Biofuels: Challenges & Opportunities James Rekoske UOP LLC, A Honeywell Company Asia Pacific Clean Energy Summit & Expo Aug 30 Sept 2, 2010 Honolulu, Hawaii 2008 UOP LLC. All rights reserved. UOP 5453-01
Honeywell Corporate Overview 125,000 employees in more than 100 countries A Fortune 100 company sales of $34.5 billion in 2008 Global leader in advanced technology products, services and solutions Specialty Materials UOP Transportation & Power Systems 15% 15% 34% 36% Aerospace Automation & Control Technology Company, Financially Strong and Global
UOP Overview Leading supplier and licensor of processing technology, catalysts, adsorbents, process plants, and technical services to the petroleum refining, petrochemical, and gas processing industries. UOP Technology Furnishes: 60% of the world s gasoline; 85% of the world s biodegradable detergents; 60% of the world s para-xylene. 3000 employees worldwide. 2008 Financials: $1.9 billion in sales. Strong relationships with leading refining and petrochemical customers worldwide. UOP s innovations enabled lead removal from gasoline, the production of biodegradable detergents, the first commercial catalytic converter for automobiles. 2003 National Medal of Technology Recipient Developing Sustainable Solutions for Global Transport Sector UOP 5054-03
Global CO 2 Emissions by Energy Source, Region & Sector Global House Gas Emissions China surpassed the US in 2008 China and India have low per capita emissions Power and Transport sector the largest CO 2 emitters Sustainably produced Renewables will play an increasingly important role in these sectors
Biofuels: A Quickly Changing Landscape 2007 All biofuels are good More, faster No criteria to measure impact of adopting biofuels Availability of inexpensive bio feedstocks Government mandates and incentives favor ethanol and biodiesel 2008 Not all biofuels are good Concern for food chain impact & competition for land/water Measured biofuel adoption Utilization of LCA analysis to qualify : link to GHG, energy, sustainability Bio feedstocks tracking energy prices Government mandates/ incentives increasingly technology neutral Emphasis on real biofuels 2009 Credit Crisis: Stimulus focused on Tech UOP Position Emphasis on life cycle analysis as a way of measuring sustainability Ensure technology is feedstock flexible Focus on 2 nd generation technologies Create partnerships between feedstock suppliers and fuel producers Increasing Awareness of Potential Impact
UOP Vision for Renewable Transport Fuels Building on UOP technology and expertise Produce real drop-in fuels instead of fuel additives/blends Leverage existing refining, transportation, energy, biomass handling infrastructure to lower capital costs, minimize value chain disruptions, and reduce investment risk. Focus on path toward second generation feedstocks & chemicals Oxygenated Biofuels Renewable Energy Hydrocarbon Biofuels Ethanol Biodiesel Fuel & Power Diesel Jet Gasoline First Generation Other Oils: Camelina, Jatropha Second Generation Natural oils from vegetables and greases Lignocellulosic biomass, algal oils UOP 5149-05
Camelina: Key Attributes Initial Camelina Market Current markets Northwest US and Southern Canada Wide-spread acreage as rotation crop > 200 million gallons by 2012 in the US Future Camelina Market Low input oil seed crop (member of mustard family) Rotation crop with wheat Can grow on marginal land Cost: $0.40-$0.70 per gallon less than soybean and palm oil Native to Northern Europe More than 3,000 years old: used as lamp oil in Greece and Rome
Vol% Yield Pilot Plant Testing Results Refined Oils Alternate Feeds Cost Advantage 120 Vol% 1st Stage (De-Ox) Straight Chain Paraffin Yields 100 80 60 40 20 0 0 1000 2000 3000 4000 5000 6000 Hours On Stream Jatropha Soybean Partially HT soybean Fully HT soybean Tallow Canola Tallow 2 Palm Oil Tallow 3 Tall Oil Tallow 4 Catalyst stability solidly established Basis for current feed contamination specification defined UOP 5202B-05
Vol% Yield More Pilot Plant Testing Results 120 Refined Oils Alternate Feeds Cost Advantage Vol% 1st Stage (De-Ox) Straight Chain Paraffin Yields 100 80 60 40 Diesel yields palm Diesel yields algae Diesel yields jatropha Diesel yields FFA 20 0 0 200 400 600 800 1000 1200 1400 Hours On Stream Stable operation further demonstrated on inedible & 2nd generation oils UOP 5202B-06
