High-resolution in situ analysis of biomass pyrolysis by combining quantitative synchrotron µCT and 3D particle-resolved simulations
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Design Study for Bio-Oil Production from Biomass Using a Dual Fluidized-Bed Reactor
To evaluate the re-design and reconfiguration of a dual-fluidized bed (DFB) gasification system into a recirculating pyrolysis reactor, Computation Fluid Dynamic (CFD) simulations of the system were conducted. The Barracuda Virtual Reactor® computational particle fluid dynamic code was used to perform simulations of the pyrolysis process. Modeling of the chemical reaction kinetics for both gas phase and solid particle phase were included. The recirculating pyrolysis reactor shown in Fig. 1a is based on a bubbling-bed biomass pyrolyzer and a riser combustor to convert the remaining char. The operational differences in the re-configuration of the DFB gasification system into a recirculating pyrolysis system for the production of bio-oil are (1) replacement of a low-surface area inert bed material with a high-surface-area bed material that has acidic properties to provide catalytic activity for the production of bio-oil with reduced oxygen content, (2) lower temperature and residence time for bio-oil production from pyrolysis, (3) replacement of the fluidization gas in the bubbling bed pyrolyzer from steam to nitrogen, and (4) the reduction of pyrolyzer freeboard volume. The bed material used for catalytic pyrolysis is Sasol 300 (300-micron dia., bulk density 0.94 kg/l, and surface area 130 m2/g) and is a theta-alumina with mild acidity. This is in comparison with previous standard bed material Carbo HSP (430-micron dia., bulk density 2.01 kg/l, and surface area 0.03 m2/g) used for gasification. For bio-oil production, pyrolysis in the bubbling bed requires temperatures in the range of 550 C in comparison with gasification temperatures near 850 C. To attain this lower temperature requires management of the energy mass balances, with control of the bed material recirculation rate between bubbling bed pyrolyzer and riser combustor, the introduction of a nitrogen purge in the pyrolyzer, and adjusting the pressure balance between the two vessels. To extract bio-oil from the pyrolysis reactor with a snorkel, two different freeboard configurations were evaluated. In Fig. 1 b the existing high freeboard configuration is shown and in Fig. 1 c the reduced freeboard design is presented. The introduction of a nitrogen purge for the high free board configuration provided the highest bio-oil production from the CFD simulations. To decrease the bed-material circulation rate, primary and secondary air on the combustor side were reduced, and the pressure on the combustor was slightly increased. A portion of the biomass and bio-oil was observed to be transported to the combustor, leading to a smaller pyrolysis yield. The control of the pyrolyzer temperature is performed by controlling the circulation rate. Good fluidization of the bubbling bed and cascade PID control are required to keep the temperature from oscillating due to large time delay experienced when changing primary and secondary air. (a) (b) (c) Figure 1. (a) Dual Fluidized Bed pyrolysis system configuration, (b) mole fraction of nonpolar biooil in high freeboard configuration, and (c) mole fraction of nonpolar bio-oil in low freeboard configuration with nitrogen purge introduced in both configurations.
