Integrated Home Energy from

Waste & Biomass

Tom Horgan and Noa Simons
February 6, 2009

Outline
Executive Summary
Introduction
Research Summary
Integrated Home Energy System (IHES)
Wrap Up

Executive Summary
We propose to build and market an integrated
home energy system.
Multi-fuel (Biomass, MSW, Sewage), Clean Gasification based
Multiple energy conversion options (CHP, Gas Gen, LF, FC) with
ability to run from NG/LPG if available

Rationale:
Lean (saves $), Green (recycle), Mean (self sufficiency)
Clean Gasification - Enabling Technology for BTLTF
(Biomass To Liquid Transportation Fuel)
Direct competition with crude products unrealistic

Introduction
Preconception
Alternative energy field was exploding with oil prices
reaching $150/barrel in 2008
Modern science applied to BLTTF has yielded many new
concepts ready for advancement & commercialization
New technologies could make old concepts more viable

Expectation
Research literature, talk to scientists, down-select
concepts, develop business plan and commercialize

Introduction
Reality
Majority of research dollars to bioethanol and biodiesel
Liquefaction, pyrolysis - low grade fuels for heating
Low fraction of alkanes, upgrading methods in research phase

FT synthesis only proven route to diesel

Highly Capital Intensive (pure syngas), nonselective

Methanol is doable trouble as a transportation fuel

MTG considered failed technology (durene)
Gasification technology major obstacle for all three
Inefficient (drying), expensive (multistep cleaning)

Energy density of green biomass of crude (out of the

ground)
Electricity is more valuable than liquid fuels

Introduction
Distributed Generation
Electricity is the most valuable form of energy
Electricity generation only ~33% efficient nationwide (line
losses)
Household waste contains 30% of total energy used
On site generation saves money, is green and enables
sense of self sufficiency

Critical Technology
Core technology development for distributed generation
is same for all biomass conversion processes
(gasification, cleaning, drying)

Integrated Home Energy from Biomass & Waste

The State of Energy

Market Opportunity (2008 Data)

http://www.eia.doe.gov/

The State of Energy

Usage & Losses

https://eed.llnl.gov/flow/images/LLNL_Energy_Chart300.jpg

The State of Energy

World Oil Reserves

Estimates on proven reserves are historically low (reserve

growth) and have been running out since the 30s
Unproven (P50) and untapped reserves available (arctic)
Prices may not rise a quickly as predicted
http://en.wikipedia.org/wiki/Oil_reserves

The State of Energy

1% of All Biomass
On Earth

(~ 50 cubic miles
proven reserves as
of 2008)
Note: All of the
dewatered sludge
in NYS contains
enough energy for
~ 30 gas stations
http://spectrum.ieee.org/jan07/4820

The State of Energy

Comparing Fossil & Biomass Fuel Conversion
Fossil Fuel: Millions of years worth of algae (crude) &
biomass (coal) cooked and condensed by the earth
Biofuels: Wood, sludge, farm waste, etc that needs to
be dried and converted
Crude Oil (raw) 42.7 MJ/kg
Gasoline Diesel -

43.5 MJ/kg (~80%)

42.8 MJ/kg (~85%)

Biomass/Solids 6 to 20 MJ/kg
MTG Gasoline FT Diesel -

43.5 MJ/kg (< 50%)

42.8 MJ/kg (< 60%)

5 to 15x more input energy for BTLTF

http://www.eia.doe.gov/

The State of Energy

Market Volatility

http://www.eia.doe.gov/

Research Summary
Research efforts
Focused on evaluation of BTLTF technologies
such as Fischer Tropsch, Methanol, MTG
Uncovered issues with gasification that
prohibited commercialization
Shifted to catalytic gasification and ionic liquids
as means of addressing issues
Settled on distributed generation as the most
promising route to profitability in biomass
conversion

Research Summary
Conclusions
Competing with crude on transportation fuels is
a very tall order
Electricity has higher value and is easier to
achieve w/ biomass
Gasification is core technology for both BTLTF
and electricity generation
Distributed generation competes with electricity
on site using waste & wood (or NG)
Integrated Home Energy System (IHES)

