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Volkswagen, 4.11.2004, Autovision
Dr. Eckart HeinlGroup Research
The BtL-Project RENEW of the European Union
Managed by VW
The BtL-Project RENEW of the European Union
Managed by VW
VOLKSWAGEN AG
Volkswagen, 4.11.2004, Autovision
finance: budget 20 M€ funding 10 M€
duration: 4 years start: 01 / 2004
partners: 31 from 8 countries
core group: VW, DC, Renault, Volvo, Choren, Cutec, Chemrec, Abengoa, EC renewable energy
coordinator: Dr. Frank Seyfried, Volkswagen AG
renewable fuels for advanced powertrains renewable fuels for advanced powertrains
Key Data
Volkswagen, 4.11.2004, Autovision
Motivationvoluntary commitment of European car manufacturers (ACEA)
Gasoline+ Diesel
Diesel
CO2-emissions [g/km]
1995
new passenger car fleet
year2000 2005
180
160
140
A C E A
- 25%- 25%
target140g/km
target140g/km
Volkswagen, 4.11.2004, Autovision
Motivation
H2
natural gas
biofuels 5,75% 7% 8%
2% 5% 10%
- 2% 5%
7,75% 14% 23%Total
increasing support of renewable energies by the EU • mid term: blends of conventional fuels with biofuels and “Gas to
Liquids”; natural gas partly supported by EU and energy industry
• long term: priority of hydrogen as sustainable fuel by policy and industry
15 %
> 30 %
10 %
5 %
a few %
new proposal2020
new proposal2020202020202015201520102010
LPG
Volkswagen, 4.11.2004, Autovision
• Integrated approach ACEA / EC fuel directive– current biofuels have not the potential to substitute fossil fuels
in significant amounts– the full plant usage has best biofuel potential
• Objectives – evaluation of most efficient conversion technology - ecological
(LCA) and economical – substitution potential for biofuels– biofuel specification for current and future ICEs– commonly agreed strategic recommendations
Motivation/Objectives
Volkswagen, 4.11.2004, Autovision
Scope
Biomass
SunDiesel HCCI-fuel DME Ethanol
Gasification
Fuel Synthesis Lif
e C
ycle
Assessm
en
tb
en
ch
mark
of
kn
ow
n r
ou
tes
SynGas: CO + H2
Volkswagen, 4.11.2004, Autovision
Op
tim
ised
fu
els
for
new
d
rive t
rain
s
SP 1O
pti
mis
ed
pro
cesses f
or
FT-
fuel
SP 2 SP 5
Op
tim
isati
on
of
b
ioeth
an
ol p
rod
ucti
on
DM
E p
rod
ucti
on
-
from
bla
ck liq
uor
-
SP 3 Biomass and process assessment
- biomass potential
- life-cycle assessment
- economical impact
- suitability for ICEs
- production
assessmentTraining2 summer schools
SP 6
SP 4
Structure
Volkswagen, 4.11.2004, Autovision
SP 1 Fuel Optimisation
Objectivesproduction of optimised BtL fuel for conventional diesel engines and new combustion processes
Partner and responsibilities• UET fuel production• DC common rail engine tests• VW unit injection (PD) engine tests• Renault tests on a HCCI engine test bench• CERTH upgrading the product• ITN analysing the fuels
Volkswagen, 4.11.2004, Autovision
• Commonly agreed fuel specifications:
kerosene kerosene high
diesel diesel wide range
density 0.77…0.83g/ml
0.77…0.83g/ml
0.82…0.85g/ml
0.75…0.83g/ml
LHV*density
35…36 MJ/l 35…36 MJ/l 35…36 MJ/l 35…36 MJ/l
IBP > 150°C > 150°C > 200°C > 150°C
FBP < 200°C < 260…280°C
< 320…370°C
< 320…370°C
cetan no. 41…45 40…45 52…54 > 51
aromates < 1% < 1% < 1% < 1%
SP 1 Fuel Optimisation
• 300 l of kerosene high and 600l of diesel have just been delivered to DC• 600 l of kerosene high have just been delivered to VW• 150 l of naphtha (FBP < 150°C) have just been delivered to Renault
Volkswagen, 4.11.2004, Autovision
Results SP 1
overview:overview: GTL fuels GTL fuels vsvs conventional fuel conventional fuel
synthetic GTL fuels / main characteristics :
- GTL10 : cetane equivalent to conventional / usual Diesel, but highly volatile
- GTL 20 : “intermediate” volatility, but with noticeably higher cetane
Usual Diesel( 124 A )
Density 15°C kg/m3 672,6 736,1 834Distillation : IBP °C 43 152,5 162
10% °C 61 159,5 19650% °C 95 167,0 27290% °C 126 185,5 33795% °C - - 348FBP °C 166 208 359
Cetane number - 45-55 64,5 54
GTL 20“Kerosine” Item Unit GTL 10
“Naphta”
Volkswagen, 4.11.2004, Autovision
preliminary results about fuel effects in a HCCI-enginepreliminary results about fuel effects in a HCCI-engine
influence of GTL fuels on soot emissions
power (BMIP) increase at constant 3700 r.p.m. with 3 different intake manifold pressures
2,0 bar 2,4 bar 2,7 bar
Usual Diesel
GTL10
GTL20
Usual Diesel
GTL10
GTL20
Usual Diesel
GTL10
GTL20
0
0,5
1
1,5
2
2,5
3
3,5
5 6 7 8 9 10 11BMIP ( BarAbs )
So
ots
( F
SN
)
0
0,5
1
1,5
2
2,5
3
3,5
5 7 9 11 13BMIP ( BarAbs )
So
ots
( F
SN
)
0
0,5
1
1,5
2
2,5
3
3,5
5 7 9 11 13BMIP ( BarAbs )
