Alternatives to fossil jetfuel and related challenges

Transcription

1 Alternatives to fossil jetfuel and related challenges CLIB Duesseldorf Manager of Biofuels Business Unit Fraunhofer UMSICHT Folie 1

2 Biofuels Unit at UMSICHT Vision and Scope of R&D VISION : Creation of an affordable, sustainable future with chemistry Development of catalytic processes for Biofuels & Chemicals Scale-up and Pilot Plant Operation Employed raw materials are mainly bio-based: Fat & oils, sugars, alcohols, hemi-cellulose, residues Member of European Biofuels Technology Platform (workgroup conversion) Folie 2

3 Process Development - Biofuels and Biorefinery» Several reactors / distillation units«feed ~ 0,05-2 kg/h Fully automated EEx or similar protection High temperature and pressure Fast and affordable sample production Screening of process conditions Generation of cost and engineering data Analytical profiling of fuels & chemicals Folie 3

4 Statement of IATA *) on the development of Biojetfuel Biofuels offer the greatest hope for aviation to reduce its carbon emissions. Savings of up to 80% are on the table if the industry can get it right. There are tough challenges to overcome: aside from technical issues, biofuels must be competitive in price and available in quantity. It s not only about emissions. Biofuels offer opportunities to developing countries **) to grow new livelihoods and reduce dependency on imported fossil fuels, as well as the obvious benefits to the environment and the industry. These are compelling reasons for governments to get on board. If airlines wait until the price is right and commercial quantities are available, biofuels might never happen *) Paul Steele, IATA Aviation Environment Director Folie 4 *) IATA Magazine AIRLINES International December Jan 2011 **) e.g Workshop Mexico Bioturbosina

5 The fuel price challenge More than 30% of operating costs are due to fuel 1100 $/t Folie 5 Sep. 2011

6 Facts and boundary conditions for Biojetfuel *) Aviation is the strongest growing transport sector (~ 4,5% annually) 3% of man-made and 12% of transport CO2-emissions are due to aviation EU27: air-traffic consumes 53, major airlines 20 mil. tons Kerosene (world =200) Logistic infrastructure (refineries, pipelines, oil ) is not evenly distributed Very strong growth of aviation activities is expected in Southeast Asia CO2-tax (EU-ETS) and introduction of Biofuels for aviation are game changers EU target is 2 mil. tons (sustainable) Kerosene by 2020 Current norm for Biojetfuel ist ASTM D a (Aug. 2011) Biofuels are state-of-the art for cars for aviation they are in their infancy! Folie 6

7 Value Chain for Biojetfuel The focus is on the most important parts of the value-chain Technology integration (preferred is drop-in ) Raw Materials & Inbound Logistics Production Int. Logistics, R&D, QC, Formulation, Blending Marketing & Sales Branding Certification Outbound Logistics Storage Pipelines Primary Customer Secondary Customer Partner(s) Raw materials Large/Small Technology Development, IP, Manufacturing, Catalysts Folie 7

8 Folie 8 Chemistry of jetfuel distribution of hydrocarbons"c15""c11""c10""c8""aromatics""polyaromatics"c11 C12 C10 C13 C9 C14 C15 C8

9 Topics covered in this presentation a) State-of-the-art Alternative Fuels > see also IATA report 2010 > serious alternatives are evaluated by ASTM b) Selected Alternative New Approaches Folie 9

10 State-of-the-art Alternative Fuels via Fischer-Tropsch Fischer-Tropsch Processes: CTL, GTL, BTL Basis Steps to Biojetfuel (FT): Sourcing of coal, (natural) gas, biomass / waste *) Gasification of feedstock to syngas (CO/H2) and ash (!) FT-synthesis of fuel: mixture of alkanes, naphtha, olefins Hydroprocessing of mixture (hydro-treating & -cracking) Separation of fuel mixtures by distillation > 50% of fuel costs are due to investment Folie 10 *) A combination of coal and biomass is possible too

