Vortrag Unibo PDF

Renewable Energy and Energy
Management
Prof. Dr. Andreas Hornung

Fraunhofer UMSICHT
Institutsteil Sulzbach-Rosenberg
University of Birmingham
Universit di Bologna
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Fraunhofer UMSICHT
Introduction
Fraunhofer is Europes largest application-oriented

research organization with a global presence
Research and development
International research with focus on direct use for both

private and public sector, and for the benefit of society
Application-orientated fundamental research
Entrepreneurship
Institutes organized as profit-centers
A third of the budget are revenues

from industrial projects
Spin-offs are promoted
Contracting parties/ clients
Industrial and service companies
Public sector
Facts and figures
> 22,000 staff members
Sulzbach-Rosenberg
> 66 research institutes
UMSICHT Institute
1.9 bn annual research budget
10 Offices & Project Centers in Asia Pacific
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Center for Energy Storage

Structure
Project partners
Funding
Sulzbach-Rosenberg / Oberhausen
20 million
Straubing / Stuttgart
System
analysis
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Chemical
storage
Catalysis and process
Bavarian State Ministry of Economy,

Infrastructure, Transport and Technology
Chemical storage
Methods/technical
implementation
Heat storage

Structure
New building 2016
Technikum
Haus 4
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Structure
System analysis
Energy
Raw materials
Storage demands
Chemical storage
Thermochemical conversion (BioPyroEnergy)
Conversion of H2 and CO2
Synthesis short- and long chain alkanes and alcohols
Thermal storage
Latent- and thermochemichal storage units
Components of compressed air energy storage
Storage of CHP plants
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Introduction
Fraunhofer UMSICHT can offer end-to-end innovative

waste-to-energy solutions
Consulting &
Studies
From the
idea
Development &
Design
Construction
to the
product
Pilot plant
operation
Processimplementation
Feasibility Economy Ecology Safety Legal / Political Framework
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The German Energiew ende

A showcase for the commitment of
an industrial nation towards
becoming a renewable society and
the central role of bioenergy
Transition
Fraunhofer UMSICHT
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AGENDA
1. Fraunhofer-UMSICHT, Institute Branch Sulzbach-Rosenberg

2. Global Challenges in energy supply
3. European energy market

4. The German Energiewende
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Global challenges
S carecity of raw m aterials
S upply of non-renw eable energy res ources
Crude oil
41 64
23
59 134
75
Natural gas
40
Uranium
325 365
126
Black coal
2.712
2.838
262
Soft brown coal
4.014
500
Years
1000
1500
Reserves
2000
2500
3000
3500
4.276
4000
Resources
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Quelle: BGR 2009; Darstellung verndert. Nur konventionelles Erdl und Erdgas
Globale Challenges
Global Equality
Energy cons um ption in MWh/pers on/y ear
Res s ource cons um ption in Mg/pers on/y ear
53
115
12
32
5
3
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Quellen: Sustainable Europe Research Institute, www.materialflows.net, 2007,
US Energy Information Administration, International Energy Annual, 2008
Clim ate politics

Copenhagen 2009: unable to fulfill the high ex pectations
11
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AGENDA


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Estimated world wood pellet production trends
World wood pellet production in ktonnes
16,000
292
49
Australasia + South Africa
14,000
South America
4,320
North America
12,000
561
50
168
47
Other Europe & Russia
4,100
EU27
10,000
53
92
8,000
43
52
2,235
6,000
2,665
1,435
3,135
1,337
864
806
9
507
4
1,998
1,654
92
1,256
28
64
4,000
2,000
840
988
2
1,205
1,275
4
1,360
2000
2001
2002
2
816
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1,754
2003
2,278
2004
8,764
9,286
7,507
6,072
4,696
3,100
2005
Source: Ecofys
2006
2007
2008
2009
2010
Wood pellet trade streams above 10 ktonnes (2010)
Source: Ecofys
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EU wood pellet markets
Large s cale pow er generation

Dis trict heating and CHP
Bulk res idential heating
Bag res idential heating
Ex porting countries
Source: Ecofys
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Current energy m ix ture of s om e EU-m em bers
60%
50%
40%
Oil
Gas
Carbon
30%
Nuclear
Biomass, biogas
Hydropower
20%
Other renewables
10%
0%
Germany
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France
Poland
Sweden
Renew able energy potential

S olar
Wind
Spain, Italy
UK, Northern Germany and France
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EU "20-20-20"
Climate and Energy Package 2009:
A 20 % reduction in EU greenhouse gas emissions from 1990

levels
Raising the share of EU energy consumption produced from

renewable resources to 20 %
20 % improvement in the EUs energy efficiency
EU directives 2003/30/EC & 2009/30/EC
10 % share of renewable energy in the transportation sector
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EU "20-20-20"
Dev elopm ent from tw o ex am ple m em bers
United Kingdom
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S w eden
AGENDA


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Germany some facts
Area:
357,000 km
Inhabitants :
80.5 mil. people
GDP:
32600 (42,800 $)
Unem ploy ed Youth:
7,6 %
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Energy production
S RU-S zenario: replacem ent of conv entional pow er
plants
Gros s electricity produktion 2005 2050
700
600
500
400
300
200
100
0
2005
2010
2015
Conv entional pow er plants

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2020
2025
2030
2035
Expansion of conventional plants
2040
2045
2050
Renew able Energies
Inversity of supply and demand
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Challenges for the future energy s upply