BASIC BIOLOGICAL SCIENCES,BIOMASS FUELS↗
Catalytic Upgrading of Thermochemical Intermediates to Hydrocarbons (Final Report)
A lot of activity in catalytic pyrolysis and hydroprocessing occurred in the past 10-15 years with notable successes and failures; however, very little technical information is available in the open literature from pilot-scale studies such as those performed in this project. Besides, the next step along the technology commercialization pathway is to scale-up the catalytic biomass pyrolysis process, integrate this technology with a hydroprocessing unit, and demonstrate the long-term operation and performance of the integrated process; notably, these were achieved in this project. RTI International has developed a single-step catalytic biomass pyrolysis process to produce a hydrocarbon-rich bio-crude intermediate. This bio-crude is more thermally stable and has lower oxygen content than conventional biomass fast pyrolysis oil, so it can be effectively and efficiently upgraded with traditional hydroprocessing technology to produce gasoline and diesel. Our partner, Haldor Topsøe, has developed a strategy for hydroprocessing bio-crude intermediates based on extensive catalyst and process development in support of converting vegetable oils and waste greases into high-quality diesel fuel. The goal of the originally proposed project was to demonstrate an advanced biofuels technology that integrates a catalytic biomass pyrolysis step and a hydroprocessing step to produce infrastructure-compatible biofuels. The specific technical goals of this project were 1) to optimize the catalytic biomass pyrolysis process to achieve high degree of deoxygenation, while maximizing the bio-crude production, 2) improve bio-crude thermal stability, 3) evaluate the impact of bio-crude quality in the hydroprocessing step, 4) minimize hydrogen demand of the integrated process, and 5) maximize biofuels yields. This project showed that it is technically feasible to use non-zeolitic solid acid catalyst to consistently generate bio-crude with 20% oxygen content and that these liquids can be effectively hydrotreated into low oxygen fuel blendstocks. The reproducibility of the small-scale pyrolysis yields at the 1 tonne/day scale is an achievement worth noting and the effect of pyrolysis temperature on biocrude yields and quality was investigated at the pilot scale. Additionally, advanced analytical techniques were used to analyze bio-crude to investigate the effect of process conditions and feedstock on the concentration and speciation of oxygen-containing compounds. Insights into the impact of oxygen content and oxygen speciation on bio-crdue upgrading were also sought. Clearly, more successful upgrading correlated with bio-crudes with lower oxygen content. This was most evident when partially upgraded bio-crude with 55-90% less oxygen compared to the starting bio-crude was blended with straight run diesel and hydrotreated without any noticeable increase in pressure drop across the reactor or any measurable loss of hydrodenitrification (HDN) activity. Minimizing hydrogen demand while maximizing biofuels yield are the desired outcomes for the integrated process. In summary, several technical challenges remain before catalytic biomass pyrolysis becomes a commercial reality, most notably bio-crude yields and quality still need to be improved. The integrated catalytic biomass pyrolysis hydroprocessing scheme being developed produces intermediates that can be refined for use as drop-in hydrocarbon replacement fuels. From a technology perspective, this advanced biofuel technology produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum refining and distribution infrastructure. From a business perspective, this technology does not face potential market limitations as other nonhydrocarbon biofuels caused by oxygenated blending limitations and fuel certification for light-duty vehicle applications.
09 BIOMASS FUELS↗
Pretreatments for the continuous production of pyrolytic sugar from lignocellulosic biomass
Fast pyrolysis of lignocellulosic biomass yields little sugar or anhydrosugars compared to pyrolysis of pure polysaccharides because naturally abundant alkali and alkaline earth metals (AAEM) in biomass catalyze the fragmentation of pyranose and furanose rings. Sugar yields can be increased dramatically by pretreating the biomass with sulfuric acid prior to pyrolysis, which passivates the catalytic activity of the metals by converting them into thermally stable salts. However, depolymerization of lignin in biomass also depends on the catalytic activity of AAEM. Thus, passivating AAEM has the unintended consequence of slowing the rate of depolymerization and volatilization of lignin, resulting in a transient melt phase that agglomerates and can foul pyrolysis reactors. Here, to overcome this problem, various non-alkali metal sulfates were tested as replacements for sulfuric acid. Iron in the form of ferrous sulfate proved the most effective in depolymerizing lignin without fragmenting pyranose rings. Conventional nitrogen-blown pyrolysis of ferrous sulfate pretreated corn stover achieved WHSV of 4 h –1 compared to only 0.6 h –1 for acid pretreated corn stover. Autothermal (air-blown) pyrolysis of ferrous sulfate pretreated corn stover showed even more dramatic improvement, increasing WHSV from 1 h –1 to 10 h –1 compared to acid pretreated corn stover under autothermal operation. Fermentable sugar yields from the pyrolysis of corn stover increased from 0.9 wt% to 11.8 wt% on a biomass basis, a 13-fold increase as a result of the ferrous sulfate pretreatment. These advantages combine to increase volumetric sugar productivity from 62 g L –1 h –1 for conventional pyrolysis of untreated corn stover to 2041 g L –1 h –1 for autothermal pyrolysis of ferrous sulfate treated corn stover.
