Uwe Zwiefelhofer Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur Tel: +6 03 2164 6446 Fax: +6 03 2164 5448 Email: [email protected]

Uwe ZwiefelhoferLurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur

Tel: +6 03 2164 6446 Fax: +6 03 2164 5448 Email: [email protected]

Conversion of Biomass UsingConversion of Biomass Using

Proprietary Technologies Proprietary Technologies

– – Lurgi‘s ExperiencesLurgi‘s Experiences

EU-Malaysia Biomass Stakeholders Knowledge Exchange Session

Biomass to Fuels in 1950’s ….

… the direct approach….

This Presentation

Lurgi at a Glance

Biomass Availability

Conversion of Biomass: Challenges, Concepts

Technology Overview and Status

Economics

This Presentation

Lurgi at a Glance




Economics

Technology andEPC Expertise

Total Customer Focus Innovative SolutionsSingle Line

Responsibility

Technology andEPC Expertise

Total Customer Focus Innovative SolutionsSingle Line

Responsibility

dMarket Leader CTC, GTC, Biofuels

Proprietary Technologies

Studies, Basic -, Detail Engineering, Licence, Procurement

Project Management, Turn Key Execution

Technical Services

1500 Engineers, that deliver Innovative Technologies and Plants from One Hand for Oil, Coal and Gas Industry

Member of

Lurgi at a Glance

Lurgi Portrait

Research and Development

Lurgi at a Glance

E&C : Engineering and Construction

Vitry

Houston

Champigny

Hyderabad

Harima

Hangzhou

1 500 Employees in 6 Engineering Centers

E&C Cryogenics

Frankfurt Krakow

Delhi

Johannesburg

Houston

1 300 Employees in 8 Engineering Centers

Beijing

E&C Lurgi

Shanghai

Air Liquide : Relies on > 100 years of in-house Engineering and Technologies Engineering Capabilities: Doubled with Acquisition of Lurgi Strong Force: 2800 Engineers in the E & C Activities

Chemicals, Fuels & Energy

Traditional(from crude oil)

Alternative (from gas & coal)

Renewable(from biomass)

Lurgi at a Glance

Technology Portfolio

Sel. Refinery technologies

Hydrocracker FCC HDS Aromatics Polymers Petchems

Gasification Syngas Hydrogen Methanol MTP DME FT SNG MPG

Biodiesel Ethylester Fatty Acid Fatty Alcohol Bioethanol Biomass to

Liquids (R&D)

Refinery

Fuels / Gases

Crude Oil Coal

PetroChemistry

Gasification

Pro

du

ctL

urg

i Te

chn

olo

gie

sF

ee

dst

ock

ChemBio

Chem

MethanolFischerTropsch

Bio-Ethanol:Gasoline

DME

DieselLPG

EnergyCrops

Biomass

SNG

Chemicals ChemicalsPolymers

Methan-ation

H2

Fer

men

tatio

n

Tra

ns-E

ster

ifica

tion

MTP

PropylenePolypropylene

M15M100

FormaldehydeAcetic Acid etc.

MTBEAdditives

Pyrolysis

Petrofuels Petro-chemicals

Reforming

CerealsOil

SeedsNat. Gas

Gasification

SulfurManagement

SynGasConditioning

CleanSynGas

Raw SynGas

HeavyResidues

BioSyncrude

Food, Oleo-

Chemicals

Bio-Diesel:Diesel

Synfuel

Green Diesel

CO2

Pressing /Extraction

Gasification

HydroTreating

Native / WasteBio Oils

Pre Treatment

Coldbox

CO

H2 / CO

Lurgi at a Glance

Lurgi – Technologies for Fuels and Chemicals

Refinery

Fuels / Gases

Crude Oil Coal

PetroChemistry

Gasification

Pro

du

ctL

urg

i Te

chn

olo

gie

sF

ee

dst

ock

ChemBio

Chem

MethanolFischerTropsch

Bio-Ethanol:Gasoline

DME

DieselLPG

EnergyCrops

Biomass

SNG

Chemicals Chemicals

Methan-ation

H2

Fer

men

tatio

n

Tra

ns-E

ster

ifica

tion

MTP

PropylenePolypropylene

M15M100

FormaldehydeAcetic Acid etc.

MTBEAdditives

Pyrolysis

Petrofuels Petro-chemicals

Reforming

CerealsOil

SeedsNat. Gas

Gasification

SulfurManagement

SynGasConditioning

CleanSynGas

Raw SynGas

HeavyResidues

BioSyncrude

Food, Oleo-

Chemicals

Bio-Diesel:Diesel

Synfuel

Green Diesel

CO2

Pressing /Extraction

Gasification

HydroTreating

Native / WasteBio Oils

Pre Treatment

Coldbox

CO

Traditional

RefineryPetroChemistry

Alternative Renewable

GtL = Gas to LiquidCtL = Coal to Liquid

BtL = Biomass to Liquid

BiodieselBioethanol

H2 / CO

Lurgi at a Glance

Lurgi – Technologies for Fuels and Chemicals

This Presentation

Lurgi at a Glance




Economics

Huge quantity and availability of oil palm related biomass:EFB, Palm Kernel Shells, Fibers, Trunks, Fronds….