Change of s tructures
2050
Today
Environmental compatibility
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Acceptance
Authorization
Remuneration
Introduction
Conventional power supply
Controllable
Supply
Demand
Consumption
Generation
Haushaltsgeld.net, Andreas Carjell, Viktor Mildenberger , Petra Bork, Dieter Schtz, Andreas Morlok / alle pixelio.de
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Introduction
Future power supply
Controllable
Supply
Demand
Consumption
Generation
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Introduction
Future power supply
Controllable
Load transfer
Supply
Demand
Consumption
Efficiency
Generation
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Controllable
Grids
Regional
decoupling
Introduction
Grids and Storage
Demand
Storage
Temporal
decoupling
Supply
Load transfer
Consumption
Efficiency
Generation
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System research
Powerproduction in Bavaria 2023
Biomass
Biomasse
9%
Windpower
Windkraft
18%
Photovoltaics
Photovoltaik
14%
Gas
Gas
33%
Coal
Steinkohle
8%
Hydropower
Wasserkraft
17%
Surplus
berschuss
1%
Eigene Darstellung nach Energiekonzept 2011
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System reseach
Compensation Demand
GIS grid
Grid 0,083 x 0,083

ca. 9 x 6 km
6.953 cells
N-S length: 886 km
W-O width: 636 km
Ideal distribution network within each cell
C.Doetsch: Future Electric Energy Storage/Balancing Demand, IEA, Paris, 23.01.13
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Background
Analysis of 146 Regions
Base facts
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Basis BMU leadscenarios 2010

146 regions
Allocation according to number inhabitants
and structure
Ideal distribution network within each region,
no exchange between regions
Background
Compensation demand, sorted
20
10
2030
Power [GW]
ca. 1 TWh
0
1000
2000
3000
-10
-20
4000
5000
time [h]
6000
7000
8000
ca. 27,7 TWh
-30
-40
-50
-60
-70
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Background
Compensation demand, sorted
20
10
2030
Power [GW]
ca. 1 TWh
0
1000
2000
3000
4000
-10
5000
time [h]
6000
7000
8000
ca. 27,7 TWh
-20
-30
-40
-50
-60
-70
20
ca. 3,3 TWh
10
2050
Power [GW]
1000
2000
3000
-10
4000
5000
time [h]
6000
7000
8000
-20
-30
ca. 80 TWh
-40
-50
-60
-70
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Thermal conversion of biomass and efficiency strategies
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Gliederung der Vorlesung
Thermal Conversion
Efficiency
Process elements
Examples of integration
To do
Conclusion
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Thermal conversion in combination with CHP

high
gasification Gas engines
Power
Oxygen
Combustion Steam and gas turbines
Reforming Gasmotoren/Dual-Fuel-engines
Pyrolysis Dual-Fuel-engines
low
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Efficiency of a process
All related to the primary energy content of the biomass
Total enfficiency = Efficiency unit 1 X efficiency unit 2 X .
S ingle efficiencies
Losses of energy of biomass in conversion process
Heat losses
Chemical energy to power
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Increasing efficiency by
Less process units
Less complex gas cleaning
Alternative engines
Gas or diesel engine, counter piston engine
Increase of the amount (yield of conversion) of biomass used within a
conversion process
Use of process waters Reforming
Use of process water within AD
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Process elements 1
Pyrolysis
Hot gas filter
Feedstock preparation
Condensation
Heat carrier
Electrostatic precipitator
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Process elements 2
Cyclon
Heat exchanger
gasifier
Biomass feed
Gas cleaner
Pyrolysis
CHPs
Ash-Separation
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Process elements 3
EBRI Video zur Veranschaulichung

Beispiel aus der Praxis
1:12
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Thermal conversion of biomass

combined CHP solutions
A. Gasification - Syngas Gas engines ..Gssing, Ulm
limited to a few biomasses, high invest
B. Pyrolyse - gasification - Syngas Gas engines ..KIT, Wehrle
more biomass types possible, high Invest
C. Pyrolyse /Reforming Gasification Dual Fuel Motoren ..EBRI
high efficient, flexible feeds
D. Pyrolyse/Reforming BAF Dual Fuel engines..WSE
low invest, biomass and fossil residues
E. Thermo-catalytic-Reforming Dual Fuel engines..Umsicht

low invest, richt in gas, low in char, highly integrated
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Measures
Simplification of the gas treatment
Hot gas filter
catalytic tar cracker
Tar stripping
Cyclone
Cooler
Quench
Electrostatic precipitator
Can be all removed despite the quench.
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Increased cold gas efficiency by reforming
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Steam Reforming
more power in the gas
H2
CO
CO2
CH4
CxHy
N2
45
Zusammensetzung [Vol.%]
40
35
30
25
20
Less water and gas phase, more power

in the gas
15
10
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14
14
14
14
13
13
13
Effizienzsteigerung durch integrierte Konversion von

Biokohle
Ash content of biochar works as reforming catalyst
Cleaner process gas, higher amount of synthesis gas, less char

Lower TAN numbers
TAN: mg KOH/ g for titration to neutral
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Winkler process for the conversion of coal

Application for biochar and Pyrolysis water
- ambient pressure and 600 C
Pyrolysekoks
Ascheaustrag
Pyrolysewasser
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TAN (total acid number) organic phase mg KOH/g

Wood, fast pyroylsis
140
Sewage sludge
19
De-Inking Sludge
33
Brewers grain
60
Wood , intermdediate Pyrolysis
39.5 48
TCR , AD digestate
Biodiesel
up to 3
Diesel
0,1
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Reduced process elements for scale down.
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Summary
Cost of feedstock
flexibility in feedstock
Primary conversion Losses Power Total

combustion steam turbine
Pyrolysis gasification gas engine
TCR process
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100%
10%
75%
25%
100%
15%
35%
45%
45%
32%
25%
38%
Haloclean
Pilot Anlage 500 kg/h und industrielle

Anlage 20.000 t/a
Pyrolyse von Stroh bzw. Raps
Verwendung der Pyrolysegase auf

BHKWs;
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Verwendung der Pyrolysele
100 kg/h unit
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Der Pyroformer
100 kg/h
Aston University in EBRI Birmingham

400 KWel
Zyklon
Wrmeaustauscher
Vergaser
Biomassevorlage
Gaswscher
Pyroformer
BHKWs
Asche-Separation
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Erweitertes Bioenergiekonzept
Bioabfallvergrung und thermokatalytisches Reforming
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Konzept der Biobatterie

