Commercial Aviation Alternative Fuels Initiative (CAAFI)

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1 Commercial Aviation Alternative Fuels Initiative (CAAFI) CAAFI R&D Initiatives Out-Year Process and Feedstock Developments Dave Daggett Marty Bradley Washington, DC Sept 30 - Oct 1, 2009

2 CAAFI R&D Panel Strategy R&D Panel Generate Ideas/Solutions "Define the R&D required to enable the development of commercial aircraft drop-in alternative fuels derived from multiple sources. Identify promising, new, innovative developments in alternative fuels." 2

3 Emissions are a key driver of alternative fuels Carbon Neutral Timeline Ongoing Fleet Renewal / Technology Development ATM Investments / Improvements Forecasted Emissions Growth w/o Reduction Measures CO 2 Emissions Low Carbon Fuels Baseline Presented to ICAO GIAAC/3 February 2009 by Paul Steele on behalf of ACI, CANSO, IATA and ICCAIA

Industry success on CO 2 neutral fuels: Successful flight test

sustainable biofuel sources Demonstrated technical feasibility

of viable commercial markets 20% Coconut & Babassu 50% Jatropha

Dec 2008 Jan 2009 Jan 2009 Increasing level of test objectives

4 Industry success on CO 2 neutral fuels: Successful flight test program demonstrated sustainable biofuel viability Identified sustainable biofuel sources Demonstrated technical feasibility on various engine / airframe combinations Promoted development of viable commercial markets 20% Coconut & Babassu 50% Jatropha 50% Algae & Jatropha 50% Camelina, Jatropha & Algae Feb 2008 Dec 2008 Jan 2009 Jan 2009 Increasing level of test objectives COPYRIGHT 2009 THE BOEING COMPANY Slide provided by The Boeing Company 4

The R&D group leadership is coordinating with the Environmental group leadership to identify needed fuel research areas and assess overall fuel acceptability

5 The R&D group leadership is coordinating with the Environmental group leadership to identify needed fuel research areas and assess overall fuel acceptability MIT s LCA on alternative fuels Possible issues to work together: Life cycle GHG Water usage Conversion efficiency Land use changes Economic sustainability others? 5

6 Purpose of the R&D Workshop: (1) Review a sample of recent alternative fuel research programs (2) Conduct initial Fuel Readiness Level (FRL) assessment (3) Update CAAFI R&D roadmaps 6

7 Agenda 2 nd Day Background Presentations FRL & Roadmapping Time Item # and Topic Focal 08:00 08:30 Check in (breakfast available in cafeteria) 08:30 09:00 Welcome from USDA K. Merrigan 09:00 09:30 USDA programs C. Cassidy 09:30 09:50 NASA programs B. Bomani/A. Chait 09:50 10:10 DARPA programs D. Kirkpatrick 10:10 10:25 Break 10:25 10:45 AFRL programs T. Edwards 10:45 11:05 EU s Alpha Bird program M. Braun-Unkhoff 11:05 11:25 DOD biofuel summit summary K. Lewis 11:25 11:45 DOE forecasting K. Lewis 11:45 12:00 Fuel Readiness Level M. Bradley 12:00 12:10 Prepare for afternoon D. Daggett 12:10 13:40 Lunch 13:40 15:20 Process Breakout M. Bradley 13:40 15:20 Feedstock Breakout D. Daggett 15:20 15:40 Break 15:40 16:40 Report back on breakout sessions 16:40 17:00 Concluding remarks 7

8 R&D Workshop Splinter Sessions Feedstocks Dave Daggett Processes Marty Bradley 8

Could NASA s TRL be used as a template for a Fuel Readiness Level?

Commercialization validated 7) Fuel approval 6) Full scale

evaluation 5.1 3) Proof of concept 5.3 8 4.

9 Could NASA s TRL be used as a template for a Fuel Readiness Level? NASA s TRL CAAFI s FRL 9) Production capability established 9 8) Commercialization validated 7) Fuel approval 6) Full scale technical evaluation 5) Process validation 4) Preliminary technical evaluation 5.1 3) Proof of concept ) Technology concept formulated 1) Basic principles observed 2 1 FRL R&D-Prod. / Cert. 9

10 Will estimate a FRL for feedstocks The most well known, used or promising alternative fuel feedstocks are: Fats Animal fats (e.g. tallow, lard, yellow grease) Fossil Fuels - Natural Gas Coal Oil Seeds Castor Halophytes Jatropha Palm oil Rapeseed, Canola or Camelina Soy Other oilseed crops (e.g. peanut, sunflower) Oleoresins (hydrocarbon resin secretions) Copaiba Other Sources - Algal sources Bacteria (e.g. cyanobacteria) Sugars Cellulosic biomass Waste Products - Waste vegetable oil / Municipal Waste? 10