Research Summary
Future & Concurrent Research
Robust Gasification
Gasification drawbacks are major impediment to
commercialization
Conversion processes all require clean syngas
(particulate and tar)
Conversion processes require different H2/CO ratio
Microchannel FT synthesis requires pure H2/CO (free
of N2 and CO)
Robust gasifier concept incorporates advanced
cleaning, CO2/N2 filtration and shift catalyst for
control of H2/CO ratio
Solution for all gasification processes

Integrated Home Energy

Household Mass Balance (Family of 4)

Food
Water
Paper
Plastics

MSW

Water
Sewage
Average
Average Usage:
Usage: ~320
~320 MJ/day
MJ/day
Waste:
Waste: ~~ 100
100 MJ/day
MJ/day (~30%)
(~30%)

290 GPD
0.1% Solids
~ 7 MJ/day

8 Kg/day
~91 MJ/day

Integrated Home Energy

Concept (micro CHP)

Wood
Chips

Syngas
Feed Prep

MSW

Water
Sewage

Air
Slag

Dewater

WGS

Dryer

N2/CO2
Removal

Gasifier

Cleaning/
Scrubbing

Integrated Home Energy

IHES Concept
IHES is micro CHP Unit that supplies heat and
power to residence
Gasifier accepts MSW and Biomass
feedstocks
NG/LPG can also fuel generator and be used
for start up energy/emergency back up
Net metering provides opportunity for net
positive gain

Integrated Home Energy

Business Case (Avg Household, 4 people)

Usage: 320 MJ/day 60% Electric, 40% Thermal

Annual Cost: $1800
Waste = 30% of Total Usage (92% MSW, 8% Sewage)
Assume 60% gasifier efficiency, 30% electric and 70%
thermal recovery
Gasify all MSW and 50kg wood per day
All electricity supplied with heat in excess
Wood cost = ~ $330 annually

Annual Savings = $1800 - $330 = $1470

NG could supplement in absence of wood
http://www.eia.doe.gov/

Integrated Home Energy

IHES Component Development
Feed preparation/pretreatment
Chipper/shredder must be able to prepare both
wood and MSW
Grind/mixing for uniform gasification

Dewatering
Advanced dewatering for on site sewage
treatment (much later development)

Drying
Recover internal heat to pre-dry feed for
improved efficiency

Integrated Home Energy

IHES Component Development
Gasifier
Must supply heat & syngas from a variety of waste
and biomass feedstocks

Gas Cleaning
Cyclone, cold water quench followed by sand filter.
Research advanced methods.
CO2/N2 membrane filtration (much later
development for microchannel FT)

Water Gas Shift

Design and implement WGS for H2/CO control

Integrated Home Energy

IHES Component Development
Energy Storage
Battery module for start up.
NG functionality can also support start up and back
up capability

Controls & Software

Control methods for WGS (control steam on outlet
temp)
Control methods for heat rejection
Control methods for load following (much later
development)

Integrated Home Energy

Phased Development Plan
Phase 1: Proof of Concept with Advanced Gasification
Development (6 months)
Assemble and test a simple downdraft gasifier/gas
generator system on wood (Zanoni)
Downselect and purchase gasifier, gas generator, chipper, etc
Research/validate wood gasification (mc, wood type, etc).
Assemble/test and develop heat rejection, gas cleaning

Advanced Gasifier Development (Horgan)

Test & Development, MSW gasification methods
Evaluate methods of feed prep, required temperatures, etc
Research/development/test CHP functionality

Integrated Home Energy

Phased Development Plan
Phase 1: Cost Estimates*
Hardware

Purchase 2 gasifiers, NG generator (~ $10 to 15K)

Misc tools/test equipment ($1 to $3K)
One Computer - Zanoni ($1K)
Additional Hardware for BOP ($3 to 5K)

Salaries: 2 x $90K * 0.5 = $90K

Rental: $1 to $1.5K /per month = $6 to $9K
Total: ~ $120,000
* Should have Zanoni do this right

Integrated Home Energy

Phased Development Plan
Phase 2: Prototype Demonstration with More Gasification
Development (6 months)
Integrate advanced gasification, generator and CHP loop
into homogeneous unit (Zanoni)
Validate CHP functionality/software & controls
Develop detail drawings, design system layout & enclosure
Assemble and test prototypes