09 BIOMASS FUELS↗
Molten-Phase Unsaturation Enhanced Pyrolytic Upcycling of Polyolefins
Fast pyrolysis is a robust deconstruction technology for chemically upcycling waste plastics without losing significant carbon to noncondensable gases. However, fast pyrolysis of polyolefins often produces hydrocarbons with broad molecular weight distributions, mainly waxes, which can also negatively affect the commercial reactor operation and downstream upgrading of the products. We discovered that combining molten-phase thermal treatment with subsequent fast pyrolysis offers a facile method to enhance polyolefin pyrolysis and catalytic upgrading. The molten-phase thermal treatment increased unsaturated C–C bonds in the treated polyolefins. During subsequent pyrolysis, the preheated polyolefins significantly reduced wax range hydrocarbons in the condensable products without an increase in gas formation. Here, the wax yields from pyrolysis of high-density polyethylene (HDPE) preheated to 295 °C and low-density polyethylene (LDPE) preheated to 275 °C were 20.5% and 26.5%, respectively, compared to 38.6% and 46% produced from pyrolyzing untreated polyolefins. When catalytically pyrolyzed using a zeolite catalyst, the preheated polyolefins promoted higher yields of olefins during ex-situ catalytic pyrolysis and higher yields of aromatic hydrocarbons during in-situ catalytic pyrolysis. During ex-situ catalytic pyrolysis, ethylene yields were 23.3% and 24.7% for the preheated HDPE and LDPE compared to 16.7% and 9.3% for untreated HDPE and LDPE, respectively.
Aromatic compounds↗
Catalytic Bio-crude Production in a Novel, Short-Contact Time Reactor
RTI has developed a catalytic fast pyrolysis (CFP) process to produce biomass-based hydrocarbon replacement fuels. From a technology perspective, this advanced biofuels process produces liquid transportation fuels that can leverage capital expenditures in the existing petroleum distribution infrastructure. From a business perspective, this technology does not face potential market limitations caused by oxygenate blend limitations for light duty vehicle applications. A promising catalyst has been developed with excellent potential for deoxygenation to produce a hydrocarbon-rich biocrude that is more suitable for upgrading with traditional hydroprocessing technology. The role of the catalyst is to control the chemistry during biomass pyrolysis to produce a biocrude in a single step that has lower oxygen content and is more thermally stable than conventional biomass fast pyrolysis oil. Catalyst properties are optimized to minimize gas and coke production and improve catalytic deoxygenation and biocrude yields. Results from this project have demonstrated that biocrudes from catalytic fast pyrolysis contain <20 wt% oxygen, with the organic fraction as low as 12% oxygen. These oxygen numbers are > 50% lower compared to traditional fast pyrolysis oils. The biocrude produced from our CFP process can be upgraded to gasoline range hydrocarbons. A very conservative approach for upgrading included a preliminary stabilization step followed by a hydroprocessing step. The oxygen content in the upgraded product was decreased by 97% (to less than 3wt %) from the oxygen content of the biocrude sample. Additionally, the acid content was reduced by 99% from the acid content of the biocrude sample. In an optimized integrated process, the CFP step and the hydroprocessing (upgrading) step need to be carefully balanced to maximize the input biomass energy that is recovered in the finished biofuels. Hydrogen utilization and carbon recovery during both catalytic biomass pyrolysis and biocrude upgrading need to be optimized to maximize energy recovery in the finished biofuel. A nominal 1 ton per day (TPD) catalytic biomass pyrolysis system was designed based on the laboratory experimental data. The system was designed to achieve the short residence times (0.5–2 sec) and high heat transfer rates required for maximum liquid biocrude yields while optimizing process integration to maintain catalyst activity by continuous regeneration. The catalytic biomass pyrolysis reactor is a continuously circulating single-loop transport reactor design that is flexible enough to allow sensitivity studies around temperature, residence time, biomass feed rate, and catalyst-to-biomass ratio (i.e., catalyst circulation rate) for process optimization. For a nominal 100 lb/hr feed rate of dry biomass, the products include ~25 lb/hr char and coke, ~20 lb/hr permanent gases, and ~55 lb/hr condensable vapors. Pyrolysis temperatures are 350–600°C, and the system is operated close to ambient pressure. Production of the catalyst developed within the project was scaled up to provide enough material (200kg) for bench-scale testing. The 1TPD bench-scale unit was fabricated, installed and commissioned with this project. Biocrude samples from wood were produced in this unit with the CFP catalyst with material balance > 90%. The intermediate biocrude yields and chemical composition compare well with previous laboratory results and a hydroprocessing strategy for upgrading the resulting biocrude was developed. The experimental results obtained within this project were used to develop a process model for a 2000 TPD commercial facility. Detailed flow sheets were developed for all major unit operations in the process and provided a basis for an economic analysis to develop capital and operating costs. Estimates of the biofuel production costs were used to develop internal rates of return for the yields and compositions measured for the current state of technology at the end of this project and for the yields anticipated for an optimized (nth plant) scenario as additional process improvements are made.
