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

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

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

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”?

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

Introduction Reality –Majority 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)

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

The State of Energy Usage & Losses

World Oil Reserves – “Proven” vs “Unproven” The State of Energy

Market Opportunity 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 MJ/kg (~80%) –Diesel MJ/kg (~85%) Biomass/Solids – 6/20 MJ/kg –MTG Gasoline MJ/kg (< 50%) –FT Diesel MJ/kg (< 60%) 5 to 15x more input energy The State of Energy

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)

Research Summary Fischer Tropsch Synthesis –Gasification –Synthesis –Upgrading

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)

Research Summary Methanol Synthesis Compressor Methanol Convertor Syngas Recycle Loop Cooling/ Distillation Syngas (H2, CO (CO2, N2)) Purge Gas DesulphSMR GasifierCleaning Natural Gas Coal or Biomass Methanol Steam O2, Air 2H2 + CO  CH3OH 50 Atm, 270C Copper Oxide Catalyst  H = -92 kJ/mol MTG Process

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

Research Summary Methanol to Gasoline 320C Alumina 400/420C Zeolite Light HC, CO2, H2 2CH 3 OH  CH 3 OCH 3 + H 2 O CH 3 OCH 3  H 2 O + C 2 – C 5, alkenes, cycloalkanes, aromatics

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).

Research Summary Gasification –First 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 (H 2, CO, others)

Research Summary Gasification Reactors – Small Scale –Downdraft Gasifier Outside dimensions (w/ hopper): 4ft h x 1.5ft d Syngas production rate: ~ 35 ft 3 /lb of 15% wood Max Capacity: ~700 lbs wood/day ft 3 /h (320 MJ/h) Outlet Temp: 50/75C after cyclone/filter $2300 Assembled $1400 Not Assembled

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 Robust GasificationHoly Grail: Robust Gasification –Gasification System that receives ANY carbonaceous feedstock and returns pure syngas with tunable H2/CO ratio.

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

Research Summary Economic/Energy Comparison

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

Integrated Home Energy Household Mass Balance (Family of 4) Food Water Paper Plastics Water Sewage MSW 290 GPD 0.1% Solids ~ 7 MJ/day 8 Kg/day ~91 MJ/day Average Usage: ~320 MJ/day Waste:~ 100 MJ/day (~30%) Average Usage: ~320 MJ/day Waste:~ 100 MJ/day (~30%)

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

Concept Water Sewage Syngas Slag Gasifier Mechanical Grinder/Mixer DewaterWGS Dryer/ Pellitizer Cleaning/ Scrubbing N2/CO2 Removal MSW Integrated Home Energy Wood Chips Air

Concept Syngas Gasifier Mechanical Grinder/Mixer DewaterWGS Dryer/ Pellitizer Cleaning/ Scrubbing N2/CO2 Removal Integrated Home Energy Wood Chips, MSW, Sewage Energy Storage Slag Air Start Up 2 kW Syngas Generator

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 < 1% –BTLTF: Particulate & tar free, H2/CO tunable, N2/CO2 free

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

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

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 – energy.html –Dewatering Required if sewage is used but energy content does not justify expenditure

Integrated Home Energy Component Technologies –Gasification Specs: Atmospheric, air blown, direct heated, 5kW Numerous technologies available. Requires full scale evaluation process for down selection – – – – – – Many more…

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: –

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: > 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 Energy Overall Approach –Contact NREL for Concept Evaluation –Visit Community Power & NREL 2/15 –Evaluate additional gasification technologies for residential scale and down select

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, < $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, < $10,000

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, < $100,000 –Phase 4 – Advanced Concept Development Transportation Fuel Synthesis –Evaluate CO2 and N2 removal technology –Evaluate microchannel technology –3 to 5 years, < $1 million

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

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

Backup Slides

Fuel Value The State of Energy

1% of All Biomass On Earth (~ 50 cubic miles proven reserves as of 2008) =

Research Summary Fischer Tropsch Synthesis- –Gasification – covered as a separate topic –FT Synthesis Reaction Chemistry

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

Research Summary Fischer Tropsch Synthesis- –Reactor Design Types

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) c

Research Summary Methanol Synthesis –Commercial Production mainly from NG (coal) –Max Thermal Efficiency ~65% Single pass 25%, Exothermic, Thermo constraints

Research Summary Gasification Reactors - Industrial

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

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

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

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

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

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 (~10 18 ), 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 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 (~10 18 ), 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 Summary Argyropoulos Patents –Low Energy Pyrolysis of Wood – WO 2008/ 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/ IL dissolved wood is easily hydrolyzed by enzymes to release Glucose for production of bioethanol –Polymers and Composites from Dissolved Wood – US 2008/ IL dissolved wood can be blended with co-polymers, polymers and functional additives to form eco-friendly (degradable) composites

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

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)

Research Summary Economic/Energy Comparison

Research Summary Gasification Reactions

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

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

Berkshire Energy Lab Robust Gasifier - Concept 1 Mechanical Grinder/Mixer Dryer/ Pellitizer Gasifier Cyclone/ Scrubber Shift Syngas Steam Control Temp Control Biomass Res Solid Waste Sewage Sludge Solvent? Char/Slag H2 Sensor

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?

Distributed Energy Systems Slide on Plug Power (Saratoga Energy) financials – partner? Slide comparing liquid fuels to electricity – why methanol won’t work Picture of unit

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

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???