11 State-of-the-art Alternative Fuels from Fats and Oils *) So-called Hydrogentated Vegetable Oil (HVO) or Hydroprocessed Renewable Jet (HRJ) Basis steps to Biojetfuel (HRJ): Sourcing and multistep purification of plant / waste oils Synthesis: Hydrotreating, Hydrocracking, Isomerisation Separation of fuel mixtures by distillation Major players are Neste Oil and UOP Most advanced green technology at the moment > 50% of fuel costs are due to raw materials Folie 11 *)sustainable feedstock: camelina, jatropha, animal and frying residues

12 Limiting factor vegetable oils Mil. Tons Palm oil is (at least currently) a wanted feedstock for food and biofuels (Diesel and Kerosene) World Vegetable Oils Year Total veg. oils Rapeseed Soybean Palm Oil Folie 12 Data from:

13 Competition for palm oil Energy Cosmetics, Soaps Food Palm oil utilization (world) Informe de mercado semanal 21, 2007 Without subsidies palm oil will probably not go into fuels Folie 13

14 New Alternative Fuels considered by ASTM (not in D7566) Synthesized Kerosenes Aromatics (SKA)- e.g. alkylated benzenes (important for elastomeric seals and fuel lubricity) Fischer-Tropsch aromatics can currently not be used Hydroprocessed synthetic paraffinic kerosene derived from fermented alcohols. Initially focused on iso-butenol. Now other variations will be considered as well Co-mingling petroleum and biomass in refinery hydroprocessing to optimize efficiencies is currently not allowed. Separate processing and blending is required. Synthetic biology - genetically engineered micro-organisms convert sugar to pure hydrocarbons Pyrolysis of cellulosic biomass to synthetic crude products for additional (Hydro-)processing to yield biofuels Folie 14

15 Jetfuel via synthetic biology - Amyris Bioconversion of sugar cane Biofene TM (Farnesene) H 2 Farnesane (Isomers) Production in Biomin in Piracicaba as a JV with Grupo São Martinho (Brazil) Squalane (from Biofene) will be first product on commercial sale Also envisioned are industrial lubricants, polymers, kerosene Analysis of sustainability for Amyris jetfuel from sugarcane is currently funded by Boeing, Embraer, Inter-American Development Bank (IBD) ASTM screening for farnesane jetfuel has been started Folie 15

16 The land, distribution and logistic challenge According to OECD (2007) the earth provides 1,5 billion ha farmland 3,4 billion ha grassland 4 billion ha forest About 440 Mil. ha arable land is still available 80% of the available arable land is located in Latin America and Africa 50% of the available land is distributed over 7 countries: Angola, Congo, Sudan, Brazil, Argentina, Bolivia, Columbia Refineries and infrastructure are not located where the available land is Hence, waste and off-gases e.g. CO/CO2 are to be used to generate fuels Biomass production not in need of land is desirable e.g. ALGAE, WASTE Folie 16

17 EU project focus on algae in 2010 was on Biodiesel *) Demonstration of large scale sustainable production of bio-fuels based on low cost microalgae cultures (10-ha-site) Folie 17 *) e.g. ALLGAS-project incl. UMSICHT

18 General challenges for algae-based biofuels New SPECS for algae oil raw material are required So far norms have been developed for vegetable oils Many components in algae like PUFA-, phospholipids are much higher than in vegetable oils New components like chlorophyl, carotenoids, hydrocarbons, sugarlipids and minerals are encountered New ways of pretreatment and QC are to be developed Many different types of algae exist, some algae are food Cost for dry algae are ~ 1,5 *) - 4 /kg (20-30 % are oil) *) Norsker, Wijfels, Barbosa (2010): 100 ha plant (incl. CAPEX & OPEX) tube / panel or open pond reactor with many PE-parts, free of charge CO 2 and nutrients, optimized stirring and pumping system Folie 18