UOP/ENI Ecofining Diesel Superior technology that produces diesel, rather than an additive Uses existing refining infrastructure, can be transported via pipeline, and can be used in existing automotive fleet Two units licensed in Europe and two in NAmerica with first commercial start-up in 2012 Excellent blending component, allowing refiners to expand diesel pool by mixing in bottoms Can be used as an approach to increase refinery diesel output Process Comparison vs. Biodiesel Natural Oil/ Grease + Methanol Natural Oil/ Grease + Hydrogen Petrodiesel Biodiesel (FAME) Diesel Performance Comparison Biodiesel + Glycerol + Propane Diesel NOx Baseline +10-10 to 0 Cetane 40-55 50-65 75-90 Cold Flow Properties Baseline Poor Excellent Oxidative Stability Baseline Poor Excellent
UOP Renewable Jet Process Initially a DARPA-funded project to develop process technology to produce military jet fuel (JP- 8) from renewable sources Targets maximum Jet production Jet Fuel can meet all the key properties of petroleum derived aviation fuel, flash point, cold temperature performance, stability Certification of Jet as a 50% blending component in progress Natural Oil/ Grease Natural Oil/ Grease Built on Ecofining Technology Deoxygenating/ Isomerization Deoxygenating/ Selective Cracking/ Isomerization DARPA Project Partners Diesel Jet Available for License since Q1 2010
Properties of Synthetic Paraffinic Kerosene (SPK) for Demo/Certification Description Jet A-1 Specs SPK (Jatropha) SPK (Camelina) SPK (Jatropha/ Algae) Flash Point, o C Min 38 46.5 42.0 41.0 Freezing Point, o C Max -47-57.0-63.5-54.5 JFTOT@300 o C Filter dp, mmhg max 25 0.0 0.0 0.2 Tube Deposit Less Than < 3 1.0 <1 1.0 Net heat of combustion, MJ/kg min 42.8 44.3 44.0 44.2 Viscosity, -20 deg C, mm 2 /sec max 8.0 3.66 3.33 3.51 Sulfur, ppm max 3000 <1 <1 <1 Over 200,000 US Gallons of Bio-SPK made for US Military and commercial airline demonstration flights Certification supply work has uniquely allowed UOP to test the process and the catalyst at large Demo Capacity US Military accelerating certification program Fuel Samples from Different Sources Meet Key Properties UOP Proprietary
Completed Commercial Airline Flight Demonstrations Feedstock: Jatropha oil Successful ANZ Flight Demo Date: Dec. 30, 2008 Feedstock: Jatropha and algal oil Successful CAL Flight Demo Date: Jan. 7, 2009 Feedstock: Camelina, Jatropha and algal oil, KLM European Test Flight: November 23, 2009 Camelina
Completed US & NATO Military Testing Military Demonstrations Up to 600,000 gallons of fuel made from camelina, algae and animal fats being produced for DESC U.S. Air Force A-10 Thunderbolt II (camelina) Navy F/A-18 Hornet (camelina) Royal Netherlands Air Force Apache Helicopter (algae & used cooking oil) Jet Fuel Meets Flight Specifications
Certification-Qualification Phase - ASTM D4054 Fuel Qualification Process Specification Properties FRL 4.2 Fit-For-Purpose Component/Rig Engine/APU Properties Testing Testing FRL 6.1 FRLs 6.2 & 6.3 FRL 6.4 Accept ASTM Review & Ballot Reject Re-Eval As Required ASTM Specification ASTM Research Report ASTM Specification ASTM Balloting Process OEM Review & Approval FRL 7: Fuel Class Listed in Int l Fuel Specifications Slide courtesy of Mark Rumizen, FAA/CAAFI
MJ (Input)/MJ (Output) g CO 2 eq./mj g CO 2 eq./mj Life Cycle Analysis for Renewable Jet Fuel 1.6 Cumulative Energy Demand 90 house Gases 1.4 1.2 1 0.8 0.6 0.4 0.2 0 0 Kerosene Non-renewable, Fossil Renewable Biomass Renewable, Water Jatropha Jet Tallow Jet Soy Jet Non-renewable, Nuclear Renewable, Wind, Solar, Geothe 80 70 60 50 40 30 20 10 0 Kerosene Jatropha Jet Cultivation Fuel Production Use Camelina Jet LUC Error Bar Tallow Jet Oil Production Transportation Soy Jet 5000 4000 3000 2000 1000 0-500 Significant GHG Reduction Potential Basic Data for Jatropha Production and Use. Reinhardt, Guido et al. IFEU June 2008 Biodiesel from Tallow. Judd, Barry. s.l. : Prepared for Energy Efficiency and Conservation Authority, 2002. Environmental Life-Cycle Inventory of Detergent-Grade Surfactant Sourcing and Production. Pittinger, Charles et al. 1, Prarie Village, Ka : Journal of the American Oil Chemists' Society, 1993, Vol. 70.
