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At least 73 records · Page 4

Can a Nuclear-Assisted Biofuels System Enable Liquid Biofuels as the Economic Low-carbon Replacement for All Liquid Fossil Fuels and Hydrocarbon Feedstocks and Enable Negative Carbon Emissions?

This report integrates the results of a series of studies and workshops to address the question: Can a nuclear-assisted biofuels system enable liquid biofuels as the economic low-carbon replacement for all liquid fossil fuels and hydrocarbon feedstocks and simultaneously enable negative carbon emissions? “Economic” is defined as economically competitive relative to other low-carbon replacement options for crude oil. “All” refers to the capability to replace the 18 million barrels of oil per day used by the United States. “Nuclear-assisted” refers to the provision of massive quantities of low-carbon heat and hydrogen at the refinery to fully utilize the carbon content of the cellulosic biomass feedstocks for liquid hydrocarbon production. A system is proposed that decarbonizes about half of the U.S. economy while improving long-term soil productivity and sequestering carbon from the atmosphere. In the U.S. almost half the energy consumed by the final customer is in the form of liquid hydrocarbons produced from crude oil. Liquid hydrocarbons are used as (1) an energy source, (2) a method for daily-to-seasonal energy storage, (3) a chemical feedstock, (4) a chemical reducing agent, (5) a method to enhance high-temperature heat transfer in many furnaces and industrial processes and (6) other purposes. As a consequence, the U.S. consumes ~18 million barrels of crude oil per day to produce liquid hydrocarbons. While there are substitutes for liquid hydrocarbons for some applications, our assessment is that the costs and difficulty will dramatically increase if liquid hydrocarbon use goes much below the equivalent of 10 million barrels per day of crude oil. New uses of liquid hydrocarbons to partly replace coal and natural gas could increase demand beyond the equivalent of 10 million barrels of oil per day. One can produce and burn liquid hydrocarbons from biomass without any net addition of carbon dioxide to the atmosphere. Plants grow by removing carbon dioxide from the atmosphere; thus, burning biomass does not result in any net addition of carbon dioxide to the atmosphere. Biomass is typically 40% oxygen. To remove this oxygen to create hydrocarbon liquids, there are two options. The first option is to use biomass as (1) a feedstock, (2) an energy source to operate the process and (3) a supply of carbon to remove the biomass oxygen as carbon dioxide. The second option is to use external heat and hydrogen to remove the oxygen as water and produce liquid hydrocarbons. The use of massive quantities of external heat and hydrogen for hydrocarbon liquid fuels production reduces the biomass feedstock per unit of liquid hydrocarbon product by more than a factor of two reducing land use by more than a factor of two. Many cellulosic feedstocks unsuitable for liquid hydrocarbon production are viable feedstocks with external heat and hydrogen inputs. As a result, there is sufficient cellulosic feedstocks to meet U.S. and global liquid fuels hydrocarbon demand without significant impacts on food and fiber prices. The heat and hydrogen (heat plus electricity) are produced using base-load nuclear power plants—the most economic form of nuclear energy. If low-price natural gas, there is also the option of producing hydrogen from natural gas with sequestration of the carbon dioxide. The biomass is locally processed in depots to produce commodity feedstocks that can be shipped long distances to large biorefineries (250,000 barrels per day, oil equivalent) similar to existing refineries except modifications of front-end processes. The depot system enables local recycle of nutrients back to the soil. The biorefinery can produce variable quantities of liquid hydrocarbon fuels and carbon dioxide for sequestration enabling removal of carbon dioxide from the atmosphere. Preliminary estimates are that the liquid hydrocarbon costs are equivalent to crude oil at between $60 and $70 per barrel. The largest cost is for hydrogen with biomass feedstocks and refinery costs a smaller fraction of the total cost.

