Integrated Micro-Refinery for the Direct Production of Premium
Synthetic Fuels from Waste and Stranded Carbonaceous Feedstocks
Dennis Schuetzle, PhD, President,
REI International
BETO IDL Workshop
Golden, CO
March 20, 2014
1
Overview of Micro-Refinery Technology
Stage 1
Syngas Production
Biomass Residues
Stage 3
Catalytic
Conversion
Direct “Drop-In
Fuel Production
(new Greyrock
technology)
Biomass Crops
Stage 4
Distribution of
Synthetic Fuels
Premium, Synthetic
Diesel Fuel
Reformulated
Gasoline Blendstock
Thermochemical
Conversion
CO2 Emissions
Wax Production
(old technology Sasol, Shell, etc.)
Natural Gas
Flared NG
Refinery Processing
Hydro-Cracking
Isomerization
2
Overview of Micro-Refinery Technology
REII Headquarters:
Demonstration Plant:
Feedstocks Tested:
Feedstock Input:
Product Output:
Sacramento, CA
Toledo, OH
Biomass, Natural Gas, Carbon Dioxide & Waste Organic Materials
2.5 – 25 dry, ash-free tons / day
56 gal/daft of premium fuel per 1,000 lbs. of C Input (from biomass)
Thermochemical Conversion (TCC)
Pyrolysis & Steam Reforming
Waste
Carbon
Feedstocks
Liquid Fuel Production (LFP)
Direct Fuel Production
Syngas
Premium
“Drop-In”
Fuels
Toledo Demonstration Plant (2012-2014)
4
Overview of Micro-Refinery Technology – Unit Processes
5
Thermochemical Conversion (TCC) System
(Unit Processes #1-4a)
6
Liquid Fuel Production System
(Unit Processes #4b-#8)
7
Carbon Mass Conversion Efficiency
Ash (Average % C Conversion = 84%)
Carbon Mass Conversion Efficiency
Syngas (Average % C Conversion = 90%)
8
Distribution of Products Generated from the Input of 1,000 lbs. of Carbon
for the Determination of Carbon Mass Balance
Components
CO
CH4
CO2
Benzene
C2-C6 HC's
Fuels
Tailgas
Alcohols (in water)
Wax
Biochar
Lbs. of C in Products Lbs. of C in Products Lbs. of C in Products
Generated from TCC
Input into LFP
Generated by LFP
440
440
0.0
227
227
47.9
144
144
3.8
20.0
20.0
20.0
4.3
4.3
0.0
0.0
0.0
409
0.0
0.0
0.0
148
0.0
0.0
0.0
0.0
307
11.8
2.1
0.0
Tars
Scrubber Water
0.51
0.39
0.0
0.0
0.0
0.0
Total
984.2
835.3
801.6
Feedstock to Fuel Carbon Conversion Efficiency = 40.9%
Summary of Carbon Conversion and
Fuel Production Results
%C
Conversion
Feedstocks
Fuel Production
MeOH
Carbon
(lbs./hr.)
CO2
Carbon
(lbs./hr.)
Rice Hulls
Carbon
(lbs./hr.)
Wood
Carbon
(lbs./hr.)
C input
compared to
syngas C out
Gallons
per 1,000
lbs. of C
input
Gallons per
dry ash free
ton biomass
input
16a
232
110
0.0
0.0
83%
54
na
17a
222
143
0.0
0.0
81%
51
na
17b
216
0.0
87
0.0
94%
53
na
17c
91
0.0
110
0.0
85%
53
na
17d
0.0
0.0
142
0.0
86%
61
61
17e
0.0
0.0
0.0
220
84%
54
54
17f
0.0
0.0
0.0
524
85%
58
58
17g
149
95
0.0
0.0
83%
52
na
Run #
Synthetic Diesel Fuel
Composition and Properties
Meets all ASTM Specifications
High Cetane (68-72) and No Sulfur
Excellent Storage Stability (> 3 Years without Alteration)
Improves Fuel Economy by up to 3-4%
Cloud Point and Pour Point of -14 & -18 oC
Excellent Lubricity – Improves Engine Durability and Reduces Repairs
Reduces Tailpipe Emissions from 2006-2014 Model Vehicles by up to 50% &
By 50-85% for Older Model and Off-Road” Vehicles
Recommended 20 Vol.% Blend level with Petroleum
Diesel for Current Model Diesels (2006-2014) and up to
100% for Older and “off-road” Diesel Vehicles
Synthetic
Diesel
Traditional
Diesel
Reformulated Gasoline Blendstock
Composition and Properties
Reformulated Gasoline Blendstock
Meets all ASTM specifications
Octane (RON/MON) of 60-65 and no sulfur
Excellent storage stability (> 3 years without alteration)
Recommended 10% blend level with petroleum gasoline
Summary of Fuel Production Results from
Various Feedstocks
Feedstock Types
MeOH* &
CO2
MeOH & MeOH &
CO2 &
CO2 & Rice Hulls
Rice Hulls Rice Hulls
"Drop-in" Fuel
Products
Wood
MeOH &
CO2
Concentration (Volume %)
Reformulated Gasoline
Blendstock (C5-C7)
29.3
23.3
29.3
28.4
28.6
23.0
Premium Diesel
(C8-C24)
70.5
75.6
69.3
69.5
68.5
76.8
* MeOH : Methanol
13
2- Technical Performance
Synthetic Diesel Fuel Tests on Heavy-Duty Diesel Engines
2 – Technical Performance
Results of Heavy Duty Diesel Engine Tests
The % Difference in Emissions between the 20%
Synthetic Diesel Fuel Blend and Certification Diesel Fuel for a Heavy-Duty Diesel Engine
% Difference
(20% Blend vs.
Certification Fuel)
Emission Species (grams/Kw-hr)
THC
CH4
NM HC
NOx
CO
CO2
PM
Engine Out
Emissions
-10.0
-9.2
-10.0
No
Diff.
-11.0
-0.8
-21.0
Tail-Pipe
Emissions
(after control)
Near
zero
Near
zero
Near
zero
Below
0.20
EPA std.
-16.0
-0.8
Near
zero
The Difference in Fuel Economy, Work and Power at 1,200-1,600 rpm for the
20% Synthetic Diesel Blend compared to the EPA/CARB Certification Fuel
BSFC Fuel
Economy (miles/gallon)
Work
Output (KW-hr)
Power
Output (KW-hr)
+ 0.7
+ 0.3
- 0.6
Schematic for the GBTL Hybrid Commercial Plant in
Northern California
Location of the GBTL Commercial Plant in
Northern California
GBTL Plant Specifications