So
ots
( F
SN
)
3700 rpm 3700 rpm 3700 rpm
Results SP 1
Power (J/m3) Power (J/m3)Power (J/m3)
Volkswagen, 4.11.2004, Autovision
SP 2 Process OptimisationObjectivesoptimised process for Fischer-Tropsch fuel production
Partner and responsibilities
• CUTEC fluidised bed gasification, FT-fixed bed
reactor • FZK pyrolysis and entrained flow gasification • BKG, TUV gas treatment and FT-synthesis• IGNG exergetic analysis• ITN analysis of the fuels• EdF process integration and upscaling• CERTH catalyst development• VW suitability of fuel from engine tests
Volkswagen, 4.11.2004, Autovision
SP 2 Process Optimisation
*)Source: FUTURE Energy GmbH
Fischer Tropsch reactor gasification gas cleaningbiomass conditioning
assessment of different process routes for Fischer-Tropsch BtL-fuels
comparison of: - entrained flow and fluidised bed gasification- different FT reactor concepts
*)
Volkswagen, 4.11.2004, Autovision
gasification and
gas cleaning
gas engine and
generator
additional gas cleaning
additional gas cleaning
compressorcompressor
cloride and sulphur removal
cloride and sulphur removal
Fischer Tropsch reactor
Fischer Tropsch reactor
rawproduct
rawproduct
off gasoff gas
SP 2 Process Optimisation
Fischer Tropsch synthesis in side streamGüssing power plant 8 MW th. ; 2.5 MW el.
• development of flow chart and interaction with biomass CHP• gas cleaning• design of slurry reactor
Volkswagen, 4.11.2004, Autovision
SP 3 Black Liquor GasificationObjectivesdetail engineering of DME production from black liquor
Partner and responsibilities
• Chemrec & STFIevaluation of pilot plant data and
simulation - full scale (250-300 MWth) and
- demonstration scale (45
MWth ) plant• Södra Cell evaluating the impact of the unit in a pulp mill host plant• VTEC performing heavy duty engine tests• Ecotraffic developing a distribution strategy for the products
Volkswagen, 4.11.2004, Autovision
SP 3 Black Liquor Gasification
• basic engineering finished
• 2 alternatives in DME production are assessed at the moment: two steps or one step by Haldor Topsoe
• start of construction: mid 2005
forest
pulp mill
combined recovery and fuel synthesis
pulp wood
forest residual
fuel (DME)
pulp
biomass transformer
smart issue:present high value biomass (black liquor) is replaced by minor value biomass (forest residues) for energy purposes in the pulp mill
Volkswagen, 4.11.2004, Autovision
SP 4 Bioethanol ProductionObjectivesoptimisation of bioethanol production
Partner and responsibilities
• Abengoa assessment of the common enzymatic
pathway as a benchmark
• AICIA consideration of the thermochemical
pathway, including gasification-, and
catalyst tests as well as final process
simulation and optimisation
Volkswagen, 4.11.2004, Autovision
SP 5 Biofuel AssessmentObjectivesbiofuel assessment
Partner and responsibilities
• EC BREC assessment of biomass resource and
potentials
• ESU-services Life Cycle Analysis
• IEE assessment of micro- and socio-economics
• EEE technical assessment
• PSI thermochemical gaseous fuel production
Volkswagen, 4.11.2004, Autovision
Results SP 5RENEW_EU-25 geography
SOUTH
WEST
EAST (CEE-8)
UK and Ireland
NORTH
Alpineregion
e.g.: straw: cereal straw 771 PJ permanent crops residues
74 PJ maize 61 PJ total 906 PJ
22 Mtoe20…60% are available for energy/~ local conditions
potential of straw, wood and energy crops has been evaluated for the EU 25 using literature and statistical data
Volkswagen, 4.11.2004, Autovision
Results SP 5
0 200 400 600 800 1000 1200 1400 1600
CEE-8
North: FIN, SE, DK
West: GR, FR, BE, Lux, NL
UK + IR
South: GR, SP, IT, PR, BG,RO
Alpine (CH + AT)
PJ/year
Cereals straw
Maize residues
Permanent crops res.
Logging residue
Thinning residue
Wood ind. by-products
E-crops (100% set-aside)
total: 3632 PJ (86 Mtoe)
alpine (CH + AT)
south: GR,SP,IT,PR,BG, RO
UK + IR
west: GE,FR,BE,Lux,NL
north: FIN,SE,DK
CEE-8
0 200 1000800600400 1200 1400 1600
Volkswagen, 4.11.2004, Autovision
Conclusion
biomass potential Europe
biomass potential Europe
optimised fuel optimised fuel
process evaluation- costs- efficiency- ecology
process evaluation- costs- efficiency- ecology
commonly agreed strategic recommendations
commonly agreed strategic recommendations
first fuel tests process parameters
provision and costs
assess-ment
recommen-dations
2004 2005 2006 2007 2008
Volkswagen, 4.11.2004, Autovision
For further informations:
www.renew-fuel.comwww.renew-fuel.com
Thank you for your Thank you for your attention!attention!Thank you for your Thank you for your attention!attention!