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Integrated Home Energy from Waste

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Title: Integrated Home Energy from Waste


1
Integrated Home Energy from Waste Biomass
  • Tom Horgan and Noa Simons
  • February 6, 2009

2
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

3
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

4
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?

5
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

6
Introduction
  • Reality
  • Majority of research dollars to bioethanol and
    biodiesel
  • 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)

7
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

8
The State of Energy
  • Usage Losses

https//eed.llnl.gov/flow/images/LLNL_Energy_Chart
300.jpg
9
The State of Energy
  • World Oil Reserves Proven vs Unproven

http//en.wikipedia.org/wiki/Oil_reserves
10
The State of Energy
  • Market Opportunity

http//www.eia.doe.gov/
11
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 - 43.5 MJ/kg (80)
  • Diesel - 42.8 MJ/kg (85)
  • Biomass/Solids 6/20 MJ/kg
  • MTG Gasoline - 43.5 MJ/kg (lt 50)
  • FT Diesel - 42.8 MJ/kg (lt 60)
  • 5 to 15x more input energy

http//www.eia.doe.gov/
12
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 1yr ROI
  • Dynamotive works with multiple customers on
    retrofitted applications (bigger/stainless steel
    pumps, motors etc)

13
Research Summary
  • Fischer Tropsch Synthesis
  • Gasification
  • Synthesis
  • Upgrading

14
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 CO2
    and N2)
  • Dilute syngas leads to large reactors (higher
    cost)

15
Research Summary
  • Methanol Synthesis

Desulph
SMR
Natural Gas
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
16
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

17
Research Summary
  • Methanol to Gasoline

2CH3OH? CH3OCH3 H2O
320C Alumina
CH3OCH3 ? H2O C2 C5, alkenes, cycloalkanes,
aromatics
400/420C Zeolite
Light HC, CO2, H2
18
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).

19
Research Summary
  • Gasification
  • First step in FT, methanol, MTG, FC, generator
  • Biomass is heated under low oxygen conditions
    (Atmospheric, gt 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)

20
Research Summary
  • Gasification Reactors Small Scale
  • Downdraft 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

http//www.allpowerlabs.org
21
Research Summary
  • Gasification - Issues
  • 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.

22
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

23
Research Summary
  • Economic/Energy Comparison

24
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

25
Integrated Home Energy
  • Household Mass Balance (Family of 4)

Food 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)
26
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/
27
Integrated Home Energy
  • Concept

Wood Chips
Syngas
MSW
Water Sewage
Air
Slag
28
Integrated Home Energy
  • Concept

2 kW Syngas Generator
Wood Chips, MSW, Sewage
Energy Storage
Syngas
Air
Slag
Start Up
29
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 lt 1
  • BTLTF Particulate tar free, H2/CO tunable,
    N2/CO2 free

30
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

31
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

32
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-to-energy
    .html
  • Dewatering
  • Required if sewage is used but energy content
    does not justify expenditure

33
Integrated Home Energy
  • Component Technologies
  • Gasification
  • 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_En
    gineering_UK.pdf
  • http//www.croreyrenewable.com/index.html
  • http//www.associatedphysics.com/ProdServices/Gasi
    fication.html
  • http//www.phoenixenergy.net/
  • http//gasbiopower.com/home
  • http//www.primenergy.com/Gasification_idx.htm
  • Many more

34
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
  • N2/CO2 Removal
  • Enabling technology for residential scale
    (microchannel) Fischer Tropsch process
  • Membrane filter technology
  • http//www.mtrinc.com/co2_removal_from_syngas.html

35
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 gt 30 Electric, gt 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

36
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

37
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, lt 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, lt 10,000

38
Integrated Home Energy
  • Phased Development Plan
  • Phase 3 Advanced Concept Development
  • Advanced Gasification
  • Purchase H2, CO sensor or GC
  • Integrate shift catalyst/steam and controls
  • Test on fuel cell in cooperation with Plug Power
  • 1 to 2 years, lt 100,000
  • Phase 4 Advanced Concept Development
  • Transportation Fuel Synthesis
  • Evaluate CO2 and N2 removal technology
  • Evaluate microchannel technology
  • 3 to 5 years , lt 1 million