Bedarfsgerechte Kopplung einzelner
Technologieelemente
Pyroformer Birmingham
Cowatec Sulzbach-Rosenberg
Haloclean Karlsruhe
WSE Newport
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Erweitertes Bioenergiekonzept
Konzeptionelles Anlagendesign an einer Biogasanlage
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Pyrolysis
Various reactors and three main pyrolysis procedures in practice

Fast pyrolysis
Intermediate pyrolysis
Slow pyrolysis
Most significant difference is the residence time of the solid phase
within the reactor seconds, minutes, up to hours and correlated energy
transfer and temperature distribution
Gas phase residence times for fast and intermediate pyrolysis are usually
below 2s
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Fast Pyrolysis Reactors

Rotating cone
Fluidised bed
HeissZyklon
Sand-Loop
Biobrennstoff
l
Gas
Heiss-Zyklon
Kondensator
Biobrennstoff
kalter
Biobrennstoff
Dampf
Koks
Sand
Bett
l, Gas
heisse Scheibe
Sand Loop
Koksverbrennung
zum
von
Koksverbrennung
siehe auch
Vortex Reaktor
rotierende, heisse
Scheibe, Zylinder,
Messer
Gas-Loop
Circulated fluidised bed

HeissZyklon
SandLoop
Koks
Koksverbrennung
Gas-Loop
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Twin screw
l
Gas
zirkulierende Wirbelschicht
Bio brennstoff
ablative reactor
Heizer im Sand-Loop
LR-Mischreaktor
Kondensator
Biobrennstoff
Heiss-Zyklon
Gas
l
Koks
Vakuumpyrolyse
A.V. Bridgwater*, P. Carson and M.

Coulson
A com paris on of fas t and s low
py roly s is liquids from m allee
Int. J. Global Energy Issues, Vol. 27,

No. 2, 2007
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Conclusion from recent literature!
...
...
A.V. Bridgwater*, P. Carson and M. Coulson
A com paris on of fas t and s low py roly s is liquids from m allee
Int. J. Global Energy Issues, Vol. 27, No. 2, 2007
to be agreed upon, but only for woody biomass
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intermediate
Mallee, fast pyrolysis at 500 C

75 % Liquid, 9 % Char, 11 % Gas
Beach wood
450 C
Wheat straw
450 C
fast
Wheat straw
500 C
Mallee, slow
500 C
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A.V. Bridgwater*,
P. Carson and M. Coulson
Fraunhofer UMSICHT
A com paris on of fas t and s low py roly s is liquids from m allee
Int. J. Global Energy Issues, Vol. 27, No. 2, 2007
Simulation of tar formation

Different reaction mechanism
and Different Reactants
Oligomers
Chain Fragments
Tar
Chemical Structure
Molecular Weight Distribution
Modified
Chains
Side
Groups
Propagatio
n
Cellulose
Glucan
Xylan
Lignin
Products
Char
May cause sensible variation

on the overall kinetic rate
parameters as change the
operative conditions
Gas
Each biomass component is

considered as structural
reactant with an average
chemical composition
Each polymer type has its own

thermo-chemical characteristics and
must be considered separately
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0.2
0.05
0.18
0.045
H2
O
(m/z 155)
(m/z 151)
Arbitrary units
0.16
0.14
0.12
0.1
0.08
0.06
0.04
(m/z 136)
10
0.02
0.015
15
20
25
30
C/m in
0.6
10
15
20
25
30
C/m in
0.5
0.02
CO2
Heating rate: 25C/min
136 - 4-(Hydroxy-prop-2enyl)guaiacol
0.018
0.4
0.016
Arbitrary units
Arbitrary units
0.03
0.025
0.005
CO2 (m/z
44)
0.035
0.01
0.02
Water (m/z
18)
(Oxy-allyl)guaiacol
0.04
Arbitrary units
0.3
0.2
0.1
0.014
0.012
0.01
0.008
0.006
0.004
0.002
0
0
10
15
20
25
30
0
0
C/m in
10
15
20
25
30
C/min
0.05
0.3
0.045
CO
0.25
0.04
155 Syringol
CO (m/z 28)
Methane (m/z
15)
Abundance
Arbitrary units
0.035
0.2
0.15
0.1
0.02
0.01
0.005
0
0
0
10
15
C/min
80 A. Hornung ITC-TAB
0.025
0.015
0.05
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0.03
20
25
30
10
20
C/min
30
0,55
Tar
Weight fraction
0,5
0,45
0,4
0,35
Heating rate
0,3
450
470
490
510
530
Tem perature C
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550
570
590
Haloclean a first approach for intermediate pyrolysis of biomass
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Pyrolysis of 19 t of straw in 2005, production of 6 t of

biochar slurries to be gasified for syngas production!
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Investigated materials
Feed
Yield
Energy (MJ/kg)
Tempera
ture
Coke
Liquids
Gas
Coke
Liquid
Olive stones 169,3 kg
450C
30%
47%
23%
30
Oil: 30 Water: 10
Rice husk 86,3 kg
450C
41%
41%
18%
21
Oil: 27 Water: 10
15
450C
33%
57%
10%
30
Oil: 34 Water: 2
26
500C
15%
52%
33%
26
Oil: 35 Water: 2,5
26
450C
38%
45%
17%
24
Oil: 16 Water: 2,5
19
550C
25%
50%
25%
24
450C
23%
56%
21%
500C
21%
57%
22%
Coco nut 13 kg
450C
34%
52%
14%
Rice bran
500C
20%
38%
42%
Brewers grain 2 kg
450C
23%
51%
26%
Wheat straw >15t

(2005)
450C
30%
50%
20%
Amount
RawMat
Rape seeds 611,15 kg

Rape residues 1292 kg
19
Beechwood 148,7 kg
3 kg
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22
25
Oil: 21 Water: 6
16
Products from pyrolysis of straw

(Feed approx. 1.4 kg/h, residence time 4 min (solid), 2s (gas))
80
60
40
20
0
325 C
350 C
375 C
385 C
400 C
Coke
wt%%
Koks
Gew.
73
48
38,2
36,2
33,5
wt%
lOil
Gew.
%
18
34
37,7
41,6
34,6
GasGew.
wt%%
Gas
18
24,1
22,2
31,9
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Haloclean - Intermediate Pyrolysis 12.000 t/a

