Beau Hoffman US Case Studies on Energy Conversion R&D Technology - - PowerPoint PPT Presentation

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Beau Hoffman US Case Studies on Energy Conversion R&D Technology - - PowerPoint PPT Presentation

Mar 27, 2023 436 likes •641 views

BIOENERGY TECHNOLOGIES OFFICE Beau Hoffman US Case Studies on Energy Conversion R&D Technology Manager Recovery from Waste US Dept of Energy, Bioenergy Technologies Office 1 | Bioenergy Technologies Office MSW Report to Congress Congressional

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1 | Bioenergy Technologies Office

BIOENERGY TECHNOLOGIES OFFICE

US Case Studies on Energy Recovery from Waste Beau Hoffman

Conversion R&D Technology Manager US Dept of Energy, Bioenergy Technologies Office

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2 | Bioenergy Technologies Office

MSW Report to Congress

Congressional interest is largely driven to solve waste disposal challenges “Deliver a report to the Appropriations Committee a report on R&D opportunities to improve the economic viability of municipal solid waste‐to‐energy” For existing WTE facilities:

  • Current Gen AD Improvements

– Co‐digestion advancements – Advanced biogas cleanup – Conversion of biogas to fuels and co‐products – Advanced AD reactor design

  • Advanced waste preprocessing and handling strategies

– High precision sorting – Development of quality control specs (for waste feedstocks) – Preprocessing/pretreatment processes to remove contaminants

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Case Study 1 – Catalytic Biogas Upgrading

Questions: Devin Walker dwalker@t2cenergy.com John Kuhn jnkuh@usf.edu

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4 | Bioenergy Technologies Office

Case Study 1 – Catalytic Biogas Upgrading

24 SCFM LFG Feed 75 Gal/Day Diesel Mobile Pilot Unit (completed 2018) 2016: 2012:

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Case Study 1 – Catalytic Biogas Upgrading

฀ ฀ ฀ ฀ ฀

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Case Study 1 – Catalytic Biogas Upgrading

  • Excellent middle

distillate boiling point distribution

  • Boiling points align

with commercial diesel

  • Waste derived

cleaner burning fuel Fuel Analysis

  • Low aromatics (Less particulate/soot

formation)

  • Zero sulfur (No SOx Emissions)
  • Isomers improve cold temp properties

Hydrocarbon Family TRIFTS Diesel Commercial Diesel Paraffins 68.61 19.95 Isomers 29.98 31.60 Olefins 0.86 0.92 Aromatics 0.3 39.48 Cyclics 0.25 8.05

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Case Study 1 – Catalytic Biogas Upgrading

$(5,000,000) $‐ $5,000,000 $10,000,000 $15,000,000 $20,000,000

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Discounted Cumulative Cash Flow Years Plant Profitability at Various Wholesale Diesel Prices w/ RIN (600 scfm Biogas)

WS Price $3.5 WS Price $3.0 WS Price $2.5 WS Price $2.0 WS Price $1.5 WS Price $1.0

  • At current WS pump price of 2.15 NPV = $10.6MM
  • RIN = $4.25/gal diesel (D3 ~ $2.50/RIN)
  • Initial Construction Capital $3.9 MM
  • Breakeven No RIN credit at 646

SCFM biogas production rate

  • Production Cost = $1.72/gal
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Case Study 2 – Hydrothermal Liquefaction

Wet waste requires a simple and robust process technology

PNNL’s bench‐scale continuous HTL system

Conversion technology must be:

 Simple, scalable, robust  Process a range of feedstocks and high ash levels (>20%)  Able to convert directly with minimal dewatering (or by blending in of dry materials)  Achieve high carbon yields to liquid hydrocarbons (40‐60%)

Hydrothermal liquefaction (HTL) is…

The conversion of solid biomass in hot, compressed water into liquid components

  • HTL produces a gravity‐separable biocrude with low oxygen

content (5–15 %) that can be upgraded to drop‐in blendstocks

HTL Conditions Temp: 330-350°C Pressure: 2900 psig tres: 10-30 min Hydrotreating Conditions Temp: 400°C Pressure: 1500 psig H2 Sulfided NiMo on Al

Wet biomass material (sludge, manure, algae) Stable biocrude oil (up to 60% C‐yield) Fuel blendstocks (95%+ yield)

Questions: Justin Billing Justin.Billing@pnnl.gov Lesley Snowden‐Swan Lesley.Snowden‐Swan@pnnl.gov

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  • A fixed-bed hydrotreater is critical to quantify catalyst lifetime
  • Process improvements dropped the MFSP by over $2/GGE

Throughput increased 34% (WHSV of 0.29/h to 0.39/h) – catalyst, capital cost Time-on-stream increased from 300 to 550 hours – catalyst cost

  • A two-year catalyst life will further reduce MFSP by $0.80/GGE

Case Study 2 – Hydrothermal Liquefaction

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Case Study 2 – Hydrothermal Liquefaction

0% 10% 20% 30% 40% 50% 60% 70% 80%

gasoline (IBP‐184°C) jet (153‐256°C) diesel (184‐390°C) heavies (>390°C)

Mass Yield* %

Sludge (GLWA) Sludge (CCCSD) Sludge/FOG (80/20) (CCCSD) Swine Manure

  • Engine testing at CSU of 5% blends in

diesel shows NO negative impact on performance or emissions

  • Simulated distillation shows product is

 Rich in diesel  High in cetane (~70)

