ideas with power and energy - p2 infohouse · cryofuels’ lpmrc prototype • 85 gpd • 5...

www.cryofuelsystems.com

IDEAS WITH POWER AND ENERGY


Near Term Availability of

Cost- Effective Liquid Natural Gas

CryoFuel Systems, Inc. John A. Barclay

July 25, 2001


Global Energy Systems are in TransitionPE

RC

ENTA

GE

OF

TOTA

L M

AR

KET

100

80

60

40

20

0 1850 1900 1950 2000 2050 2100

Oil and Nautural Gas Liquids

Methane

Sustainable economic Growth

Hydrogen

Gases Liquids

Solids

Petroleum oil

Methane

"City Gas" hydrogenWhale oil

Non-sustainable economic Growth Coal

Wood

YEAR From Hefner (1993)


The Transportation Sector

• ~650 million vehicles worldwide; steady growth

• US has ~190 million vehicles now; ~3% growth

• In the US only ~0.05% of transportation sector fuel is Natural Gas (CNG or LNG) –Yet ~28% of overall energy supply in US from NG

– A key barrier to change is lack of established fueling infrastructure – catch 22 with fleets

– Distributed LNG/LCNG stations dispensing competitively priced fuel are essential


NGVs are on the move

• Economic drivers

• Air Quality Emissions

• Greenhouse gas-global 0 100 200 300

Thousands

400 500

warming is serious

• Energy security issues

• >1 MM NGVs Worldwide

A rg e n t in a

It a ly

US A

B ra z il

R u s s ia

Ve n e z u e la

N e w Z e a la n d

C a n a d a

Eg yp t

P a k is t a n

T rin id a d

In d o n e s ia

M a la ys ia

Tha ila n d


CryoFuel Systems, Inc. designs, manufactures, and operates innovative distributed cryogenic gas purification and liquefaction systems for waste gas recovery and for producing transportable clean fuels.


CryoFuel’s Technology Development

• Cryogenic engineering capabilities • Conventional Liquefier Development

– 8 years and several million dollars – Analysis of best cycles for small scale applications.– Improvements to reduce costs in small applications:

• Cycle selection and optimization; • Component design (heat exchangers); • System integration for energy regeneration and recuperation.

• Gas separation technology development • Advanced Liquefier Development

– Magnetic and other refrigeration cycles—breakthrough technology.


CryoFuel’s LNG/LCNG Fueling StationNatural Gas Boil-off Vapor Return

Supply Line

LNG

LNG Withdrawal Line

Hig

h Pr

essu

re N

atur

al G

as

W in

Liquefier Cold Box

CNG Line

Vap

oriz

ing

HEX NG

Liquefier

Cryogenic Pump

CNG Buffer Volume Storage Tank

NG-Driven Motor

Regenerative

Purifier System Compressor

CNG

LNG

Withdraw

al Line

LNG Storage Reservoir LNG

LNG Transfer Vapor Return

LNG Line


CryoFuels’ LPMRC Prototype

• 85 gpd • 5 refrigerant system

• 300 psig max refrigerant pressure

• 50 psig process gas pressure

• Scaling to 5,000 gpd is no problem – many larger LNG liquefiers use MRC technology


Proprietary Cryogenic Bulk Purification:The Key to Open the Waste Gas Niche

INPUT 50% CH4 and 50% CO2 as input

OUTPUT CH4 had <0.5% CO2 CO2 had <0.1% CH4

SUPERIOR TO COMPETING TECHNOLOGIES

Energy efficiency Separation factor Saleable byproduct


a ay From EPA "Candidate" Landfill Projects Only

Landfill Gas Potential in the West LNG G llons/d

LNG gallons/day

AZ 783,714

226,135

Note: Some of these may not have collection systems installed, tax credits available, yet those may be required to 137,331 install collection systems and there are efforts65,034 93,095 ID underway to renew the tax credit program.

AZ CA ID MT NV OR UT WA

More than enough waste gas to supply the market demand!

Data derived from EPA Candidate Site data base www.cryofuelsystems.com

Unique Competitive AdvantageEquipment Sized to Match the Niche

Distribution of Landfills

250

200

150# of Landfills

100

50

0

0-5 5-10

10-15

15-20

20-25

25-30

30-35

35-40

40-45

45-50

LNG (Thousand gallons/day)


Fuel Processing & Distribution

Landfill Flare

Liquefier

Trash Truck

Li i

LNG

CryoFuels Storage & Wholesale Dispenser

Heavy Duty LNG Truck

ght Duty CNG Veh cle



Post Purification Module

ProcessStream

Pre-Purification Module

Bulk Purification Module

Liquefier

Refrigeration Module

CryoFuel’s Modular Processing Equipment


Post Purification Module

ProcessStream

Pre-Purification Module

Bulk Purification Module

Liquefier

Refrigeration Module

(1) Power, eg. Genset

GENSET

(2) CO2 Recovery

CO2

(3) Oxygen Removal(4) LNG Storage LNG

O2

(5) Dispensing(6) LCNG or Pipeline Production

(1)

(2)(3)

(4)

(5)

(6)

Options extend System capabilities


1. Gas from the landfill flare station enters the purifier.

2. The gas is compressed and chilled to remove water and heavy organic materials

3. Water and heavy organic chemicals are vaporized and burned in the flare.

4. Purified gas enters the adsorption beds to filter any remaining trace chemicals.

5. Last impurities are removed and incinerated in the flare.

6. Clean landfill gases, which are now methane (CH4), nitrogen (N2), and carbon dioxide (CO2), enter the vacuum cold box.

