Thermochemical Conversion of Forest Thinnings

March 8th, 2005

– Thesis Defense –

University of Washington, Energy and Environmental Combustion Laboratory 1

 Agenda

• Thinning of Forests

• Bio-fuel Production

• Comparison of Alternatives

• Conclusions

Agenda,02-07-05,PYR
University of Washington, Energy and Environmental Combustion Laboratory 2
Many forests in the western US are at elevated risk to wildfire

Forest or Tinderbox?
- Western US Forests -
• Periodic natural fires regenerate the forest ecosystem by burning out brush and small diameter
trees
—Decreased competition among remaining trees
—Returns nutrients to soil

• Years of active fire suppression on private and public land in the west have led to unnaturally
high forest fuel loads
—Small-diameter trees (<6” diameter)
—Brush
—Dead wood

• High fuel density enables ‘wildfires’

—Burns hotter than natural fires
—Can consume both large and small trees
—Long eco-system recovery
—Expensive to fight
—Dangerous for firefighting personnel

• As of 2002, the US Forest Service listed 120 million

acres at “unnatural risk” for wildfire

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University of Washington, Energy and Environmental Combustion Laboratory 3
One way to reduce the risk of wildfire is to mechanically thin overstocked forests

Mechanical Thinning
- Overview -

Mechanical Thinning

Before – High Risk Forest After – Thinned Forest

• Mechanical thinning involves the removal of small diameter trees to create a more natural forest
—Simulate end-state of a natural burn
• Numerous benefits to thinning include:
—Decreased risk of wildfire
—Improved resistance to insect infestation and disease
—Remaining trees grow larger and faster due to decreased competition

• However, thinnings have little traditional commercial value

—Thinning can not pay for itself (unless combined with commercial logging – highly contentious)
—So what do you do with all the material you remove from the forest?

Source: Reynolds Forestry Consulting - RFC, Inc

011,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 4
Thinnings have a number of energy and non-energy uses

Uses for Thinnings

- Overview -

Energy Uses Non-Energy Uses

• Wood chip cogeneration • Pulp and paper

—Production of power and low-grade heat or steam
from wood chips • Forest products
—Emerging small-wood industries
• Co-fire —OSB production at small scale
—Substitute wood chips for fraction of coal at —Long-term carbon capture opportunity
conventional power plant
• Disposal
• Produce a bio-fuel —Landfill
—Methanol: commodity chemical, transportation fuel —Pile burning
—Bio-oil: industrial fuel, refining feedstock
—Wood Pellets: residential fuel

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University of Washington, Energy and Environmental Combustion Laboratory 5
Of special interest are “stranded” thinnings harvested far from industrial centers

“Stranded” Thinnings
- Key Concerns -
Okanogan National Forest
- Example - • “Stranded” thinnings are typified by long
transportation distance to end-use markets

• For long transportation distances, fuel density

becomes a key concern and fuel densification
will reduce transportation costs

Wood Wood Bio-oil Methanol

Chips Pellets

Low-grade High-grade Low-grade High-grade

Solid Fuel Solid Fuel Liquid Fuel Liquid Fuel
350 kg/m3 640 kg/m3 1200 kg/m3 790 kg/m3
• 763,000 acres at risk to wildfire
―More than 70% total forested acreage
―Urgent thinning need
• But densification comes at a cost…
• “Stranded” thinnings
―No local market for pulp
―East of Cascade Crest (east-west barrier) and distant
from Spokane

009,02-07-05,PYR.ppt Source: Rural Technology Initiative

University of Washington, Energy and Environmental Combustion Laboratory 6
 Agenda

• Thinning of Forests

• Bio-fuel Production

• Comparison of Alternatives

• Conclusions

Agenda,02-07-05,PYR
University of Washington, Energy and Environmental Combustion Laboratory 7
We are interested in optimal size and location for the bio-fuel production facility

