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Current Status of Biofuels Production and Use for Commercial Aviation

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Current Status of Biofuels Production and Use for Commercial Aviation CurrentCurrent StatusStatus ofof BiofuelsBiofuels ProductionProduction andand UseUse forfor CommercialCommercial AviationAviation ClaudioClaudio BertelliBertelli GlobalGlobal BusinessBusiness DevelopmentDevelopment ManagerManager UOPUOP LLC,LLC, AA HoneywellHoneywell CompanyCompany BIO 2010 - V Seminario Latinoamericano y del Caribe de Biocombustibles 17-18 August Santiago, Chile © 2009 UOP LLC. All rights reserved. Discussion Topics y Introduction y Semi renewable jet fuel: Hydroprocessed renewable jet synthetic paraffinic kerosene (HRJ SPK) y Fully renewable jet fuel: The Path to 100% Renewable Jet Fuel Honeywell Corporate Overview • 125,000 employees in more Transportation & Power Systems than 100 countries • A Fortune 100 company – Specialty Materials sales of $34.5 billion in 2008 Aerospace • Global leader in advanced 15% technology products, 36% services 15% UOP and solutions 34% Automation & Control Technology Company, Financially Strong and Global UOP Overview • Leading supplier and licensor of processing technology, catalysts, adsorbents, process plants, and technical services to the petroleum refining, petrochemical, and gas processing industries for over 90 years • UOP Technology Furnishes: 60% of the world’s gasoline; 70% of the world’s modern detergents; 60% of the world’s para-xylene 2003 National Medal of • ~3000 employees worldwide Technology Recipient • ’08 Financials: ~$2 billion sales; • Strong relationships with leading refining and petrochemical customers worldwide • 70+ processes in 6,000+ units in hydrocarbon processing industry; 300+ catalysts, adsorbents; 31 of 36 refining technologies in use today created by UOP Track Record Of Technology Innovation UOP Renewables Vision • Building on UOP technology and expertise • Produce real “drop-in” fuels instead of fuel additives/blends • Leverage existing refining, transportation, energy, biomass handling infrastructure to lower capital costs, minimize value chain disruptions, and reduce investment risk. • Focus on path toward second generation feedstocks & chemicals Renewable Oxygenated Biofuels Hydrocarbon Biofuels Energy Fuel & Ethanol Biodiesel Fuel & Diesel Jet Gasoline PowerPower “Other” Oils: Camelina, Jatropha First Second Generation Generation Natural oils from Lignocellulosic vegetables and biomass, greases algal oils Market Drivers/Enablers Aviation Emissions Are Growing Rapidly EU GHG Emissions by Sector as an Index of 1990 Levels y EU Emission Trading Scheme 180 extending to aviation sector: - Aviation emissions: Fastest growing of any sector 160 - 2012 Emissions: 97% of 2005 140 - 2013 Emissions, 95% of 2005 120 y US Military’s National Security driven goals to achieve both greater substitution (~50% by 100 Index 100 =1990 Index 100 =1990 2020) & GHG reduction, 80 y Aviation industry OEM’s drive to render fleets compatible with 60 upto 50% biojet 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Year Source: ICAO y Major Airline initiatives to use Int Aviation Waste biojet Energy Total (Without LUCF) Industrial Processes Transport Agriculture y Accelerated certification efforts y 2nd gen feedstock initiatives: - Camelina, Jatropha, Algal Forecast of Industry CO2 Emissions Key Drivers of Emissions Reductions Using Less Fuel - Efficient Airplanes - Operational Efficiency Changing the Fuel - Sustainable Biofuels Low carbon fuels a key part of emissions reduction Presented to ICAO GIACC/3 February 2009 by Paul Steele on behalf of ACI, CANSO, IATA and ICCAIA UOP RE&C Technologies & Capabilities Feed Process Product Natural Oil/Fats EcofiningEcofiningTMTM Green Diesel Hydrogen ProcessProcess Green Jet (if req) HVO: ‘000’s barrels/day Natural Oil/Fats RenewableRenewable JetJet Green Jet Process Hydrogen Process Green Diesel Envergent Technologies – UOP/Ensyn JV RapidRapid ThermalThermal Green Power / Fuel Oil (now) Biomass ProcessingProcessing (Pyrolysis)(Pyrolysis) UpgradingUpgrading ProcessProcess Green Fuels (2012) Sustainable technologies – feedstock flexible & 2nd Gen ready UOP Proprietary Viable Sustainable Biofuel feedstock alternatives: Commercial Scale Production Algae Jatropha Ready in 8 to 10 years Ready in 2 to 4 years Challenges Challenges • Technological • Limited to warm innovation climates only needed for • Mechanical processing harvesting isn’t • Algal Oil mature extraction key hurdle Halophytes Camelina Ready in 5 to 7 years Ready Now Challenges Challenges • Proven at pilot • Limited total scale potential owing to • Improve yield agronomy for • Somewhat tied to cost reduction grain market swings Viability is based on timing, technology and local resources Honeywell Green Jet FuelTM DARPA Project Partners • Started