Periodic Reporting for period 1 - BL2F (Black Liquor to Fuel by Efficient HydroThermal Application integrated to Pulp Mill)
Reporting period: 2020-04-01 to 2022-03-31
BL2F project aims to develop continuous and commercially viable HydroThermal Liquefaction (HTL) conversion technology to produce sustainable drop-in biofuel for aviation and marine transport. The target is to (i) decarbonize the aviation and marine industry and to reduce its carbon footprint by at least 80% and (ii) utilize the abundantly available but rather underutilized, non-food, side stream of the pulp industry – Black Liquor (BL). HTL converts BL into high quality biocrude or fuel intermediate at high temperature and pressure using supercritical water as a solvent and/or catalyst. BL, however, contains inorganic salts acquired from the cooking process in the kraft pulping and therefore makes it challenging to use this BL directly into HTL. These salts either crystallizes or forms a brine solution at the supercritical condition (above 374 C and 221 bar) resulting in the plugging of the reactor walls and process tubes. These salts can be removed in the HTL process. A novel integrated HTL (IHTL) reactor, thus proposed in the BL2F project, simultaneously removes the salts from BL and carries out the HTL reaction to produce different product phases, the most critical for BL2F being raw HTL-crude. An estimated 90% of the salts can be removed using the novel IHTL reactor while at the same time maintaining the economics and operability of the whole process. Raw HTL-crude, condensate of the top product from IHTL, is then refined by reacting it with Hydrogen to reduce the oxygen content from 10% to 5% in an Integrated Hydrogen De-Oxygenation (IHDO) step. A novel catalyst which facilitates the reduction of Oxygen content in IHDO, is being developed as part of the BL2F project. The produced product from IHDO, called as biocrude or fuel intermediate in BL2F project glossary, has to be refined further (2nd stage refining) to produce the drop-in biofuel (BL2F is not directly involved in 2nd stage refining). The Hydrogen required in IHDO process is obtained from the Aqueous Phase reforming (APR).
The project is progressing well, although some challenges were faced due to the COVID-19 situation. The online meetings and teleconferencing have worked well, and no major challenge was faced in managing the project virtually (WP8). First face-to-face general meeting is planned in Finland in the month of October 2022.
WP1, led by Tampere University, focuses on developing the IHTL technology and commissioning the pilot plant for the same in the University premises. A review article by the master thesis student at Tampere University has already been published in the open literature. This review article focused on the effect of different process parameters, solvents, and catalyst on the HTL of BL. As part of Task 1.1 the BL, sourced from soft wood (mainly spruce and pine) and hard wood (eucalyptus and birch), were characterized to identify the different components of BL and the report (D1.1) has already been published for the same. The design of the IHTL reactor has been finalized and the pilot plant containing the novel IHTL reactor will be commissioned and tested at TAU by the end of August 2022. The CFD modelling of the IHTL reactor has also started and is progressing well. However, the lack of validation data can pose a challenge. As part of Task 1.5 Four industrially relevant materials - 254SMO, P91, C-275 and 699XA are shortlisted after the pre-screening test to conduct the HTL reactions.
WP2 focuses on studying the behavior of different salts in a model salt solution at the supercritical condition to develop a strategy for the continuous salt extraction from BL. The phase equilibria data were obtained from HP-DSC instrument over a wide temperature range of interest (300 - 400 °C). The results indicate that selectively extracting carbonates from the model salt solution favors the continuous salt separation strategy. A paper has been published by the PSI on this. As part of Task 2.3 to produce Hydrogen from APR, process design and catalyst has been selected.
For the IHDO development, WP3 focuses on the selection and testing of catalyst. After selection of suitable support materials, the catalyst samples are to be tested in batch and continuous reactors. The main challenge for this WP has been the lack of real HTL biocrude feed (supposed to be produced by TAU). The work in this WP, as a result, is currently progressing with the model biocrude mixture.
The activities in WP4 focuses on the process design for IHTL plant, upgrading of bio-oil, and the integration of the IHTL plant into the pulp mill. The process design includes process flow diagrams with main and auxiliary process equipment operating at the desired operational conditions. The material and energy flows will be used to evaluate the impact of the IHTL on the pulp mill performance.
WP5 aims to evaluate the environmental and economic sustainability and circularity by developing the Life Cycle Assessment (LCA) and circularity assessment methodology. BUL is currently collecting the data to identify the primary data for assessment however the lack of real process data form the pulp mill due to the confidentiality issues is slowing the progress. They, as a result, are using the expert knowledge, pulp mill model, and literature to collect the data.
