Two Years Experience of the BioDME ProjectTwo Years Experience of the BioDME Project-- A complete Wood to Wheel ConceptA complete Wood to Wheel Concept

tcbiomass 2013Chicago, September 4, 2013

Ingvar Landälv,Luleå University of Technology

Sweden

Agenda

• Why was the BioDME project initiated?

• The project at a glance in 3.5 minutes

• How does the process work ?

• How was the Start-Up?

• How has the availability been?

• Did we meet BioDME Production goals?

• Is BioDME distribution difficult?

• Do the trucks function according to expectation?

• Where do we go from here?

European Project BioDME7th Framework Programme2

Volvo Group Trucks Technology3 European Project BioDME

7th Framework Programme

From VOLVO’s ”Climate Issues in Focus”Summary of results for different criteria and fuels

7 Trucks on show

Source: http://www.volvogroup.com/SiteCollectionDocuments/V olvo%20AB/values/environment/climate_issues_in_focu s_eng.pdf

Why

was

the

Bio

DM

E p

roje

ct in

itiat

ed?

CO2 emissions and primary energy usage per km of dr iving differs a lot depending on selected well-to wheel p athway

26 February 2013

4

Fuels 2010

-200

-100

0

100

200

300

400

0 100 200 300 400 500 600

Total WTW energy (MJ / 100 km)

WT

W G

HG

em

issi

ons

(g C

O2

eqv

/ km

)

Conventional gasoline

Conventional diesel

RME: Gly as chemical

RME: Gly as animal feed

Syn-diesel: CTL

Syn-diesel: GTL

Syn-diesel: Farmed wood

Syn -diesel: Waste wood, Black liqour

DME: CTL

DME: GTL

DME: Farmed wood

DME: Waste wood, Black liqour

EtOH: Wheat, Straw CHP, DDGS as AF

EtOH: Sugar cane (Brazil)

EtOH: Wheat, Straw CHP, DDGS as fuel

EtOH: Farmed wood

EtOH: Wheat straw

EtOH, Wheat, Lignite CHP, DDGS as AF

EtOH, Wheat, Lignite CHP, DDGS as fuel

EtOH, Wheat, NG GT+CHP, DDGS as AF

EtOH, Wheat, NG GT+CHP, DDGS as fuel

Biogas, municipal waste

Biogas, liquid manure

Biogas, dry manure

CTL

GTL-DME

GTL-syndiesel

Ethanol

Biogas, liquid manure

Gasoline and diesel

Source: WtW study Eucar/Concawe/JRC 2005, 2010 Vehicles(basis for EU RED/FQD default values)

RME

DME & FT

Biogas

Why

was

the

Bio

DM

E p

roje

ct in

itiat

ed?

The BioDMEconcept

Production of DME from Biomass and utilisation as fuel for transport and for industrial use

Starting date: 1 September 2008Duration 52 monthsContact: per.salomonsson@volvo.com

Total budget 28.4 M€EU funding: 8.2 M€Energimyndigheten: 9.6 M€

EUROPEAN PROJECTGrant agreement No:TREN/FP7EN/218923

BioDME Project Partners

- BioDME Plant engineering, construction and operation

- BioDME Plant owner

BioDME Project Coordinator- Engine development- Vehicle manufacturing- Field test responsible

- DME injection systemdevelopment

- Laboratory support toplant operation

- DME production technology provider

- BioDME distribution- BioDME filling stations

- DME fuel specification- Fuel Additive development

The Project at a Glance

In June 2012 Volvo together with Project Partners p roduced a film which in 3 ½ minute summarizes the BioDME pr oject covering e.g.

• Location

• Principle of the DME production concept utilizing B lack Liquor

• Potential for a Pulp Mill and for Sweden

• Truck performance

• Etc

European Project BioDME7th Framework Programme7

FILM

Pre-commissioning, Commissioning & Start-Up 2011

European Project BioDME7th Framework Programme8

June 2011

European Project BioDME7th Framework Programme9

Aminewash

H2S / CO2 to pulp mill incinerator

COshift

Carbonfilter

MeOHSynthesis 1

MeOHSynthesis 2

First single-pass MeOH synthesis featuring > 95% yie ld

Sulphurguard

MeOH (recycled)DME Product

DMEsynthesis

Water

DP-1unit

SyngasCompressor

Gas conditioning & Cleaning

DME synthesis &product purification

Off gases

Black LiquorOxygen

Gasification

Raw Methanol

DME storage

Block Flow Diagram

DME day tanks

How does the process work ?

