Advanced Synthetic Jet Fuels from Combined Algae and Coal Conversion

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1 Advanced Synthetic Jet Fuels from Combined Algae and Coal Conversion 4th International Freiberg Conference on IGCC and XtL Technologies Rocco Fiato, Sam Zaszepinski, and Dick Bauman (Accelergy Corporation); Paul Pansegrau, Ted Aulich, Chad Wocken, Josh Strege, Ben Oster, Marc Kurz, Ramesh Sharma, Tom Erickson, and Carsten Heide (EERC) May 4, 2010

2 Holy Grail of Fuel Production Clean Zero CO 2, CO 2 -Neutral, or Lower CO 2 Signature than Traditional Technologies Low Water Consumption Domestically Produced/ Secure Food-Friendly Does Not Compete with Food Production Directly or Indirectly Needs to Be Low Cost! Green -1-

3 Accelergy EERC Partnership Addresses Challenges in CBTL Developing clean integrated coal- and biomass-to-liquids (CBTL) process for beneficial CO 2 utilization Direct coal conversion via Accelergy s microcatalytic coal liquefaction (MCL ) Accelergy technology/eerc R&D support Biomass conversion via catalytic hydrodeoxygenation and isomerization (CHI) EERC technology/accelergy commercialization CO 2 capture, storage, and recycle EERC/Accelergy and other partners Fuel upgrading EERC/Accelergy Additional program areas Conversion of residues via gasification Algae reactor development -2-

4 Accelergy Setting the Standard for Cleaner Jet Fuels Accelergy is a leader in producing high-performance fuels at less cost to both the environment and the customer: By combining the coal-to-liquids (CTL) and biomass-to-liquids (BTL) processes, Accelergy removes 20% of the CO 2 emissions associated with standard refining methods, while producing 20% more energy per pound. Jet fuel exceeds the military JP-8 and commercial Jet-A standards for use on all jets and is currently being used by the Air Force as the industry benchmark for 100% synthetic (not petroleum-based) fuels. Cleaner fuels that reduce nitrogen oxide and particulate emissions and enabling use of higher efficiency engines. Accelergy has a technology license agreement with the ExxonMobil Research and Engineering Company and is backed by a group of world-class investors: Advent International, Goldman Sachs, Lux Capital, Mobius VC, Nth Power, Sequoia Capital China, and Technology Partners. -3-

5 EERC One of the World's Leading Developers of Energy and Environmental Technologies 11 Centers of Excellence Coal Utilization Technologies Center Emission Control Technologies Center National Center for Hydrogen Technology (NCHT) Center for Climate Change & Carbon Capture and Storage Center for Air Toxic Metals (CATM ) Centers for Renewable Energy and Biomass Utilization Water Management Center National Alternative Fuels Center Center for Oil and Gas Great Plains Applied Energy Technology Center Center for Environmental Chemistry and Reclamation The EERC is recognized as one of the world's leading developers of: Cleaner, more efficient, and innovative energy technologies to guarantee clean, reliable energy supplies. Environmental technologies to clean and protect our air, water, and soil. -4-

6 Dedicated Partnerships with the Private Sector, Government, and the Research Community Since 1987, the EERC has had nearly 1100 clients in 51 countries and all 50 states. Client Specs: Private corporations: 798 International market: 142 Governmental clients: 93 Academia: 52 EERC Foundation The cornerstone of the EERC s success is a practical, market-driven, problem-solving approach that consistently meets client needs. -5-

7 MCL Is Commercially Ready and Economically Viable Description Technology Microcatalytic direct coal conversion licensed from ExxonMobil Research and Engineering Company Feedstocks Bituminous coal Subbituminous coal Products Cycloparafinic jet distillate Diesel fuel Background (>$1B invested) Developed over 70s 90s Demonstrated to 250 tons coal/day and service factor of 91% Direct Coal Liquefaction Slurry Preheat Furnaces Liquefaction Reactors Solvent Hydrogenation Benefits over Fischer Tropsch (FT) High efficiency 3 4 bbl/ton of coal vs. 2 bbl/ton of coal for indirect liquefaction (FT) Lower capital expenditure (CAPEX) (30% lower) Less water (75% less) Less greenhouse gases (GHGs) (30% less) Accelergy is further developing the technologies for different commercial settings and coals. -6-

8 Accelergy s Stand-Alone MCL Coal to Liquids Coal Feed MCL Hydrogen Coal Liquids -7- Cycloparaffinic Fuels Gasification Liquefaction Upgrading CO 2 Residues... Provides high-quality cycloparaffinic fuels.

9 CHI Is Being Scaled Up Description Technology Nanocatalytic direct biomass conversion Feedstocks Lipid biomass (e.g. camelina, waste oils, yellow grease, algae) Products Isoparafinic diesel fuels Jet fuel Bio-naphtha Background (> $50M invested) Winner of DARPA innovative biomass to JP-8 award First 100% renewable jet fuel Design of pilot plant at refinery Commercial Catalysts Direct Biomass Liquefaction Benefits Uses nonfood biomass materials Flexible feedstock alternatives Highly efficient relative to indirect processes Scale efficiencies and fuel formulation synergies associated with MCL integration To date, this is the only existing technology that produces 100% renewable, drop-incompatible jet fuels. -8-

10 Many Different Feedstock Have Been Utilized Feedstocks utilized: Oils - Algae, canola, camelina, coconut, corn, crambe, cuphea, and soy Fats - Tallow Wastes - Yellow and brown greases Free fatty acids - Corn and soy Blends -9-

