A Commercialization Case Study of a New Technology for Conversion of CO 2 Emissions to Alcohol Fuels for Stimulating Economic Growth By Mark A. Edelman, Ph.D. Iowa State University & AGG LLC, Gary C. Young, Ph.D. P.E. Bio-Thermal-Energy Inc., John C. Wooley, EE-CO2 LLC, and Eric Wagner, Ph.D. Technip Stone & Webster Process Technology, Inc. Presented to: International Association for Energy Economics 37 th Annual IAEE International Conference Wyndham New Yorker Hotel 481 8 th Avenue, New York, NY 1 June 15-18, 2014 1
The Inventor: Dr. Gary C. Young, Ph.D., P.E. Retired after 40+ years of experience from the oil and gas industry in such areas as R&D in coal gasification, gas processing, enhanced energy recovery, agricultural chemical development, food, chemical, pharmaceutical processing & operations, and process project economics. Current focus is on the production of Advanced Biofuels from CO 2 emission sources using a proprietary CO 2 conversion technology that he developed. Has 4 patents & additional patents pending on the BTE technology. Inventor of 22+ patents of which many are owned by his company, Bio-Thermal- Energy, Inc. (BTE). Licensed professional engineer in the states of: California, Texas, Illinois, Iowa, and Wisconsin. Author of “Municipal Solid Waste to Energy Conversion Processes: Economic, Technical, and Renewable Comparisons” published by John Wiley & Sons, Inc., 2010. Book covers several topics: Gasification/Pyrolysis and Combustion, MSW Processes to Energy & High Value & Specialty by-products, MSW Gasifiers & Process Equipment, Wind Energy, Hydroelectric Energy, and Waste Heat Recovery. Native of Nebraska and received B.S., M.S. and Ph.D. degrees in chemical 2 engineering from the University of Nebraska and he presently resides in Cedar Rapids, Iowa.
The Collaborators � EE-AGG Joint Venture Commercialization Company � Exclusive license for BTE technology. � John Wooley, President, experienced business executive based in Austin, TX � Mark Edelman, Ph.D. ag economist ISU Professor based in Ames, IA & Joint Venture Company Treasurer � Technip Stone & Webster Process Technology Inc. � Technip: multi-national engineering firm with projects in over 40 countries & 38,000 employees: http://www.technip.com/en � Eric Wagner, Ph.D. P.E. Engineering Technical Director based in Claremont, CA 3
THERMAL GASIFICATION PROCESS CONVERTS CARBON DIOXIDE (CO2) INTO SYNGAS (CO & H2) Bio-Thermal-Energy, Inc. (B-T-E) has proprietary process for the conversion of Carbon dioxide (CO2) into synthesis gas “Syngas.” The Syngas can be converted further into “fuels and chemicals,” for example, Ethanol, Methanol, and Gasoline using commercially available technologies. CO2 + Carbonaceous Input + Steam � Syngas(CO & H2) Syngas (CO & H2) � Green Advanced Biofuels 4 4
STEP 1 PROCESS: CONVERSION OF CO 2 TO SYNGAS (CO & H 2 ) Combines CO 2 with carbonaceous inputs and steam using high temperature “non-catalytic” gasification. A simplified representation of B-T-E’s over-all process technology for the conversion of CO 2 to SYNGAS is as follows: CO 2 + C (Carbonaceous input) + H 2 O (Steam) � Syngas (CO & H 2 ) where Carbonaceous materials could be and/or a mixture of: Coke, Carbon Black, Coal, Charcoal, Wood, Switch Grass, Corn Stover, Tires, Municipal Solids Waste (MSW), Methane (Natural gas), and Steel Mill Gas. 5
CO 2 to Syngas proprietary process illustrated in block flow diagram (BFD) where the CO 2 source is from a Corn-to-Ethanol Plant: CO 2 RECYCLE B-T-E's Syngas GASIFICATION CO Cleanup PROCESS Carbon dioxide (CO 2 ) - Source Syngas H 2 & (High (Corn-to-Ethanol Plant) (CO & H 2 ) CO 2 Heat Temperature Recovery & H 2 O/Steam Non-catalytic) Oxygen (O 2 ) Vitrified Slag Carbonaceous Material and/or Mixture: Methane (Natural Gas), Coke, Carbon black, Coal, Charcoal, Wood, Switch grass, Corn Stover, Tires, MSW, Steel Mill Gas, etc. 6 CO 2 + C (Carbonaceous material) + H 2 O (Steam) � Syngas (CO & H 2 )
PROPRIETARY PROCESS “Demonstrated” at Pilot Scale Proprietary process demonstrated experimentally at a scale of 12.5 ton per day in private sector pilot plant facilities located in Pennsylvania. Results were verified by 3 rd party. Syngas produced in pilot plant used feed comprising: CO 2 , Steam, and a carbonaceous inputs. As a non-catalytic process, a carbonaceous material is fed to a high temperature gasifier which can consist of gases, liquids, solids and/or a mixture. CO 2 feed to the gasifier does not require separation from an industrial gaseous stream. However, impurities in a gaseous stream influence process equipment size and capital costs. 7