11 Some literature reviews of biomass for biofuel (1 of 3) -- Positive Studies: Billion-Ton study, DOE & USDA (2005) 1.3 tons biomass/year by 2030 to replace 1/3 of petroleum. 90-Billion Gallon study, Sandia & GM (2008) 15B from corn ethanol & 85B from cellulosic by Biomass Ph.D. thesis, M. Hoogwijk (2004) Abandoned agricultural land and at rest land could supply 4-8X the world s liquid fuel demands. Increasing biomass feedstock study, BR&Di (2008) Can the US meet the future renewable fuel standards? Yes! 11

12 Some literature reviews of biomass for biofuel (2 of 3) -- Positive Studies con t: Bio-energy resources model, H. Yamamoto (1999) Large supply of energy crops available in developed countries but developing countries will have greatest supply from crop residues. Renewable energy scoping study, IPCC (2008) Biomass and solar are under-developed. Detailed model to follow. Agricultural biomass roadmap, DOE (2003) A sustainable billion tons/year of biomass by 2030 is possible. R&D is required for it to be affordable. Strategies for GHG-reducing technology commercialization, DOE (2009) 300 Federal policies are in place to help overcome many risks cost is the greatest challenge. 12

13 Some literature reviews of biomass for biofuel (3 of 3) -- Not so positive studies: Corn ethanol opponent, D. Pimentel (at least 11 papers from Large-scale biofuel production is not an alternative to the current use of oil and is not even an advisable option to cover a significant fraction of it. Photosynthesis too inefficient, M. Hoffert (2002) Energy demand growth is too high. 10TW of from biomass requires >10% of earth s surface (all present human agriculture) Food Vs. Fuel debate, environmental groups (2008/2009) Mandating the use and production of these fuels without fully understanding their effect on food production and the environment - as current US biofuel policy does - is irresponsible and dangerous. The Clean Energy Scam (Grunwald; May 2008; Time) Land use changes (i.e. deforestation) to grow biomass will overwhelm any benefits. 13

14 CAAFI Roadmap (1 of 6) Feedstock Sept 5, Optimized castor study Camelina assessment Jatropha harvesting prototype Optimized castor plot Oilseed inventory study 9K gal of salicornia oil Oil Seed Plants Large scale regional solution farms developed Halophytes NEEDS YOUR UPDATES Please fill out worksheet or provide Excel file Euphorbia analysis Salicornia analysis Halophyte assessment Seashore mallow analysis DOE Algae Roadmap Euphorbia prototype plots Optimized Halophytes Cost of algae study Modified Halophyte prototype plots Algae Large scale Halophyte farms developed GMO Halophyte test plot 8M tons salicornia oil (2019) Cyanobacteria study Dewater study Oil extraction Algae strain study Algae demo plants Heavy metal removal study Light & CO 2 level study GMO Cyanobacteria study Results from DARPA project USDA algae funding report Cellulosic New algae Techs ready Cyanobacteria Large scale Cyanobacteria Scaled demo algae plants plant developed GMO developed algae GMO plants for sugar ORNL Billion Ton study BCIWG report Cellulose to biojet flight demo (via synthetic biology) Cellulosic Ethanol becomes cost competitive Cellulose to biojet demo plant (via pyrolysis) Large scale cellulose farms Cellulose/ sugar/ algae prototype demo Revise EISA to include biomass credit Other CAAFI biofeedstock roadmap DOE s CBTL study done USDA feedstock roadmap USDA feedstock rankings & R&D plan Terra Preta test plot for CBTL *LCAs of biofuels are included in the Environmental team s roadmap DOE s CBTL & algae demos done USDA advanced biofuel summary 9/25/09 = Done = In work = Not Funded

15 R&D Workshop Splinter Sessions Feedstocks Dave Daggett Processes Marty Bradley 15

16 FRL Description CAAFI Toll Gate FRL Description CAAFI Toll Gate Fuel Qty 1 Basic Principles Observed and Reported Feedstock and process basic principles identified 2 Technology Concept Formulated Feedstock and complete process concept identified 3 Proof of Concept Small Fuel Sample Available from Lab Basic Fuel Properties Validated (Thermal Stability/Freezing Point) Preliminary Technical Evaluation Process Validation 8 Commercialization Validated 9 Production Capability Established CAAFI Fuel Readiness Level (FRL) System Perf. & Integration Studies Entry Criteria/Specification Properties* Evaluated (MSDS/D1655/MIL 83133) Laboratory Production Development Subscale Production Demonstrated Scalability of Production Demonstrated Pilot Plant Capability Enabled Business Model Validated for Production Go-Ahead Airline/Military Purchase Agreements Full Scale Plant Operational Full-Scale Technical Evaluation Fuel Approval Fit-For-Purpose Prop s Evaluated* Turbine Hot Section Component/Rig/Emissions Testing Engine/APU Testing Fuel Class/Type Listed in Int l Fuel Standards Legend: R & D Certification/Qualification Business & Economics *Includes determination of maximum allowable blend percentage 500 ml 10 gal 80 gal 4K gal 20K gal 225K gal 16