Black Liquor Gasification

European Project BioDME7th Framework Programme10

Syngas

Carbonfilters

Filtercloggingresolved

Black Liq.

Changed qualitydue to alteredash recyclein mill fr 2009

Operate with lower syngas ratethan design

Installedon-stream

steam regene-ration

20 ton bls/d but withlower LHV than design

How was the Start-Up?

Synthesis Gas Preparation

Feed Gas

Steam

Water

Synthesis Gas

MDEA

WGS

AGRSGS-cat CO2, H2S

• Demonstration of Sulphur-rich synthesis gas water s hift

Added superheat via extra heater

MoreS componentsthan design

How was the Start-Up?

Single-pass Methanol synthesis– breaking the equilibrium limitation

Guard-reacto r

MPS

Raw MeOH

Synthesis GasLPS

S-guard

MeOH-cat

Carbonyl-guard MeOH reactors

• Stoichiometric syngas at P > 130 bar in synthesis

• Sulphur & Carbonyl Guards demonstrated

Membranefailure

Shorterlife thanPlanned*

How was the Start-Up?

*) due to higher S load than design

DME Synthesis & Distillation

• 99.5% DME directly from raw methanol

• Reduced wax production and wax removal demonstrated

DME reactor DME Purification

Light byproduct

Wax

MeOHDME

MeOH

DME-cat

Water

Minorredesign

How was the Start-Up?

BioDME Production

European Project BioDME7th Framework Programme14

Over 4 ton DME/dwas reached in Sep -12

The plant incl. gasification isoperated by 2 operators per shift

Key operation data:Gasification at 30bar/1050˚CMethanol synthesis at 130 barDME synthesis at 15 bar

BioDME toStorage

Black Liquorto gasification

Gasification

GasCleaningGas Shift,

Synthesis&

Distillation

SmurfitKappaKraftlinerPulp Mill

Did we meet BioDME Production goals?

BioDME Plant Non-availability 1H, 2012

European Project BioDME7th Framework Programme15

How has the availability been?

On stream factor, PLANNED: 50% of calendar timeOn stream factor, ACHIEVED: approx. 65% of calendar timeOn stream factor, ACHIEVED: approx. 78% of planned operation timeLongest run: 26 days followed by a planned stop

BioDME Quality Control

• Quality control of BioDME and participating in DME ISO standardization process

– Development of analysis methods for BioDME from storage tank, from the trailer and from filling stations

– LPG residues observed in filling stations, originating from trailer [1].

European Project BioDME7th Framework Programme16

Typical analysis of produced BioDME ISO draft [2]

C2 ppm wt 15

10000C3 ppm wt 160

C4 ppm wt 600

Methanol ppm wt 120 500

Water ppm wt 40 300

CO2 ppm wt 100 1000

DME (by difference)

% wt > 99.8 > 98.5

First unloading Dec. 201113 000 kg BioDME

[2]. Bollon, F. 7th Asian DME Conference, Niigata, Nov 16-18, 2011

[1]. Öhrman, O. et al. Quality control of BioDME produced via black liquor gasification. 7th Asian DME Conference, Niigata, Nov. 16-18, 2011.

Did we meet BioDME Production goals?

BioDME Production 390 tons by end of Project

European Project BioDME7th Framework Programme17

0

50

100

150

200

250

300

350

400

450

dec-11

jan-12

feb-12

mar-12

apr-12

maj-12

jun-12

jul-12

aug-12

sep-12

okt-12

nov-12

dec-12

jan-13

feb-13

mar-13

apr-13

maj-13

Pro

du

ced

Bio

DM

E,

ton

B

C

D

E

A

F 500 tons April 20, 2013

A. Authority inspectionB. Change of ceramics and catalystsC. HolidaysD. Main DME storage full + ceramic repairE. Rebuild for steam supported atomizationF. No operation during change of ownership

Did we meet BioDME Production goals?