under DARPA contract to develop process technology to produce military jet fuel from renewable sources. • Leverages Ecofining process technology. Demonstration Flights • Fuel meets stringent requirements for flight. • Military has ordered up to 600,000 gallons. • Extend to commercial aviation in partnership with OEMs. UOP Stage Gate Process for Process Development: Green Jet Process Offered Commercially Scoping Techno-Economic Idea Studies Evaluation Pending Decision Validated Initiated Initiated to Proceed Idea Stage 1 Stage 2 Stage 3 Stage 4 Stage 5 Generation First Concept Develop- Product Scoping Selection ment Commercial Unit Launch Gate 1 Gate 2 Gate 3 Gate 4 Gate 5 Idea Project Dev’t Scale-up Product Post- Screening Selection Approval Approval Launch Launch Approval Review • Passed Gate 4 in December 2009 • Ready For Process Design #1 in 1Q 2010 Enables UOP to guarantee new technology Renewable Jet (Bio-SPK) Chemistry CO2 + H C Feedstocks HO 3 CH3 CH3 Rapeseed Free Fatty Acid O + Free Fatty Acid H H2 O H3 C CH3 Tallow MW=200-300 2 Jatropha O CH3 CO H C Soybean 2 3 CH3 O H3 C HC O + Algal Oils CH3 CH2 Palm Oil O O H3 C H C CH3 CH H2 O 3 Camelina 3 Triglyceride StraightStraight Chain Chain Paraffins Paraffins O Triglyceride Feed UOP Catalyst Greases MW=700-900 y Natural oils contain oxygen, have high UOP Catalyst H molecular weight. 2 y First reaction removes oxygen – product is CH3 CH3 diesel range waxy paraffins CH3 Synthetic CH CH3 H3 C 3 y Second reaction “cracks” diesel paraffins to Paraffinic H3 C Synthetic ParaffinicKerosene + smaller, highly branched molecules Kerosene H3 C CH3 CH CH y End product is same as molecules already + 3 3 present in aviation fuel H3 C CH3 y End product is independent of starting oil Feedstock flexible, but with consistent product properties Synthetic Jet Fuels Petroleum Synthetic Jet Fuels Conventional D 1655 Refinery Processes Fischer-Tropsch (FT) Coal Syn Gas Crude Oil (CO, H2) Natural Gas Syn-Crude D 7566 Annex 1 Biomass Gasify FT Process Hydroprocessed Renewable Jet (HRJ) from Bio-Oils Jet Fuel Hydroprocessing Plant/Algae Bio-Crude Oils Oil Extraction Slide courtesy of Mark Rumizen, FAA/CAAFI UOP Renewable Jet Process Selective Product Deoxygenation Feedstocks Hydrocracking Separation Hydrogen Rapeseed Tallow Jatropha Light Fuels Soybean CO2 Algal Oils SPK Palm Oil (Green Jet) Camelina Greases Green Diesel Water Recycle y Feedstock flexible y Optimised for 50% SPK yield y Makes valuable hydrocarbon co-products - Green Diesel - Green Naphtha - Green LPG y Ability to swing anywhere between ‘Max SPK’ and ‘Max Green Diesel’ production to meet market demand Commercial scale, proven technology Properties of SPK for Demo/Certification SPK SPK SPK Jet A-1 (Jatropha/ Description Specs (Jatropha) (Camelina) Algae) Flash Point, oC Min 38 46.5 42.0 41.0 Freezing Point, oC Max -47 -57.0 -63.5 -54.5 JFTOT@300oC Filter dP, mmHg max 25 0.0 0.0 0.2 Tube Deposit Less Than < 3 1.0 <1 1.0 Net heat of combustion, MJ/kg min 42.8 44.3 44.0 44.2 Viscosity, -20 deg C, mm2/sec max 8.0 3.66 3.33 3.51 Sulfur, ppm max 3000 <1 <1 <1 y Over 20,000 US Gallons of Bio-SPK made for demonstration flights y Certification supply work has uniquely allowed UOP to test the process and the catalyst at large Demo Capacity Fuel Samples from Different Sources Meet Key Properties Use of Green Jet Fuel: Semi-Synthetic Jet Fuel (SSJF) Natural Oils & y Green Jet Fuel can meet all Crude Oil the key properties of petroleum Fats derived aviation fuel yFlash point UOP Renewable Oil Refinery yFreeze Point Jet Process yStability yHeat of Combustion Synthetic Fossil Jet Fuel Paraffinic y SPK does not contain aromatics Kerosene so must be blended with a source of aromatics, such as 50-100% 0-50% fossil jet fuel Fully Fungible “drop-in” Renewable Fuel A ‘drop-in’ biofuel for aviation The Bio-SPK Program yIn 2008-2009, an industry team conducted testing of biofuel (Bio-SPK). yThe goal was to determine the feasibility of sustainable biofuels at blends up to 50%(v). •Evaluate & select feedstocks •Identify & pilot processing methods •Flights & Engine Tests •Conduct fuel property tests Results published in AIAA-2009-7002: “Sustainable Bio-Derived Synthetic Paraffinic Kerosene (Bio-SPK) Jet Fuel Flights and Engine Tests Program Results” Certification-Qualification Phase - ASTM D4054 Fuel Qualification Process Specification Fit-For-Purpose Component/Rig Engine/APU Properties Properties Testing Testing FRL 4.2 FRL 6.1 FRLs 6.2 & 6.3 FRL 6.4 ASTM Review Accept & Ballot Reject Re-Eval ASTM As Required ASTM ResearchResearch ASTM Report Specification Report ASTM ASTM Balloting OEM Review & Specification Process Approval FRL 7: Fuel Class Listed in Int’l Fuel Specifications Slide courtesy of Mark Rumizen, FAA/CAAFI ASTM D7566 Issued 1st Sept 09 D1655 5.1 Materials and y Body of Spec Applies to Manufacture Finished Semi-Synthetic
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