Final Report of the European BioDME Project
5th International DME Conference Ann Arbor, April 18, 2013
Per Salomonsson
Production of DME from Biomass and Utilisation
as Fuel for Transport and for Industrial Use
Starting date: 1 September 2008
Duration 52 months
Contact: [email protected]
Total budget 28.4 M€
EU funding: 8.2 M€
Energimyndigheten: 9.6 M€
EUROPEAN PROJECT Grant 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 system
development
- Laboratory support to
plant operation
- DME production
technology provider
- BioDME distribution
- BioDME filling stations
- DME fuel specification
- Fuel Additive development
Some Facts About the BioDME Plant
European Project BioDME
7th Framework Programme
DME
production
capacity:
4 tons / d
Pipe
installation:
~ 10 000 m
Hand valves &
on/off valves:
~ 1400 pieces
Instruments: ~ 450 pieces
Vessels: ~ 30 pieces
Heat
exchangers:
~ 25 pieces
Process Plant
Foot Print:
20 x 30 m
Investment
cost (excl
gasification):
~ 22 million €
Gasification
Gas
Cleaning
Gas Shift,
Synthesis
&
Distillation
SmurfitKappa
Kraftliner
Pulp Mill
BioDME to
Storage
Black Liquor
to gasification
BioDME Production
European Project BioDME
7th Framework Programme
Over 4 ton DME/d
was reached in Sep -12
The plant incl. gasification is
operated by 2 operators per shift
Key operation data:
Gasification at 30bar/1050˚C
Methanol synthesis at 130 bar
DME synthesis at 15 bar
Synthesis Gas Preparation
Feed Gas
Steam
Water
Synthesis Gas
MDEA
WGS AGR SGS-cat CO2, H2S
• Demonstration of Sulphur-rich synthesis gas water shift
Single-pass Methanol Synthesis
– breaking the equilibrium limitation
Guard-
reactor
MPS
Raw MeOH
Synthesis Gas LPS
S-guard
MeOH-cat
Carbonyl-
guard MeOH reactors
• Stoichiometric syngas at P > 130 bar in synthesis
• Sulphur & Carbonyl Guards demonstrated
DME Synthesis & Distillation
• 99.5% DME directly from raw methanol
• Reduced wax production and wax removal demonstrated
DME reactor DME Purification
Light
byproduct
Wax
MeOH DME
MeOH
DME-cat
Water
BioDME Production
390 Tons by end of Project
European Project BioDME
7th Framework Programme
0
50
100
150
200
250
300
350
400
450
12/2
01
1
01/2
01
2
02/2
01
2
03/2
01
2
04/2
01
2
05/2
01
2
06/2
01
2
07/2
01
2
08/2
01
2
09/2
01
2
10/2
012
11/2
01
2
12/2
01
2
01/2
01
3
Pro
du
ce
d B
ioD
ME
, to
n
A: Authority Inspection
B: Maintenance stop
C: Holiday period
D: Maintenance stop
E: Equipment installation A
B
C
D E
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 BioDME
7th Framework Programme 10
Typical analysis of produced BioDME ISO draft [2]
C2 ppm wt 15
10000 C3 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. 2011
13 000 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.
Piteå
Stockholm
Jönköping
Göteborg
Fuel Distribution
European Project BioDME
7th Framework Programme 11
• 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
Fuel Delivery
• DME from methanol used as back-up
• First delivery of BioDME in Dec 2011, 100% since Feb 2012
• 60 % BioDME overall
European Project BioDME
7th Framework Programme 12
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
100000
Jun
Au
g
Oct
De
c
Feb
Ap
r
Jun
Au
g
Oct
De
c
Feb
Ap
r
Jun
Au
g
Oct
De
c
lite
r D
ME
DME deliveries
BioDME
Fossil
Acc deliveries
2010 2011 2012
Fuel and Lube Oil Specification
• Materials compatibility with liquid DME
– Big difference within polymer families from different suppliers
– Within polymer families XIIR, HNBR, FFKM and EPDM, it is possible
to find convenient products
– Good behavior of PTFE and PI (Polyimide)
– No problem of corrosion (in agreement w literature)
• Engine oil specification and field test evaluation
– Tested oils adequately protect the engine and full drain intervals can
safely be kept
– All oils contribute to some deposit formation in the fuel system at
different levels, the mechanism is being studied
European Project BioDME
7th Framework Programme 13
European Project BioDME
7th Framework Programme 14
DME Fuel Injection Equipment
• The pump supplied for DME is an application of a current Delphi diesel
production unit.
• The injector is a bespoke design required for DME application
• Design adaptation to DME properties (valve optimisation, sealings, tolerances,..)
• The mileage accrued by the field trucks is has proven the concept to be a
success.