Biomass from Palm Oil Production

T.L. Kelly-Yong et al. / Energy Policy 35 (2007)

World annual oil palm biomass generation from 1980 to 2005

0,7 t

Mesocarp Fibres

1 t Crude Palm Oil generates…

1,1 t

Empty Fruit Bunches

2,4 t

Oil Palm Frond Leaves and Trunks



0,3 t

Palm Kernel Shells

...more than

4.5 tonnes

of

Waste

Biomass** Excludes POME and Palm Kernel Cake

BTL Plant

Total Waste Biomass Generation (2006):

Malaysia:

approx 72 million tonnes



approx 9.6 million tonnes gasoline and diesel

or

80 % of Malaysia‘s gasoline and diesel consumption

World:

185 million tonnes

This Presentation

Lurgi at a Glance




Economics

Model shows the volume of different materials which is equivalent to 1 ltr of hydrocarbon oil

How to design the logistics of Large-scale plants?


A Major Issue – Energy Density

Energy density [GJ/m3]

Eg EFB: 1.5

Central syngas and fuel production

250 km

Diesel: 36


Distributed Biomass

Transportation Radius

25 km

Oil/Slurry: 20 Regional intermediate fuel production

e.g. at Oil Palm Mills

FastPyrolysis

FastPyrolysis

Biomass

Storage & Transport of Bio-Oil

Oxygen

HighTemp.Gasifi-cation

HighTemp.Gasifi-cation Methanol

to FuelsMethanolto Fuels

Chemicals

GasCleaning

GasCleaning

MethanolMethanol

SynfuelsFischerTropschFischerTropsch

Sulphur CO2

Fuels

Bioliq-Process: Joint Development by FZK *) / Lurgi and sponsored by FNR*)R


The Bioliq BTL Development

EFB, Trunks...

Decentralised Bio Syncrude Plants

Plant size:

20 – 100 MW Input

35,000 – 180,000 tpa Biomass

Source: FZK

Centralised Synfuels Plant

Plant size:

1,000 – 5,000 MW Input -> 9 mil tpa Biomass -> 1,2 mil tpa Synfuel

This Presentation

Lurgi at a Glance




Economics

M

HeizerSandkreislauf

M

Slurry

M

HeaterSand Cycle

M

Straw, Hay a.o.

Shredder

Cooler

Double Screw Reactor

Co

ld,

sh

red

de

d s

tra

w

ho

t s

an

d c

a.

50

0

Pyrolysis Coke

Pyrolysis gas

Pyrolysis Oil

Slurry

Source: FZK

Coke

The Lurgi flash-coker

Technology Overview & Status

Pyrolysis Process of Lurgi / FZK

Converting different types of waste Biomass to

“Bio Syncrude”

Mechanically fluidized sand at 500°C (no dilution by gas),

fast transport with good radial mixing

(2 s gas retention time)

fast heat transfer, „ball milling“ effect


Results Fast Pyrolysis Process of Lurgi / FZK - Plant


Synthetic Fuels from Biomass Pyrolysis Plant

12 t/d Fast Pyrolysis Demo Plant in Germany

Process heat

Gas

Fast Pyrolysis

Extraction Conversion

Turbine

Gasification

Charcoal

Liquid

Engine

Co-firing

Boiler

Chemicals

Charcoal applications

Heat

Electricity

Transport fuels etc

Pyrolysis heat

Sources: IEA Bioenergy: T34:2007:01


Applications of Bio-Oil

FastPyrolysis

FastPyrolysis

Biomass

Oxygen

Gasifi-cation

Gasifi-cation

Methanolto Fuels

Methanolto Fuels

Chemicals

GasCleaning/

Condi-tioning

GasCleaning/

Condi-tioning MethanolMethanol

SynfuelsFischerTropschFischerTropsch

Sulphur CO2

Fuels

Bioliq-Process: Joint Development by FZK *) / Lurgi and sponsored by FNR*)R

EFB, Trunks...

*) FZK = Forschungszentrum Karlsruhe

FNR = Fachagentur fuer Nachwachsende Rohstoffe


The Bioliq BTL Development

This Presentation

Lurgi at a Glance




Economics

P

rod

uctio

n co

st

Pyrolysis gasification, FT-Synthesis

Biomass Transport

Biomass Harvest & Collection

Mineral Oil Tax

Refinery ConversionCrude Delivered

(Capacity, 1 mil tpa) (Fossil) at

Sources: Forschungszentrum Karlsruhe

• BTL – Fuels require political support on international level (tax, mandate, etc)

• CER can help to increase economics (for non-annex 1 countries)

Economics of Biomass to Liquids

Economic Framework

32Straw

Slurry tra

nsport8

18

Transportion of straw

Oxygen

Gasification and FT- synthesis

Fast pyroylsis

5

12

18

52

Staff

40% - 60% Labour cost (European basis)

Sources: Forschungszentrum Karlsruhe


Production Cost Estimate

0

20

40

60

80

100

120

140

160

0

2

4

6

8

10

12

Costs of Feedstocks (onweight basis)

Costs of Feedstocks (onenergy basis)

USD / t USD / MMBTU

Natural Gas

Coal (High

Caloric Value)

Coal (Low

Caloric Value)

Straw (Germany)

Oil Palm Empty Fruit

Bunches (Malaysia)


Costs of Feedstocks

Economics of BTL depend to a great extent on feedstock sourcing – Asia is predestined to utilize their rich biomass resources for BTL

Summary

Major technologies in the BTL process chain are commercially available today

A political framework, incentives and CDM are crucial for the deployment of BTL

Lurgi offer‘s the entire process chain for BTL

Thank

You

The Sun and Plants Deliver Enough Renewable Energy and Raw Materials for Mankind‘s Needs

Documents

Uwe Zwiefelhofer Lurgi Sdn Bhd A-9-1 Wisma HB Megan Avenue II Jalan Yap Kwan Seng 50450 Kuala Lumpur Tel: +6 03 2164 6446 Fax: +6 03 2164 5448 Email: [email protected]