Converting Municipal Solid Wastes to Drop-In Hydrocarbon Fuels Extending the Feedstock Choices for the IH 2 * Process Dhairya D. Mehta 1, Vikrant Urade 1, Madhusudhan Rao 1, Laxmi Narasimhan 1, Alan del Paggio 2 1 Shell Technology Centre Bangalore, India 2, USA *IH 2 is a trademark of Gas Technology Institute
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Content Introduction to the IH 2 Technology Municipal Solid Waste Existing practices Preparation/ Characterization protocol Experiments through IH 2 technology Yield profile Hydrocarbon quality Summary 3
IH² Technology Overview 4
FUEL WATER GAS REACTOR REACTOR IH² Process Simplified Schematic FUEL GASOLINE JET FUEL DIESEL BIOCHAR HYDRO- PYROLYSIS HYDRO- CONVERSION HYDROGEN PLANT BIOMASS WOOD CHIPS AGRICULTURAL RESIDUE ALGAE MSW SEPARATOR COMPRESSOR 5
IH 2 Technology Salient Features Continuous catalytic thermochemical process (residence time: minutes ) Feedstock agnostic with yields in 26-30 wt% basis MAF feed Flexible process: Can be integrated with refinery, sugar mill, etc. Produces high quality hydrocarbon transportation fuels Gasoline, Jet and Diesel 72-92% GHG reduction depending upon feed & configuration ~70% energy content recovery 6
Drop In Replacement Fuels US GASOLINE Meets ASTM D4814-16d Octane ~ 86 S < 10 ppm Fully renewable RBOB E10 blend anticipated JET FUEL GRADE WORLD-WIDE Meets Jet A/A-1 Specs S < 2 ppm US DIESEL Meets ASTM D975-15c Cetane Number 44 S < 10 ppm EU PETROL EN 228: Petrol RON 87 vs 95 S ~10 ppm Premium blend stock Freezing Point <-60 C No napthalenes Low aromatics CPK EU DIESEL EN 590:2009+A1:2010 Cetane Number 48 S < 10 ppm Premium Blend Stock 7
Municipal Solid Waste (MSW) Feedstock: Preparation Protocol & Characterization 8
MSW Management Existing Practices Worldwide MSW generation to double by 2025 compared to 2012 3 North America 1 European Union 2 Cost ($/ tonne) 3 Waste Generated, million tonnes 258 241 Recycling & composting 35% 47% Combustion 13% 27% 70-200 Landfill 53% 26% 40-100 1 https://www.eia.gov/energyexplained/index.cfm?page=biomass_waste_to_energy (2014) 2 http://ec.europa.eu/eurostat/statistics-explained/index.php/municipal_waste_statistics (2015) 3 What a Waste World Bank s Urban Development and Local Government Unit of the Sustainable Development Network (2012) 9
Typical MSW Sorting Workflow Mixed Waste (Dry and Wet) Trommel/ Size-based Separation For further processing and composting Inerts Refuse- Derived Fuel (RDF) 10
Processing Raw RDF into Pellet Form RDF Drying Dry RDF (<30 wt% Moisture) Size- Reduction Crushed RDF Size-Selection Pelletization 10-25 mm RDF Pellets Inerts (Ash) Removal IH 2 Process Feedstock Granulation 11
RDF Properties Value Bulk Density/ g cc -1 0.25-0.35 Moisture/ wt% 3-20 Ash/ wt% 6-10 C/ wt% 55-70 H/ wt% 6-9 O/ wt% 20-40 Thermogravimetric analysis was used to semi-quantitatively determine the plastic content in RDF samples 12
Experimental Results from Bench- Scale Processing of MSW 13