09 BIOMASS FUELS↗
Optimization of fluorescence and surface adsorption of citric acid/ethanolamine carbon nanoparticles for subsurface tracers
The tunable fluorescence and biocompatibility of fluorescent carbon nanoparticles (FCNs) makes them appealing tracers in geothermal, environmental, and clinical applications. Here, we address FCNs synthesized from reaction and pyrolysis of citric acid and ethanolamine. We examine the fluorescence and the adsorption of these FCNs as critical parameters that influence their use in applications. FCN fluorescence was observed to develop during pyrolysis and measured at pyrolysis temperatures ranging from 190 to 250 °C. Transmission electron microscopy shows that the FCN average diameter of approximately 13 nm is unaffected by pyrolysis temperature. However, pyrolysis temperature strongly affects fluorescence, which peaks at 210 °C. Here, the surface hydrophobicity of the FCNs increases with pyrolysis temperature as measured by retention on reverse phase chromatography. Together, these results suggest that particle surface functionalities provide both fluorescence and hydrophilicity, and that these surface functionalities are destroyed with excessive pyrolysis. To examine their surface adsorption, quartz crystal microbalance measurements demonstrate that pyrolysis temperature increases FCN adsorption on mineral surfaces. Surfaces with greater hydrophobicity show greater FCN adsorption. Adsorption is unaffected by the presence of mono- or divalent ions in solution. This suggests adsorption by hydrophobic interaction for the Fe 2 O 3 , SiO 2 , and AlSiO surfaces studied.
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↗
The Identity and Chemistry of C 7 H 7 Radicals Observed during Soot Formation
Here we used aerosol mass spectrometry coupled with tunable synchrotron photoionization to measure radical and closed-shell species associated with particle formation in premixed flames and during pyrolysis of butane, ethylene, and methane. We analyzed photoionization (PI) spectra for the C 7 H 7 radical to identify the isomers present during particle formation. For the combustion and pyrolysis of all three fuels, the PI spectra can be fit reasonably well with contributions from four radical isomers: benzyl, tropyl, vinylcyclopentadienyl, and o-tolyl. Although there are significant experimental uncertainties in the isomeric speciation of C7H 7 , the results clearly demonstrate that the isomeric composition of C 7 H 7 strongly depends on the combustion or pyrolysis conditions and the fuel or precursors. Fits to the PI spectra using reference curves for these isomers suggest that all of these isomers may contribute to m/z 91 in butane and methane flames, but only benzyl and vinylcyclopentadienyl contribute to the C 7 H 7 isomer signal in the ethylene flame. Only tropyl and benzyl appear to play a role during pyrolytic particle formation from ethylene, and only tropyl, vinylcyclopentadienyl, and o-tolyl appear to participate during particle formation from butane pyrolysis. There also seems to be a contribution from an isomer with an ionization energy below 7.5 eV for the flames but not for the pyrolysis conditions. Kinetic models with updated and new reactions and rate coefficients for the C 7 H 7 reaction network predict benzyl, tropyl, vinylcyclopentadienyl, and o-tolyl to be the primary C 7 H 7 isomers and predict negligible contributions from other C 7 H 7 isomers. These updated models provide better agreement with the measurements than the original versions of the models but, nonetheless, underpredict the relative concentrations of tropyl, vinylcyclopentadienyl, and o-tolyl in both flames and pyrolysis and overpredict benzyl in pyrolysis. Our results suggest that there are additional important formation pathways for the vinylcyclopentadienyl, tropyl, and o-tolyl radicals and/or loss pathways for the benzyl radical that are currently unaccounted for in the present models.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Small-Scale Engineered High Flexibility Gasifier