Advanced Gasifier Development (Horgan)

Test & Development of integrated shift for H2/CO control
Research/development of membrane CO2/N2 removal

Integrated Home Energy

Phased Development Plan
Phase 2: Cost Estimate
Hardware:
Custom designed gasifier & system components ($100 to
$150K)
NG Generator ($3K)
Shift reactor, software & controls ($15K)

Software: Solid Works ($10K)

Salaries: 2 x $90K * 0.5 = $90K
Rental: $1 to $1.5K /per month = $6 to $9K
Total: ~ $235/285K

Integrated Home Energy

Intellectual Property
Multifuel, gasification based CHP system for
residential use
Robust Gasifier: multi-fuel, with H2/CO control and
advanced cleaning technology

Patents
Multiple patents for multi-fuel gasifier with specific
processing methods
None found for IHES system as conceived

Integrated Home Energy

Competition
No direct competition in Multi-fuel, gasification
based residential scale systems
Community Power Corp Wood fueled
systems for farms/light industrial
Main competition Micro CHP NG Systems
Marathon Engine Systems: NG Micro CHP for hot
water systems
Freewatt: Forced hot air w/ 1.2 kW Honda
Generator heat following
http://www.marathonengine.com

Conclusions
Integrated home energy system is
marketable technology (< $10K in 5 years)
Gasification development supports future,
large scale work
Need a lab and team to search the biomass
research database

Backup Slides

The State of Energy

Fuel Value

http://www.eia.doe.gov/

Research Summary
Liquefaction & Pyrolysis
Do not synthesize transportation grade fuel without
upgrading (undeveloped)
Pyrolysis oils are corrosive
Biopetrol model is liquefaction of sludge to fuel
oil/burn on site business plan claims 1yr ROI
Dynamotive works with multiple customers on
retrofitted applications (bigger/stainless steel pumps,
motors etc)
Storrs process (describe & why shut down)

Research Summary
Fischer Tropsch Synthesis
Gasification
Synthesis
Upgrading

Research Summary
Fischer Tropsch Synthesis Gasification covered as a separate topic
FT Synthesis Reaction Chemistry

Research Summary
Fischer Tropsch Synthesis Product Distribution

Low Temp FT
200/240C
Cobalt
waxes
Hi Temp FT
300/350C
Iron
liquids

Research Summary
Fischer Tropsch Synthesis Reactor Design Types

Research Summary
Fischer Tropsch Synthesis Chain growth a function of temp, pressure, catalyst
type & condition, reactor design
Exothermic reactions lead to poor temp control and
wide distributions
Slurry reactors are best but suboptimal
Microchannel reactors may play but still new (Velocys)
The more pure the syngas the better (even for CO2
and N2)
Dilute syngas leads to large reactors (higher cost)

Research Summary
Methanol Synthesis
Natural
Gas

Desulph

SMR
2H2 + CO CH3OH

Coal or
Biomass

Gasifier

Cleaning

Steam
O2, Air
Syngas (H2, CO (CO2, N2))

Compressor

Purge
Gas

Methanol
Convertor

50 Atm, 270C
Copper Oxide
Catalyst
H = -92 kJ/mol

Cooling/
Distillation

Syngas Recycle Loop

MTG
Process

Methanol

Research Summary
Methanol Synthesis
Commercial Production mainly from NG (coal)
Max Thermal Efficiency ~65%
Single pass 25%, Exothermic, Thermo constraints

http://bioweb.sungrant.org/Technical/Bioproducts/Bioproducts+from+Syngas/Methanol/Default.htm

Research Summary
Methanol Synthesis
Methanol Demand
37% formaldehyde (resins/glues for particle board and ply wood)
21% MTBE (gasoline additive that reduces exhaust emissions)
14% acetic acid (chemicals for adhesives, coatings and textiles)

Used directly as a fuel

Burns cleaner than gasoline (Higher Octane)

Corrosive to engine parts, gaskets, etc
Slower burning (advance ignition time)
Cold starting an issue (lower vapor pressure)
Absorbs water

Research Summary
Methanol to Gasoline
2CH3OH CH3OCH3 + H2O
320C Alumina

CH3OCH3 H2O + C2 C5, alkenes,

cycloalkanes, aromatics
400/420C Zeolite

Light HC, CO2, H2

Research Summary
Methanol to Gasoline
Product Composition

The aromatic portion is at the high end of the gasoline spec

(6/29%)
Aromatics are about 20% Durene low melting point (icing).
Separation is expensive.
Actual efficiency 44% (Hamiton).

