Growing the World s Fuels

Transcription

1 Growing the World s Fuels May, 2013

2 Converting algae derived Biocrude into high quality Diesel Neil Osterwalder, Dan Sajkowski, Ben Saydah

3 Overview Background Algae production Bio-crude production Bio-crude properties Process New Diesel properties Sapphire Confidential 3

4 1st Step: Cultivation of Algae Algae grow rapidly and continuously, all year Ponds are harvested daily and some of the biomass is removed for processing The remaining algae quickly replicate and replace the harvested portion The result is a consistent biomass density, set for optimal growth SAPPHIRE PROPRIETARY 4

5 2 nd Step: Harvesting Sapphire uses a Dissolved Air Flotation (DAF) system to concentrate algae Solution enters the DAF in dilute concentration DAF technology adapted for algae 1. Cluster: chemicals are applied which make the algae stick together 2. Float: air bubbles float algae to the surface 3. Skim: floating algae harvested with a skimmer After the DAF, the algae is concentrated SAPPHIRE PROPRIETARY 5

6 3 rd Step: Bio-crude production 1. HTL Reaction: Algae slurry is reacted at pressure and Temperature 2. Extraction: solvents are used to extract bio-crude components SAPPHIRE PROPRIETARY 6

7 Bio-crude % free fatty acids Amides other nitrogen compounds Elemental analysis show: high Nitrogen content 4-5wt% high Oxygen content 8 wt % Total C,H,N,S content %C %H %N %S 74% 11% 9% 5% 1% %Not ID Sapphire Confidential 7

8 Nitrogen compounds in bio-crude Total C,H,N,S content Nitrogen composition %C %H %N %S %Not ID 74% 11% 9% 5% 1% Nitriles, Amides N- Aromatics Amides and nitriles are easily hydrogenated compounds Sapphire Confidential 8

9 Upgrading of Bio-crude Biocrude/Diesel blend Hydrotreater Distillation Diesel Blending of bio-crude with a refinery stream Catalyst selection Work-up for diesel range product Sapphire Confidential 9

10 Feed composition Feed composition 86.6 wt% Red Diesel 13.2 wt% Bio-crude Nitrogen content ppm Oxygen content ppm Carbon content form bio-crude 9.7% Biocrude/Diesel blend Hydrotreater Distillation Diesel Sapphire Confidential 10

11 Oil before hydrotreating Sapphire Confidential 11

12 Hydrotreating conditions Biocrude/Diesel blend Hydrotreater Distillation Diesel 2000 SCF/Barrel H C/698 F reactor temperature 124 bar/1800 psi H 2 pressure Albemarle Ni/Mo-Catalyst Sapphire Confidential 12

13 Before and after Sapphire Confidential 13

14 Oil after hydrotreating Biocrude/Diesel blend Hydrotreater Distillation Diesel Sapphire Confidential 14

15 Distilling Diesel fraction Biocrude/Diesel blend Hydrotreater Distillation Diesel 63 wt% Diesel from Diesel/algae blend 80% 60% Diesel 40% 20% 0% IBP -450 F 650 F+ Cold Trap Cold Trap IBP -450 F Diesel 650 F+ At least 86 % Carbon from algae in Diesel cut Nitrogen: less than 1 ppm Oxygen: not detected Carbon 14 analysis: Pure Bio-crude contains 18% C14 Hydro treated Diesel cut 3% C14 (diluted 7.4 times) Sapphire Confidential 15

16 After hydrotreating Sapphire Confidential 16

17 What happens to free fatty acids and free acid amides? Sapphire Confidential 17

18 Arbitrariy units C14-C18 increase 100% 186% 13% 42% 75% Red Diesel Final Blend Sapphire Confidential 18

19 Diesel properties Biocrude/Diesel blend Hydrotreater Distillation Diesel Diesel cut is all in spec except for conductivity and lubricity Key properties: Red Diesel Hydrotreated Algae oil/red Diesel D93 Flash Point F Flash Point C D976 Cetane Index D2500 Cloud Point F Could Point C Sapphire Confidential 19

20 Co-processing with existing refinery streams Issues with high Nitrogen/Oxygen content: Very exothermic reaction Water production Co-processing of bio-crude and diesel in a hydrotreater is an excellent way to upgrade bio-crude to high quality diesel Co-feed it in the refinery Bio-crude feed Sapphire Confidential 20

21 Summary Bio-crude can be co-processed with e.g. Diesel and close to 90 % of bio-derived carbon is in the Diesel fraction Ni/Mo catalyst showed great performance to hydrogenate nitrogen and oxygen to NH 3 and H 2 O No coking issues with the catalyst Higher cetane number for Diesel product Bio-crude can be co-processed in a ULSD hydrotreater Sapphire Confidential 21

22 Thanks Sapphire Confidential 22

23 Questions Sapphire Confidential 23