A Techno-Economic, Sustainability and Experimental Assessment of the Direct Methanation of Biodiesel Waste Glycerol
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i A techno-economic, sustainability and experimental assessment of the direct methanation of biodiesel waste glycerol Robert White Submitted in accordance with the requirements for the degree of Doctor of Philosophy as part of the integrated PhD with MSc in Bioenergy Doctoral Training Centre in Bioenergy, Energy Research Institute, School of Chemical and Process Engineering, The University of Leeds October 2018 The candidate confirms that the work submitted is his/her own and that appropriate credit has been given where reference has been made to the work of others. ii This copy has been supplied on the understanding that it is copyright material and that no quotation from the thesis may be published without proper acknowledgement. © 2018 The University of Leeds and Robert William White iii Acknowledgements Whilst this PhD has been submitted in my name, it takes a great deal more than one individual to complete a body of work such as this. Firstly I would like to thank my supervisors, Dr Valerie Dupont and Prof. Timothy Cockerill for their support, guidance and patience throughout the last four years. I would also like to thank the following from my research group: Oliver Grasham for listening to my ideas and always having the time to have a discussion, Robert Bloom for our chats in the laboratory and Sergio for his help calibrating the micro GC. My colleagues from the first year and second year of the bioenergy CDT are deserving of my thanks and gratitude and include, in no particular order: Diarmaid Clergy, Andrew Dyer, Gillian Finnerty, Luke Conibear, Hana Mandova, Lee Roberts, Charlotte Stead and Kiran Palmer as well as Jeni Spragg, Charlotte Weaver, Nicola Wood, Daisy Thomas, Iram Razaq, and Ric Birley. Several members of staff made this work possible and I would like to thank the energy building engineering technicians; Kevin Dyer, Scott Prichard, Gurdev Bogall as well as the lab 1.10 technicians Adrian Cunliffe and Karine Alves Thorne I would also like to thank the Engineering and Physical Science research council (ESPRC) for my studentship and Freddy from the University of Yucatan, Mexico, for his guidance with life cycle analysis and collaboration. Someone who should not go unmentioned is my long suffering partner, Emma Johnson. My gratitude for her patience, kindness and love knows no bounds and has been pivotal in the completion of this work, and retention of my sanity. Finally I would like to thank my family, my mother Ricamor, my father Duncan, and my brother Edward who have made me what I am today. iv Abstract Crude glycerol from biodiesel production is a potential feedstock for energy in many parts of the world. A concept that is yet to be explored is the conversion of glycerol to a methane rich gas known, in this case, as bio-SNG, by taking advantage of steam reforming and methanation reactions in a single reactor. This process is known as direct methanation. Direct methanation is a type of low temperature steam reforming and is performed at temperatures lower than those commonly used for hydrogen production from organic feedstock. When applied to glycerol, it is termed ‘GLT-SR’ in this thesis. GLT-SR allows glycerol to be transformed into a gaseous energy vector that can be converted to energy on- site at the biodiesel refinery to offset fossil natural gas usage, for instance, in the energy intensive bean or seed crushing stage. The present work identifies the feasibility of a GLT-SR process using a design process framework and included process modelling in Aspen Plus, technoeconomic and environmental energy life cycle impacts analysis and laboratory scale experiments using pure glycerol to avoid any unknown impacts of contaminants contained in crude glycerol. Based on the thermodynamic analysis and process model, the optimum conditions favouring methane production and energy efficiency were 8 atm, with a feed molar steam to carbon ratio of 2.56 and an inlet temperature of 474 K. When compared to natural gas, bio-SNG from soybean based glycerol had the potential to decrease global warming potential with a trade-off of increased eutrophication, terrestrial ecotoxicity and freshwater aquatic ecotoxicity potential. The economic analysis based on biodiesel plants located in the USA, determined that a gas price of USD$6-7 per million BTU was necessary to achieve acceptable rates of return and coincided with the states of Missouri and Arkansas. A gasification rig was constructed and laboratory experiments confirmed that reducing the temperature were essential to maximising methane production. At steady state roughly 90% of the glycerol was converted to carbon gases with the most effective conditions achieving 66% of the CH4 conversion at equilibrium at 673 K (400 °C), steam to carbon ratio 2.5, pressure 1 atm and weight hourly space velocity of 0.54 hr-1. Thus current process conditions showed the process was operating away from the desired equilibrium for maximum CH4. Based on economics and environmental analysis, the process is feasible but would rely on an optimised process to maximise CH4 production and further trials to determine the impact of glycerol contaminants. v Table of Contents Acknowledgements ................................................................................................................ iii Abstract ................................................................................................................................... iv Table of Contents ..................................................................................................................... v List of Tables ........................................................................................................................... xi List of Figures ........................................................................................................................ xiii Abbreviations ...................................................................................................................... xviii Nomenclature ....................................................................................................................... xxi Achievements ..................................................................................................................... xxiii i. Journal Papers ................................................................................... xxiii ii. Magazine Articles ............................................................................. xxiii iii. Conference Proceedings ................................................................. xxiii iv. Conference Oral Presentations ....................................................... xxiii v. Conference Poster Presentations .................................................... xxiii vi. Prizes ............................................................................................... xxiv 1 Introduction ................................................................................................................... 1 1.1 Research Motivation ............................................................................................. 1 1.1.1 Decarbonising Transport ................................................................................... 2 Replacing fossil diesel with biodiesel ........................................................................ 2 1.1.2 Decarbonising heat ........................................................................................... 5 1.1.2.1 Renewable and synthetic natural gas ..................................................... 7 1.1.2.2 Synthetic natural gas from fossil fuels .................................................... 8 1.1.2.3 Biomass gasification for synthetic natural gas ..................................... 11 1.1.2.4 State of biomass to synthetic natural gas technologies ....................... 12 1.1.2.5 Biodiesel glycerol as a feedstock for decarbonising heat ..................... 14 1.1.2.6 Crude vs Pure Glycerol .......................................................................... 16 1.1.2.7 Steam reforming and methanation ...................................................... 20 1.2 Research Justification .......................................................................................... 22 1.2.1 Direct methanation of glycerol for Bio-SNG ................................................... 23 vi 1.2.2 Process Integration in a Soybean Biodiesel Refinery ....................................... 24 1.3 Research Objectives ............................................................................................. 26 1.4 Research Challenges and Novelty ........................................................................ 27 1.5 Applying the design process to assess the feasibility of the direct methanation of glycerol 29 1.6 System Boundaries ............................................................................................... 30 2 Process Simulation ........................................................................................................ 32 2.1 Introduction ......................................................................................................... 32 Steady state and dynamic equilibrium ......................................................................... 33 2.2 Literature Review ................................................................................................. 35 2.3 Design Needs .......................................................................................................