19 Cracking of waste fats/oils - e.g. Greasoline Technology *) Gasoline Kerosene Diesel LPG-Gas Coke CO 2 /CO/H 2 Crude Algaeoil Part of Pilot Plant Folie 19 *) funded by BMU and EU; spin-off in Aug. 2011

20 Folie 20 Jetfuel from lignocellulose (waste) Redrawn from production of jet and diesel fuel range alkanes from waste hemi-cellulose derived aqueous solutions (Huber et al. 2010) Critical success factor is APR-Technology (Virent )OOHOHnOOHOHOHHOOOOOO+OOOOOOOOOHHydrolysisDehydrationCondensationMildHydrogenation+H2O-H2O+H2OOOHHydrotreating+H2Tridecane"C13"+CondensationOOAqueous Phase Reforming

21 Biofuels from alcohols Swedish Biofuels Biobased gasoline, diesel and jetfuel produced by condensation of lower alcohols made by fermentation Recently cooperation with LanzaTech for BioJetfuel announced *) Carbon monoxide (CO) is converted to ethanol (LanzaTech), followed by chemical condensation to alkanes (Swedish Biofuels) Jetfuel evaluation by ASTM us under consideration **) Technology package is not completely transparent (from patents) Folie 21 *) *)

22 Fitting it into a refinery Other Gases Gas Fuel Gas Gas Processing Amine Treating Merox Treaters Refinery Fuel H 2S LPG Butanes Claus Sulfur Plant H 2S from Sour Water Stripper Sulfur Gas H 2 Gas H 2 Light Naphtha Hydrotreater Isomerization Plant Isomerate New Technology Crude distillates or gas mixture Crude Oil Atmospheric Distillation Atmospheric Bottoms Vacuum Distillation Air Heavy Naphtha Jet Fuel Kerosene Diesel Oil Atmospheric Gas Oil Evacuated noncondensibles Gas Light Vacuum Gas Oil Vacuum Residuum Asphalt Blowing Merox Treater H 2 Hydrotreater Heavy Vacuum Gas Oil Gas H 2 Hydrotreater Asphalt Jet Fuel and / or Kerosene Diesel Oil Heavy Vacuum Gas Oil Gas H 2 FCC Feed Hydrotreater Gas Delayed Coker Gas Fluid Catalytic Cracker (FCC) Catalytic Reformer Hydrocracker Petroleum Coke Gas H 2 Gas H 2 Coker Naphtha (after hydrotreating and reforming) Coker Gas Oil Reformate Hydrocracked Gasoline Diesel Oil Gas i-butane Butenes Alkylation Pentenes Gas H 2 Alkylate Naphtha FCC Gasoline Hydrotreater FCC Gas Oil Fuel Oil Gasoline Blending Pool Refinery and products Folie 22 Redrawn fron Wikipedia

23 Summary and outlook Big challenges are ahead of sustainable Biojetfuel Cooperation of many unfamiliar players required to make Biojetfuels fly Biofuels demand coupling of hitherto not linked value and supply chains (petrochemicals, agriculture, food, fodder, crop-sciences, biology, chemicals) Sustainability requires to find a balance between ecological, economical and social targets, which are by nature contradictory (TRILEMMA) Broad Biojetfuel evaluation by ASTM has been started, be prepared for surprises Many new players try to get a foothold into the market - outcome uncertain Prices for key commodities like energy, fuels and new commodities like CO2, algae, waste streams almost certain guarantee for an interesting journey ahead Folie 23

24 Thank you for listening Leading R&D personnel at Business Unit Biofuels Dr. Anna Fastabend Dr. Jürgen Grän-Heedfeld Dipl.-Ing. Andreas Menne Dipl.-Ing. (FH) Karl Meller Dr. Anna Greve Dipl.-Wirt.-Chem. Klaas Breitkreuz Dr. Volker Heil Folie 24

25 Fraunhofer UMSICHT Organization of Business Units X X X X X X = active in the field of Biorefinery / Fuels Folie 25

26 Sustainability Trilemma Folie 26