Global Biomass Based Fuel Potential: Ag and Forest Residues Forest Resources Agricultural Resources US Annual Biomass Potential 386 998 US Biomass: 1.4 B MTA Key Regions Biomass: 0.5 B MTA Total 1.9 B MTA Total Resource Potential 1366 0 200 400 600 800 1000 1200 1400 Million dry tons per year Agriculture Harvest Wood Wood (from 5% Residues* Key Residue Regional Annual ResidueBiomass Fuel Potential available land) Total Argentina 14.3 0.3 0.1 1.4 4.7 21 Brazil 111.5 5.4 2.4 31.5 36.6 187 Canada 10.6 4.2 1.9 0.6 2.7 20 China 33.3 6.0 2.7 28.9 1.2 72 Colombia 6.1 0.2 0.1 2.0 4.9 13 India 50.2 6.9 3.1 75.2 0.0 135 Mexico 10.2 0.9 0.4 6.8 1.0 19 CBI 10.3 1.0 0.5 7.4 1.0 20 Total 246.4 24.9 11.2 153.8 52.2 488 *These are the values for 2017 residues from crops studied, under the baseline case. Source: Oakridge National Labs & USDA Ag & Forest Based Biomass Could Contribute Up to >30% Substitution of the Global Transport Pool
Envergent Technologies LLC UOP / Ensyn Joint Venture Formed in October 2008 Provides pyrolysis oil technology for fuel oil substitution and electricity generation Development of technology for upgrading pyrolysis oil to transportation fuels Leading process technology licensor~$2 billion in sales, 3000 employees Nearly 100 years of refining technology development, scale-up and design Modular process unit supplier Global reach via Honeywell & UOP sales channels Over twenty years of commercial fast pyrolysis operating experience Developers of innovative RTP TM fast pyrolysis process Seven commercial RTP units designed and operated Second Generation Renewable Energy Company Global Reach
Lignocellulosic Biomass Processing Options Direct Combustion Heat & Power Fast Pyrolysis Pyrolysis Oil Upgrading Transport Fuels Solid Biomass SynGas Gasification Fischer Tropsch Hydrocracking/ Dewaxing Envergent Route to Energy Fermentation/ Catalysis Bioethanol/ Biobutanol
Pyrolysis Oil to Energy & Fuels Vision Forest Fiber P P Energy/ Fuels P P Electricity Production Fuel Oil Substitution Available for Sale Biomass Fast Pyrolysis Pyrolysis Oil Ag Residue Transport Fuels (Gasoline, Jet, Diesel) Commercially available in 2012 Phased Commercialization
Pyrolysis Oil Energy Applications RTP Unit Gasification Fuel Burner Gas Turbine Stationary Diesel Engine Optimized UOP Upgrading Technology Syngas Fischer Tropsch Heat Electricity CHP Hydrocracking/ Dewaxing Gasoline, Diesel & Jet Replacement of fossil fuel for heat/steam generation Production of green electricity Alternate revenue stream from external sale Future upgrading to transportation fuels Multiple Applications for Pyrolysis Oil, a Renewable Fuel Available Today ENV 5233-09
Integrated Biorefineries Process Technologies Oil (Palm, Camelina) Transport Fuels (Diesel, Jet) Residue from Oil Extraction RTP Pyrolysis Fuel Oil for Electricity Production Transport Fuels (Diesel, Jet) Sustainable Biorefineries are technically feasible today
Summary Renewables are going to make up an increasing share of the future fuels pool - Multitude of bioprocessing approaches possible - Fungible biofuels are here First generation biofuels, though raw material limited, are an important first step to creating a biofuels infrastructure Second generation feedstocks, cellulosic waste and algal oils, have the potential to make significant contributions Jet Technology demonstrated and flight tests completed UOP is developing technology pathways to green fuels via the PyOil route that integrate well with petroleum refineries Algal oils successfully converted to specification green fuels in UOP Labs UOP 5054-22