First test of liquids from pyrolysis on dual fuel engines
Filter unit
Indirect cooling
Heat transfer
carrier
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Pyroformer Intermediate Pyrolysis and combined

Reforming
Biomass
Pyrolysis vapours
Biomass IN
Char back
Biochar
Dry ing - Torrefaction - Py roly s is Reform ing - Char Conditioning
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Pyroformer
Prof. Dr. A. Hornung
EBRI/Aston University
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Experimental set-up
Biochar
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Extended concept for biogas plants

Pyrolysis & Reforming
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A. Hornung, Aston Universitiy
Cyclone
Heat Exchangers
Gasifier
Feed units
Scrubber
Pyroformers
Engines
Char Discharge
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150 kW dual fuel multi cylinder Internal combustion CI engine from NEK
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Diesel
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Biodiesel
PO
PO-BD Blend
Lister Engine
Parameters
Cylinders
Power (kW)
2
15
Speed (rpm)
1000
Injection
Aspiration
Direct
Nature
As ton- IIT Ropar Energy for rural dis tricts

Wheat Straw
Pelletiser
Straw Pellets
Pyroformer
Heat
Non condensable gas
Condenser
CHP
Heat +Power
Bio-oil
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Bio char
Combustion
Unit
Downscaling of the technology
This is the view of the components of the container plant.
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Technology can be build simplified and at low cost!
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Containerized mobile Pyroformer unit with engine
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To improve the overall net energy yield obtained from

residual municipal solid waste (MSW), through a
combination of thermal pyrolysis and anaerobic digestion
This research will contribute towards:
utilising residual MSW to produce energy, instead of using landfill
increasing the net energy yield from MSW
meeting the Governments objectives in renewable energy
reducing GHG emissions
producing greener energy
producing digestate and char which can be applied to the land
providing alternatives for companies/local government for waste and

carbon management
producing decentralised heat and power

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The integrated pyrolysis and AD process
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Fraunhofer UMSICHT
Folie 114
Fraunhofer UMSICHT
Oil from digestate ThermoCatalyticReforming TCR

Product comparison
Unit
TCR digestate
Flashpyrolysis Wood8
Vegetable oil9,10
% (m/m)
75,3
37,1
77,5
% (m/m)
10,5
8,1
11,8
% (m/m)
1,4
0,3
2,7
% (m/m)
0,6
max. 10,0 mg/kg
% (m/m)
11,0
54,5
10,7
Water
% (m/m)
1,2
35,6
max. 75g/kg
Ash
% (m/m)
< 0,1
0,4
max.0,01
TAN
mg KOH/g
3,8
LHV
MJ/kg
33,8
14,4
36
Source: 8 D. Meier, et al., 2007; 9 DIN EN 51605 ; 10 Jrgen Karl, 2006
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NACH vORNE
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Folie 130
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D. Woolf, et al.:Sustainable biochar to mitigate global climate change in Nature Communications 2010
Folie 131
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Folie 134
Fraunhofer UMSICHT
Power to Products & Cross Energy Management (P2P)3

The Biobattery
Power to
Products
H2 + CO2
Power to
Products
Char post-reforming
Bio-Methanisation
Oil
Power to
heat
Heat
storage
Thermal Catalytic Reforming
Storage
Gas
Biogas plant
Conditioning
Anaerobic digestate
Dual-fuel CHP motor
Power to
Products
CO2
Product to
Power
Folie 135
Fraunhofer UMSICHT
Use of biogenic residue and waste streams

Dry fermentation of biogenic
waste
Agriculutral biogas plants
Dried anaerobic digestate
7500 biogas plants in Germany
140 compost facilities in Germany
60 Mt residues, mainly used as fertilizer.
From 2015 additional 4 Mt expected due

to changes in the waste directive
In many cases, a gate fee has to be paid

prior to application to land
Folie 136
Fraunhofer UMSICHT
The Biobattery
Central technology elements
Folie 137
Fraunhofer UMSICHT
Pyrolysis
Reforming
Biogas
Gasifier
Biobattery
Concept
Biogas digestate
Synthesis gas
Electricity
Dual-Fuel-Engine *
*Oil mixed gemischt mit
Biodiesel
Industrial biowaste
Residues from
agriculture
Oil
Heat
Bunker fuels
Dep. from feedstock
Fertilizer
Sewage Sludge
Biochar
Use of all products

Municipal Biowaste
Folie 138
Fraunhofer UMSICHT
Combustion

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Fraunhofer UMSICHT
Biobattery
Thermo Catalytic Reforming
Challenges
The Solution
Sustainable and cost-effective energy

sources from biomass residues is needed
worldwide
In some cases, there are significant costs

for disposal of biomass residues
For example, for fermentation residues

from biogas plants due to eutrophication
problems
Often threatened Sustainable

Competitiveness of many methods of
market changes
Regular changes in market prices for input

materials or products
Significant country-specific differences in

the market environment and regulatory
Tie-up of capital
Folie 140
Fraunhofer UMSICHT
Fraunhofer UMSICHT developed Thermal

Catalytic Reforming
Suitable for wide range of solid biomass
Energy-efficient process
High quality of fuels
Robust and capital-efficient solution for
decentralized applications
High flexibility of a technology can be
standardized
TCR for digestate

Key component
Key Advantages
High quality of bio energy products
No expensive filtering requirements
Syngas enriched gas directly suitable for dual
fuel CHP engines
Variable product yields to accommodate
different application scenarios
Fully continuous process
Decomposition of biomass in an ambient pressure

thermal rector with controlled temperature zones
Activated bio char catalyzes cracking of higher
molecular weight organic compounds
Integrated reforming of bio oil and bio char using
the water vapor present in the reactor
Yielding high quality bio energy products in
variable composition:
Low particle, syngas enriched pyrolysis gas (bio syngas)
Low tar & reduced acidity bio-oil
Biochar and ash as solid products
Folie 141
Fraunhofer UMSICHT
Pyrolysis Units at Fraunhofer UMSICHT (2kg/h and 60 kg/h)
Extended bioenergy concept