This project advances a small-scale gasification unit as the first step in syngas-based hydrogen, chemicals, and synthetic fuels production. This unit is associated with an enhanced flexibility to different carbonaceous feedstocks including different types of coals, biomass, and plastics. The purpose of the project was to demonstrate feasibility and efficiency of coal pyrolysis in an auger reactor (pyrolyzer); supplemental methane and pyrolysis gas conversion into syngas in a proprietary non-catalytic converter; combined performance of pyrolyzer and non-catalytic converter to convert coal into syngas The proposed technology is based on an application of an intermediate speed pyrolysis at the temperature range 400-600°C as the first stage of biomass processing. At an industrial scale, an incorporation of coal pyrolysis into a feeding machine – auger-reactor allows to decrease its capital cost. At a pilot scale, it permits to employ electricity to build a compact device for testing of downstream equipment. The auger-reactor (pyrolyzer) generates pyrolysis gas and char practically from any carbonaceous feedstocks but their compositions and quantities are determined by their types. Pyrolysis gas is converted into syngas (mix of H 2 and CO) in a novel, proprietary hydrogen flame assisted non-catalytic converter which employs O 2 instead of air as an oxidizer. This reactor (converter) allows an easy adjustment to different pyrolysis gas compositions and tolerates a presence of sulfur and nitrogen contaminants. Our technology assumes carbonaceous feedstocks gasification with oxygen to allow the products H 2 , CO or CO 2 to be not diluted in N 2 and ready for the following synthesis of chemicals and fuels. Due to the same reason, it permits a more efficient CO 2 capture for its transport and storage. An implementation of our small-scale gasification process may overcome economic constrains by a flexible acceptance of coal, biomass, and plastics as well as their unsorted mixtures to make syngas for the following production of pure hydrogen, chemical and/or synthetic fuels.
42 ENGINEERING↗
Laboratory simulated hydrothermal alteration of sedimentary organic matter from Guaymas Basin, Gulf of California
High temperature alteration of sedimentary organic matter associated with marine hydrothermal systems involves complex physical and chemical processes that are not easily measured in most natural systems. Many of these processes can be evaluated indirectly by examining the geochemistry of the hydrothermal system in the laboratory. In this investigation, an experimental organic geochemical approach to studying pyrolysis of sedimentary organic matter is applied to the hydrothermal system in the Guaymas Basin, Gulf of California. A general survey of hydrothermal oils and extractable organic matter (bitumen) in hydrothermally altered sediments identified several homologous series of alkanones associated with a high temperature hydrothermal origin. The alkanones range in carbon number from C11 to C30 with no carbon number preference. Alkan-2-ones are in highest concentrations, with lower amounts of 3-, 4-, 5- (and higher) homologs. The alkanones appear to be pyrolysis products synthesized under extreme hydrothermal conditions. Hydrous pyrolysis and confinement pyrolysis experiments were performed to simulate thermally enhanced diagenetic and catagenetic changes in the immature sedimentary organic matter. The extent of alteration was measured by monitoring the n-alkanes, acyclic isoprenoids, steroid and triterpenoid biomarkers, polycyclic aromatic hydrocarbons and alkanones. The results were compared to bitumen extracts from sediments which have been naturally altered by a sill intrusion and accompanied hydrothermal fluid flow. These pyrolysis experiments duplicated many of the organic matter transformations observed in the natural system. Full hopane and sterane maturation occurred after 48 hr in experiments at 330 deg C with low water/rock mass ratios (0.29). A variety of radical and ionic reactions are responsible for the organic compound conversions which occur under extreme hydrothermal conditions. Short duration pyrolysis experiments revealed that a portion of the hydrocarbons generated from kerogen was observed to go through alkene intermediates, and the rate of alkene isomerization was influenced by the ionic strength and catalytic mineral phases. Confinement of the organic pyrolysate to the bulk sediment accelerated the rates of the biomarker epimerization reactions, suggesting that these reactions are influenced strongly by the association of the inorganic matrix, and that the relative rates of some ionic and radical reactions can be influenced by the water/rock ratio during the pyrolysis experiments.
