Ethanol's Role in Reducing Carbon Emissions from Transportation Fuels- and Paul Kamp Whitefox Technologies USA American Coalition for Ethanol ...
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Ethanol's Role in Reducing Carbon Emissions
from Transportation Fuels –
and
How to Get Your Ethanol Plant to Net Zero
Paul Kamp
Whitefox Technologies USA
American Coalition for Ethanol Conference 2021
Technologies to Achieve
Decarbonization in Fuel
Ethanol Production
I. RFS2 Summary on Carbon
Emissions
II. Where Are We Now?
III. Where Does Corn Starch
Ethanol Go Next? 5 Yr. Plan
IV. Whitefox Overview, as Part of
Overall Plant Carbon Reduction
Whitefox ICE® Installation in Council Bluffs, Iowa USA – 47,200
gallons/day (179,000 LPD) ethanol capacity
© Whitefox Technologies Limited 2021
Leveraging Existing Ethanol Industry = Most Viable Path to Large-Scale Carbon Reductions from Liquid Fuel 3 © Whitefox Technologies Limited 2021
Definitions from EISA 2007 (RFS2)
Energy Independence and Security Act
•
Corn starch (only) is specifically excluded ?
© Whitefox Technologies Limited 2021
Co-Location of Cellulosic and Corn Ethanol
3rd Party CI Assessment
(15 MMgy Inbicon Cellulosic Plant, ICM 50 MMgy baseline, EPA and CARB Guidelines
2013 Study, LCAssociates (Stephan Unnasch) © Whitefox Technologies Limited 2021
5
Example of
Ultra-Low CI Cellulosic Ethanol, D3 RINs
Corn Ethanol CI reduced to < Advanced Biofuel Threshold
100,000
2022 Biofuel Scenarios, Fuel Production
GHG Emissions (g CO 2 e / mmBtu)
90,000 30 year time horizon
80,000
Advanced Biofuel Tailpipe
70,000 Threshold
60,000
Fuel and feedstock transport
50,000
40,000
Agriculture and Land Use Change
30,000
20,000
Net Emissions
10,000
0
2005 26 M gal. Starch Co- Base Dry
Gasoline C5/C6 Located Mill NG,
In this example: Corn Ethanol CI = 49
Baseline Inbicon with DDGS Cellulosic Ethanol CI = 10
Stover Inbicon Excess Steam and Power from Biomass Refinery
CHP provides Heat & Power to Both Plants
Cellulosic Corn Ethanol
Ethanol
7 © Whitefox Technologies Limited 2021
Outline Dr. Michael Wang, ANL • Background – RFS2 definitions • Corn starch cellulosic co-location • LCAssociates – conclusion reached • Old Delta-T slide • Same Technologies that give Brazilian and Cellulosic their low scores • Now approaching Advanced Biofuels – get there with ILUC, Farming • Fortunately Corn Starch ethanol is perfectly good • List of things plants are doing • Whitefox Distillation and dehydration – Innovation • Milling – substrates • CHP – Cogen – Let down turbines • CCS • Cellulosic and CKF • MVR • Cultural Bias again corn ethanol in Sacramento, Washington DC and Eastern Beltway, EU, • Elitist Think-tanks with the Privilege of Philosophical Indignance • Africa, China, Asia, Midwestern US – of course its good, its good for farming • Crack in the Cultural Bias – latest DOE FOA – grain starch is permissable
Overcoming Cultural Bias Against Corn Ethanol New DOE BETO FOA specifically allows grain starch Cost < $2.50 , Demonstrate 70% GHG reduction.
