1. Conversion of Biomass Using Proprietary Technologies
EU-Malaysia Biomass Stakeholders Knowledge Exchange Session
Conversion of Biomass Using
Proprietary Technologies
– Lurgi‘s Experiences
Uwe Zwiefelhofer
Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng Kuala Lumpur
Tel: Fax:

2. Biomass to Fuels in 1950’s ….
… the direct approach….

3. This Presentation Lurgi at a Glance Biomass Availability
Conversion of Biomass: Challenges, Concepts
Technology Overview and Status
Economics

4. This Presentation Lurgi at a Glance Biomass Availability
Conversion of Biomass: Challenges, Concepts
Technology Overview and Status
Economics

5. Lurgi at a Glance Lurgi Portrait
1500 Engineers, that deliver Innovative Technologies and Plants from One Hand for Oil, Coal and Gas Industry
Studies, Basic -, Detail Engineering, Licence, Procurement
Proprietary Technologies
Market Leader CTC, GTC, Biofuels
Project Management, Turn Key Execution d
Member of
Technical Services
Technology and
EPC Expertise
Total Customer Focus
Innovative Solutions
Single Line Responsibility
Research and Development

6. Vitry Houston Champigny Hyderabad Harima Hangzhou Frankfurt Krakow
Lurgi at a Glance E&C : Engineering and Construction
Vitry
Houston
Champigny
Hyderabad
Harima
Hangzhou
1 500 Employees in 6 Engineering Centers
E&C Cryogenics
Frankfurt
Krakow
Delhi
Johannesburg
Houston
1 300 Employees in 8 Engineering Centers
Beijing
E&C Lurgi
Shanghai
Air Liquide : Relies on > 100 years of in-house Engineering and Technologies Engineering Capabilities: Doubled with Acquisition of Lurgi Strong Force: Engineers in the E & C Activities

7. Chemicals, Fuels & Energy
Lurgi at a Glance Technology Portfolio
Traditional
(from crude oil)
Alternative
(from gas & coal)
Renewable
(from biomass)
Chemicals, Fuels & Energy
Sel. Refinery technologies
Hydrocracker
FCC
HDS
Aromatics
Polymers
Petchems
Gasification
Syngas
Hydrogen
Methanol
MTP
DME FT
SNG
MPG
Biodiesel
Ethylester
Fatty Acid
Fatty Alcohol
Bioethanol
Biomass to Liquids (R&D)

8. Lurgi at a Glance Lurgi – Technologies for Fuels and Chemicals
Feedstock
Crude Oil
Native / Waste Bio Oils
Nat. Gas
Coal
Biomass
Energy
Crops
Cereals
Oil
Seeds
Pressing / Extraction
Refinery
Pre Treatment
Reforming
Gasification
Pyrolysis
Hydro Treating
BioSyncrude
Heavy
Residues
Bio
Chem
Chem
Gasification
Gasification
Raw
SynGas
Petro
Chemistry
Lurgi Technologies
Sulfur
Management
SynGas
Conditioning
CO2
Trans-Esterification
Fermentation
H2 / CO
CleanSynGas
MTP
DME
Methanol
Fischer
Tropsch
Methan-
ation
Cold box
Petrofuels
Green Diesel
Petro-
chemicals
Fuels / Gases
MTBE
Additives
Diesel
LPG
M15
M100
Synfuel
SNG H2 CO
Bio-Ethanol:
Gasoline
Bio-Diesel:
Diesel
Product
Chemicals
Chemicals
Polymers
Propylene
Polypropylene
Formaldehyde
Acetic Acid etc.
Food,
Oleo-
Chemicals

9. Traditional Alternative Renewable
Lurgi at a Glance Lurgi – Technologies for Fuels and Chemicals
Traditional
Refinery
PetroChemistry
Alternative
Renewable
GtL = Gas to Liquid
CtL = Coal to Liquid
BtL = Biomass to Liquid
Biodiesel
Bioethanol
Feedstock
Crude Oil
Native / Waste Bio Oils
Nat. Gas
Coal
Biomass
Energy
Crops
Cereals
Oil
Seeds
Pressing / Extraction
Refinery
Pre Treatment
Reforming
Gasification
Pyrolysis
Hydro Treating
BioSyncrude
Heavy
Residues
Bio
Chem
Chem
Gasification
Gasification
Raw
SynGas
Petro
Chemistry
Lurgi Technologies
Sulfur
Management
SynGas
Conditioning
CO2
Trans-Esterification
Fermentation
H2 / CO
CleanSynGas
MTP
DME
Methanol
Fischer
Tropsch
Methan-
ation
Cold box
Petrofuels
Green Diesel
Petro-
chemicals
Fuels / Gases
MTBE
Additives
Diesel
LPG
M15
M100
Synfuel
SNG H2 CO
Bio-Ethanol:
Gasoline
Bio-Diesel:
Diesel
Product
Chemicals
Chemicals
Propylene
Polypropylene
Formaldehyde
Acetic Acid etc.
Food,
Oleo-
Chemicals