WP6 aims to exploit the project results and ensures the continuity after the project completion. Evaluation on the policy framework for advanced biofuels use & production, as well as recommendations were provided to enhance the potential of a successful market uptake of the technology. As part of this WP, study on the market potential of 8 European countries for the 3 main key exploitable results is currently being conducted.
The Dissemination and Communication work package (WP7) communicates, disseminates, and engages stakeholders, via social media, website, publications, and attendance to events. A Communication & Dissemination plan and a visual identity for the project have been created during the 1st reporting period. BL2F has participated in 8 different events and carried out a social media awareness campaign.
WP1, led by Tampere University, focuses on developing the IHTL technology and commissioning the pilot plant for the same in the University premises. A review article by the master thesis student at Tampere University has already been published in the open literature. This review article focused on the effect of different process parameters, solvents, and catalyst on the HTL of BL. As part of Task 1.1 the BL, sourced from soft wood (mainly spruce and pine) and hard wood (eucalyptus and birch), were characterized to identify the different components of BL and the report (D1.1) has already been published for the same. The design of the IHTL reactor has been finalized and the pilot plant containing the novel IHTL reactor will be commissioned and tested at TAU by the end of August 2022. The CFD modelling of the IHTL reactor has also started and is progressing well. However, the lack of validation data can pose a challenge. As part of Task 1.5 Four industrially relevant materials - 254SMO, P91, C-275 and 699XA are shortlisted after the pre-screening test to conduct the HTL reactions.
WP2 focuses on studying the behavior of different salts in a model salt solution at the supercritical condition to develop a strategy for the continuous salt extraction from BL. The phase equilibria data were obtained from HP-DSC instrument over a wide temperature range of interest (300 - 400 °C). The results indicate that selectively extracting carbonates from the model salt solution favors the continuous salt separation strategy. A paper has been published by the PSI on this. As part of Task 2.3 to produce Hydrogen from APR, process design and catalyst has been selected.
For the IHDO development, WP3 focuses on the selection and testing of catalyst. After selection of suitable support materials, the catalyst samples are to be tested in batch and continuous reactors. The main challenge for this WP has been the lack of real HTL biocrude feed (supposed to be produced by TAU). The work in this WP, as a result, is currently progressing with the model biocrude mixture.
The activities in WP4 focuses on the process design for IHTL plant, upgrading of bio-oil, and the integration of the IHTL plant into the pulp mill. The process design includes process flow diagrams with main and auxiliary process equipment operating at the desired operational conditions. The material and energy flows will be used to evaluate the impact of the IHTL on the pulp mill performance.
WP5 aims to evaluate the environmental and economic sustainability and circularity by developing the Life Cycle Assessment (LCA) and circularity assessment methodology. BUL is currently collecting the data to identify the primary data for assessment however the lack of real process data form the pulp mill due to the confidentiality issues is slowing the progress. They, as a result, are using the expert knowledge, pulp mill model, and literature to collect the data.
WP6 aims to exploit the project results and ensures the continuity after the project completion. Evaluation on the policy framework for advanced biofuels use & production, as well as recommendations were provided to enhance the potential of a successful market uptake of the technology. As part of this WP, study on the market potential of 8 European countries for the 3 main key exploitable results is currently being conducted.
The Dissemination and Communication work package (WP7) communicates, disseminates, and engages stakeholders, via social media, website, publications, and attendance to events. A Communication & Dissemination plan and a visual identity for the project have been created during the 1st reporting period. BL2F has participated in 8 different events and carried out a social media awareness campaign.
BL2F supports the EU’s vision of becoming world leader in biofuel technology and developing a unique and cost-effective IHTL technology and integrating it to the pulp mill will increase its portfolio. The companies in the consortium cover the complete value chain – from pulp mill to transportation to biofuel production and sales thus building new and feasible value chain and business opportunity. The produced biocrude from the HTL process is superior in quality, contains an oxygen content of 5% reduced from 37% in the original BL and has a heating value of 39 MJ/kg increased from 23 MJ/kg in the original. The BL2F project, further aims to integrate the newly developed IHTL process with the existing pulp mills. This approach has several benefits, for instance, the existing special systems for gas and waste handling at a pulp mill can be adjusted to handle the waste streams from HTL. Compared to a standalone green field facility, the integration can result in a cost savings of up to 45% mainly due to lower operational and capital costs.