Bio-fuel Network
- Layout -

Logging Deck
Option 1: Mobile Bio-fuel Production
―Highly mobile unit built on semi-trailer Option 4: Relocatable Bio-fuel Production
―10 dry tons per day throughput ―Relocatable facility located at edge of forest in
―Spends days to a week at logging deck industrial zone (grid electricity available)
―15 year lifetime ―500 dry tons per day throughput
―In position for duration of thinning operation (20
year lifetime)
Option 2: Transportable Bio-Fuel
Forested
Production
Area ―Modular design readily transported in
several semi-trailer containers
Logging Road ―100 dry tons per day throughput
―Spends months at collection area
―15 year lifetime

Option 3: Stationary Bio-fuel Production

Major Road ―Stationary facility located at edge of forest in
industrial zone (grid electricity available)
―Sized so single facility consumes entire daily
production from forest
―Lifetime equal to duration of thinning operation

007,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 8
Producing a high-grade solid fuel, like pellets, is primarily a mechanical process

Pellet Production
- Process Flow -

Flue Gas
Additives
Power Power Power
31 kWhr/ton water 127 kWhr/dry ton 114 kWhr/dry ton

Dryer Grinding
to 10% moisture to 3 mm
Pelletization

• Pellets formed by high pressure

extrusion of ground wood through die
Exhaust ―Pressure raises temperature to over
Legend
100oC
―Lignin begins to flow and acts as an
Solid Phase Pile Burner Diesel Engine “adhesive” when cooled
Process
Gas Phase Power
• Limited research opportunities
Problem
Mineral Ash Diesel Fuel ―Grinding requirement fixed by
Primary Path
standardized pellet size
―Mature technology with respect to
Input or Secondary Path
woody biomass

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University of Washington, Energy and Environmental Combustion Laboratory 9
Fast pyrolysis produces a low grade bio-fuel, commonly referred to as bio-oil

Low-grade Liquid Bio-fuel Production

- Overview -

• Fast pyrolysis is defined as the thermal decomposition of biomass by rapid heating in the absence of oxygen

• Three categories of decomposition products

Component Yield (dry mass%)

• Condensable Vapors • 70-80%

• Light Gas • 10-15%
• Char • 10-15%

• Condensed vapors are collectively referred to as ‘pyrolysis oil’ or ‘bio-oil’

―Mixture of oxygenated hydrocarbons and water – water is the most common single species
―High density liquid fuel (1200 kg/m3) with moderate heating value (16-19 MJ/kg)
―Potential applications for industrial heating, power generation, and chemical feedstock for bio-refining

• Bio-oil has a number of undesirable characteristics

―Low pH (2.5-3) due to organic acids (e.g. acetic acid)
―High solids content (1% by mass) – incompatible with downstream applications requiring low solids content (e.g. gas turbines)
―High water content (20-30%) – immiscible with hydrocarbon fuels due to polar nature
―Over time, chemical composition changes (non-equilibrium) increasing viscosity and water content and decreasing volatility
• Fast pyrolysis reactor development driven by char-related issues
―Rapid, isothermal heating: lower temperatures favor char formation – substitution effect
―Short vapor residence time (1-2 seconds max): char catalyzes cracking of condensable vapors to light gas
―Rapid and effective char removal: char fines entrained in bio-oil accelerate ‘aging’ effects

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University of Washington, Energy and Environmental Combustion Laboratory 10
Production of bio-oil involves relatively few process steps

Bio-oil Production
- Process Flow -
Flue Gas

Power Power Power

31 kWhr/ton water 127 kWhr/dry ton 40 kWhr/dry ton Power

Dryer Grinding Fast Pyrolysis Cyclone

to 10% moisture to 3 mm Reactor Separation

Heat

Char
Heat Exchanger
and Ash
Exhaust

Vapor
Dual Fuel Diesel Suspension Light
Legend
Process Power Quench
Engine Combustor Gas
Solid Phase