11 World s First 100% Renewable JP-8: EERC Coconut Soy JP-8 vs. Petroleum JP-8 EERC Proprietary -10-

12 Renewable JP-8 Successfully Tested in a Rocket EERC JP-8 JP-8 Mil. Spec. Aromatics, vol% (min.) 25 (max.) Heat of Combustion, MJ/kg (min.) Flash Point, C (min.) 68 (max.) Freeze Point, C (max.) Density, kg/l (min.) (max.) Initial Boiling Point, C 158 Distillation T10, C (min.) 205 (max.) Final Boiling Point, C (max.) - Flowmetric EERC Rocket Launch -11-

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17 Backup Renewable JP-5 EERC JP-5 JP-5 Mil. Spec. Aromatics, vol% (max.) Heat of Combustion, MJ/kg (min.) Flash Point, C (min.) Freeze Point, C (max.) Density, kg/l (min.) (max.) Initial Boiling Point, C Final Boiling Point, C (max.) F-22 Raptor F/A-18 Hornet -16-

18 Backup Hydrotreated Renewable Jet (HRJ) Fuel EERC HRJ Aromatics 0.7 % max. HRJ D7566 Heat of Combustion, MJ/kg (min.) Flash Point, C (min.) Freeze Point, C (max.) Density, kg/l (min.) (max.) Distillation T10, C (max.) Final Boiling Point, C (max.) JFTOT (325 C, pass/fail) Pass Pass Trace Metals (pass/fail) Pass Pass Embraer EMB

19 Accelergy s MCL-CHI Coal and Biomass to Liquids Coal Feed MCL CO 2 Hydrogen Coal Liquids Cycloparaffinic Fuels Gasification Liquefaction Upgrading Residues CHI Biomass Feed Triglyceride Fatty Acids Raw Paraffins Isoparaffinic Fuels Hydrodeoxygenation Isomerization Provides cost-competitive 100% synthetic drop-in-compatible fuels that can be tailored across a wide range of civilian and military applications. -18-

20 Photobioreactor (PBR) Controls Algae Growth Description Technology Closed-loop algae production system develop by A2BE and Raytheon Flow rate optimization to maximize algae oxygen production Feedstocks Industrial CO 2 Products Algal lipid biomass Algal protein biomass Oxygen Closed Conversion of CO 2 into Algae A2BE s CC&R Machine Adapts to Multiple Algae Species and Harvesting Technologies Cyanobacteria Algae Saltwater Algae Rotating Screen Centrifuge Benefits Radical increase in algae production per acre Closed system mitigates contamination Algae agnostic Oxygen production and capture allows Oxyfuel applications Background Demonstrated at scale Freshwater Algae Diatom Algae Universal Industrial CC&R Machine Air Flotation Bio-Harvesting The EERC has been demonstrating algae-to-jet fuel conversion. -19-

21 PBR Is Fully Integrating CBTL Coal Feed MCL CO 2 Hydrogen Coal Liquids Cycloparaffinic Fuels PBR Gasification Liquefaction Upgrading CO 2 Recovery Residues Dried Algae Algae PBR and Recovery Drying CHI Algae Biomass/Fatty Acid Separation Triglyceride Fatty Acids Hydrodeoxygenation Raw Paraffins Isomerization Isoparaffinic Fuels And facilitating the final step toward a low-carbon world. -20-

22 CBTL Overcomes Disadvantages of Biomass-Only or Coal-Only Conversion Processes Biomass to Liquids + Coal to Liquids CBTL Meets EPA GHG Target Land Requirements Possible No Yes Very Large Small 1/10 Smallest (bioalgal) JP-8/JP Quality Blendstock Blendstock Premium CARB Gasoline Quality Low High High Net Power Production Potential Exporter Importer Balanced Net O 2 Production Exporter (A2BE) Importer Balanced Production Cost per Barrel Very High Low Low -21-

23 The Carbon Ends Up in the Fuel Less CO 2 Is Produced Indirect CTL (Conventional FT) MCL CBTL Coal 2 barrels 3 barrels+ 4 barrels+ 1 Ton 1.6 tons CO tons CO tons CO 2 Note: All numbers are rough representations. -22-

24 Relative GHG Footprint for Current Coal-to-Liquid vs. Accelergy ICTL Current CTL Stand-Alone Relative GHG Footprint Conventional Refining 100% 55% 50% -70% GHG Determined by Coal: Biomass Feed Ratio Accelergy MCL Stand-Alone Accelergy CBTL Stand-Alone Accelergy BTL Stand-Alone Accelergy Integrated Coal-to-Liquid (ICTL) Accelergy MCL direct liquefaction lowers CO 2 to 55% of current levels. Biomass coconversion reduces CO 2 from 0% to 50% of current level. Depending on relative coal-to-biomass feed ratio (0% would require a ~60/40 carbon atom feed ratio of coal to biomass). Stand-alone biomass conversion reduces CO 2 to -70% of current level (excluding credits for other regulated emission reduction from fuel performance). Note: Current technology represented by coal gasification and FT synthesis to hydrocarbons has overall thermal efficiency of ~50% and GHG ~1.8x conventional petroleum analogs; formal life-cycle assessment in progress. -23-

25 Backup CO 2 Capture and Sequestration (CCS) at the EERC EERC CCS Work The EERC leads one of seven Regional Carbon Sequestration Partnerships that the U.S. Department of Energy and other partners are funding to demonstrate CCS across North America. The plains CO 2 reduction (PCOR) partnership is finishing four Phase II small-scale demonstrations and developing two Phase III commercial-scale demonstrations. The Partnership for CO 2 Capture is currently evaluating several platforms for capture in partnership with key stakeholders. -24-

26 Questions? Carsten Heide Associate Director for Intellectual Property Management and Technology Commercialization Energy & Environmental Research Center 15 North 23rd Street, Stop 9018 Grand Forks, North Dakota Thank you! -25-