Biomass to Green Gasoline by the TIGAS Technology

Finn Joensen, Haldor Topse A/S

fj@topsoe.dk

DTU International Energy Conference 2012

Haldor Topse

committed to catalysis for more than 70 years

Anchored in fundamental research

Headquarters in Denmark
Engineering offices in Denmark, USA,
India and Russia
Catalyst Manufacture in Denmark and USA

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Edmonton

Moscow
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Catalysts, technology & services for

Kuala Lumpur

Fertilizer industry

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Buenos Aires

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Introduction
Easy oil is fading out
Exploitation & upgrading is becoming more difficult
Continuing increase in demand
Synfuels and catalysis are part of the equation
TIGAS offers a variety of options for adapting gasoline
production to existing fuel and energy infrastructure
Natural gas/associated gas coal biomass waste
Direct (syngas) indirect(methanol) stand alone cogeneration
Blendstock diluent regular/premium gasoline
1,000 50,000 bbl/d

Topsoe Improved Gasoline Synthesis

from natural gas, coal, biomass or waste to clean transportation fuels

Syn Gas

Methanol to Gasoline

MeOH

Gasoline

CO/H2 CH3OH

CH3OH Gasoline + H2O

Syn Gas

Syngas to Gasoline

MeOH
/DME

Gasoline

CO/H2 DME

DME Gasoline + H2O

Combined MeOH and DME Synthesis

H (kJ/mol)
2H2 + CO

= CH3OH

91

2CH3OH

= CH3OCH3 + H2O

24

CO + H2O = CO2 + H2

3H2 + 3CO = CH3OCH3 + CO2

41

246

Syngas to MeOH/DME Equilibrium

100

Maximum conversion is
obtained at H2:CO 1

MeOH / DME

100%

60

MeOH

40

T = 250C
H2 = 51
CO = 48
CO2 = 1

20

20

40

60

Pressure (bar g)

80

60%
CO2
40%

20%

CO
H2

0
0

MeOH
H2O

DME

80%

Equilibrium, mol%

Conversion (H2+CO)

80

100

0%
0.5

1.5

H2/CO

2.5

TIGAS - Historical Perspective

1983-1986: 8 bpd Demonstration Facility
Houston, TX

lb/h Test Facility

Denmark

2011: Current MTG Test Facility

Denmark

Wood-to-Gasoline Demonstration

20-25 bbl/d, Des Plaines, IL, 2010-2014

DOE Award No. DE-EE0002874

Syn Gas

Syngas to gasoline once-through

MeOH
/DME

Gasoline
100

Biogasoline Demonstration Plant

Green Gasoline from Wood Using Carbona Gasification and Topsoe TIGAS Processes

BIOMASS
BIOMASS

GASIFIER

TAR REFORMER

TAR REFORMER

GASIFIER
OXYGEN

Gas
Cleaning

MeOH
MeOH/DME
/DME

Gasoline

http://www.energy.gov/news2009/releases.htm

OXYGEN
ASH
ASH

Entire value chain: biomass in gasoline out

Project objectives
Demonstrate a technology for thermochemical
conversion of woody biomass to gasoline
Pilot plant data will support the design of
commercial plants based on gasification of
woody biomass
Conduct single engine emission test and fleet
testing in preparation of EPA registration of
green gasoline

Pilot plant location

GTI Energy &
Environmental
Technology Campus
Des Plaines, Illinois

1
3

1. Flex-Fuel Test Facility

Carbona gasifier
2. Gas conditioning
Tar reformer
Scrubber
3. Morphysorb
CO2 & H2S removal
4. TIGAS syngas to gasoline
Guard reactor
MeOH/DME reactor
Gasoline reactor
5. SulfaTreat
Sulfur scavenger
6. High-pressure oxygen
and nitrogen supply

Syngas compressor and tank farm

Biorefinery facility
Gasification & Tar reforming
(existing)
Morphysorb AGR unit
(existing)
Utility units & control system
(existing)
Syngas compression
(new)
TIGAS synthesis unit
(new)
Gasoline & waste water tanks
(new)

TIGAS module A2 & MeOH/DME reactor lift

DME REACTOR LIFT
UPRIGHTING A2 MODULE

LIFTING ABOVE ROOF

LOWERING INTO BAY

Biogasoline Project Schedule

DOE grant
Project started
Engineering completed
Existing equipment upgrades completed
TIGAS construction completed
Comissioning & shakedown completed
Test run completed
Long term testing campaigns
Engine fleet testing
Technology evaluation & commercialization plan

Process Flow Sheet

Gasifier

Scrubber

Morphysorb

TIGAS
Off-gas

Gasoline

Wood
chips
Oxygen
steam

Water

Tar reformer

Syngas
compressor

Guard bed

Separator

Test #1 technical data

Integrated TIGAS operation periods
Hours of operation
TIGAS unit
Gasoline production Period 1 (03/12-13)

56 hours
9 hours

Gasoline production Period 2 (03/18)

15 hours

Gasoline production Period 3 (03/21-22)

23 hours

Total gasoline production time

47 hours

Gasoline produced

14 bbl

Syngas (H2+CO) conversion

86%

Methanol in process condensate

< 10 ppm

Octane number (R+M)/2

> 96

First TIGAS gasoline product

Gasoline Yield & Properties

High selectivity
- 80-90 % Gasoline
- remainder essentially LPG

Octane (R+M)/2 > 87

Major component: i-paraffins
Aromatics < 30 %
Benzene < 0.5 %
Olefins 5-10%
No sulfur
Cn

Syngas to MeOH/DME Equilibrium

100

T = 250C
MeOH / DME

MeOH / DME

80

Feed Gas (mol%):

Conversion (H2+CO)

Enabling Air-Blown Gasification

60

MeOH
MeOH

40

H2 = 51
CO = 48
CO2 = 1

20

40 % N2

0
0

20

40

60

Pressure (bar g)

80

100

STG Air Blown (once-through)

Syn Gas/N2

Gasoline/power co-generation

MeOH
/DME

Gasoline

Skive District Heating/Power Plant

16 MWth

Gedankenexperiment
2 atm (Air)

N2
7 MWth
16 MWth

~ 100 bbl/d

Economics
4000 t/d
5700 bpd gasoline
4760 bpd gasoline

Green Gasoline*
Gasoline $2.9/gal
~ $120/bbl gasoline
Crude oil breven $90/bbl
*No carbon credits assumed
(94% carbon footprint reduction)

Oxygen

Air

Wood consumption
(TPD)

4000

4000

Gasoline production
(bpd)

5700

4760

+125

Power generation
(MWe)

Summary
Easy oil is fading out
Exploitation & upgrading is becoming more difficult
Continuing increase in demand
Synfuels and catalysis are part of the equation
TIGAS offers a variety of options for adapting gasoline
production to existing fuel and energy infrastructure
Natural gas/associated gas coal biomass waste
Direct (syngas) indirect(methanol) stand alone cogeneration
1,000 50,000 bbl/d
Blendstock diluent regular/premium gasoline

Acknowledgement
Financial support by U.S. Department of Energy
Energy Efficiency & Renewable Energy is gratefully
acknowledged

www.topsoe.com

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