Gas Phase
Mineral Ash
Diesel Fuel Bio-oil
Liquid Phase 7.5% energy 92.5% energy

Problem Heat
Storage
Exchanger
Primary Path
Waste
Heat
Input or Secondary Path

Power
10 kWhr/ton bio-oil Bio-oil

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University of Washington, Energy and Environmental Combustion Laboratory 11
Most research has been focused on the production of high-grade bio-fuels

High Grade Liquid Bio-fuel Production

- Overview -

• Gasification
Gasification ―Thermal decomposition of biomass in oxygen deficient
environment (fuel rich)
―Produces a syngas of CO, H2, CO2, and H2O (and N2)
• Dependent Processes
―Some clean-up requirements Dirty Syngas
driven by gasification
• Gas Clean-up
Gas Clean-up ―Tar
―Particulate
―Alkali metal vapor
Clean Syngas
• Largely stand-alone • Liquid Fuel Synthesis
―Developed for use in Bio-fuel ―Optimize CO and H2 concentrations in syngas
petrochemical industry Synthesis ―Gas to liquid (GTL) process
―New interest for extraction
of “stranded” resources (e.g.
natural gas)
High-grade Liquid Bio-fuel

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University of Washington, Energy and Environmental Combustion Laboratory 12
For example, gasification and tar removal are closely coupled

Biomass Gasification
- Gasification and Tar Removal -

• Syngas produced by the gasifier must be free of nitrogen

―Higher gas volume increases capital cost
―Catalysts less effective when syngas diluted by nitrogen

• Two gasification options being pursued:

Entrained Flow Gasification Indirect Gasification
Syngas Syngas + Tar

• Wet scrubbing
+ Removes most tar
Wood Entrained Flow Wood Indirect – Lose tar energy
Particles Gasifier Chips Gasifier – Waste water stream
– Thermodynamic penalty for quench

Oxygen • Catalytic tar cracking

+ Recover tar energy
– Not all tar removed
External Steam – Short catalyst lifetime
Air Separation Heat
Air Nitrogen
Unit
• Re-circulate tars
• Very high capital cost at smaller scale + Removes most tar
• High power consumption + Recovers tar energy
– Thermodynamic penalty for quench
– May produce PAH (carcinogenic)
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University of Washington, Energy and Environmental Combustion Laboratory 13
The devil is in the details. Key issues include gas cleaning, gasifier design, and
heat and power integration.
Legend
Methanol Production Solid Phase
- Process Flow -
Gas Phase

Power Flue Gas Power Power, Heat

Liquid Phase

Problem

Gasification Coarse Sizing Drying Gasifier Primary Path

Input or Secondary Path

Diesel
Heat
Fuel
Dirty Syngas
Aux. Power
Pile Burner
Generation
Power

Catalyst Water Power

Gas Wet Gas

Catalytic Tar Bag Filtration Syngas
Cleaning Multi-cyclone Cleaning
Cracking (350oC) Compression
(100oC)

Particulate > 5μm Particulate > 2μm, Residual Contaminants,

Alkali Metals Waste Water Clean Syngas

Steam Steam Power Power Purge

Power
Gas Power
Generation
Methanol Heat
Methanol
Synthesis Steam Reformer Water-Gas Shift CO2 Removal
Methanol
Synthesis
(890oC) (330oC) (127oC)
(260oC)
CO2, Acid Gasses

014,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 14
Clearly, each bio-fuel has advantages and disadvantages

Bio-Fuel Comparison
- Summary -

Wood Chips Pellets Bio-oil Methanol

Transportation Cost -- + ++ ++
Technical Readiness ++ + - --
Product Value -- - - ++
Production Cost ++ - + --
Feedstock -- -- +
N/A
Requirement
Potential for N/A -- ++ ++
Improvement?

How do we quantify these trade-offs?