09 BIOMASS FUELS↗

Fuel quality processing study, volume 1

A fuel quality processing study to provide a data base for an intelligent tradeoff between advanced turbine technology and liquid fuel quality, and also, to guide the development of specifications of future synthetic fuels anticipated for use in the time period 1985 to 2000 is given. Four technical performance tests are discussed: on-site pretreating, existing refineries to upgrade fuels, new refineries to upgrade fuels, and data evaluation. The base case refinery is a modern Midwest refinery processing 200,000 BPD of a 60/40 domestic/import petroleum crude mix. The synthetic crudes used for upgrading to marketable products and turbine fuel are shale oil and coal liquids. Of these syncrudes, 50,000 BPD are processed in the existing petroleum refinery, requiring additional process units and reducing petroleum feed, and in a new refinery designed for processing each syncrude to produce gasoline, distillate fuels, resid fuels, and turbine fuel, JPGs and coke. An extensive collection of synfuel properties and upgrading data was prepared for the application of a linear program model to investigate the most economical production slate meeting petroleum product specifications and turbine fuels of various quality grades. Technical and economic projections were developed for 36 scenarios, based on 4 different crude feeds to either modified existing or new refineries operated in 2 different modes to produce 7 differing grades of turbine fuels. A required product selling price of turbine fuel for each processing route was calculated. Procedures and projected economics were developed for on-site treatment of turbine fuel to meet limitations of impurities and emission of pollutants.

Ohara, J. B.↗

Wood-to-Fuel for California's Transportation Sector using Autothermal Pyrolysis (Progress Report for FRD-17-002)

Accomplishments this period: Subcontract with Frontline BioEnergy, LLC has been executed and is in place (Task 1). List of TAC members is awaiting input from the CEC including any additional members of their own choosing before we finalize confirmation with the listed individuals. This is also holding off on the documented TAC Member commitment, and the DRAFT TAC Meeting Schedule, as we need to know who is approved to be on the TAC before we get commitments and start setting meetings. We are awaiting input from the CEC as to a requested date for the CPR#1. It was originally set for the beginning of July (July 7th), but as the CEC needs to conduct this, we need their input on the revised date. The additional wood feed stock was sent to ISU for analysis of autothermal pyrolysis products on July 15. The Kern refinery continues to express interest in using the bio-oil produced from the demonstration in one or more of their plants. We believe this analysis information will be a critical component of what we share at our first Workshop later this summer

09 BIOMASS FUELS↗

Online Biogenic Carbon Analysis Enables Refineries to Reduce Carbon Footprint during Coprocessing Biomass- and Petroleum-Derived Liquids

To mitigate green-house gas (GHG) emissions, governments around the world are enacting legislation to reduce carbon intensity in transportation fuels. Coprocessing biomass and petroleum-derived liquids in existing refineries is a near-term, cost-effective approach for introducing renewable carbon in fuels and enabling refineries to meet regulatory mandates. However, coprocessing biomass-derived liquids in refineries results in variable degrees of biogenic carbon incorporation, necessitating accurate quantification to verify compliance with mandates. Existing refinery control and instrumentation systems lack the means to measure renewable carbon accurately, reliably, and quickly. Furthermore, accurate measurement of biogenic carbon is key to ensuring refineries meet regulatory mandates. In this Perspective, we present existing methods for measuring biogenic carbon, point out their challenges, and discuss the need for new online analytical capabilities to measure biogenic carbon in fuel intermediates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Feedstock and Catalyst Impact on Bio-Oil Production and FCC Co-Processing to Fuels

NREL's thermochemical biomass conversion research is focused on ex-situ upgrading of biomass fast-pyrolysis (FP) vapors as an efficient route to completely biogenic pyrolysis-based fuel precursors, fuels, and value-added chemicals depending on catalyst and process conditions. A near term pathway being developed uses these liquids for co-processing with petroleum feedstocks to assess biogenic carbon incorporation in hydrocarbon fuel feedstocks for potential refinery use. In this work, the impact of feedstock and catalyst on catalytic fast pyrolysis oil (CFPO) composition was determined with the oils then assessed for biogenic fuel production via FCC (fluidized catalytic cracking) co-processing. Biomass vapors were generated via fast pyrolysis with destabilizing vapor components (char, inorganics, tar aerosols) removed by hot gas filtration to produce clean vapors more responsive to catalytic upgrading. A Davison Circulating Riser (DCR), a petroleum industry standard for fluidized catalytic cracking (FCC) catalyst evaluation, was coupled to a custom pyrolyzer system designed to produce consistent-composition pyrolysis vapors as feed to the DCR. Pyrolysis vapors, derived from pure hardwood and softwood, were upgraded using commercially available modified zeolite-based catalysts to produce CFPOs. These upgraded oils were analyzed via 31P and 13C NMR spectroscopy, GCxGC-TOF/MS, carbonyl and ultimate analysis (CHNO), and simulated distillation (SIMDIS) to assess both oil chemistry and distillation behavior as they relate to catalyst and feedstock type for producing fungible hydrocarbon product liquids. These exploratory vapor-phase-upgrading results demonstrated the feasibility of producing refinery-compatible hydrocarbon fuel intermediates entirely from biomass-derived fast-pyrolysis vapors using an industry-accepted DCR system for catalytic upgrading. The FCC co-processing results demonstrated the feasibility of using CFPOs with VGO feeds in FCC refinery operations to produce biogenic carbon containing fuels.