Heats of Reaction Lignocellulosic Biomass PE/ HDPE Hydropyrolysis/ kj kg -1 400 650-1000 Hydrodeoxygenation/ kj kg -1-2700 0 Net/ kj kg -1-2300 650-1000 Cozzani et al Ind. Eng. Chem. Res., 1995,34, 2006-2020 14
Bench-Scale Experiment Parameter Unit Feedstock P. Sylvestris Low Plastic MSW High Plastic MSW First Stage Catalyst S-4261 S-4261 S-4261 Second Stage Catalyst S-4232 S-4232 S-4232 Hydrogen addition %wof MAF 5.5 5.1 4.2 1st Stage WABT C 413 418 438 2nd Stage WABT C 361 361 362 Pressure barg 22.4 22.4 22.4 C4+ Hydrocarbon yield %wof MAF 24.9 27.7 39.7 C1-C3 Hydrocarbon yield %wof MAF 17.1 14.7 23.1 CO+CO 2 Yield %wof MAF 12.1 11.8 0.0 Water yield %wof MAF 41.5 38.9 26.7 Char yield %wof MAF 13.1 12.4 21.7 15
Comparison of Hydrocarbon Product Properties Analyses of Total Hydrocarbon Product P. Sylvestris RDF (High Plastic) Density 0.81 0.83 g/ml at 15 C Total Acid Number (TAN) <0.05 <0.05 mg KOH/g IP-391 Analysis Monoaromatics 36.0 44.8 wt% Diaromatics 3.3 6.1 wt% Tri+aromatics 0.5 1.9 wt% Elemental Analysis Carbon 87.6 88.4 wt% Hydrogen 12.5 11.3 wt% Oxygen <0.01 <0.01 wt% Sulfur 229 14 ppmw Nitrogen 2.5 19 ppmw 16
Type mass % in liquid Type mass % in liquid Type mass % in liquid Hydrocarbon Liquid Quality Comparison Detailed Hydrocarbon Analysis 18.0 14.0 16.0 12.0 14.0 10.0 12.0 n-paraffins Isoparaffins Olefins 14.0 12.0 10.0 n-paraffins Isoparaffins Olefins 8.0 10.0 Naphthenes 8.0 Naphthenes 8.0 6.0 Aromatics 6.0 Aromatics 6.0 4.0 4.0 4.0 2.0 2.0 2.0 0.0 0 2 4 66 88 10 10 12 12 14 14 16 16 Carbon Number 0.0 0 2 4 6 8 10 12 14 16 Carbon Number Feedstock: Pinus Sylvestris Feedstock: RDF (High Plastic) 17
Feed & Product Photograph 18
Summary Advantaged Feedstock: Preparation: Bulk density <0.3 g cc -1, Ash content <10% IH 2 process is able to exploit the synergy of co-processing plastics and lignocellulosic biomass Product Yield/ Quality: Liquid hydrocarbon yield higher by up to 15% points on weight basis Carbon conversion efficacy to liquid hydrocarbon ~45-50%, similar to lignocellulosic feedstock Detailed hydrocarbon analysis indicates a higher RON for MSW derived gasoline fuel Challenges going forward: Feedstock quality & variability Scalability 19
Acknowledgement Process design, process assurance, intellectual property rights, MBU (0.5kg/hr semi continuous) and IH 2-50 pilot (50kg/d continuous) scale testing. Experimental fluidization dynamics, cold flow modeling, solids handling. Exclusive FEED provider for the IH 2 process at commercial scale. Supplier of reformer technology for 1000 tonne/day and above. Suppliers of wood yard technology and biomass drying/sizing Turnkey provider of Bangalore MBU and EEFB units, GTI IH 2-50. Supplier of reformer technology for 500 tonne/day plants and below Hydrocarbon fuel specifications, fuel qualifications, LCA, process safety and design considerations, demonstration unit funding and site host, etc Financial support. Engine testing partner to perform required emissions and engine testing Solids handling experts, lock hopper designs, screw mfgs Regulatory agency for D-code pathways, emissions guidelines, etc. Consent needed prior to sale of IH 2 fuels in US. Fuel specifications 20