Spreadsheet: 2254d94b-87f5-4065-b432-173bd5553e6d
Sheet: NREL Fast Pyr design case

Process Indicators for Cellulosic Thermochemical Production of Biofuels via Pyrolysis/Liquefaction
PROJECT TITLE:: | NREL Nov. 2010 Fast Pyrolysis to Transportation Fuels design case (NREL/TP-6A20-46586), H2 purchased Scenario
 |  |  |  | [Metrics projected to commercial scale, based on demonstrated data]
TECHNICAL DATA INPUTS
EVALUATION DATE:: |  | 2012-01-27 00:00:00
Section | Parameter | Value(s)* | Basis/Justification** | Notes / Directions / Examples
Process Description | Provide a block flow diagram and brief (one paragraph) description of the major process steps/unit operations and technologies employed. Include the type of major equipment and the type of catalyst used as appropriate for each major step. Include relevant process information (e.g. temperatures, pressures, residence times, etc.). | [see attached]
Product (s) and By-Products | List all product and by-products serving as revenue for process/plant | naphtha/diesel blendstock, fuel gas |  | Example Products: renewable gasoline, naptha, renewable diesel                                                                                                                                 Example by-products: wax, electricity
 | Refinery Insertion Point for Liquid Fuel(s)/Product(s) | intermediated refinery insertion point (middle distillates stream) |  | Example: crude oil fed to refining front end.  Example, naphtha blended with refining intermediate naphtha stream.  Example: finished diesel
Feedstock (as delivered) | Feedstock Type | Corn Stover |  | Examples: wood chips, switchgrass
 | Feedstock Energy content (BTU/lb) (LHV, dry basis) |  | HHV, USDA data ([NAME], 2010)
 | Feedstock Cost ($/BDMT) | 83 | based on USDA data, including delivery costs | BDMT is bone dry metric ton
 | Nominal form or size (inch) | 0.4-1 inch | USDA data, [NAME], 2010 | Example: switchgrass round bails, 1/4" wood chips, etc.
 | Moisture (wt%) | 0.25 | USDA data, [NAME], 2010
 | Ash content ( wt %) (dry basis) | 0.06 | USDA data, [NAME], 2010
 | C, H, N, O, S (wt %) (dry basis) | 47.28, 5.06, 0.8, 40.63, 0.22% | Adapted from USDA data, [NAME], 2010
Drying and Grinding | Grinding energy use (kWh/BDMT) | not available (included in total power requirement) | assuming hammer mill size reducer and energy estimated using [NAME] et [NAME] (Biomass and Bioenergy, 2004, 27(4), 339) empirical equation for corn stover
(If applicable) | Final Moisture (wt %) | 0.07 | [NAME] based on simulation
 | Final Nominal particle size (inch) | <0.3 mm particles
Thermochemical Conversion | Temperature (deg C) | 480 | based on recommendations for bubbling fluidized bed pyrolyzer described in NREL paper ([NAME], [NAME]/TP-510-37779, 11/2006)
 | Pressure (psia) | 14.7
 | Residence Time (seconds) | 0.5
 | Catalyst(s) usage/replacement rate(s) (kg/BDMT) | NA |  | List catalysts individually
 | Catalyst(s) cost ($/kg cat) | NA |  | List catalysts individually
 | Hydrogen Source and Consumption in Conversion (kg/BDMT) | NA
Conversion Exit Yield & | % inlet C as usable for biofuel  (%)  [all C except char, losses] | 0.71 | based on USDA data for corn stover pyrolysis in pilot bubbling fluidized bed of quartz sand ([NAME], 2010)
Characteristics | Gas Yield (kg/BDMT) | 129
 | Char/Ash Yield (kg/BDMT) | 164 |  |  |  | wet basis or dry basis and why? Or (wt % of BDMT or C fed)
 | Water Yield (kg/BDMT) | 108
 | Bio-Oil Yield (kg/BDMT)
 | Bio-Oil Energy content (BTU/lb) (LHV, wet basis) | 9509 (HHV)
 | Bio-Oil Moisture Content (wt%) | not available
 | Bio-Oil TAN (mg/g) | not available
 | Bio-Oil Oxygen Content (wt%) | 0.3794
 | Additional Bio-Oil Characteristics | not available
 | Energy Efficiency  across Thermochemical Conversion (%)  (LHV) | not available |  | (Dry oil out)/(Biomass plus other input fuels in)
Bio-Oil Stabilization | Catalyst(s) usage/replacement rate(s) (kg/kg of Bio-oil feed) | not available |  | List catalysts individually
(If applicable) | Catalyst(s) cost ($/kg cat) | not available |  | List catalysts individually
 | H2 Source and Consumption in Stabilization (kg/kg of Bio-oil feed) | N/A
 | [NAME] Yield (kg/kg of Bio-oil feed) | 0.9995
 | Water Yield (kg/kg of Bio-oil feed) | N/A
 | [NAME] and Ash Reduction in Stabilization (wt%) | not available
 | Metals Reduction in Stabilization (wt%) | 0.98 | assumed guard bed performance for reduction of metals to 10 ppm levels to protect hydrotreating cats
 | [NAME] (BTU/lb) (LHV, wet basis) | [same as above]
 | [NAME] Moisture Content (wt%) | [same as above]
 | [NAME] (mg/g) | [same as above]
 | [NAME] (wt%) | [same as above]
 | Fresh Bio-Oil Viscosity (cP) | N/A
 | Aged Bio-Oil Viscosity (cP) and Aging Methods/Time | N/A
 | Additional Stabilized Bio-Oil Characteristics | N/A
 | Energy Efficiency  across Upgrading (%)  (LHV) | N/A
Upgrading to Fuel(s)/Product(s) | Catalyst(s) usage/replacement rate(s) (kg/kg oil feed) | $1.8MM/yr catalyst costs | based on typical catalyst replacement costs for petrochemical hydrotreating and hydrocracking unit operations | List catalysts individually
(If applicable) | Catalyst(s) cost ($/kg cat) | not available |  | List catalysts individually