Research Summary
Gasification
First step in FT, methanol, MTG, FC, generator
Biomass is heated under low oxygen conditions
(Atmospheric, > 600C)
Steam sometimes added
Volatile material driven of leaving char, steam
and tars
Char reacts with air and steam to form syngas
(H2, CO, others)

Research Summary
Gasification Reactions

Research Summary
Gasification Reactors Small Scale
Downdraft Gasifier

Outside dimensions (w/ hopper): 4ft h x 1.5ft d

Syngas production rate: ~ 35 ft3/lb of 15% wood
Max Capacity: ~700 lbs wood/day - 1000 ft3/h (320 MJ/h)
Outlet Temp: 50/75C after cyclone/filter
$2300 Assembled
$1400 Not Assembled

http://www.allpowerlabs.org

Research Summary
Gasification - Issues
Gasification rated primary barrier to commercialization
of BTLTF System
Very pure syngas required (essentially H2/CO)
Systems diluted with N2, CO2 lead to large reactors
Substantial Cleaning & Scrubbing required
Biomass variability leads to syngas variability

Holy Grail: Robust Gasification

Gasification System that receives ANY carbonaceous
feedstock and returns pure syngas with tunable H2/CO
ratio.

Research Summary
Gasification Reactors - Industrial

Research Summary
Economic/Energy Comparison

Research Summary
Economic/Energy Comparison

Research Summary
Ionic Liquids
Air and moisture stable salts electrically conductive, low vapor
pressure, liquid at room temp
Composed of 100% ions - large organic cat ions (~10 18), small
inorganic anions (much less)
Applications: Stable solvents, acid scavenging, cellulose
processing, petrochemical synthesis, transport medium, many
others
Dissolve wood & other organics (0.2 to 2mm, < 150C, <
30min)
Safety: Low vapor pressure and highly recyclable. Some are
combustible. Many are toxic if released to the environment.

Research Summary
Ionic Liquids
Air and moisture stable salts electrically conductive, low vapor
pressure, liquid at room temp
Composed of 100% ions - large organic cat ions (~10 18), small
inorganic anions (much less)
Applications: Stable solvents, acid scavenging, cellulose processing,
petrochemical synthesis, transport medium, many others
Dissolve wood & other organics (0.2 to 2mm, < 150C, < 30min)
Safety: Low vapor pressure and highly recyclable. Some are
combustible. Many are toxic if released to the environment.

Research Summary
Argyropoulos Patents
Low Energy Pyrolysis of Wood WO 2008/098036 A1
IL Pyrolysis: Wood dissolved in IL, 190/200C (20 min), 10% more tar,
12% less char , 10% higher/more selective yield of distillates than Fast
Pyrolysis
Fast Pyrolysis: Pretreated w/ organic solvents, 425/500C (2s), tar, char,
liquids (200+ intermediates)

Low Energy Glucose from Wood for BioEthanol US 2008/053139

IL dissolved wood is easily hydrolyzed by enzymes to release Glucose for
production of bioethanol

Polymers and Composites from Dissolved Wood US

2008/053151

IL dissolved wood can be blended with co-polymers, polymers and functional

additives to form eco-friendly (degradable) composites

Research Summary
Ionic Liquids
Potential for Transportation Fuel Synthesis
IL Pyrolysis produces a much narrower range of hydrocarbons
with higher potential for catalytic cracking to trans fuels
Sludge dissolution and homogenous processing to fuels
Catalytic Gasification of Dissolved Wood (Syngas)
Other undiscovered routes to aliphatics/aromatics
Petrochina Gasoline by alkylation of C4 olefins with iso-butane in
ionic liquids

Research Summary
Catalytic Gasification
Project Concepts
Low Energy Catalytic Biomass Syngas Gasification
Investigate routes with lower temps and pressures. Preprocessing.