10. This Presentation Lurgi at a Glance Biomass Availability
Conversion of Biomass: Challenges, Concepts
Technology Overview and Status
Economics

11. Energy from renewable resources can be increased from
Biomass Availability High Potential Worldwide but Development Required
Energy from renewable resources can be increased from
~10% today to ~30% by 2050 4 34
111
137
North America
Japan
Ameri
Near East &
North Africa 1 2 32 39
W.Europe 14 40
harvesting residues
Oceania
America 15 60
100
125
E.Europe 8 17
East Asia 10 21
178
221
410
sub-Saharan 41
149
331
Caribean &
Latin America
253
315 46 68
CIS &
Baltic States
South Asia
33,8
95,9
112,8
47,9
46,3
42,3
14,1
12,7
MBDOE
World energy consumption 2005 ~ 240.MBDOE - Biomass ~ 10%
World energy consumption 2050 ~ 380.MBDOE - Biomass utilized realisticly ~ 30%
Source: Utrecht University Faaji 2006

12. Huge quantity and availability of oil palm related biomass:
Biomass Availability Biomass from Palm Oil Production
T.L. Kelly-Yong et al. / Energy Policy 35 (2007)
World annual oil palm biomass generation from 1980 to 2005
Huge quantity and availability of oil palm related biomass:
EFB, Palm Kernel Shells, Fibers, Trunks, Fronds….

13. ...more than 4.5 tonnes of Waste Biomass*
Biomass Availability Biomass from Palm Oil Production
1,1 t
Empty Fruit Bunches
...more than
4.5 tonnes of
Waste
Biomass*
* Excludes POME and Palm Kernel Cake
1 t Crude Palm Oil generates…
0,7 t
Mesocarp Fibres
0,3 t
Palm Kernel Shells
2,4 t
Oil Palm Frond Leaves and Trunks

14. World: 185 million tonnes Total Waste Biomass Generation (2006):
Biomass Availability Biomass from Palm Oil Production
Total Waste Biomass Generation (2006):
Malaysia:
approx 72 million tonnes
approx 9.6 million tonnes gasoline and diesel
BTL Plant or
80 % of Malaysia‘s gasoline and diesel consumption
World:
185 million tonnes

15. This Presentation Lurgi at a Glance Biomass Availability
Conversion of Biomass: Challenges, Concepts
Technology Overview and Status
Economics

16. How to design the logistics of Large-scale plants?
Conversion of Biomass: Challenges, Concepts A Major Issue – Energy Density
Model shows the volume of different materials which is equivalent to 1 ltr of hydrocarbon oil
How to design the logistics of Large-scale plants?

17. Regional intermediate fuel production
Conversion of Biomass: Challenges, Concepts Distributed Biomass
Transportation Radius
25 km
Oil/Slurry: 20
Energy density [GJ/m3]
Eg EFB: 1.5
Regional intermediate fuel production
e.g. at Oil Palm Mills
Central syngas and fuel production
250 km
Diesel: 36
Our concept, the Karlsruher BtL-concept, considers the low energy density and the distributed occurrence of biomass and the need for large industrial plants for fuel production. (As an example, a typical oil refinery has a capacity of 1 Mio.t/a.)
Firstly the biomass, in this case straw with an energy density of 1.5 GJ/m3, is harvested and collected within a radius of around 25 km, fitting to the rural infrastructure.
In de-central pre-treatment plants, an intermediate fuel in form of a suspension or slurry, is produced, which can easily be handled in regard to transport, storage, and pumping. The slurry already has an energy density of around 20 GJ/m3 making it suitable for transport over long distances.
In large central plant these slurries are gasified to produce syngas, which then is converted to the desired fuels.

18. Conversion of Biomass: Challenges, Concepts The Bioliq BTL Development
Bioliq-Process: Joint Development by FZK *) / Lurgi and sponsored by FNR*) R
Oxygen
High
Temp.
Gasifi-
cation
Methanol
to Fuels
Chemicals
Gas
Cleaning
Synfuels
Fischer
Tropsch
Sulphur
CO2
Fuels
Fast
Pyrolysis
Biomass
EFB, Trunks...
Decentralised Bio
Syncrude Plants
Plant size:
20 – 100 MW Input
35,000 – 180,000 tpa Biomass
Centralised Synfuels Plant
Plant size:
1,000 – 5,000 MW Input > 9 mil tpa Biomass > 1,2 mil tpa Synfuel
Storage & Transport of Bio-Oil
Source:
FZK