7. A cryogenic refrigerator drives the purification and liquefaction process.

8. Pure CO2 is cryogenically separated for resale.

9. N2 & CH4 are separated from the product stream.

10. N2 & CH4 is used to drive the engine for the plant. N2 is released back into the atmosphere.

11. High purity CH4 is now LNG fuel ready for distribution.

CONDENSATESUMP

CHILLER TSA REGENERATION WASTE

CO2 - LNGSEPARATION

CO2

COLD BOX

N2,

CH4

CH4

AMBIENTFLARE

CLEAN LFG

ENGINE

WASTE HEAT

FUELGAS

LNG

CO2

FLARE

LEACHATE

LFG1

2

3

4

56 8

9

10

117

Landfill Gas Purification and LNG Production

T 360.794.3755

F 30.794-4636


CryoFuel Sets an Industry Milestone

• Hartland Landfill, Victoria, B.C.

• Funded by CryoFuel, CAFI, and NR Can

• First LNG 17 November 2000 – 96% CH4 in LNG

• First landfill gas to LNG system with CO2 product– 99% pure CO2

• All major subsystems proven in pilot unit


Hartland Pilot Project Achieved All Key Objectives

• Produces LNG with ~96% CH4 from poor LFG – 38-46% CH4; 23-33% CO2; 38-14% N2; 0.4-1.1% O2 (generally first case)

• Produces 99% pure CO2 • All four process modules validated our design calculations

– Pre-purification module works • Addition of O2 removal; regeneration of adsorption beds, and other features

into the first 5,000 LNG gallon/day unit. – Bulk purification module works

• CO2 freezing heat exchanger improvements identified • Zeolite TSA polishing bed improvements identified • Operational changes to obtain continuous operation

– Liquefaction module works • Operational changes to enable smooth transition among HEXs

– Post-purification module works


Hartland Pilot Project Results

• Overall energy efficiency depends upon N2 concentration in LFG – Genset is a CAT engine converted to run on NG with diesel ignition – 90% generator and 32% engine gives ~28% overall conversion efficiency – Total o/p ~142 kW; therefore chemical energy input required ~500 kW – LFG flow rate required at 46% CH4 and 14% N2 is ~170 scfm @ 850 LNG – Overall system efficiency is ~64% – As N2% increases the LFG requirement decreases due to N2 rejection

• LFG demand decreases as engine fed by N2/CH4 mixture as LNG o/p drops • At ~38% N2 there is excess N2/CH4 that is returned to flare

– Overall system efficiency with ~29% N2 is ~30%. • System is very robust with regard to composition

– The same unit can produce from ~6000 LNG gal/day to ~3000 LNG gal/day as the N2 concentration varies.

– Strong incentive for LFG owner to manage landfill well to increase capital utilization and increase project ROI


Multiple Sources…Multiple Products

Sources Price @ Source Wholesale Price Price at End User Value Added

~$0.25/MMBtu

$0.40/LNG Gallon $5.25/MMBtu $0.72/LNG Gallon

LNG in Vehicle ~$0.40/MMBtu

$1.20/DEG Taxes

Storage $9.25/MMBtu

Distribution ~$1.00/MMBtu Dispensing

$0.48/LNG Gallon $ Margin$5.59/MMBtu

~$3.50/MMBtu $0.69/LNG Gallon

$8.04/MMBtu www.cryofuelsystems.com

LNG Cost Components($0.25/MMBTU Feedstock)

$/G

allo

n

Return on Capital Feedstock for

$0.60

$0.80

LNG Feedstock for

$0.40 SystemMaintenance:

$0.20 Parts Maintenance:

$0.00 Materials Maintenance:5000 3000 1500 Labor Operator LaborGallons/Day

CO2 Sales Revenue Potentially Worth $0.02-0.10/gallon. Not Shown www.cryofuelsystems.com

Economic Advantage of LNG

Diesel LNG Wholesale from waste gas site $0.40 Transportation/Distribution .10 Delivered to Station $1.158 .50 Federal Tax .243 .119 State & Local Tax .299 .111 Energy Content Adjustment 0 .511 Delivered to Tank 1.70 1.241 Fuel Savings per diesel gal $0.459


5,000 GPD Plant

• Spec Gas: (to produce 5,000 gpd) – CH4-45% CO2-39% N2-10% O2<2% H2O saturated – 1.2 MMscf/day

• Production rate function of gas composition (eg 2% N2 yields > 5,500 gpd from same inlet flow)

• LNG quality: >97% CH4 (Note: if higher N2 tolerable, production increases significantly)

• CO2: ~20 tons/day. Hartland is 99+% pure • Price: ~$1.3 MM excluding genset. Progress payments

assumed. • O&M: ~$100,000 per year assuming operator involvement

spread over multiple projects.


LNG from Landfill Gas: The Business Requirement

• Gas resource owner • Gas field operator • Equipment design/build/installer • Project owner/financier • Project operator • Products marketer • Products offtaker (wholesale? retail?) • LNG consumption technology supplier • LNG consumer


ideas with power and energy - p2 infohouse · cryofuels’ lpmrc prototype • 85 gpd • 5...

Documents