17 How FRL Relates to TRL and MRL FRL Description CAAFI Toll Gate FRL Description CAAFI Toll Gate Fuel Qty MRL USAF/NASA TRL 1 Basic Principles Observed and Reported Feedstock and process basic principles identified 1 2 Technology Concept Formulated Feedstock and complete process concept identified 3 Proof of Concept Small Fuel Sample Available from Lab Basic Fuel Properties Validated (Thermal Stability/Freezing Point) Preliminary Technical Evaluation Process Validation 8 Commercialization Validated 9 Production Capability Established System Perf. & Integration Studies Entry Criteria/Specification Properties* Evaluated (MSDS/D1655/MIL 83133) Laboratory Production Development Subscale Production Demonstrated Scalability of Production Demonstrated Pilot Plant Capability Enabled Business Model Validated for Production Go-Ahead Airline/Military Purchase Agreements Full-Scale Technical Evaluation Fit-For-Purpose Prop s Evaluated* Turbine Hot Section Component/Rig/Emissions Testing Engine/APU Testing ml 3 1. Basic Fuel Properties Observed and Reported 10 gal 4 2. Fuel Specification Properties 80 gal 4K gal 20K gal 225K gal Pathfinder 7 Fuel Fuel Class/Type Listed in Int l Fuel Approval Standards Full Scale Plant Operational Fit for Purpose 4. Extended Lab Fuel Property Test 5. Component Rig Testing 6. Small Engine Testing 8. Validation/Certification 9. Field Service Evaluations Legend: R & D Certification/Qualification Business & Economics *Includes determination of maximum allowable blend percentage 17

18 Will Estimate FRL for Processes 1) SASOL F-T jet fuel process 2) Generic F-T jet fuel process (includes CTL, GTL, BTL) 3) FAME biodiesel (FAME/Virgin flight fuels) 4) Hydrotreated Renewable Jet (HRJ) fuel 4a) Bio-SPK more general process than 4) 5) Other catalytic processes 6) Synthetic biology process (for cellulose to alkenes) 7) Bacteria produced jet fuel 8) Synthetic aromatic additives to allow higher blend percentage 9) Other Documentation will be collected to substantiate FRL s 18

19 R&D Roadmaps & Milestone Database R&D Roadmaps were updated at January R&D Workshop 10 Swimlanes Spreadsheet database used to track each milestone Information includes author, org., date, FRL, funding status October update will include substantiation for each changed or added milestone pdf report, web link, single chart summary, or cross reference to another organization s roadmap 19

20 Category CAAFI Roadmap (2 of 6) Planning, Protocol, and Performance Biomass Summit CAAFI Biofeedstock Roadmap (10.1) AlphaBird Kick-Off Meeting (10.3) Nat. Biofuels Action Plan (10.5) (10.20) DoE Algae Roadmap Meet g (10.6) AFRL Active, USDA CAAFI Biomass Compr ve Feedstock Workshop Feas. Integrated Rankings & CAAFI Study Roadmap R&D Plan Workshop (10.10) (10.11) (10.13) (10.15) (10.16) CAAFI Workshop (10.18) USDA Advanced Biofuel Summary (10.19) R&D Planning Activities 250 Certification Protocol Development Performance Studies Sustainable Alt. Fuel Roadmap (DRAFT) (10.2) CAAFI Workshop (10.4) Cert. Process Dev (1.5) R&D Workshop (10.7) AFCO Biofuel Cert. Roadmap (Draft) (10.8) AF combustion "rules and tools" pgm begins (1.1) Swift Turbine Fuel Testing (7.2) DoE Algae Roadmap (10.9) Effort to Codify Contaminant levels for DXXXX (1.2) USDA Feedstock Roadmap (10.12) Cert. Process Dev. D4054 (1.7) AF Rule & Tools Released (1.4) R&D Workshop (10.14) Cert. Process Dev (1.7) AFRL Biomass Feas. Study (7.4) R&D Workshop (10.17) AlphaBird Program Complete (10.21) See Also CAAFI Certification Roadmap NEEDS YOUR UPDATES Please fill out worksheet or provide Excel file Rentech NG F-T evaluation beg. (7.1) Syntroleum R-8 HRJ evaluation completed (7.3) Completed Funded Plans (Public/Private) Unfunded Needs Result Target Vision (#.#) Milestone Number See Database for details 9/25/09