008,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 15
 Agenda

• Thinning of Forests

• Bio-fuel Production

• Comparison of Alternatives

• Conclusions

Agenda,02-07-05,PYR
University of Washington, Energy and Environmental Combustion Laboratory 16
Net thinning cost is an appropriate metric to compare different scenarios

Net Thinning Cost

- Framework -

Net Thinning
Cost

Gross Thinning
Revenue
Cost

• Bio-fuel
• Power
• Heat

Bio-Energy
Thinning Transportation
Production

• Harvesting • Transportation of • Bio-fuel production

activities wood chips or • Co-fire or cogeneration
densified bio-fuel

018,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 17
 Net Thinning Cost
- Base Case Results -

• Transportation Distance 450 km (~280 miles)

• Thinning Yield 7.5 wet tons/acre
• Thinning Duration 10 years
• Annual Acreage Thinned 80,000 acres

Transportable Stationary Relocatable

Mobile Bio-fuel Bio-fuel Bio-fuel Bio-fuel
Production Production Production Production

• Wood Pellets $162/wet ton $93/wet ton $59/wet ton $61/wet ton

• Bio-oil $159/wet ton $81/wet ton $54/wet ton $58/wet ton

• Methanol $214/wet ton $126/wet ton $59/wet ton $74/wet ton

• Wood Chip Cogeneration $75/wet ton

• Co-fire $63/wet ton

• Pulp Sale $71/wet ton

031,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 18
For shorter transportation distances, co-fire is preferred by a wide margin

Transportation Distance Sensitivity

- Base Technology - Disposal preferred beyond
this point
Two drivers required for
Landfill round-trip distance Pulp Sale
$80

$75 Wood Chip Pellets

Cogeneration
$70

$65 Net thinning cost for methanol

and bio-oil converge
Net Thinning $60 Methanol
Cost
($/wet ton $55
thinnings) $50 Bio-oil

$45
Case Assumptions
$40 Bio-oil preferred over pulp sale
• Thinning Duration: 10 years
$35 Co-fire • Annual Acreage: 80,000 acres

$30
150 250 350 450 550 650 750

Average Transportation Distance (Deck to End-Use)

(km)

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University of Washington, Energy and Environmental Combustion Laboratory 19
Advanced fast pyrolysis for production of bio-oil is cost competitive with pulp sale
or cogeneration at shorter distances

Transportation Distance Sensitivity

- Advanced Technology -

Landfill Pulp Sale

$80

$75

$70 Wood Chip

Advanced
Cogeneration
$65 Methanol
Net Thinning $60 Net thinning cost for methanol
Cost and bio-oil converge further out
($/wet ton $55
thinnings) $50 Advanced
Bio-oil
$45
Case Assumptions
$40 Co-fire • Thinning Duration: 10 years
$35 • Annual Acreage: 80,000 acres
Bio-oil preferred over pulp sale much earlier
$30
150 250 350 450 550 650 750

Average Transportation Distance (Deck to End-Use)

(km)

021,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 20
For a given transportation distance, annual acreage thinned, and thinning
duration, we can determine the lowest net thinning cost

Mapping Bio-energy Options

- Methodology -

Scenario Results
Bio-Energy Technology Map
Facility Bio-Energy Production Net Thinning Cost - 500 km Transportation Distance, Base Technology -
Mobile Fast Pyrolysis $160/wet ton Thinning Duration (years)
Transportable Fast Pyrolysis $83/wet ton
1 3 5 7 9 11 13 15
Stationary Fast Pyrolysis $56/wet ton
Relocatable Fast Pyrolysis $62/wet ton 10,000
Mobile Pelletization $163/wet ton 20,000
Transportable Pelletization $95/wet ton 30,000
Stationary Pelletization $61/wet ton 40,000
Annual Acreage
Relocatable Pelletization $63/wet ton Thinned 50,000
Mobile Methanol Synthesis $215/wet ton (acres) 60,000
Transportable Methanol Synthesis $129/wet ton 70,000
Stationary Methanol Synthesis $64/wet ton 80,000
Relocatable Methanol Synthesis $83/wet ton 90,000
Co-fire $68/wet ton 100,000
Wood Chip Cogen $82/wet ton
Pulp Sale $74/wet ton
Repeat analysis for each thinning acreage and
Disposal $79/wet ton
duration for multiple transportation distances…

