
Integrated Home Energy from Waste & Biomass. Tom Horgan and Noa Simons February 6, 2009. Executive Summary Introduction Research Summary Integrated Home Energy System (IHES) Wrap Up. Outline. We propose to build and market an integrated home energy system .
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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 SummaryAlternative 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
IntroductionMajority 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
IntroductionElectricity 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
IntroductionThe State of Energy
http://en.wikipedia.org/wiki/Oil_reserves
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
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/
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 SummaryCompeting 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 SummaryRobust 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 SummaryFood
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%)
Integrated Home Energy
Heat & Power
Feed Prep
Wood
Chips
Syngas
Dewater
WGS
MSW
N2/CO2 Removal
Dryer
Water
Sewage
Gasifier
Cleaning/ Scrubbing
Air
Slag
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 EnergyUsage: 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 Energyhttp://www.eia.doe.gov/
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 EnergyGasifier
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 EnergyEnergy 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 EnergyPhase 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 EnergyPhase 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 EnergyPhase 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 EnergyPhase 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 EnergyMultifuel, 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 EnergyNo 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 EnergyGasification development supports future, large scale work
Need a lab and team to search the biomass research database
ConclusionsDo 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 SummaryGasification – covered as a separate topic
FT Synthesis Reaction Chemistry
Research SummaryProduct Distribution
Research SummaryChain 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 SummaryNatural 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
Commercial Production mainly from NG (coal)
Max Thermal Efficiency ~65%
Single pass 25%, Exothermic, Thermo constraints
Research Summaryhttp://bioweb.sungrant.org/Technical/Bioproducts/Bioproducts+from+Syngas/Methanol/Default.htm
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 Summary2CH3OH CH3OCH3 + H2O
320C Alumina
CH3OCH3 H2O + C2 – C5, alkenes,
cycloalkanes, aromatics
400/420C Zeolite
Light HC, CO2, H2
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 SummaryFirst 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 SummaryDowndraft 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 Summaryhttp://www.allpowerlabs.org
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 SummaryAir 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 SummaryAir 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 SummaryLow Energy Pyrolysis of Wood – WO 2008/098036 A1
IL Pyrolysis: Wood dissolved in IL, 190/200C (20 min), 10% more tar, 12% less char , 10% higher/more selective yield of distillates than Fast Pyrolysis
Fast Pyrolysis: Pretreated w/ organic solvents, 425/500C (2s), tar, char, liquids (200+ intermediates)
Low Energy Glucose from Wood for BioEthanol– 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 SummaryPotential 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 C4 olefins with iso-butane in ionic liquids
Research SummaryProject 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 Gas Gasification w/ Reforming
Steam vs. Autothermal, Modeling for feasibility (efficiency/cost)
Research SummarySyngas Methods
Noncatalytic Supercritical: (450/600C, 4000/6000 PSIG)
Hi Cap Cost, Limited Biomass testing
Low Temp Catalytic (225/265C, 400/800 PSIG, Pt or Ni)
Simple organics, not tried on biomass
Fuel Gas Methods
Catalytic Hydrothermal (350C, 3000PSIG, Ru or Ni)
Good carbon conversion, biomass & sludge
Supercritical Carbon Catalyzed (600C, 3700PSIG)
Good carbon conversion, coke, ash, plugging
Research SummaryNo suitable biomass gasification technology exists for FT
Require feedstock drying
Syngas must be cleaned of particulates/tars
H2/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 LabMechanical
Grinder/Mixer
Dryer/
Pellitizer
Gasifier
Biomass
Res Solid Waste
Sewage
Sludge
Solvent?
Char/Slag
Cyclone/
Scrubber
Shift
Syngas
H2 Sensor
Steam Control
Temp Control
Equipment needed (go to Fischer Scientific)
Site selection (NY, Lenox?)
New hires - skills needed (funding)
Partnerships to build
Compare w/ Community Power
Need to do gasification road show
Research Co2/N2 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???
Integrated Home Energyhttp://www.eia.doe.gov/
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, N2/CO2 removal
Integrated Home EnergyGasification
Specs: Atmospheric, air blown, direct heated, 5kW
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/ProdServices/Gasification.html
http://www.phoenixenergy.net/
http://gasbiopower.com/home
http://www.primenergy.com/Gasification_idx.htm
Many more…
Integrated Home EnergyGas Cleaning/Scrubbing
Initial: Cyclone (particulate), cold water quench followed by sand filter
Research more advanced cleaning technologies for later phases
N2/CO2 Removal
Enabling technology for residential scale (microchannel) Fischer Tropsch process
Membrane filter technology:
http://www.mtrinc.com/co2_removal_from_syngas.html
Integrated Home Energy