39
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

40
Conclusions
  • Integrated home energy system is marketable
    technology (lt 10K in 5 years)
  • Gasification development supports future, large
    scale work
  • Need a lab and team to search the biomass
    research database

41
Backup Slides
42
The State of Energy
  • Fuel Value

http//www.eia.doe.gov/
43
The State of Energy
1 of All Biomass On Earth ( 50 cubic miles
proven reserves as of 2008)

http//spectrum.ieee.org/jan07/4820
44
Research Summary
  • Fischer Tropsch Synthesis-
  • Gasification covered as a separate topic
  • FT Synthesis Reaction Chemistry

45
Research Summary
  • Fischer Tropsch Synthesis-
  • Product Distribution
  • Low Temp FT
  • 200/240C
  • Cobalt
  • ?waxes
  • Hi Temp FT
  • 300/350C
  • Iron
  • ?liquids

46
Research Summary
  • Fischer Tropsch Synthesis-
  • Reactor Design Types

47
Research Summary
  • References
  • Bio-syngas production with low concentrations of
    CO2 and CH4 from microwave-induced pyrolysis of
    wet and dried sewage sludge by Diminguez et al
    (2007)
  • http//www.adktroutguide.com/files/Weekly_Update_1
    1_7_08.doc

48
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/B
ioproductsfromSyngas/Methanol/Default.htm
49
Research Summary
  • Gasification Reactors - Industrial

50
Research Summary
  • Residential Systems
  • Develop commercially viable residential scale
    product for conversion of wood/biomass to
    electricity
  • System Concepts
  • Gasifier/SynGas Generator
  • Gasifier/Methanol Convertor/Generator
  • Gasifier/Fuel Cell

51
Research Summary
  • Residential Systems - System Concepts
  • Gasifier/SynGas 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

52
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

53
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

54
Research Summary
  • Residential Systems - System Concepts
  • Gasifier/Fuel Cell
  • Modeling Results

55
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 2mm, lt
    150C, lt 30min)
  • Safety Low vapor pressure and highly
    recyclable. Some are combustible. Many are
    toxic if released to the environment.

56
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 2mm, lt
    150C, lt 30min)
  • Safety Low vapor pressure and highly
    recyclable. Some are combustible. Many are
    toxic if released to the environment.

57
Research Summary
  • Argyropoulos Patents
  • Low 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

58
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 C4 olefins
    with iso-butane in ionic liquids

59
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 Gas Gasification w/ Reforming
  • Steam vs. Autothermal, Modeling for feasibility
    (efficiency/cost)

60
Research Summary
  • Economic/Energy Comparison

61
Research Summary
  • Gasification Reactions

62
Research Summary
  • Catalytic Gasification
  • Syngas 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

63
Berkshire Energy Lab
  • Robust Gasification
  • No 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

64
Berkshire Energy Lab
  • Robust Gasifier - Concept 1

Mechanical Grinder/Mixer
Dryer/ Pellitizer
Gasifier
Biomass Res Solid Waste Sewage Sludge
Solvent?
Char/Slag
Cyclone/ Scrubber
Shift
Syngas
H2 Sensor
Steam Control Temp Control
65
Distributed Energy Systems
  • Residential scale gasification as part of
    fundamental research
  • Potential integration with Plug Power fuel cells
    when 5 KW system reaches 15k capex (3 years)
  • Methanol synthesis research - though limited
    applications given conversions needed
  • OTHER?

66
Distributed Energy Systems
  • Slide on Plug Power (Saratoga Energy) financials
    partner?
  • Slide comparing liquid fuels to electricity why
    methanol wont work
  • Picture of unit

67
Lab Start-Up Costs
  • Equipment needed (go to Fischer Scientific)
  • Site selection (NY, Lenox?)
  • New hires - skills needed (funding)
  • Partnerships to build

68
Integrated Home Energy
  • Notes
  • 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???

http//www.eia.doe.gov/
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