19. This Presentation Lurgi at a Glance Biomass Availability
Conversion of Biomass: Challenges, Concepts
Technology Overview and Status
Economics

20. The Lurgi flash-coker Source: FZK
Technology Overview & Status Pyrolysis Process of Lurgi / FZK M
Heizer
Sandkreislauf
Slurry
Heater
Sand Cycle
Straw, Hay a.o.
Shredder
Cooler
Double Screw Reactor
Cold, shredded straw
hot sand ca. 500
Pyrolysis Coke
Pyrolysis gas
Pyrolysis Oil
Source: FZK
Coke
The Lurgi flash-coker

21. Converting different types of waste Biomass to “Bio Syncrude”
Technology Overview & Status Results Fast Pyrolysis Process of Lurgi / FZK - Plant
Converting different types of waste Biomass to “Bio Syncrude”
Mechanically fluidized sand at 500°C (no dilution by gas),
fast transport with good radial mixing
(2 s gas retention time)
fast heat transfer, „ball milling“ effect

22. 12 t/d Fast Pyrolysis Demo Plant in Germany
Technology Overview & Status Synthetic Fuels from Biomass Pyrolysis Plant
12 t/d Fast Pyrolysis Demo Plant in Germany

23. Extraction Conversion Charcoal applications
Technology Overview & Status Applications of Bio-Oil
Chemicals
Gasification
Process heat
Extraction Conversion
Transport fuels etc
Gas
Turbine
Fast Pyrolysis
Liquid
Electricity
Engine
Charcoal
Co-firing
Heat
Pyrolysis heat
Boiler
Charcoal applications
Sources: IEA Bioenergy: T34:2007:01

24. Technology Overview & Status The Bioliq BTL Development
Bioliq-Process: Joint Development by FZK *) / Lurgi and sponsored by FNR*) R
Oxygen
Gasifi-
cation
Methanol
to Fuels
Chemicals
Gas
Cleaning/
Condi-
tioning
Synfuels
Fischer
Tropsch
Sulphur
CO2
Fuels
Fast
Pyrolysis
Biomass
EFB, Trunks...
*) FZK = Forschungszentrum Karlsruhe
FNR = Fachagentur fuer Nachwachsende Rohstoffe

25. This Presentation Lurgi at a Glance Biomass Availability
Conversion of Biomass: Challenges, Concepts
Technology Overview and Status
Economics

26. … a wide spread EURO/Litre USD/bbl
Economics of Biomass to Liquids Cost of Production of BTL Fuels
… a wide spread
EURO/Litre
USD/bbl
145
116 87 58
European basis 29
500 MW
5000 MW
500 MW
5000 MW
FZK* Report FZKA 7170 July 2007
ECN Report No May 2006

27. CER can help to increase economics (for non-annex 1 countries)
Economics of Biomass to Liquids Economic Framework
BTL – Fuels require political support on international level (tax, mandate, etc)
CER can help to increase economics (for non-annex 1 countries)
Production cost
Pyrolysis gasification, FT-Synthesis
Biomass Transport
Biomass Harvest & Collection
Mineral Oil Tax
Refinery Conversion
Crude Delivered
(Capacity, 1 mil tpa)
(Fossil) at
Sources: Forschungszentrum Karlsruhe

28. 32 8 18 5 12 2 40% - 60% Labour cost (European basis)
Economics of Biomass to Liquids Production Cost Estimate 32
Straw
Slurry transport 8 18
Transportion of straw
Oxygen
Gasification and FT- synthesis
Fast pyroylsis 5 12 2
Staff
40% - 60% Labour cost
(European basis)
Sources: Forschungszentrum Karlsruhe

29. Economics of Biomass to Liquids Costs of Feedstocks
USD / t
USD / MMBTU
Natural Gas
Coal (High Caloric Value)
Coal (Low Caloric Value)
Straw (Germany)
Oil Palm Empty Fruit Bunches (Malaysia)

30. Major uncertainties in determining economics of BTL
Economics of Biomass to Liquids Major Uncertainties of BTL Costs
Major uncertainties in determining economics of BTL
Conversion efficiency of total process chain – technology integration and concept of Biomass preparation.
Cost of Biomass harvest and collection – Logistics
Cost of Biomass transport – Logistics
Areas of cost reduction
Biomass supply
Integration of conversion units into existing refinery sites
Technical optimisation

31. Summary
Major technologies in the BTL process chain are commercially available today
Economics of BTL depend to a great extent on feedstock sourcing – Asia is predestined to utilize their rich biomass resources for BTL
A political framework, incentives and CDM are crucial for the deployment of BTL
Lurgi offer‘s the entire process chain for BTL

32. The Sun and Plants Deliver Enough Renewable Energy and Raw Materials for Mankind‘s Needs
Thank
You