Syngas

  • Hydrogen

  • Methanol

  • MTP

  • DME

  • FT

  • SNG

  • MPG

  • Biodiesel

  • Ethylester

  • Fatty Acid

  • Fatty Alcohol

  • Bioethanol

  • Biomass to Liquids (R&D)

Lurgi at a Glance Technology Portfolio

Traditional

(from crude oil)

Alternative

(from gas & coal)

Renewable

(from biomass)

Chemicals, Fuels & Energy


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Lurgi at a Glance Lurgi – Technologies for Fuels and Chemicals

Feedstock

Crude Oil

Native / WasteBio Oils

Biomass

Coal

Nat. Gas

Cereals

Oil

Seeds

Energy

Crops

Pressing /Extraction

Pyrolysis

Gasification

Refinery

Pre Treatment

Reforming

HydroTreating

BioSyncrude

Heavy

Residues

Bio

Chem

Chem

Gasification

Gasification

Raw

SynGas

Petro

Chemistry

Lurgi Technologies

Sulfur

Management

SynGas

Conditioning

CO2

Trans-Esterification

Fermentation

H2 / CO

CleanSynGas

MTP

Methanol

Coldbox

DME

Fischer

Tropsch

Methan-

ation

Petro-

chemicals

Petrofuels

Green Diesel

Fuels / Gases

Bio-Ethanol:

Gasoline

Bio-Diesel:

Diesel

MTBE

Additives

M15

M100

SNG

H2

Diesel

LPG

Synfuel

CO

Product

Food,

Oleo-

Chemicals

Chemicals

Chemicals

Polymers

Propylene

Polypropylene

Formaldehyde

Acetic Acid etc.


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Alternative

Traditional

Renewable

Refinery

PetroChemistry

GtL = Gas to Liquid

CtL = Coal to Liquid

BtL = Biomass to Liquid

Biodiesel

Bioethanol

Lurgi at a Glance Lurgi – Technologies for Fuels and Chemicals

Feedstock

Crude Oil

Native / WasteBio Oils

Biomass

Coal

Nat. Gas

Cereals

Oil

Seeds

Energy

Crops

Pressing /Extraction

Pyrolysis

Gasification

Refinery

Pre Treatment

Reforming

HydroTreating

BioSyncrude

Heavy

Residues

Bio

Chem

Chem

Gasification

Gasification

Raw

SynGas

Petro

Chemistry

Lurgi Technologies

Sulfur

Management

SynGas

Conditioning

CO2

Trans-Esterification

Fermentation

H2 / CO

CleanSynGas

MTP

Methanol

Coldbox

DME

Fischer

Tropsch

Methan-

ation

Petro-

chemicals

Petrofuels

Green Diesel

Fuels / Gases

Bio-Ethanol:

Gasoline

Bio-Diesel:

Diesel

MTBE

Additives

M15

M100

SNG

H2

Diesel

LPG

Synfuel

CO

Product

Food,

Oleo-

Chemicals

Chemicals

Chemicals

Propylene

Polypropylene

Formaldehyde

Acetic Acid etc.


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This Presentation

  • Lurgi at a Glance

  • Biomass Availability

  • Conversion of Biomass: Challenges, Concepts

  • Technology Overview and Status

  • Economics


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World annual oil palm biomass generation from 1980 to 2005

T.L. Kelly-Yong et al. / Energy Policy 35 (2007)

Biomass AvailabilityBiomass from Palm Oil Production

Huge quantity and availability of oil palm related biomass:

EFB, Palm Kernel Shells, Fibers, Trunks, Fronds….


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1,1 t

Empty Fruit Bunches

1 t Crude Palm Oil generates…

0,7 t

Mesocarp Fibres

0,3 t

Palm Kernel Shells

2,4 t

Oil Palm Frond Leaves and Trunks

Biomass AvailabilityBiomass from Palm Oil Production

...more than

4.5 tonnes

of

Waste

Biomass*

* Excludes POME and Palm Kernel Cake


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BTL Plant

Biomass AvailabilityBiomass from Palm Oil Production

Total Waste Biomass Generation (2006):

Malaysia:

approx 72 million tonnes

approx 9.6 million tonnes gasoline and diesel

or

80 % of Malaysia‘s gasoline and diesel consumption

World:

185 million tonnes


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This Presentation

  • Lurgi at a Glance

  • Biomass Availability

  • Conversion of Biomass: Challenges, Concepts

  • Technology Overview and Status

  • Economics


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Conversion of Biomass: Challenges, ConceptsA Major Issue – Energy Density

Model shows the volume of different materials which is equivalent to 1 ltr of hydrocarbon oil

How to design the logistics of Large-scale plants?