Leif, Roald N.↗
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 and economical route to completely biogenic pyrolysis-based fuel precursors, potential fuels, and value-added chemicals depending on catalyst choice and process conditions. In this approach, biomass vapors are generated via fast pyrolysis with destabilizing vapor components (char, inorganics, tar aerosols) removed by hot gas filtration to produce conditioned vapors more responsive to catalytic upgrading. A Davison Circulating Riser (DCR), a petroleum industry standard for fluidized catalytic cracking (FCC) catalyst evaluation, was coupled with a custom pyrolyzer system designed to produce consistent composition pyrolysis vapors as feed to the DCR. The coupled system is shown below (Figure 1). Pyrolysis vapors, derived from pure hardwood and softwood, were upgraded using commercially available and laboratory modified zeolite-based catalysts. Upgraded oils were analyzed via 31P and 13C NMR spectroscopy, GCxGC-TOF/MS, carbonyl and ultimate analysis (CHNO), and micro distillation to assess both oil chemistry and distillation behavior as they relate to catalyst and feedstock type for producing fungible hydrocarbon product liquids. Measured process parameters identified from technoeconomic process analysis included achieving oil oxygenate contents of 20% or less, carbon-conversion efficiencies of 30% or more, and catalyst coking rates of 10% or less. A proprietary modified zeolite catalyst from Johnson Matthey produced oils that met these requirements. Using the DCR equipped with a proprietary nozzle system, a second approach focused on reducing the carbon intensity of petroleum-derived hydrocarbon fuels by FCC co-processing these CFP oils with petroleum vacuum gas oil (VGO) to produce biogenic carbon containing fuels. The vapor-phase upgrading results demonstrated for the first time 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 co-processing results demonstrated the feasibility of using CFP oils with VGO feeds in FCC refinery operations to produce biogenic carbon containing fuels.
bio-oil↗
Chapter 6: Recycling Plastic Waste to Produce Chemicals - A Techno-Economic Analysis and Life-Cycle Assessment
This study presents the results of a preliminary assessment on the technology, economics, and sustainability of using waste plastics as a feedstock to produce low molecular weight olefins via pyrolysis and gasification pathways. We also studied the formation of formaldehyde - an important polymer precursor - via the gasification of waste plastics. Process pathways for recovery of ethylene and propylene and production of formaldehyde from a simulated mixed plastic waste were constructed based on literature data. They included direct and indirect pathways based on either gasification or pyrolysis as the primary conversion step. Results of these studies have shown that significant economic challenges exist of producing olefins via pyrolysis and gasification, with the latter pathway especially difficult. Base costs of pyrolysis naphtha from waste plastics are higher when compared to the same material produced from fossil feedstocks. Base olefin costs for one direct route are two times higher than comparable costs from steam cracking of fossil naphtha. These costs are driven primarily by feedstock costs; some pyrolysis scenarios become more economically feasible when very low feedstock costs are used. Similarly, for gasification, the cost of methanol - the central intermediate - was found to be noticeable higher when produced by gasification of waste plastics compared to current selling prices, which negatively impacts all pathways that go through methanol as the central intermediate. Life-cycle assessment indicates that the production of pyrolysis naphtha from plastics is a carbon intensive operation; no major advantages were found in terms of greenhouse gas emissions for any of the pathways producing C2 and C3 olefins. The results of this study can serve as the baseline for future comparison to other plastic waste valorization processes.