Conceptual plant design on a biogas plant site
Folie 142
Fraunhofer UMSICHT

Biowaste fermentation & Thermal Catalytic Reforming
Siebreste
Bioabfall
Grrest
THE BIOBATTERY
MVA
Gas
Vorbehandlung
Fermentation
Bio wastel
BHKW
Digestate
Nachrotte
Kompost
Verwertung
Plastic waste
Biochar
Gas
Gas
Gas
Conditioning
Fermentation
CHP
Thermal Catalytic
Reforming
Folie 143
Fraunhofer UMSICHT
BAF-Reactor
Storage
Biobattery in Birmingham
Heat
and
Pow er
Severn Trent Water
Greenfinch Ltd ( Ludlow )

6,000 tpa Demonstrator
Rennie & sons(Bedford) 12,000 tpa
Folie 144
Fraunhofer UMSICHT

Analysis and heating values
H2
2
CO
CO2
2
CH44
CxHy
x
y
N2
2
40
35
30
25
H2
32 - 42 Vol.%
CO
15 - 19 Vol.%
CO2
19 - 24 Vol.%
CH4
7 - 8 Vol.%
10
2 Vol.%
Folie 145
Fraunhofer UMSICHT
14:30
14:20
14:10
Heating value 11 MJ/m
0
14:00
10 - 21 Vol.%
13:50
N2
15
13:40
CxHy
20
13:30
Product gas
composition [Vol.%]
45

Product oil
75,5 weight %
10,5 weight %
1,5 weight %
0,5 weight %
11 weight %
Water
1 weight %
Ash
< 0,1 weight %
TAN
< 4 mg KOH/g
Heating value
Folie 146
Fraunhofer UMSICHT
35,0 MJ/kg

Biochar
Low in oxygen,
Low in hydrogen
52 weight%
2 weight%
1 weight%
0,5 weight%
7 weight%
Ash
37,5 weight%
heating value 19,5 MJ/kg
C/O 10
H/C 0,45
Folie 147
Fraunhofer UMSICHT
Folie 148
Fraunhofer UMSICHT

Condtioning
Digestate
Heat
Variable substrate
Pyrolysiswater
Biogas plant
Thermal
Oil
storage
Gas
Gasification
Gas
CHP
Power
Folie 149
Fraunhofer UMSICHT
Biomass residues
Biochar

Condtioning
Digestate
Heat
Variable substrate
Pyrolysiswater
Biogas plant
Thermal
Oil
storage
Gas
Gasification
Gas
CHP
Power
Folie 150
Fraunhofer UMSICHT
Biomass residues
Biochar
Mobile heat
The mobile latent heat storage principle
Discharging
Charging
Folie 151
Fraunhofer UMSICHT

Condtioning
Digestate
Heat
Variable substrate
Pyrolysiswater
Biogas plant
Thermal
Oil
storage
Gas
Gasification
Gas
CHP
Power
Folie 152
Fraunhofer UMSICHT
Biomass residues
Biochar
Solid biofuel conditioning

Mechanical pre-treatment (Brewers Spent Grain)
Folie 153
Fraunhofer UMSICHT
Folie 154
Fraunhofer UMSICHT
Folie 155
Fraunhofer UMSICHT
Hydrogen production 600 billion Nm3/a (50 Billion Hindenburgs)
Mainly produced from fossil fuels
48 % gas, 18 % coal, 30 % oil, 4 % electrolysis
Used for
60 % NH3 production
23 % in refineries
9 % methanol production
8 % steel production
Folie 156
Fraunhofer UMSICHT
Dry cooling
Research lab
Biomass storage
Pyrolyse/gasification
Gas buffer
Folie 157
Fraunhofer UMSICHT
CHPs
Cyclone
Heat Exchangers
Gasifier
Feed units
Scrubber
Pyroformers
Engines
Char Discharge
Folie 158
Fraunhofer UMSICHT
Folie 159
Fraunhofer UMSICHT
Folie 160
Fraunhofer UMSICHT
LT Reforming subsequent pyrolysis
Sorption and
Rotary kiln
Condensation
LT Reforming
T
T
m
P
Feed
Filtration
P
T
Gasanalysis
heating value
oxygen
carbon monoxide
Coke
carbon dioxide
>C2
N2
hydrogen
water
Folie 161
Fraunhofer UMSICHT
Generating the
H2,N2,
CH4,COx
Yields with and without catalyst
60
Amount of
50
organic Phase
13,9%
40
30
20
39,4%
22,5%
35,6%
9,6%
28% 28%
23%
10
0
gas /wt %
Folie 162
Fraunhofer UMSICHT
Generating the
condensate
/ wt%
char /wt %
without catalysis
with catalysis
Measured flow rates after condensation

with and without catalysis
Volume flow m3/h
1,6
1,4
1,2
1
0,8
0,6
0,4
0,2
0
0.47
0.74
0.72
0.74
without
catalysis
with catalysis
pyrolysis gas
after
condensation
N2
Increase of pyrolysis gas through catalysis 273 l/h, i.e. 58 % increase of pyrolysis gas
Folie 163
concerning
the heating value the pyrolysis gas corresponds to 240 l/h methan
Fraunhofer UMSICHT
Generating the
Yield of Hydrogen
Folie 164
Fraunhofer UMSICHT
Generating the