California LCFS Ethanol Carbon Intensity
Corn-based Ethanol Biomass-based Ethanol Total Ethanol Gasoline (CARBOB)
101
100 96
90 89
Carbon Intensity (gCO2e/MJ)
88
80
70 65
35-40%
60 Reduction
60
50
40
38 70+%
30
Corn kernel fiber Reduction
28
20
Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1
2011 2012 2013 2014 2015 2016 2017 2018 2019 2020
Source: California Air Resources Board2021-2030 Decarbonizing Corn Ethanol
Technology Options for Producers – Path to “Net Zero”
• LUC’s & ILUC’s, properly assigned Have been reset, never been based on reality
• Farm Inputs reduce CI, developing on-farm methods Monetize Farms
• Biological improvements, CKF (Corn Kernel Fiber)
• Milling, Hi-Pro, Dry and Wet, Stillage separation, TSC
• DD&E Efficiencies, Liquid Separations PLANT OPTIMIZATION
• CHP, Cogen, Low-P and Hi-P Steam Turbines
• Advanced Heat Recovery - Dryer Exhaust, etc
• CCUS/CCUPS Overcome regulatory, location, financial and technical challenges
• MVC/MVR – vapor compression and recompression
• Ethanol to Jet “SAF”, CORSIA
• Heavy Transport Conversions, Other Fuels and Renewable Chemicals
© Whitefox Technologies Limited 2021Vital Role for Corn Starch Ethanol in “Zero Carbon” Transportation
Is Corn Starch Ethanol the Best Renewable Fuel? Probably, Yes
Carbon-Reducing Technologies required for other Fuels Pathways to achieve Ultra-
Low / Zero Carbon Scores are Same Technologies being implemented in Corn
Starch Ethanol
Corn Starch Ethanol Production is already Well-Established Processes and
Agricultural and Transportation Fuel Commerce.
With Reality-Based Adjustments to CI models for Farm Inputs, LUCs and ILUCs,
Corn Starch Ethanol is likely at a Permanent Advantage on Cost to Produce,
Efficiency, and CI.
Corn Starch Ethanol is a Practical Way to Decarbonize Transportation,
Support U.S. Farming, and offer Best Price and Air Quality Benefits to U.S. CitizensWhitefox Technologies – Introduction
“To reduce energy and water waste in industrial processes and
PURPOSE by doing so, we enable society to produce more from less.”
• Developing Membrane-Based Solutions since 2002, Improved Dehydration
Efficiency over Pressure Swing Adsorption (Molecular Sieves)
• Solutions apply to Fuel Ethanol, Other Alcohols, Bio-based Chemicals,
Sustainable Aviation Fuel, etc.
• Award winning company, Whitefox is revenue generating & EBITDA positive
• Global reach with installations in USA, UK, Spain, Germany, Guyana, Poland
• Whitefox patent portfolio (41 granted, 6 pending)
Inspired by Nature
© Whitefox Technologies Limited 2021EXPERIENCE – Fuel Ethanol Whitefox ICE® >100 Million Gallons of Installed Capacity in North America
Whitefox ICE® for Fuel Ethanol Plants
Molecular Sieve Regen and Partial 190P as Feed Streams
Proven Operations in Ethanol Industry Capacity
• Eight ICE® systems operational (>120,000 hours) Up to 30% Capacity Increase
• Five ICE® projects underway (Kansas, Iowa (2), Poland)
Debottlenecks Distillation and Dehydration
Compact footprint
Avoids Capital Cost on other Projects
Efficiency, Operations Improvement
Reduce steam and cooling requirements 10-15%
Continuous separation, no swings
Stabilizes operations, improves control
Dehydration in a single pass from high water
content
CI Reduction
1-2 point CI Reduction, verified in LCFS markets
Low carbon markets developing in Canada, US,
Worldwide
© Whitefox Technologies Limited 2020Whitefox ICE® for Fuel Ethanol Plants
Molecular Sieve Regen and Partial 190P as Feed Streams
190P SYSTEM Typical starting point:
16,000 BTU/gal
MOLECULAR
SIEVES
14,800 BTU/gal
Regen
SIDE STRIPPER /
RECTIFIER
Feed from
Beer Column
Ethanol
Depressure 14,600 BTU/gal
190P
MEMBRANE
Avoid Capital Cost on DD&E Upgrades