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Transportation Radius

25 km

Oil/Slurry: 20

250 km

Central syngas and fuel production

Diesel: 36

Conversion of Biomass: Challenges, ConceptsDistributed Biomass

Energy density [GJ/m3]

Eg EFB: 1.5

Regional intermediate fuel production

e.g. at Oil Palm Mills


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Bioliq-Process: Joint Development by FZK *) / Lurgi and sponsored by FNR*)

R

Sulphur

CO2

Oxygen

Fischer

Tropsch

High

Temp.

Gasifi-

cation

Gas

Cleaning

Synfuels

Chemicals

Methanol

Methanol

to Fuels

Fuels

Decentralised Bio

Syncrude Plants

Centralised Synfuels Plant

Plant size:

20 – 100 MW Input

35,000 – 180,000 tpa Biomass

Plant size:

1,000 – 5,000 MW Input -> 9 mil tpa Biomass -> 1,2 mil tpa Synfuel

Conversion of Biomass: Challenges, Concepts The Bioliq BTL Development

Fast

Pyrolysis

Biomass

EFB, Trunks...

Source:

FZK

Storage & Transport of Bio-Oil


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This Presentation

  • Lurgi at a Glance

  • Biomass Availability

  • Conversion of Biomass: Challenges, Concepts

  • Technology Overview and Status

  • Economics


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Straw, Hay a.o.

Shredder

M

M

Heizer

Heater

Sandkreislauf

Sand Cycle

Pyrolysis gas

Cold, shredded straw

hot sand ca. 500

Pyrolysis Oil

Cooler

Coke

Slurry

Slurry

Pyrolysis Coke

M

M

Source: FZK

Double Screw Reactor

Technology Overview & Status Pyrolysis Process of Lurgi / FZK

The Lurgi flash-coker


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Technology Overview & StatusResults Fast Pyrolysis Process of Lurgi / FZK - Plant

Converting different types of waste Biomass to “Bio Syncrude”

  • Mechanically fluidized sand at 500°C (no dilution by gas),

  • fast transport with good radial mixing

  • (2 s gas retention time)

  • fast heat transfer, „ball milling“ effect


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Technology Overview & StatusSynthetic Fuels from Biomass Pyrolysis Plant

12 t/d Fast Pyrolysis Demo Plant in Germany


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Technology Overview & StatusApplications of Bio-Oil

Chemicals

Gasification

Process heat

Extraction Conversion

Transport fuels etc

Gas

Turbine

Fast Pyrolysis

Electricity

Liquid

Engine

Charcoal

Heat

Co-firing

Pyrolysis heat

Boiler

Charcoal applications

Sources: IEA Bioenergy: T34:2007:01


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Bioliq-Process: Joint Development by FZK *) / Lurgi and sponsored by FNR*)

R

Sulphur

CO2

Oxygen

Fischer

Tropsch

Gasifi-

cation

Gas

Cleaning/

Condi-

tioning

Synfuels

Chemicals

Methanol

Methanol

to Fuels

Fuels

Technology Overview & StatusThe Bioliq BTL Development

Fast

Pyrolysis

Biomass

EFB, Trunks...

*) FZK = Forschungszentrum Karlsruhe

FNR = Fachagentur fuer Nachwachsende Rohstoffe


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This Presentation

  • Lurgi at a Glance

  • Biomass Availability

  • Conversion of Biomass: Challenges, Concepts

  • Technology Overview and Status

  • Economics


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Economics of Biomass to LiquidsEconomic Framework

  • BTL – Fuels require political support on international level (tax, mandate, etc)

  • CER can help to increase economics (for non-annex 1 countries)

Production cost

Pyrolysis gasification, FT-Synthesis

Biomass Transport

Biomass Harvest & Collection

Mineral Oil Tax

Refinery Conversion

Crude Delivered

(Capacity, 1 mil tpa)

(Fossil) at

Sources: Forschungszentrum Karlsruhe


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40% - 60% Labour cost

(European basis)

32

Straw

18

Transportion of straw

8

Slurry transport

Fast pyroylsis

Oxygen

5

18

Gasification and FT- synthesis

Staff

5

12

2

Economics of Biomass to LiquidsProduction Cost Estimate

Sources: Forschungszentrum Karlsruhe


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Economics of Biomass to LiquidsCosts of Feedstocks

USD / t

USD / MMBTU

Natural Gas

Coal (High Caloric Value)

Coal (Low Caloric Value)

Straw (Germany)

Oil Palm Empty Fruit Bunches (Malaysia)


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Summary

  • Major technologies in the BTL process chain are commercially available today

  • Economics of BTL depend to a great extent on feedstock sourcing – Asia is predestined to utilize their rich biomass resources for BTL

  • A political framework, incentives and CDM are crucial for the deployment of BTL

  • Lurgi offer‘s the entire process chain for BTL


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