Piteå

Stockholm

Jönköping

Göteborg

Fuel distribution as for LPG

European Project BioDME7th Framework Programme18

• Available technology modified for DME

• Safety regulations based on LPG

• ~200 k€ per filling station (+33% vs diesel)

• Easy to achieve

Four filling stations

200 m3 storage tank in Piteå

34 m3 trailer

Is BioDME distribution difficult?

Field test status 2012-12-31

• 10 field test trucks

• Accumulated mileage: 824 798 km / 512 600 mi

• Max truck mileage : 183 588 km / 115 000 mi

European Project BioDME 7th Framework Programme

0

100000

200000

300000

400000

500000

600000

700000

800000

900000

1000000

km

Date

Total Field test mileage

Do the trucks function according to expectation?

Emission verificationPEMS – Portable Emission Measurement System

European Project BioDME7th Framework Programme20

Cycle NOx(g/kWh)

PM(g/kWh)

HC (g/kWh)

CO (g/kWh)

EU-V EEV limits (ETC)

2.0 0.02 0.40 3.0

PEMS 20ton

1.66 0.00* 0.25 2.34

PEMS 60ton

1.72 0.00* 0.31 1.82

* Measured with AVL 483 Micro Soot Sensor

• Independent (AVL) verification after 183 000 km (11 5 000 mi) • EU-V Emissions still fulfilled

Do the trucks function according to expectation?

CHEMRECEnergy to Succeed

Chemrec Status January 2013

21

� Dec 31, 2012: Chemrec Piteå companies including pilot plants sold by

Chemrec AB to LTU Holding AB,

� Jan 1, 2013: 17 pilot plant staff employed by LTU.

� Dec 31, 2012: License agreement between licensor Chemrec AB &

HaldorTopsøe with LTU and LTU Holding. Technology rights stay with

licensors.

� Jan 30, 2013: Consortium Agreement between parties involved in

continued R&D.

� Chemrec has reduced staff awaiting long term stable regulations for

advanced biofuels. Two Chemrec Stockholm staff temporarily on leave

assigned to LTU

� Continued operation of the plants as part of LTU Biosyngas Program

10/18/2009 16

FLARE

Raw Syngas

GREENLIQUOR

Black Liquor

GAS COOLER

Oxygen

Atomizing medium

GASIFIER

QUENCH

C.W

BFW

MP-Steam

Weak Wash

CLEANSYNGAS

BFW

SULPHUR ABSORPTION

Condensate

White/Green Liquor

LP-St.

Whe

re d

o w

e go

from

her

e?

Volvo Group Trucks Technology

0

100000

200000

300000

400000

500000

600000

700000

800000

900000

1000000

km

Date

Total Field test mileage

Extended Volvo field test8 trucks, 2013-01-01 to 2014-06-30

(1000 Km / 1000 mi) Status2013-04-08

TargetJune 2014

Total mileage 970 / 603 1 475 / 917

1 truck 200 / 124 300 / 186

Extended field test

1 million kmMay, 2013

Whe

re d

o w

e go

from

her

e?

Fuel consumption

European Project BioDME7th Framework Programme23

TruckApplication

Gross weight(Min/Max/Avg)

Typical FC Diesel Equivalent(l /10 km & mi/gal))

FH-787Regional and local haul

14/26/21 ton 2.3 / 10.2

FH-711long haul

25/50/ ton 4.1 / 5.7

FH-842local start/stop

21/57/53 ton 6.1 / 3.8

Volvo through their US branch on June 6, 2013 decided to start commercial production of

DME fuelled vehicles in the US in 2015.See:

http://www.volvotrucks.com/TRUCKS/NA/EN-US/PRODUCTS/ALTERNATIVEFUELS/

CNG/Pages/DME.aspxThe link includes:

Volvo introduction, a YouTube filmDME – “The future is here”, a YouTube filmDME – “It is all around us”, a YouTube film

and other material.

See also:www.biome.euBioDME Video

http://www.youtube.com/watch?v=cF1F7luFpnc

ThankYou!

Volvo US DME truck