H2
2
CO
CO2
2
CH44
CxHy
x
y
N2
2
40
35
30
25
H2
32 - 42 Vol.%
CO
15 - 19 Vol.%
CO2
19 - 24 Vol.%
CH4
7 - 8 Vol.%
10
2 Vol.%
Folie 165
Fraunhofer UMSICHT
14:30
14:20
14:10
Heating value 11 MJ/m
0
14:00
10 - 21 Vol.%
13:50
N2
15
13:40
CxHy
20
13:30
Product gas
composition [Vol.%]
45
Hydrogen production costs
Folie 166
Fraunhofer UMSICHT
Hydrogen production costs on basis of electrolysis processes or via synthesis gases from
different fossil and renewable sources
Electrolysis processes require between 50 to 79 kWh to produce 1 kg hydrogen (40 kWh/kg)
The lowest production costs can be realised based on natural gas for 2,5 ct/kWh.
Folie 167
Quelle
Fraunhofer UMSICHT
S ource
Cos t for 1 kWh of hy drogen
Cos t of 1 kg of hy drogen
Wind pow er
8 13 ct
3.2 5.2 Euro
S olar pow er
20 ct, incl. transp., electrolysis
8 Euro
Water pow er
7 10 ct
2.8 4 Euro
Biom as s as s een today
13 ct
5.2 Euro
Natural gas
2.5 ct
1 Euro
Coal
5 12 ct (incl. sequestration)
2 4.8 Euro
S olartherm al
8 18 ct
3.2 7.2 Euro
Folie 168
Fraunhofer UMSICHT
Production costs of bio hydrogen from BtVB

A 5 MWel unit (30.000 t/a) sewage sludge as fuel (30 % via Pyrolyse) and (70
% via gasification from wood) realises about 5000 t Biochar
Given 50 % Inerts and 50 % carbon are therefore 1250 t of carbon

105 M Mol carbon or 210 t hydrogen (half stociometirc conversion of carbon
with pyrolysis water) or 2,352,000 m3 hydrogen. CO is used to fire the
engines
21 Cent per m3 H2 or approx. 2,4 /kg (6 ct/kWh, pure biochar would result
in less than 3 ct/kWh), this fuels a fuel cell car for 250 km.
Folie 169
Fraunhofer UMSICHT
Kapitel vor
Die Motoren
Folie 170
Fraunhofer UMSICHT
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Fraunhofer UMSICHT
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Fraunhofer UMSICHT
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Fraunhofer UMSICHT
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Fraunhofer UMSICHT
Folie 181
Fraunhofer UMSICHT
Folie 182
Fraunhofer UMSICHT
Old charcoal pile
Reference picture: http://de.wikipedia.org/wiki/Kohlenmeiler
Folie 183
Fraunhofer UMSICHT
Classical charcoal production (Brazil)

air inlet holes
chimney
air inlet holes
air inlet holes
gate
Reference: Energie aus Biomasse; Kaltschmitt, Hartmann,Hofbauer; 2.edition; 2009 Springer publishing company
Folie 184
Fraunhofer UMSICHT
Charcoal piles (Brazil)
REUTERS
Reference : newspaper Frankfurter Allgemeine 16. december 2007

http://www.faz.net/aktuell/wissen/natur/umweltschutz-der-klimapfennig-fuer-den-urwald-1488091.html
Folie 185
Fraunhofer UMSICHT
Mechanical fluidization
Torrefaction / Rotation cone BTG (The Netherlands)
Temperature: 200 400 C
Reference: http://www.btgworld.com/en/rtd/technologies/torrefaction
Folie 186
Fraunhofer UMSICHT
Pilot plant BTG (The Netherlands)
Reference: http://www.btgworld.com/en/rtd/test-facilities/torrefaction
Folie 187
Fraunhofer UMSICHT
PYREG 500 carbonisation plant HTC process (Germany)

Biomass reactor: about 800 C
Biomass
storage
tank
input
rotary valve
Burning chamber: about 1250 C

Energy extraction
Exhaust fan
PYREG double auger reactor
chimney
flue gas
fuel gas
Burning chamber
discharge
rotary valve
Ignition boiler
Combustion air
Reference: brochure about PYREG 500 kW carbonisation plant
http://www.pyreg.de/website/resources/documents/pyreg_dt.pdf
Folie 188
Fraunhofer UMSICHT
PYREG 500 Carbonisation plant HTC process (Germany)

Folie 189
Fraunhofer UMSICHT
PYREG 500 Carbonisation plant HTC process (Germany)

Burning
Chamber
Ash discharge
Reactor
Feedstock
distributor
Control box
Flue gas pipe with

optional heat extraction
Folie 190
Fraunhofer UMSICHT
SIFIC process
lumpy wood
gas
heater
SIFIC
retort
1 preheating zone
2 carbonisation zone
3 cooling down zone
hot gas
fan
charcoal
Reference: Energie aus Biomasse; Kaltschmitt, Hartmann,Hofbauer; 2.edition; 2009 Springer publishing company
Folie 191
Fraunhofer UMSICHT
Hydrothermal Carbonisation HTC continuous process
Reference: http://htc-anlagenbau.de/7.html and http://www.dampfturbinenkraftwerk.de/7.html
Folie 192
Fraunhofer UMSICHT
Hydrothermal Carbonisation HTC continuous process
Temperature:
Pressure:
200 C
20 bar
Reference: http://www.suncoal.de
Folie 193
Fraunhofer UMSICHT
Hydrothermal Carbonisation HTC batch process

charging with
biomass
heating
with steam
carbonisation
for about 10 h
exothermal
waste steam
Coal discharge
Reference: http://htc-anlagenbau.de/2.html
Folie 194
Fraunhofer UMSICHT
Pyrolysis rotary kiln RWE Contherm plant (Germany)

Pyrolysis with high heat value feedstock
waste gas
to boiler
pyrolysis gas
to boiler
1. Waste/Feedstock storage
2. Shredder
3. Second storage
4. Crane
5. Material valve
6. Pyrolysis rotary kiln

7. Heating system
8. Discharge of solid
pyrolysis residues
9. Fan
10. Cyclon dust filter
Reference: http://www.techtrade.de/de/index.html
Folie 195
Fraunhofer UMSICHT
Pyrolysis rotary kiln RWE Contherm plant in Hamm