Common Rail DME pump
and Injector
10 Field Test Trucks
European Project BioDME 7th Framework
Programme
Long haul, Swedish mail
Long haul, Swedish mail Regional and local
transportation
Long haul, DHL Regional and local
transportation
Development truck
Regional and local
transportation
Long haul, DHL Heavy loaded, up to 60
ton payload
Heavy loaded, up to 60
ton payload
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
Emission Verification PEMS – Portable Emission Measurement System
European Project BioDME
7th Framework Programme 17
Cycle NOx (g/kWh)
PM (g/kWh)
HC (g/kWh)
CO (g/kWh)
EUV EEV
limits (ETC)
2.0 0.02 0.40 3.0
PEMS 20 ton 1.66 0.00* 0.25 2.34
PEMS 60 ton 1.72 0.00* 0.31 1.82
* Measured with AVL 483 Micro Soot Sensor
• Independent (AVL) verification after 183 000 km (115 000 mi)
• EUV Emissions still fulfilled
Fuel Consumption
European Project BioDME
7th Framework Programme 18
Truck
Cycle
Gross weight
(ton)
FC diesel
eqv.
(l / 10 km)
FC diesel
eqv.
(mi / gal)
Compared to
diesel
FH-787
Local & regional
haul
Min 15
Max 26
Avg 20-22
2.3 10.4 Similar / lower
FH-711
Regional haul
Min 36-38
Max 60
Avg 50-52
4.3 5.5 Similar
FH-842
Local, Start & stop
Min 21
Max 57
Avg 53
6.4 3.7 higher
Summary of Field Test Experience
• Driver perception (compared to diesel truck)
– Less noise from the engine
– Good engine response
– Longer time to fuel the truck
– Positive comments about locally produced fuel,
environmental properties and absence of soot
• Volvo perspective
– Trucks function well in commercial operation
– Low fault rate given the early development stage – exceeds expectation
– DME distribution and handling works well
– Slightly shorter service intervals compared to diesel – to be improved
– Because of inherent properties of DME, it has been possible to reach very far
with a relatively limited development effort
European Project BioDME
7th Framework Programme 19
Fuel consumption
European Project BioDME
7th Framework Programme 20
Truck Application
Gross weight
(Min/Max/Avg)
Typical FC
Diesel Equivalent
(l /10 km & mi/gal))
FH-787 Regional and local haul
14/26/21 ton 2.3 / 10.2
FH-711 long haul
25/50/ ton 4.1 / 5.7
FH-842 local start/stop
21/57/53 ton 6.1 / 3.8
www.biodme.eu
BioDME Video
CHEMREC Energy to Succeed
Chemrec Status in January 2013
21
1. Chemrec Piteå companies including pilot plants sold by Chemrec AB to LTU Holding AB, 31 Dec 2012
2. 17 pilot plant staff employed by LTU, 1 Jan 2013. 3. License agreement between licensor Chemrec AB & HaldorTopsøe
with LTU and LTU Holding, 31 Dec 2012. 4. Technology rights stay with licensors. 5. Consortium Agreement between parties involved in continued
R&D, 30 Jan 2013 . 6. Chemrec has reduced staff awaiting long term stable regulations
for advanced biofuels. Two Chemrec Stockholm staff temporarily on leave assigned to LTU
10/18/2009 16
FLARE
Raw Syngas
GREEN
LIQUOR
Black Liquor
GAS
COOLER
Oxygen
Atomizing
medium
GASIFIER
QUENCH
C.W
BFW
MP-Steam
Weak Wash
CLEAN
SYNGAS
BFW
SULPHUR
ABSORPTION
Condensate
White/Green
Liquor
LP-
St.
22
Luleå University of Technology Biosyngas Program
Phase 1 (1H-2013) “Project 0” – Plant infrastructure
– Operation and maintenance of gasifier and BioDME pilots
– Financed by Swedish Energy Agency (SEA) 0.5 + 2.5 years
”Project 1” – Catalytic gasification of new feedstocks
– Pre-study 6 months
– Mixing of black liquor and pyrolysis oil (PO)
– Investigation and lab testing of Liquefied Organic Waste (LOW)
– Planning of pilot plant experiments if pre-study is successful
– Financed by SEA, LTU and industry
“Project 4” – BioDME production and use – Continued black liquor gasification development
– Haldor-Topsoe catalytic synthesis development
– BioDME production and Volvo DME vehicle field tests
– Optimization of DME filling stations
– Financed by SEA, LTU and industry
Volvo Group Trucks Technology
0
100000
200000
300000
400000
500000
600000
700000
800000
900000
1000000
km
Date
Total Field test mileage
Extended Volvo Field Test 8 trucks, 2013-01-01 to 2014-06-30
(1000 Km / 1000 mi) Status 2013-04-08
Target June 2014
Total mileage 970 / 603 1 475 / 917
1 truck 200 / 124 300 / 186
Extended field test