BIOMASS FUELS,ENERGY PLANNING, POLICY, AND ECONOMY↗
An Open-Source Framework for the Computational Analysis and Design of Autothermal Chemical Processes
The main project object was to develop software tools for simulating non-equilibrium autothermal processes, improving the prospects for identifying and designing such systems. The project demonstrates the use of these tools to simulate autothermal pyrolysis, a process recently developed at the pilot-plant scale at Iowa State University. In such process, instead of externally heating a reactor to pro-vide the enthalpy of pyrolysis, sufficient oxygen in the form of air is introduced into the reactor to support partial oxidation of reactants and products with the exothermic energy released supporting endothermic pyrolysis reactions. A fluidized bed is used to assure good mixing of biomass and oxidant and provide an isothermal reaction environment. The amount of oxygen required depends upon the kind of biomass being pyrolyzed and parasitic heat losses from the reactor. For example, for woody biomass pyrolyzed under conditions that simulate adiabatic operation, equivalence ratios can be as low as 0.06, compared to 0.20 or higher for autothermal gasifiers. By removing the heat transfer bottleneck of conventional pyrolysis, operation in autothermal mode allowed a significant increase in reactor throughput process, approaching five times the throughput of the conventionally operated pyrolyzer. Different simulation strategies were considered and developed: a zero-dimensional chemistry model was used to verify the applicability of kinetic schemes to predict biomass fast pyrolysis in autothermal conditions. Conventional chemical reactor models such as the plug flow reactor and the partially stirred reactor were used to investigate the role of mixing in the fluidized bed pyrolyzer and to establish the impact of mixing time on the gas-phase reactions. A comprehensive multiphase computational fluid dynamics (mCFD) framework, including polydisperse granular phase modeling and detailed chemical kinetics was formulated and used to model the experimental setup for autothermal biomass fast pyrolysis at ISU. Multiphase CFD was also used to investigate the role of biomass feed positioning on the mixing of biomass in the pyrolizer. Finally, a reduced order model (ROM), suitable to be implemented in process simulators was obtained. Both the mCFD and the ROM were validated against experiments.
09 BIOMASS FUELS↗
An Integrated Tool for the Coupled Thermal and Mechanical Analysis of Pyrolyzing Heatshield Materials
Materials that pyrolyze at elevated temperature have been commonly used as thermal protection materials in hypersonic flight, and advanced pyrolyzing materials for this purpose continue to be developed. Because of the large temperature gradients that can arise in thermal protection materials, significant thermal stresses can develop. Advanced applications of pyrolytic materials are calling for more complex heatshield configurations, making accurate thermal stress analysis more important, and more challenging. For non-pyrolyzing materials, many finite element codes are available and capable of performing coupled thermal-mechanical analyses. These codes do not, however, have a built-in capability to perform analyses that include pyrolysis effects. When a pyrolyzing material is heated, one or more components of the original virgin material pyrolyze and create a gas. This gas flows away from the pyrolysis zone to the surface, resulting in a reduction in surface heating. A porous residue, referred to as char, remains in place of the virgin material. While the processes involved can be complex, it has been found that a simple physical model in which virgin material reacts to form char and pyrolysis gas, will yield satisfactory analytical results. Specifically, the effects that must be modeled include: (1) Variation of thermal properties (density, specific heat, thermal conductivity) as the material composition changes; (2) Energy released or absorbed by the pyrolysis reactions; (3) Energy convected by the flow of pyrolysis gas from the interior to the surface; (4) The reduction in surface heating due to surface blowing; and (5) Chemical and mass diffusion effects at the surface between the pyrolysis gas and edge gas Computational tools for the one-dimensional thermal analysis these materials exist and have proven to be reliable design tools. The objective of the present work is to extend the analysis capabilities of pyrolyzing materials to axisymmetric configurations, and to couple thermal and mechanical analyses so that thermal stresses may be efficiently and accurately calculated.