(Germany)
Reference: http://www.techtrade.de/de/index.html
Folie 196
Fraunhofer UMSICHT
Additional pyrolysis processes
Biochar produced as intermediate product or just

mineral residues occur.
Folie 198
Fraunhofer UMSICHT
Fluidised bed
RTP (Rapid Thermal Processing) of Envergent (USA)
Temperature: ca. 500 C

Reference: http://www.envergenttech.com/files/rtp-from-envergent-2010.pdf
Folie 199
Fraunhofer UMSICHT
Retention time: < 2 s
Fluidised bed
RTP (Rapid Thermal Processing) of Envergent (USA)
Reference: http://www.envergenttech.com/files/envergent_electricity_5406_en_wp_10v1.pdf
Folie 200
Fraunhofer UMSICHT
MILENA Gasification plant (The Netherlands)
Reference: http://www.milenatechnology.com/
Folie 201
Fraunhofer UMSICHT
MILENA gasification in the ECN (The Netherlands)
Reference: Paper of ECN

http://www.ph8.nl/upload/catalog/388/337178/6/Production%20of%20Synthetic%20Natural%20Gas%20%28SNG%29%20fro
m%20biomass.pdf or to find by http://www.renewableenergy.nl (Dahlman)
Folie 202
Fraunhofer UMSICHT
Biochar
Introduction
Biochar
Reactions
Four Biochars
Biochar
C%
H%
N%
S %
As h %
O%*
HHV
(MJ/k
g)
BET S A
(m 2 /g)
Rapeseed
60.25
4.03
4.19
0.1
4.2
27.61
24.04
0.51
Sewage
Sludge
30.03
4.19
1.83
0.88
35.46
27.23
11.02
17.98
Wood
Pellets
71.58
4.62
0.54
0.22
2.64
20.4
28.78
0.073
Miscanthus
62.2
4.37
0.8
0.28
10.31
22.04
24.71
0.230
* Calculated by difference
Folie 203
Fraunhofer UMSICHT
Reactions
Biochar
Reactions
Experimental Set Up
Reaction
No
1
2
3
4
5
6
7
8
Folie 204
Fraunhofer UMSICHT
Reaction
CO2 +
C
+
H2
CH4 +
3H2
CO +
H2
C
+
C
+
C
+
CO +
Enthalpy of
Reaction at 25oC, 1
atm (kJ/mol)
+172
+131
C
H2O
2CO
CO +
H2O
CO
+206
H2 O
CO2 +
-41.2
2H2
O2
O2
O2
CH4
CO
CO2
CO2
-74.8
-111
-394
-284
Experimental Set Up
Each run: 3g biochar
Reaction time: 30 mins

50ml/1.5 mins
Folie 205
Fraunhofer UMSICHT
Results
Experimental Set Up
Res ults
Gas Com pos ition Vol' %
Wood Pellets : Tem perature
Results
70
60
H2
50
CO
40
CO2
30
CH4
20
10
C2H6
C2H4
600
650
700
750
Tem perature
800
850
900
C3H6
oC
Wood Pellets : S team Flow

Gas Com pos ition Vol %
Steam Flow: 0.172g/min/g biochar

70
60
50
40
H2
30
CO
20
CO2
10
CH4
0
0
0,05
0,1
0,15
0,2
0,25
S team Flow g/m in/g biochar
Temp: 850oC
Folie 206
Fraunhofer UMSICHT
0,3
Results
Gas Com pos ition Vol%
Mis canthus
70
60
H2
50
CO
40
CO2
30
CH4
20
C2H6
10
C2H4
0
600
700
800
Tem perature
( o C)
900
C3H6
Gas Ccom pos ition Vol%
Mis canthus
80
70
60
50
H2
40
CO
30
CO2
20
CH4
10
0

Temp: 850 oC
Folie 207
Fraunhofer UMSICHT
10
20
Tim e (m inutes )
30
40
Results
Gas Com pos ition Vol%
Rapes eed:S team Flow

70
60
50
40
H2
30
CO
20
CO2
10
CH4
0
0
0,1
0,2
0,3
S team Flow : g/m in/g biochar
Temp: 850oC
Rapes eed: Tem perature

80
70
60
50
H2
40
CO
30
CO2
20
CH4
10
0
600
650
700
750
Tem perature
800
850
900
oC

Folie 208
Fraunhofer UMSICHT
Results
S ew age S ludge: S team Flow

70
60
50
H2
40
CO
30
CO2
CH4
20
C2H6
10
0
0
0,05
0,1
0,15
Temp: 850oC
Folie 209
Fraunhofer UMSICHT
0,2
0,25
Results
Conv ers ion: Tem perature
Conv ers ion w t%
100
80
Wood
Pellets
Rapeseed
60
40
Miscanth
us
20
0
600
700
Tem perature ( o800
C)
900
Conv ers ion: S team Flow

Conv ers ion w t%
100
90
80
70
60
50
40
30
20
10
0
Rapeseed
Wood
Pellets
Sewage
Sludge
0
0,1
0,2
Folie 210
Fraunhofer UMSICHT
0,3
Bio-thermal valorisation of biomass - BtVB Process

Energy gras s
Mis canthus
Enhanced
Biogas plant
Microalgae
Integrated
Heat
OilSink
ex traction
Oils
Economy
Chem ical indus try
Minerals
Pharm aceutical indus try

2.000 3.000 EUR/t
16-17 MJ/kg
Lignin rich res idues
Algae cake
Liquid Fertilis er
Very broad
Twfeedstock
igs , leav es
Biochar turns carbon
Py roly s is
CO negativ e
S ew
age S ludge
spectrum
2
neutral into negative
Fertilis er / Black Earth
Gasifier
13-14 MJ/kg
Char
Vapours
enhanced
Gas ifier
CO2 neutral
for non woody

Wood
Cultiv ation
Heat
Broad spectrum of products
biomass
besideCHP
heat and power
Heat (4,5 MW)
Syngas
Folie 211
Fraunhofer UMSICHT
Pow er (3,5 MW)
Bio-thermal valorisation of biomass - BtVB Process