biogenic carbon↗

Opportunities and Challenges for Hydrotreating of Catalytic Fast Pyrolysis Oil to Fuels

Catalytic fast pyrolysis (CFP) provides a versatile platform for producing fuels to combat climate change and meet decarbonizing targets. In this contribution, we will discuss the hydroprocessing of CFP oils to a variety of fuels, including sustainable aviation fuel (SAF), diesel, and marine fuel. Both standalone and co-hydroprocessing with petroleum streams will be covered. Hydrotreating CFP oil at temperatures around 400 Degrees Celsius can produce a highly deoxygenated product with oxygen contents below the detection limit. However, the quality of fuel fractions produced has been a problem, manifesting as low octane numbers for the gasoline-range fraction and low cetane numbers for the diesel-range fraction. Incorporating an initial transition zone for hydrogenation during hydrotreating was shown to dramatically increase the diesel fraction cetane number from 24 to 45. A similar approach enabled the production of a cycloalkane-rich SAF fraction meeting key ASTM 4054 guidelines with respect to density, viscosity, heating value, volatility, freeze and flash point. Over 400 hours of hydrotreating for SAF was demonstrated with no signs of catalyst bed fouling, measured by pressure drop over the catalyst bed. Compared to other fuels, marine fuel is unique in that it does not require complete deoxygenation. We investigated the minimum hydrotreating requirements to produce fuel compatible with very low sulfur fuel oil, and the results suggested 30% reduction in hydrotreating costs for this approach. Co-hydroprocessing offers an opportunity to take advantage of refinery infrastructure and economies of scale although the operation is less flexible with respect to operating conditions. Co-hydroprocessing CFP oil with petroleum streams gave efficient deoxygenation at milder conditions (e.g. at temperatures of 320 Degrees Celsius) than required for standalone hydrotreating. Over 90% incorporation of biogenic carbon in the CFP oil was confirmed by carbon-14 analysis. Hydrotreating of CFP oil, whether by standalone or co-processing, can produce a variety of fuel cuts, whose quality can be tailored by changing process conditions. Challenges remain, including long-term catalyst performance and determining CFP oil quality requirements.

09 BIOMASS FUELS↗

Aviation fuels outlook

Options for satisfying the future demand for commercial jet fuels are analyzed. It is concluded that the most effective means to this end are to attract more refiners to the jet fuel market and encourage development of processes to convert oil shale and coal to transportation fuels. Furthermore, changing the U.S. refineries fuel specification would not significantly alter jet fuel availability.

Momenthy, A. M.↗

Thermal Integration of Advanced Nuclear Reactors with a Reference Refinery, Methanol Synthesis, and a Wood Pulp Plant (Rev.1)