Pronchick, Stephen W.↗
Aerothermodynamics of Pyrolizing Surfaces in Hypersonic Rarefied Flows
Direct simulation Monte Carlo (DSMC) calculations of rarefied flows about entry bodies typically employ a fixed surface temperature or a radiative-equilibrium energy balance to compute that temperature. Such boundary conditions neglect any effects of heat capacitance and heat conduction in the spacecraft heat shield and, therefore, provide an upper bound for the surface temperature. Such calculations also neglect pyrolysis from the heat shield which can be significant for a high-energy incident flow at very low densities. Accurate prediction of both heating and aerodynamic forces requires including pyrolysis and surface heat transfer in the models for gas-surface interaction employed in DSMC methods. Although these physical models have long appeared in various continuum flow calculation codes, they have only recently appeared in DSMC codes which are required to simulate rarefied flows during entry at high altitudes. In the current implementation, routines from the widely distributed Charring Material Thermal Response and Ablation (CMA) program are coupled into a DSMC code to calculate the one-dimensional heat transfer into the carbon phenolic heat shield at each point on a vehicle surface. Temperature-dependent material properties, surface re-radiation, and in-depth pyrolysis were included in the calculation, but surface ablation was neglected. Sample calculations for entry of the Galileo probe into the atmosphere of Jupiter demonstrate that including pyrolysis in the model leads to significant differences in predicted aerodynamics. Granted, the drag coefficient does not depend strongly on the surface temperature which can itself be significantly below the radiative equilibrium value during entry. However, the surface mass flux due to pyrolysis of the material is significant once the probe drops to altitudes characterized by transition flow. This leads to a noticeable increase in drag and a decrease in heating compared to a body without pyrolysis.
Haas, Brian L.↗
Chemical Characterization and Thermal Stressing Studies of Perfluorohexane Fluids for Space-Based Applications
Perfluorohexane (PFH), C6F14, is a perfluorocarbon fluid. Several PFH fluids with different isomer concentrations were evaluated for use in an upcoming NASA space experiment. Samples tested included two commercially obtained high-purity n-perfluorohexane (n-PFH) fluids and a technical grade mixture of C6F14 branched and linear isomers (FC-72(TradeMark)). These fluids were evaluated for exact chemical composition, impurity purity and high temperature degradation behavior (pyrolysis). Our investigation involved simulated thermal stressing studies of PFH fluids under conditions likely to occur in the event of an atmospheric breach within the International Space Station (ISS) and subsequent exposure of the vapors to the high temperature and catalyst present in its Trace Contaminant Control Subsystem (TCCS). Exposure to temperatures in the temperature range of 200-450 C in an inert or oxidizing atmosphere, with and without the presence of catalyst was investigated. The most aggressive conditions studied were exposure of PFH vapors to 450 C in air and in the presence of TCCS (palladium) catalyst. Gas chromatography-mass spectrometry (GC-MS) and gas chromatography (GC) analyses were conducted on the perfluorohexane samples before and after pyrolysis. The FC-72 and n-PFH samples showed no significant degradation following pyrolysis even under the most aggressive study conditions. Some trace level impurities associated with the PFH samples such as linear perfluorocarbon monohydrides or monoiodides were destroyed by pyrolysis at the upper limit. Other trace level impurities such as olefinic or cycloolefinic perfluorocarbons were converted into oxidation products by pyrolysis. The purity of PFH following pyrolysis actually increased slightly as a consequence since these trace contaminants were effectively scrubbed from the samples. However, since the initial concentrations of the thermally-impacted impurities were so low, the net effect was trivial. A potential byproduct of exposure of perfluorohexane fluids to high temperatures is the production of perfluoroisobutene (PFiB), which is extremely toxic. An ultra-high sensitivity PFiB-specific analysis based on GC-MS with negative ion chemical ionization (NICI) detection was used to evaluate the samples following thermal stressing. The perfluorohexanes examined here under conditions reflective of the ISS TCCS environment showed no signs of PFiB production with an analytical detection limit of 10 part per billion (ppb v/v).
Arnold, William A.↗
Systems and methods for producing fuel intermediates
The present disclosure relates to a method that includes pyrolyzing a biomass to produce a pyrolysis oil and upgrading the pyrolysis oil to yield a first upgraded pyrolysis oil, where the pyrolysis oil is in at least one of a liquid phase and/or a vapor phase, the pyrolyzing is performed in a pyrolysis reactor at a first temperature between 400° C. and 600° C., the biomass has a residence time of less than five seconds in the pyrolysis reactor, the upgrading is performed in a fluidized bed reactor, and the upgrading is catalyzed using a zeolite.
09 BIOMASS FUELS↗