TANK
FOD
FEED
Water
Nat. Gas + Cooling Water Savings
Operations Improvement Plantwide
STRIPPER
Natural Gas Savings Debottlenecking = Capacity, Drier Specs
~1,400 BTU/gal WHITEFOX Scalable for Future Expansion
STAND-ALONE
Water
© Whitefox Technologies Limited 2021Process Improvements - Vacuum Distillation
Debottlenecking / Reduced Loads, Higher Rate, Steam Savings, Capital Cost Avoidance
Impact of Whitefox Operations on DD&E:
6% Beer Feed Increase + 27% Decrease in Rectifier/Side Stripper Load*
120 1,070
100 1,050
Beer Flow (GPM)
Flowrates (GPM)
80 Whitefox Startup 1,030
60 1,010
40 990
20 970
*As measured by rectifier
0 950
bottoms flow
Whitefox Startup Regen Flow to Rectifier Side Stripper Bottoms Flow
Beer Feed Flow (Right Axis) Rectifier Bottoms Flow
© Whitefox Technologies Limited 2021Field Example – Continuous Advancement
Continuous Advancement
• Improve controls
• Increase product reliability
• Increase production
© Whitefox Technologies Limited 2021Whitefox ICE® - SIRE
Council Bluffs, Iowa
Membrane
Core of
4-Module
Whitefox Unit
Whitefox Technologies Limited © 2021200P / High-Grade Dehydration at Brüeggemann Alcohol
• Top EU Manufacturer of Beverage,
Pharma and Industrial Alcohols,
operating Whitefox since 2003
• Specs to >99.95 wt%
• High-Grade applications - Pharma,
Industrial, Process Reagents
Diversification Opportunities
USP and Pharma
Ultra-High Purity Dehydration
Intermediates and Reagents
Alcohol to Jet Pathway
Fuel Cell Specs
© Whitefox Technologies Limited 2021What’s next for Whitefox – ICE® XL
Path to Replacement of Molecular Sieves / No More Pressure Swing Adsorption
ICE® XL is larger version of ICE®
Higher Water % in Dehydration Feed – Reduces RC Duty and
Overhead Proof
Reduces Load on Sieves during Implementation
4,000 – 5,400 btu/gal Benefit for Typical Plant
Main Features:
• Improved Water Balance – Reduce/Eliminate Direct Steam
Injection
• Modify Pressure Cascades, Reconfigure DD&E and Operations
• Membranes are Azeotrope-Agnostic
• Optimized Heat Exchanger Network
• Can be Integrated with MVR and MVC
Project Execution
• Installed in Stages, Starting with ICE® unit
• Can Mostly be Installed in Parallel (Minimum Downtime)
© Whitefox Technologies Limited 2021Whitefox ICE® XL – Efficiency
Replacing Mol Sieves in Stages over next 5 Years
17,500 17,500
Whitefox ICE
Whitefox ICE XL
15,000 Stage 3 15,000
Total Natural Gas Energy Savings
Total Natural Gas Consumption (BTU/gal)
12,500 12,500
Whitefox ICE XL
10,000 Stage 2 10,000
(BTU/gal)
7,500 7,500
5,000 5,000
2,500 2,500
Whitefox ICE XL
Stage 4
0 0
Energy Consumption Energy Savings
Example is ICM plant with natural gas consumption of DD&E + Front End = 16,000 BTU/gal.
Total natural gas consumption of 25,600 BTU/gal (including dryers, 100% DDGS)
© Whitefox Technologies Limited 2021How to Get Your Ethanol Plant to Net Zero
Conclusions
• A Producer can develop a strategy to implement existing technologies into their corn
ethanol plant, in various combinations, to achieve ultra-low or zero CI in the next five
years
• Corn farming practices and realistic corrections into land-use change modeling
accelerate that
• Whitefox offers a low-risk path for debottlenecking, reducing energy use and optimizing
operations
• Incremental expansion steps over the next five years can significantly reduce natural gas
use and replace molecular sieve units (Whitefox ICE®-XL). It starts with Whitefox ICE®
© Whitefox Technologies Limited 2021Waste Less. Produce More.
Paul Kamp
pkamp@whitefox.com
773-583-5923
Whitefox Technologies Limited
• Canada: 403 210 2999 • Europe: +44 (0) 20 7953 8446 • USA 773 583 5923 • Email: solutions@whitefox.comYou can also read