The present report is intended to provide process flow diagrams (PFDs) and energy and mass balance data sheets for a U.S. industrial sector subset with which nuclear heat and power could be integrated—a subset that includes the oil refining, methanol and pulp and paper industries. Coupling options for integrating nuclear energy into these industries are quantitatively outlined for reference systems, and future work will extend this analysis in greater detail. Opportunities for integrating small modular nuclear reactors (SMNRs) were investigated for each of the industrial process configurations. Aspen HYSYS and Cycle-Tempo models for a high-temperature gas-cooled reactor were developed to evaluate the proposed integration. This introductory evaluation provides a general description and assessment of the operating principles, reactor coolant core outlet temperature, and reactor size to be integrated with industry. The industrial processes of oil refining and the production of methanol, pulp and paper were simulated by using Aspen HYSYS, Aspen Plus, and the PRELIM (Petroleum Refinery Life Cycle Inventory Model) tool to develop process details. Cycle-Tempo models then extend the process modeling results to obtain net energy demands (e.g., heat, steam, and electricity) when accounting for process steam and waste heat recovery. This information is intended to foster the analysis of integrating an SMNR to decarbonize industrial facilities. The SMNR would provide reliable, competitive, and sustainable clean energy while reducing carbon emissions and other environmental impacts, such as water withdrawals, consumption, and contamination. The refining industry, exhibited in Figure ES1, is a leading consumer of fossil -fuel-based heat, power, and hydrogen in the U.S. industrial sector, generating over 164 million metric tons (MMT) of CO 2 emissions in 2023. The overall mass and energy pertaining to a generalized complex refinery in the United States is reflected in Figure ES1, along with energy metrics regarding integration with a nuclear power plant (NPP). Data sheets were developed to indicate the energy requirements for the overall refinery and each refinery process. The data sheet for the overall refinery is shown in Table ES2.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Model for refining operations

Program predicts production volumes of petroleum refinery products, with particular emphasis on aircraft-turbine fuel blends and their key properties. It calculates capital and operating costs for refinery and its margin of profitability. Program also includes provisions for processing of synthetic crude oils from oil shale and coal liquefaction processes and contains highly-detailed blending computations for alternative jet-fuel blends of varying endpoint specifications.

Dunbar, D. N.↗

Co-Hydrotreating of Catalytic Fast Pyrolysis Oils with Straight-Run Diesel

Catalytic Fast Pyrolysis (CFP) of biomass provides an opportunity for producing stabilized bio-oils (CFP oils) that can be further processed into hydrocarbon transportation fuels via hydroprocessing. Standalone hydrotreating of CFP oils has been pursued and has been shown to be able to produce hydrocarbon products with low oxygen contents of <1wt%, but the process is costly due to the high requirements of hydrogen and high capital costs. The costs can be reduced by co-processing in refineries, which takes advantage of the existing refinery infrastructure and the economies of the larger scale of petroleum processing operations. In this contribution, we evaluated co-hydrotreating of CFP oil with straight-run diesel in a laboratory continuous hydrotreating reactor. The CFP oil had been produced over a bi-functional metal-acid catalyst (Pt/TiO2) and contained 17 wt% oxygen on dry basis, and it was fed to the reactor together with straight-run diesel in the proportion of 20 vol%:80 vol%. The co-hydrotreated diesel products had acceptable cetane numbers (>40), and the calculated carbon efficiencies were high (~95%) for the CFP portion of the feed mixtures. Biogenic carbon incorporation in the product was confirmed by C-14 analysis. Sulfided NiMo catalyst gave better performance with respect to the diesel product quality than CoMo did due to the higher hydrogenation activity of NiMo. A comparison of standalone hydrotreating of the CFP oil and the straight-run diesel to co-hydrotreating showed good correspondence. Major challenges and risks associated with co-hydrotreating are discussed in this presentation.

biomass↗

Industrial Requirements Status Report and Down-Select of Candidate Technologies

The report discusses the potential for implementing Integrated Energy Systems (IES) using advanced nuclear reactors to provide thermal and electrical energy to carbon-emitting industries while reducing their carbon footprint. Nine different industries were reviewed to determine their decarbonization potential, how nuclear power can fit in, and the carbon footprint of each. The report also identifies specific integration points and streams for most processes, including temperature and pressure requirements of integrating nuclear power with industrial processes. The report also provides insights on advanced nuclear reactors and their potential for us in IES for decarbonization. The target audience for the report is broad, but mainly addressed to the industry leads and nuclear reactor developers. The report recommends that in the short term, a few processes should be identified to continue research and investigation so that front end engineering design work can provide technical analysis for integrating nuclear heat and replacing existing carbon-emitting thermal sources. The work emphasized the significant decarbonization opportunity across each of the technologies looked at as well as how novel and useful nuclear integration is to reduce the environmental impact of these significant industries.