 | H2 Source and Consumption in Upgrading (kg/kg oil feed) | 0.03-0.045 | Adapted from wood pyrolysis/upgrading lab data presented publically by UOP ([NAME], J.; Nair, P.; [NAME], D.; Bain, R.; Marinangeli, R. “Converting Pyrolysis Oils to Renewable Transport Fuels: Processing Challenges & Opportunities.” National Petrochemical & Refiners Association Annual Meeting, San Diego, CA, 2008; pp. 9-11)
 | Gas Yield in Upgrading (kg/kg oil feed) | 0.6 (including water)
 | Energy Content of Gas Produced in Upgrading (BTU/lb) (LHV) | not available
 | Liquid Fuel(s)/Product(s) Yield in Upgrading (kg/kg oil feed) | 0.42 |  | List individually, if more than one liquid fuel/product is made
 | Energy Content of Liquid Fuel(s)/Product(s) (BTU/lb) (LHV) | 18000-19000 |  | List individually, if more than one liquid fuel/product is made
 | Water Yield (kg/kg oil feed) | included in lights
 | Liquid Fuel(s)/Product(s) TAN (mg/g) | 15 |  | List individually, if more than one liquid fuel/product is made
 | Liquid Fuel(s)/Product(s) Oxygen Content (wt%) |  |  | List individually, if more than one liquid fuel/product is made
 | Liquid Fuel(s)/Product(s) Mositure Content (wt%) | not available |  | List individually, if more than one liquid fuel/product is made
 | Additional Liquid Fuel(s)/Product(s) Characteristics | not available
 | Liquid Fuel(s)/Product(s) Miscibility with Petroleum Steam(s) | naphtha/diesel stream miscible |  | At designated insertion point(s); list individually for multiple streams
 | Energy efficiency across Upgrading (%) (LHV) | not available |  | (Upgraded dry oil out)/(Dry oil plus other inputs) |  | Is this a good and clear definition?
Overall Process Yield | Overall Process Yield from Biomass (unit/BDMT):                                                           --Gasoline (gal/BDMT) --Naphtha (gal/BDMT)                                                                                                --Diesel (gal/BDMT)                                                                                                  --Fuel Gas (MMBTU/BDMT)                                                                               --Export Power (kWhr/BDMT) --Other Fuel(s)/Product(s) (unit/BDMT) | 47.8 gal/BDMT naphtha 40.8 gal/BDMT diesel 1.8 MMBTU/BDMT fuel gas | simulation based on above assumptions | Provide separately for each product and by-product (e.g. diesel-gal/BDMT, LPG-gal/BDMT, export electricity kWhr/BDMT)
 | Overall Energy efficiency (%) (LHV) (GTG) | 0.7 | simulation based on assumptions | ([NAME]) and by-products out)/(Biomass plus other input fuels in); GTG-gate-to-gate
Overall Usage Rates (based on demonstrated data and projected to commercial scale) | H2 purchased (kg/gal biofuel(s)) | 0.28 | simulation based on assumptions |  |  | Is this a good and clear definition?
 | Chemicals (other than catalysts and H2) ($/gal biofuel(s)) | not available
 | Electricity usage (kWh/gal biofuel(s)) | 1.6 | simulation based on assumptions | (total power used by process, not including generation)
 | Thermal Utilities Purchased:                                                                                          --Electricity (kWhr/gal biofuel(s))                                                                                            --Natural gas (MMBTU/gal biofuel(s))                                                                             --Steam (MMBTU/gal biofuel(s)) | 138 kWhr/BDMT power | simulation based on assumptions | Utilities imported/purchased by plant (above those generated by plant)
 | Purchased water (gal/gal biofuel(s)) | not available |  | Include process water, cooling water, boiler feed water, etc.
Wastes (based on demo'd data/projected to commercial) | Waste Water for Treatment (gal/gal biofuel(s)) | not available |  | Include assumptions for water recycle/re-use |  | Do we want to separate process water, cooling tower, and boiler feed?
 | [NAME] (kg/gal biofuel(s)) | 1.5 | simulation based on assumptions
Capital Costs***  (projected to | Commercial Plant Design Capacity (BDMT/day) | 2000 |  | Design capacity for capital cost estimate (e.g. commercial nth plant)
commercial scale) | Estimated Total Capital Investment ($) | $200MM | assumed nth plant, Installed capital estimated using ICARUS, based on Aspen simulation; Indirect costs & contingency estimated using factors; Lang Factor of 5.5
Labor Costs (projected to commercial scale) | Expected Commercial Plant Staffing (FTE) | not available |  | Provide an estimate of the number of people it will take to operate the full-scale commercial plant. Include process operators and immediate supervision. Express as the number of Full Time Equivalent people.
*Provide the best value achieved to date based on actual data, if available
**Describe  the basis or justification for result reported, and the scale it was demonstrated. Examples of basis include: number of hours at steady state (steady state typically defined as continuous operation of the integrated process for ≥3 residence times), or the results of a number of replicate short runs of the isolated process step.
***For Capital estimates, please include the level of confidence in the data and provide ranges if applicable.