FOUR CASES CHOSEN TO DEVELOP 3 RD PARTY TECHNOLOGY VERIFICATION AND ECONOMIC FEASIBILITY STUDY Scenarios Examined: Case-A: 100% Coal Case-B: 10% CH 4 & 90% Coal Case-C: 50% CH 4 & 50% Coal Case-D: 100% CH 4 Case-A Case-B Case-C Case-D (lb/hr) (lb/hr) (lb/hr) (lb/hr) Gasifier Feed: CO 2 37,700 37,700 37,700 37,700 CH 4 * * * * Coal * * * * Steam (H 2 O) * * * * Oxygen (O 2 ) * * * * Gasification: (1,832/0.0) (1,832/0.0) (1,832/0.0) (1,832/0.0) (T- o F / P- psig) SYNGAS: CO * * * * H 2 * * * * CO 2 13,406 13,309 12,924 12,441 % CO 2 Reduction 64.4 64.7 65.7 67.0 H 2 /CO-mole ratio 0.394 0.527 1.029 1.595 8 * Confidential
ETHANOL FINDINGS BASED UPON TECHNIP STUDY, 2014 Carbon dioxide (CO 2 ) source will be from the fermentors of a Corn-to-Ethanol plant with capacity of 50 million gallons annually. Thus, the carbon dioxide (CO 2 ) feed is at a rate of 37,700 lbs/hr or 18.85 tons/hr. Coal cost at $35-75/ton, natural gas at $3.50- 4.50/MMBTU, and electricity at $0.025-0.050/kWh. Results are from a feasibility study by TECHNIP Stone & Webster Process Technology, Inc., Jan. – 2014. Case Ethanol Production Manufacturing Cost CO 2 -to-Ethanol plant ISBL Estimated Range Notes - 1 & -3 ($MM) Notes -1, -2, & -3 Case-A, 100%Coal 44.8 million gal/yr $182 $0.89 - $1.20 /gallon Case-B, 10%CH 4 & 90% Coal 47.7 million gal/yr $197 $0.93 - $1.25 /gallon Case-C, 50%CH 4 & 50%Coal 59.3 million gal/yr $256 $1.08 - $1.41 /gallon Case-D, 100%CH 4 73.8 million gal/yr $325 $1.19 - $1.53 /gallon Current selling price of Ethanol: $1.90 -$2.97 /gallon Note-1: Assuming an operation at 8,760 hours per year or 100%. Note-2: Includes Total CAPEX (ISBL & 50% of ISBL as OSBL and OPEX including Labor & Maintenance. Note-3: Based upon CO 2 conversion rates to Syngas of 65 – 70%. This process has not been optimized to higher CO 2 conversion rates and savings from heat recovery has not been included. 9 CO 2 + C (Carbonaceous material) + H 2 O (Steam) � Syngas (CO & H 2 ) � Bio-chemical Process � Ethanol
METHANOL FINDINGS BASED ON TECHNIP STUDY, 2014 Carbon dioxide (CO 2 ) source will be from the fermentors of a Corn-to-Ethanol plant with capacity of 50 million gallons annually. Thus, Carbon dioxide (CO 2 ) source is at a rate of 37,700 lbs/hr or 18.85 tons/hr. Coal cost at $35-75 /ton, natural gas at $3.50-4.50/MMBTU, and Electricity at $0.025-0.050/kwh. Results of a feasibility study by TECHNIP Stone & Webster Process Technology, Inc., Jan. 2014. Case Methanol Production Manufacturing Cost CO 2 -to-Methanol plant ISBL Estimated Range Notes -1 & -3 ($MM) Notes -1, -2 & -3 Case-F, 100%Coal 78.3 million gal/yr $209 $0.64 - $0.84 /gallon Case-G, 100%CH 4 183.3 million gal/yr $381 $0.63 - $0.79 /gallon Methanol Price Assumed: $1.90 /gallon Note-1: Assuming an operation at 8,760 hours per year or 100%. Note-2: Includes Total CAPEX (ISBL & 50% of ISBL as OSBL and OPEX including Labor & Maintenance) Note-3: Based upon CO 2 conversion rates to Syngas of 65 – 70%. This process has not been optimized to higher CO 2 conversion rates and savings from heat recovery have not been included. 10 CO 2 + C (Carbonaceous input) + H 2 O (Steam) � Syngas (CO & H 2 ) � F-T Type Process � Methanol
GASOLINE findings based upon TECHNIP Study - 2014 Carbon dioxide (CO 2 ) source from the fermentors of a Corn-to-Ethanol plant with capacity of 50 million gallons annually. Thus Carbon dioxide (CO 2 ) feed is at a rate of 37,700 lbs/hr or 18.85 tons/hr. Coal cost at $35-75/ton, natural gas at $3.50-4.50/MM Btu, and electricity at $0.025-0.050/kWh. Results of a feasibility study by TECHNIP Stone & Webster Process Technology, Inc., Jan. 2014. Case Gasoline Production Manufacturing Cost CO 2 -to-Gasoline plant ISBL Estimated Range Notes -1 & -3 ($MM) Notes -1, -2 & -3 Case-D 100%CH 4 98.4 million gal/yr $422 $1.25 - $1.58/gallon (6,418 barrels/day) Note-1: Assuming an operation at 8,760 hours per year or 100%. Note-2: Includes Total CAPEX (ISBL & 50% of ISBL as OSBL and OPEX including Labor & Maintenance) Note-3: Based upon CO 2 conversion rates to Syngas of 65 – 70%. This process has not been optimized to higher CO 2 conversion rates and savings from heat recovery have not been included. 11 CO 2 + C (Carbonaceous input) + H 2 O (Steam) � Syngas (CO & H 2 ) � F-T Type Process � Gasoline
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