02 PETROLEUM↗

Drivers of Thermal Instability of Catalytic Pyrolysis Oils During Hydrotreating and Co-Processing to Sustainable Fuels

This presentation goes over polymerization observed in CFPs driven by thermally labile oxygenates. Lower oxygen oils have improved stability and a few percent decrease in oxygen greatly improves stability. Further improvements could be realized via targeted catalytic development and further reduction in reactive species. High stability CFP will help enable refinery integration of biogenic carbon.

bio-oil↗

Hydrogen market survey

Summary tables are given for the domestic consumption of hydrogen. Data cover chemicals, refinery operations, steelmaking, and synthetic fuels. Data show major consumption to be in the area of synthetic fuel production from coal and oil shale.

Source record↗

Computer model for refinery operations with emphasis on jet fuel production. Volume 2: Data and technical bases

The FORTRAN computing program predicts the flow streams and material, energy, and economic balances of a typical petroleum refinery, with particular emphasis on production of aviation turbine fuel of varying end point and hydrogen content specifications. The program has provision for shale oil and coal oil in addition to petroleum crudes. A case study feature permits dependent cases to be run for parametric or optimization studies by input of only the variables which are changed from the base case. The report has sufficient detail for the information of most readers.

Dunbar, D. N.↗

Computer model for refinery operations with emphasis on jet fuel production. Volume 1: Program description

A FORTRAN computer program is described for predicting the flow streams and material, energy, and economic balances of a typical petroleum refinery, with particular emphasis on production of aviation turbine fuel of varying end point and hydrogen content specifications. The program has provision for shale oil and coal oil in addition to petroleum crudes. A case study feature permits dependent cases to be run for parametric or optimization studies by input of only the variables which are changed from the base case.

Dunbar, D. N.↗

Effect of Fuel Composition, Engine Operating Variables, and Spark-Plug Type and Condition on Preignition-Limited Performance of an R-2800 Cylinder

The preignition characteristics of the R-2800 cylinder, as effected by fuel consumption, engine operating variables, and spark plug type and condition, were evaluated. The effects on preignition-limited performance of various percentages of aromatics (benzene, toluene, cumene, xylene) in a base fuel of triptane were investigated. Two paraffins (triptane and S + 6.0 ml TEL/gal) and two refinery blends (28-R and 33-R) were preignition rated. The effect of changes in the following engine operating variables on preignition limit was determined: inlet-air temperature, rear spark plug gasket temperature, engine speed, spark advance, tappet clearance, and oil consumption. Preignition limits of the R-2800 cylinder using Champion C34S and C35S and AC-LS86, LS87, and LS88 spark plugs were established and the effect of spark plug deterioration was investigated. No definite trends in preignition-limited indicated mean effective pressure were indicated for aromatics as a class when increased percentages of different aromatics were added to a base fuel of triptane. Three types of fuel (aromatics, paraffins, and refinery blends) showed a preignition range for this cylinder from 65 to 104 percent when based on the performance of S plus 6.0 ml TEL per gallon as 100 percent. The R-2800 cylinder is therefore relatively insensitive to fuel composition when compared to a CFR F-4 engine, which had a pre-ignition range from 72 to 100 percent for the same fuels. Six engine operating variables were investigated with the following results: preignition-limited indicated mean effective pressure decreased, with increases in engine speed, rear spark plug gasket temperature, inlet-air temperature, and spark advance beyond 20 F B.T.C. and was unaffected by rate of oil consumption or by tappet clearance. Spark plugs were rated over a range of preignition-limited indicated mean effective pressure from 200 to 390 pounds per square inch at a fuel-air ratio of 0.07 in the following order of increased resistance to preignition: AC-LS97, AC-LS88, Champion C358, AC-LS86, and Champion C34S. Spark plug deterioration in the form of cracks in the porcelain had been broken away from the center electrode and were retained in the spark plug cavity, the preignition limit was decreased as much as 57 percent. When the broken pieces had been removed, the preignition limit increased from that of the undamaged porcelain as the weight of removed porcelain was increased.

Pfender, John F.↗