production of advanced biofuels via liquefaction · pdf filedan knorr, john lukas, and paul...
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The National Advanced Biofuels Consortium is a partnership of industry, national laboratory, and university members that is developing technologies to convert lignocellulosic biomass to biofuels that are compatible with the existing transportation infrastructure.
NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy Operated by the Alliance for Sustainable Energy, LLC
This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.
Contract No. DE-AC36-08GO28308
Production of Advanced Biofuels via Liquefaction Hydrothermal Liquefaction Reactor Design
April 5, 2013 Dan Knorr, John Lukas, and Paul Schoen Harris Group Inc. Atlanta, Georgia NREL Technical Monitor: Mary J. Biddy
Subcontract Report NREL/SR-5100-60462 November 2013
National Advanced Biofuels Consortium
The National Advanced Biofuels Consortium is a partnership of industry, national laboratory, and university members that is developing technologies to convert lignocellulosic biomass to biofuels that are compatible with the existing transportation infrastructure.
NREL is a national laboratory of the U.S. Department of Energy Office of Energy Efficiency & Renewable Energy Operated by the Alliance for Sustainable Energy, LLC
This report is available at no cost from the National Renewable Energy Laboratory (NREL) at www.nrel.gov/publications.
National Renewable Energy Laboratory 15013 Denver West Parkway Golden, CO 80401 303-275-3000 www.nrel.gov
Contract No. DE-AC36-08GO28308
Production of Advanced Biofuels via Liquefaction Hydrothermal Liquefaction Reactor Design
April 5, 2013 Dan Knorr, John Lukas, and Paul Schoen Harris Group Inc. Atlanta, Georgia NREL Technical Monitor: Mary J. Biddy Prepared under Subcontract No. AGV-2-22552-01
Subcontract Report NREL/SR-5100-60462 November 2013
National Advanced Biofuels Consortium
This publication was reproduced from the best available copy submitted by the subcontractor and received no editorial review at NREL.
NOTICE
This report was prepared as an account of work sponsored by an agency of the United States government. Neither the United States government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States government or any agency thereof.
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Project 30352.00 National Renewable Energy Laboratory Production of Advanced Biofuels via Liquefaction Golden, Colorado
April 5, 2013
REPORT 30352.00/01 HYDROTHERMAL LIQUEFACTION REACTOR DESIGN REPORT
TABLE OF CONTENTS
Section Page 1 EXECUTIVE SUMMARY.......................................................................................... 1-1
2 INTRODUCTION ...................................................................................................... 2-1 2.1. General ........................................................................................................ 2-1 2.2. Study Objectives ........................................................................................ 2-2 2.3. Reactor Cases ............................................................................................. 2-2 2.4. Methods and Assumptions ...................................................................... 2-6
3 HEAT TRANSFER COEFFICIENT DETERMINATION...................................... 3-1 3.1. Importance.................................................................................................. 3-1 3.2. Methods and Results................................................................................. 3-1
4 REACTOR DESIGN DESCRIPTIONS..................................................................... 4-1 4.1. Common Process Equipment .................................................................. 4-1 4.2. Case A: Indirect Heating by Feed Recycle ............................................ 4-2 4.3. Case B (and B-L): Full Heat Integration ................................................ 4-3 4.4. Case D (and D-L): Recycle Water Mixing at High Pressure................ 4-4
5 COST ESTIMATES ..................................................................................................... 5-1 5.1. Approach .................................................................................................... 5-1 5.2. Capital Cost Estimates .............................................................................. 5-4 5.3. Operating Cost Estimates ......................................................................... 5-10 5.4. Comparison of Cost Estimates ................................................................ 5-12
6 SENSITIVITY STUDIES ............................................................................................ 6-1 6.1. Overview .................................................................................................... 6-1 6.2. Liquid Hourly Space Velocity ................................................................. 6-1 6.3. Pump Selection .......................................................................................... 6-2 6.4. Heat Transfer Coefficient ......................................................................... 6-2
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7 PROCESS OPTIONS INVESTIGATED ................................................................... 7-1 7.1. Overview .................................................................................................... 7-1 7.2. Inclusion of CSTR in Reactor Design: Case C ....................................... 7-1 7.3. Energy Recovery Using Let-Down Pump Turbine .............................. 7-2 7.4. Use of 409 Stainless Steel Rather than 316L ........................................... 7-2 7.5. Evaluation of Using Molten Salt System for Heating Medium .......... 7-3 7.6. Evaluation of Jacketed Plug-Flow Reactor ............................................ 7-3 7.7. Evaluation of Case D with All Indirect Heating ................................... 7-3 7.8. Evaluation of Alternative Reactor Configurations ............................... 7-4
8 CONCLUSIONS AND RECOMMENDATIONS ............................................ 8-1 8.1. Comparison of Cases ................................................................................ 8-1 8.2. Recommended Experiments and Future Development ...................... 8-1
Appendices A Process Flow Diagrams B Design Basis C Priced Equipment Lists D Capital Cost Information E Recommended Experiments
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Project 30352.00 National Renewable Energy Laboratory Production of Advanced Biofuels via Liquefaction Golden, Colorado
April 5, 2013
REPORT 30352.00/01 HYDROTHERMAL LIQUEFACTION REACTOR DESIGN REPORT
SECTION 1 EXECUTIVE SUMMARY
National Renewable Energy Laboratory (NREL) in Golden, Colorado, contracted with Harris Group Inc. (Harris Group) to develop detailed reactor designs and capital cost and operating cost estimates for the hydrothermal liquefaction reactor system under development at Pacific Northwest National Laboratories (PNNL). The goal of the design and costing efforts was to provide guidance on the expected cost of the reactor systems as well as to highlight areas where research efforts could reduce project costs.
The primary challenges associated with the reactor section design were (1) maximizing heat integration, (2) managing the potential for poor heat transfer from the reactor effluent to the reactor feed due to the potential for high viscosities in the feed streams, and (3) minimizing cost associated with the reactor system itself, given the very high required pressures. As such, five cases were developed to try to address these challenges. In Case A, a recycle stream already at reactor temperature is immediately contacted with the feed from the feed pumps to provide indirect heating. This results in a feed stream at sufficiently high temperatures to avoid high viscosity in the feed and the corresponding low heat transfer coefficie