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University of Washington, Energy and Environmental Combustion Laboratory 21
For short transportation distances, bio-fuel production is unattractive

Bio-Energy Technology Map

- 200 km Transportation, Base Technology -

Thinning Duration (years)

1 3 5 7 9 11 13 15
Trends
10,000
• Pulp sale preferred for short
20,000 Pulp Sale durations or small scale operations
– Least capitally intensive
30,000 revenue generating option

40,000 • Co-fire preferred over wide range

Annual Acreage of durations and scales
Thinned 50,000
(acres)
60,000
Co-fire
70,000

80,000

90,000

100,000

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University of Washington, Energy and Environmental Combustion Laboratory 22
As transportation distance increases, densified bio-fuels become preferred to co-
fire and pulp sale

Bio-Energy Technology Map

- 500 km Transportation, Base Technology -

Thinning Duration (years)

1 3 5 7 9 11 13 15
Technology Map Trends
10,000 Pulp Sale Pelletization • Pulp sale preferred for very short
Stationary durations and very small scale
20,000 operations

30,000 • Pelletization preferred for

moderate to long durations or
40,000 Relocatable moderate to large thinning yields
Annual Acreage – Least capitally intensive
Thinned 50,000 Stat. densification process
(acres) Relocatable
60,000 Fast Pyrolysis • Methanol synthesis preferred only
Stationary for very long durations and high
70,000 yields
– Most capitally intensive
80,000 Relocatable densification process

90,000 Methanol • Fast pyrolysis preferred for

Stat.
moderate to large yields or
Synthesis moderate to long term operations
100,000 Stationary

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University of Washington, Energy and Environmental Combustion Laboratory 23
Near term improvements in bio-fuel production technologies are likely to make
fast pyrolysis the option of choice for long transportation distances

Bio-Energy Technology Map

- 500 km Transportation, Advanced Technology -

Thinning Duration (years)

1 3 5 7 9 11 13 15
Technology Map Trends
10,000 Pellet
Pulp Sale • Pulp sale preferred for very short
durations and very small scale
20,000 operations

30,000 • Fast pyrolysis preferred for most

other yields and durations of
40,000 Relocatable operations
Annual Acreage – Smaller, shorter duration thinning
Thinned 50,000 favor relocatable production
(acres) – Larger, longer duration thinning
60,000 favor stationary production
Advanced
Fast Pyrolysis
70,000 Stationary

80,000

90,000

100,000

003,02-07-05,PYR.ppt
University of Washington, Energy and Environmental Combustion Laboratory 24
When co-fire is not an option, as might be the case in Washington, advanced fast
pyrolysis becomes the lowest cost option even for short transportation distances

Bio-Energy Technology Map

- 200 km Transportation, Advanced Technology, No Co-fire -

Thinning Duration (years)

1 3 5 7 9 11 13 15
Technology Map Trends
10,000 • Co-fire may not be an option in
some regions due to a scarcity of
20,000 coal-fired power plants

30,000 • Pulp sale preferred for short to

moderate durations or small to
40,000 Pulp Sale moderate scale operations
Annual Acreage
Thinned 50,000 • Fast pyrolysis preferred for large
(acres) or long duration thinning
60,000 operations

70,000
Advanced
80,000
Fast Pyrolysis
Stationary
90,000

100,000

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University of Washington, Energy and Environmental Combustion Laboratory 25
 Agenda

• Thinning of Forests

• Bio-fuel Production

• Comparison of Alternatives

• Conclusions

Agenda,02-07-05,PYR
University of Washington, Energy and Environmental Combustion Laboratory 26
 Bio-fuel Production
- Conclusions -

• Bio-fuel production at a stationary facility outside the forest is preferred over

production within the forest
—Economics
—Lower capital unit costs (scale effect)
—Low cost power (grid electricity vs. diesel generators)
—Better labor utilization
—High availability (better capital utilization)
—Practicality
—Three-shift operation uncommon within the forest, but is common in industry
—Equipment for production of bio-fuels generally designed in expectation of fixed, continuous
operation