21 Category CAAFI Roadmap (3 of 6) Fuel Property Testing Swift Turbine Research Fuel Report Formulation 50% HRJ Studies (5.8) (5.10) Chemical Kinetics Mechanism Development for Combustion of F-T Fuels (5.12) Fuel Thermal Stability Studies for new alternative fuels (5.18) Fuel Property Testing Shell in situ Shale kero evaluation (5.1) Basic Fuel Prop. (5.2) Spec. Prop. (5.4) Swift Turbine Fuel Materials compatibility (5.7) Fit-for- Purpose Prop. (5.6) Fuel Thermal Stability Studies for 3 F-T (5.9) HRJ Fuel Award (5.25) HRJ Extended Prop. (5.11) 250 Eval. of Mat Compat. Cand. 1 (5.13) Fuel Thermal Stability Studies for available Biofuels (5.14) Ground Fire Protect (5.15) Fuel Sys. Comp nts (5.16) Eval. of Mat. Compat. Cand. 2 (5.17) NEEDS YOUR UPDATES Please fill out worksheet or provide Excel file Survivability/ Vulnerability (5.19) Infrastructure (5.20) Eval. of Fuel Tox. Cand. 2 (5.23) Fuel Property Testing (Military) Gov t Fuel Buy 1 (5.3) Gov t Fuel Buy 2 (5.5) From AFRL/AFCO Combined Roadmap - BioJet Certification - Being Updated FFP Report HRJ 50/50 (5.30) HRJ Delivery #1 & #2 (5.26, 5.27) HRJ Delivery #3 (5.28) HRJ Delivery #4 (5.29) FFP Report 100% Synth (5.31) Eval. of Fuel Tox. Cand. 1 (5.21) HRJ SE&V (5.22) Completed Funded Plans (Public/Private) Unfunded Needs Result Target Vision (#.#) Milestone Number See Database for details 9/25/09

22 Category CAAFI Roadmap (4 of 6) Component and Engine Testing Biofuel Comb Rig Test (2.8) Biofuel APU & Eng Test (2.9) Testing of F-T and Biofuels Concept 1 (2.10) Indiana F-16 Study (2.11) Testing of F-T and Bio fuels Concept 2 (2.20) Testing of F-T and Bio fuels Concept 3 (2.24) Evaluation of Biofuels Using NASA DC-8 (2.29) Component & Engine Testing 250 F-15 F-T Fuel Eng Test (2.2) F-22 F-T Eng Test (2.4) HRJ Compn t Tests (2.7) Swift Fuel Eng Testing (2.11 and 2.12) Eval. of 2 F-T Fuels Using NASA DC- 8 (2.15) HRJ Small Engine Demo (2.17) Swift Fuel Eng Testing (2.16) HRJ Cand. Fuel 1 A/B Eng. Test (2.23) All USAF Sys F-T Certification (2.25) Cand. Fuel 2 A/B Eng. Test (2.28) HRJ Cand. 2 APU Tests (2.26) See Also CAAFI Certification Roadmap NEEDS YOUR UPDATES Please fill out worksheet or provide Excel file Component & Engine Testing (Military) F-T Fuel GSE/ESOH/ Infrastructure Certification (2.3) F-16 F-T Eng Test (2.6) From AFRL/AFCO Combined Roadmap - BioJet Certification - Being Updated F-35 F-T Eng Test (2.18) HRJ Comngld. (FT/Bio) A/B Eng. (2.19) HRJ Cand. 1 APU Test (2.22) Comngld. (FT/Bio) A/B APU (2.27) Completed Funded Plans (Public/Private) Unfunded Needs Result Target Vision (#.#) Milestone Number See Database for details 9/25/09