Wood Pyrolysis Wood HTL 50/50 Wood/Algae HTL Certification Diesel EtOH to Diesel Sludge HTL Algae HTL

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Case Study 2 – Hydrothermal Liquefaction

$0.0 $1.0 $2.0 $3.0 $4.0 $5.0 $6.0 $7.0 $8.0

2018 SOT 2018 SOT no NH3 removal 2019 SOT 2019 SOT no NH3 removal 2022 Projected 2022 Projected no NH3 removal

Minimum Fuel Selling Price, $/GGE

Balance of Plants Biocrude Hydrotreating / Hydrocracking Biocrude Transportation HTL Water Treatment HTL Biocrude Production Sludge Dewatering

$7.16 $5.11 $4.69 $6.74 $3.11 $2.77

  • Annual state of technology (SOT) assessment tracks progress toward goal
  • Progress via increased hydrotreating catalyst life and reactor throughput
  • Increased feed solids, separations, heating configuration and upgrading

(throughput and catalyst life) will enable the 2022 goal

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Case Study 2 – Hydrothermal Liquefaction

$0.0 $1.0 $2.0 $3.0 $4.0 $5.0 $6.0

Baseline (SOT) Sludge/FOG (80/20) Swine manure

MFSP, $/GGE

Balance of Plants Biocrude Hydrotreating / Hydrocracking Biocrude Transportation HTL Water Treatment HTL Biocrude Production Feedstock dewatering

$5.11 $4.44 $4.54

  • Blending FOG, even at low levels, improves

economics of waste water sludge

  • Higher biocrude yields for manure and FOG reduce

MFSP by $0.60‐70/gge

0.1 0.2 0.3 0.4 0.5 0.6

$4.0 $4.2 $4.4 $4.6 $4.8 $5.0 $5.2 $5.4 $5.6 $5.8 5 10 15 20

Biocrude Yield, g/g feed (DAF)

MFSP, $/GGE Weight % FOG blended with sludge MFSP Yield

SOT

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Case Study 2 – Hydrothermal Liquefaction

  • Wet waste resources are highly co‐located

 80% of non‐sludge waste is generated within 25 miles of a wastewater treatment plant (WWTP) that is ≥ 1 M Gal/day

  • Collection and blending reduces costs via larger plant scale
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Case Study 3 – Advanced CO2 Sorbents

Synthetic, porous metal‐organic frameworks + amines

Combine benefits of aqueous amines and adsorbents “step‐shaped adsorbents”

  • “Step‐shaped” adsorption = less energy needed to regenerate
  • High selectivity for CO2 = higher product purity
  • Solid phase = easy to handle, increased safety (vs aqueous amines)

Questions: Jason Husk Jhusk@mosaicmaterials.com

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Case Study 3 – Advanced CO2 Sorbents

Sorbents for PSA and amine scrubbers…

  • exhibit low working capacities
  • require large pressure and/or

temperature swings to be cycled Mosaic’s phase change adsorbents…

  • exhibit very large working

capacities

  • require small pressure and/or

temperature swings to be cycled

Mosaic Typical PSA Process

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Case Study 3 – Advanced CO2 Sorbents

  • 1.2MM grant from California Energy

Commission (CEC) thru Sept 2018

  • 40% Reduction in OPEX

with Mosaic’s Gen‐1 concept system compared to traditional amine scrubbing

  • 15% Reduction in CapEx, and plans to

pursue further cost reductions

  • Stability testing of MOF‐based pellets

performed at Davis WWTP

– CO2 capacity maintained over 1000+ cycles

  • In‐house manufacturing at 1 kg /week,

currently supporting multiple orders.

  • Year 1: Pilot system designed/fabricated by

Mosaic Materials, EPC Subs

  • Year 2: Pilot system deployed at host site

to demonstrate efficacy of CO2 removal unit

Sources: American Biogas Council, SoCalGas

Pipeline injection

  • r vehicle

CNG Biogas Upgrading Digestion produces biogas Waste received

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Case Study 4 – Next Gen AD

Project goal: Improve the techno‐economic viability of biopower production by developing a sustainable two‐phase anaerobic membrane bioreactor (AnMBR) system that diverts organic fraction of municipal solid waste (OFMSW) and food waste from landfills and incineration while generating methane and renewable bioproducts. Project outcome: A scalable, high performance, low‐cost, two‐phase modular AnMBR to extend the economic viability of AD to smaller scales

  • Modular high rate rumen inspired AD technology

Dynamic Membrane: Filtering biofilm formed on support structure of ~ 10 – 100 microns

2nd Phase Magna Tree

Questions: Meltem Urgun‐Demirtas Demirtas@anl.gov

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Case Study 4 – Next Gen AD

Ruminant Inspired Dynamic AnMBR hydrolyzes a high fraction of lignocellulose > 60% in a short time

VFA concentration and VFA yield during operation of the rumen reactor

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Case Study 4 – Next Gen AD

  • Modelling AnMBR performance
  • Previous AD models have been developed to model
  • ne stage AD.
  • A model is needed that evaluates the feasibility of

different waste stream combinations and the process performance from the lens of two stage AD.

  • Why? Hydrolysis step is rate limiting and varies with

biodegradability of waste.

  • New C++ version of the ADM1 model allows ~40x

speedup in computational time while maintaining robustness of results

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Questions? Beau.Hoffman@ee.doe.gov