Low Energy Catalytic Sludge Syngas Gasification

Investigate routes with lower temps and pressures. Preprocessing.

Catalytic Fuel Gas Gasification w/ Reforming

Steam vs. Autothermal, Modeling for feasibility (efficiency/cost)

Research Summary
Catalytic Gasification
Syngas Methods
Noncatalytic Supercritical: (450/600C, 4000/6000 PSIG)
Hi Cap Cost, Limited Biomass testing

Low Temp Catalytic (225/265C, 400/800 PSIG, Pt or Ni)

Simple organics, not tried on biomass

Fuel Gas Methods

Catalytic Hydrothermal (350C, 3000PSIG, Ru or Ni)
Good carbon conversion, biomass & sludge

Supercritical Carbon Catalyzed (600C, 3700PSIG)

Good carbon conversion, coke, ash, plugging

Berkshire Energy Lab

Robust Gasification
No suitable biomass gasification technology exists for
FT
Require feedstock drying
Syngas must be cleaned of particulates/tars
H2/CO ratio must be fixed at 2
Feedstock variability significantly impacts gas quality.
Ability to gasify any carbonaceous feed is highly
beneficial (residential)
May be a commercial product in itself

Berkshire Energy Lab

Robust Gasifier - Concept 1

Biomass
Res Solid Waste
Sewage
Sludge

Mechanical
Grinder/Mixer

Dryer/
Pellitizer

Solvent?

Cyclone/
Scrubber

Gasifier

Char/Slag

Shift
H2 Sensor
Steam Control
Temp Control

Syngas

Distributed Energy Systems

Residential scale gasification as part of
fundamental research
Potential integration with Plug Power
fuel cells when 5 KW system reaches
$15k capex (~3 years)
Methanol synthesis research - though
limited applications given conversions
needed
OTHER?

Distributed Energy Systems

Slide on Plug Power (Saratoga Energy)
financials partner?
Slide comparing liquid fuels to electricity
why methanol wont work
Picture of unit

Lab Start-Up Costs

Equipment needed (go to Fischer Scientific)

Site selection (NY, Lenox?)
New hires - skills needed (funding)
Partnerships to build

Integrated Home Energy

Notes

Compare w/ Community Power

Need to do gasification road show
Research Co2/N2 removal
Need to talk about CHP in gasifier vs FC
Energy storage? Charge batteries? What is efficiency
of battery charging and usage?
Microchannel Gasifier Gasify smaller amounts of
feed with faster throughput???

http://www.eia.doe.gov/

Integrated Home Energy

Syngas Conversion Comparison
Gas Generator
Efficiency: Unknown on Syngas
CHP: Gasifier yes, Generator no
Other: Use NG generator, off-the-shelf gasifier

Fuel Cell
Efficiency: > 30% Electric, > 80% Overall, ~ 60% w/ Gasifier
CHP: yes
Other: built in desulph, tar cracking

Liquid Fuels
Efficiency: ~ 50% overall with significant development
CHP: yes
Other: Microchannel, N2/CO2 removal

Integrated Home Energy

Component Technologies
Gasification
Specs: Atmospheric, air blown, direct heated, 5kW
Numerous technologies available. Requires full
scale evaluation process for down selection

http://noest.ecoundco.at/news/docs/1277_Biomass_Engineering_UK.pdf
http://www.croreyrenewable.com/index.html
http://www.associatedphysics.com/ProdServices/Gasification.html
http://www.phoenixenergy.net/
http://gasbiopower.com/home
http://www.primenergy.com/Gasification_idx.htm

Many more

Integrated Home Energy

Component Technologies
Gas Cleaning/Scrubbing
Initial: Cyclone (particulate), cold water quench
followed by sand filter
Research more advanced cleaning technologies for
later phases

N2/CO2 Removal
Enabling technology for residential scale
(microchannel) Fischer Tropsch process
Membrane filter technology:
http://www.mtrinc.com/co2_removal_from_syngas.html