23 Category CAAFI Roadmap (5 of 6) Flight Testing Airbus 380 GTL flight (4.4) 747 Flight ANZ 50% HRJ Jathropa (4.15) 737 Flight CAL 50% HRJ (4.16) NEEDS YOUR UPDATES Please fill out worksheet or provide Excel file Flight Testing Flight VAA 20% FAME (4.3) F-15 F-T Fuel Flight (4.6) 747 Flight JAL 50% HRJ Camelina (4.17) See Also CAAFI Certification Roadmap B-1 F-T Fuel Flight (4.5) C-17 F-T Fuel Flight (4.7) KC-135 F-T Cert. Complete (4.13) T-38 F-T Fuel Flight (4.12) A-10 F-T Flight (4.18) B-2 F-T Fuel Flight (4.21) T-6 F-T Flight (4.22) HH-60 F-T Flight (4.19) Eval. Of Pathfinder A/C Cand.1 (4.29) Eval. Of Pathfinder A/C Cand. 2 (4.31) Bio & FT-Bio High Alt. Flights (4.33) Flight Testing (Military) From AFRL/AFCO Combined Roadmap - BioJet Certification Being Updated KC-135 F-T Fuel Flight (4.8) F-22 F-T Fuel Flight Test (4.9) C-5 and C-130 F-T Fuel Flight (4.14) CV-22 F-T Flight (4.23) RQ-4 Flight (4.35) F-35 F-T Flight (4.24) Bio & FT- Bio Fighter Flights (4.32) Bio & FT- Bio Fighter FSE (4.34) Completed Funded Plans (Public/Private) Unfunded Needs Result Target Vision (#.#) Milestone Number See Database for details 9/25/09

24 Category Production Studies Production R&D Other CAAFI Roadmap ( 6 of 6) Production Studies and R&D NEEDS YOUR UPDATES Please fill out worksheet or provide Excel file DOE CBTL R&D Awards (8.10) Naphthenic drop-in HRJ PoC (8.1) DARPA Algal Biofuel Kick-Off (9.1) DARPA Algal Biofuel Kick-Off (8.2) Naphthenic drop-in HRJ - Pilot demo (8.4) Basic Eng Package for Commercial HRJ Plant (8.3) F-T Reactor Baseline LCA Conference (6.2) Study - Alt. Biomass Processes Cellulosic (9.6) DOE CBTL Study (9.5) Studies (8.5) CRC Aviation fuels meeting (6.4) Study Req. Biomass & Prod. Quantities (9.4) DARPA Algal Biofuel Phase I Complete (9.2) DARPA Algal Biofuel Phase I Complete (8.6) Construction of Renewable Oil Refinery (6.6) Alt. Biomass Processes Cellulosic ( ) Aromatics for Green Jet from ligno-cellulosic pyrolysis oil pilot with wood, corn stover (8.15) F-T Reactor Studies and Catalyst Development (8.7) DoE Cellulosic Ethanol Demo (8.16) Naphthenic drop-in HRJ subscale (8.8) Commission and Start-up of Renewable Oil Refinery (6.7) DARPA Algal Biofuel Phase II Complete (9.3) DARPA Algal Biofuel Phase II Complete (8.9) Cellulosic ethanol oligimerization to Jet lab/pilot (8.17) Aromatic fraction for Green Jet from lignocellulosic pyrolysis oil commercial (6.8) Cellulosic Ethanol oligimerization to Jet commercial (6.9) CRC Aviation Fuels Meet g (6.1) OMEGA- Aviation (6.3) Completed Design for renewable Oil Refinery (6.5) See Also CAAFI Business Roadmap See Also CAAFI Environment Roadmap Completed Funded Plans (Public/Private) Unfunded Needs Result Target Vision (#.#) Milestone Number See Database for details 9/25/09

25 Agenda 2 nd Day Background Presentations FRL & Roadmapping Time Item # and Topic Focal 08:00 08:30 Check in (breakfast available in cafeteria) 08:30 09:00 Welcome from USDA K. Merrigan 09:00 09:30 USDA programs C. Cassidy 09:30 09:50 NASA programs B. Bomani/A. Chait 09:50 10:10 DARPA programs D. Kirkpatrick 10:10 10:25 Break 10:25 10:45 AFRL programs T. Edwards 10:45 11:05 EU s Alpha Bird program M. Braun-Unkhoff 11:05 11:25 DOD biofuel summit summary K. Lewis 11:25 11:45 DOE forecasting K. Lewis 11:45 12:00 Fuel Readiness Level M. Bradley 12:00 12:10 Prepare for afternoon D. Daggett 12:10 13:40 Lunch 13:40 15:20 Process Breakout M. Bradley 13:40 15:20 Feedstock Breakout D. Daggett 15:20 15:40 Break 15:40 16:40 Report back on breakout sessions 16:40 17:00 Concluding remarks 25

Aviation Alternate Fuels Roadmap Level 1 / Scenario 1

Aviation Alternate Fuels Roadmap Level 1 / Scenario 1 Category 2005 2007 2010 2015 2030 2050 Market Drivers Environmental, Political, Resources Anticipated Fuel Price Availability (% Demand Filled) Concerns