• Transportable and mobile scale facilities should be considered for research,

development, and demonstration (RD&D)
—Investment cost for a single unit fairly low
—Easy to test and stage investment
—Once technology proven, scale-up to larger facilities to realize lowest projected costs

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University of Washington, Energy and Environmental Combustion Laboratory 27
Different options are preferred for different transportation distances

Technology Summary
- Conclusions -

< 400 km > 400 km

Transportation Distance Transportation Distance

Small Disposal Disposal

Operation
Pulp Sale
Pellets

Moderate Advanced Fast

Operation Pyrolysis
Co-fire
Fast Pyrolysis

Large
Operation Methanol

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University of Washington, Energy and Environmental Combustion Laboratory 28
This analysis allows us to answer a few key questions

Bio-Energy from Thinnings

- Conclusions -

• Does the conversion of thinnings to bio-energy make economic sense?

—Yes. But, with current technology, only when the transportation distance to end-use
exceeds 400 km.
—Bio-energy will not pay for thinning. But the economics are stronger than for disposal
in almost all cases

• Which bio-energy technologies are most promising?

—Co-fire with coal for transportation distances less than 400 km
—Fast pyrolysis for bio-oil where transportation distances are longer

• Where are non-energy options preferable?

—Pulp sale for short durations and low yields where transportation distances are less than
600 km
—Disposal for very short durations and low yields where transportation distances are
longer

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University of Washington, Energy and Environmental Combustion Laboratory 29
 Next Steps

• Forestry
—Estimated probabilities for various acreage yields and durations
—Economics of forest products

• Model
—Rail transportation and hybrid rail-truck transportation networks
—Other bio-fuel production technologies
—Solid fuel briquettes
—Fischer-Tropsch fuels
—Other bio-fuel end-uses
—Close-coupled gasification-combustion applications
—Biomass Gasification Combined Cycle (BiGCC)
—Improved visualization of results

• Research
—Methods for improved bio-oil combustion
—Large feedstock fast pyrolysis

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University of Washington, Energy and Environmental Combustion Laboratory 30
 Questions?

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University of Washington, Energy and Environmental Combustion Laboratory 31
Net thinning costs are lowest for stationary bio-fuel production. The small penalty
for transporting chips out of the forest is outweighed by large reductions in bio-
fuel production cost.
Bio-oil Production
- Cost Detail -
Mobile Transportable Stationary
$200 $159/wet ton $81/wet ton $54/wet ton
thinnings thinnings thinnings

Transportation $8
$150
– Bio-oil $8 Transportation $12
– Wood Chips $2
– Bio-oil $101
Net Transportation $12
Thinning $100
Production
– Wood Chips $7
– Bio-oil $6
Cost $141
($/ton wet
Production
thinnings) $52 Production
$50 $27

Harvest Harvest Harvest

$40 $40 $40
$0

Note: Revenue increase due to higher

Revenue Revenue Revenue yields of bio-oil for stationary and
transportable production
$19 $23 $26
-$50
1Higher cost due to higher bio-oil yield for transportable conversion
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University of Washington, Energy and Environmental Combustion Laboratory 32
An interesting extension of this analysis is to forecast costs for technical
advances and the benefit of learning scale

Advanced Technology Case

- Assumptions -

Fast Pyrolysis Methanol Synthesis

Base Case Advanced Case Base Case Advanced Case

• 3 mm chip size • 6 mm chip size • Wet, cold gas cleaning • Hot, dry gas cleaning
Technology • Hammer-milling • Coarse sizing only
required

• 1st unit costs • 10th unit costs • 1st unit costs • 1st unit costs
• Justified by successful • No successful
Learning Scale first generation commercial
demonstrations demonstration

Substantial cost reduction Modest cost reduction, Enhanced practicality

These scenarios represent advanced, but realistically near-term process evolutions

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University of Washington, Energy and Environmental Combustion Laboratory 33