Oil ex traction
Microalgae
Chem ical indus try

Pharm aceutical indus try
,
Liquid Fertilis er
Py roly s is
CO2 negativ e
Cultiv ation
Fertilis er / Black Earth
Char
Gas ifier
CO2 neutral
Heat
CHP
Syngas
Folie 212
Fraunhofer UMSICHT
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Algae
CO2
Carbohydrates
Radiation
Lipids
Heat
Proteins
Nutrients
Vitamins
Water
Pigments
Haematococcus pluvialis, light Microscope view
www.igb.fraunhofer.de
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Power
Heat
Power
Biogas
Algae
CO2
gases
CO2
Residues
Biogas unit
Cleaned exhaust
bioreactor
Szenario ueberherrn einscannen
Algae separation
Pyrolysis
Gasification
Heat
wet
dry
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Algae based biomass
Nutrients
It is not enough to use biomass instead of fossil fuels

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Biochar application Brazil (11 tons per ha).

Embrapa Research Station, Manaus, Brazil, Photo C. Steiner
The classical way is biochar from wood we are looking for alternatives
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Materials and Methods Soxhlet Extraction

Soxhlet extraction of
Chlorella vulgaris Beijerinck Biochar
Fractions:
-
F1 (251.7 mm), F2 (1.7 0.9 mm),

F3 (0.90.4 mm)
LUQUE DE CASTRO, M. D. & PRIEGO-CAPOTE, F.

(2010) Soxhlet extraction: Past and present
panacea. Journal of
30 g Char with 500 ml HPLC water
2, 4 and 6 hours extraction duration
Colorimetric analysis of Pb2+, K+, Na+
Chromatography A, 1217, 2383-2389.
Cl-, SO42-, NO3-, PO43Folie 220

Fraunhofer UMSICHT
Elution of metal compounds Na+ and K+

Concentration K+ /ppm
Concentration Na+ /ppm

105
2050
1950
1850
1750
1650
1550
100
95
90
2
4
Ex traction tim e /h
2
Extraction time /h
F1 F2 F3
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Elution of non-metal compounds Cl- and NO3Concentration of NO3- /ppm
Concentration Cl- /ppm

130
120
110
100
90
4
2
4
Extraction time /h
F1 F2 F3
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2
4
Extraction time /h
Elution of non-metal compounds PO43- and SO42Concentration SO42- /ppm
Concentration PO43- /ppm

50
340
40
310
30
280
20
250
10
220
2
Extraction time /h
F1 F2 F3
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4
Extraction time /h
Results key- experiment

Concentration in ppm
Most of the element show
3200
highest release after 2 hours
2900
2600
K
2300
2000
Released percentages:
1700
2
300
250
200
150
100
50
0
~ 100 % of all Sulphate in
Cl-
form of Sulphur
Na+
- ~ 100 % of Potassium
PO4-P
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4
Extraction duration in h
90 % of Chlorine
4-6 % of Sodium
4.5 % of Phosphorous
SO42-
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BiocharI
Carbon storage value
Fertiliser value
Amelioration properties
+ other
Quelle: Marta Camps Arbestain; A Biochar Classification System (and a Brief Introduction of IBI Guidelines)
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HO
O
CH +
O
3C
O
O
CH
CH
O +
O +
C
HO
C
C
C
O
C
HO
O +
C
C
C
CH
O
O
O
C
HO H
O
O
O +
CH
CH
O +O
O +
C
O
O H+
C
HO
C
CH
HO
CC C
O +
C
C
O +
O
C
C
CH
CH
O
O
HOH
O
O
H
OH O
3HC O
O
H
O
HO
H
O +
O +
O
OH +
O
O +O
HO
O +
O
0.1
0.3
~600C
HO
O
O
C
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HC
C
O
O
HO H O H
O
O
O
O
CH +
CH +
H
O O O
3C
H
C
CH +
C
O
Quelle: Lehmann et al., 2010, in: Imperial College Press, London
O
HO H
Pyrolysis Intensity
CO
0.3
0.5
~400C
0.5
1.0
~200C
OH
O/C
0.7
H/C
1.5
Temperature
HC HO
O +
CH
OH
OH
OH
OH
3CO O
+
CH3
OH
OH
O
HO
HO
HO
CH2 O
OH
OH
O
OH
CH +
OH
HO
O
OH
OH
OH
OH
H
HO
O
H
O
H
O O
H
H
OH
OH
H
O
OH
3C
H2O
OH
OH
CO, CO2, CH4

volatile organics
Relative Proportion
HO
HO
Turbostratic Carbon
Amorphous Carbon
Cellulose, Lignin etc.
Business Development
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Proces s Technology
As an additional option the pyrolysis-reforming process

can be combined with the bio-activated fuel process
Biogas digestate
Fertilizer
Organic waste & residues
Biochar
Pyrolysis-Reforming
Reactor
Thermal Power Plant
Agricultural residue
Pyrolysis
Vapors
... and many other
organic wastes
Bio Syngas
Dual fuel power generation
Crude Bio Glycerol
Bio-Activated Fuel
Reactor
or other long chain
oils & fats as well
as plastics wastes
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Bio-Aliphatic fuel
Decentral power & heat
generation
Proces s Technology
Bio-Activated Fuel reactor cracks melted plastics waste

utilizing the bio-oil contained in hot pyrolysis vapor
Key Advantages
Hot pyrolysis vapor

containing bio-oil is
flowed through heated
long chain oil or polymer
melt
Cracking of long chain
oils, waxes and waste
polymers at reduced
temperatures (200-450 C)
without catalyst
Avoids creation of chars
Yields dual fuel engine quality

fuels:
Bio-aliphatic Diesel fuel
Clean lean gas fuel rich in

H2, CO, CO2 and CH4
aqueous phase
Residues from feedstock

impurities
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BAF
Reactor
Yields engine quality bio-aliphatic fuel for

dual fuel CHP engines
The fuel is stable for storage and

transportation
High energy efficiency of the overall process
Bio-oil reduces required cracking

temperature
Avoids creation of waxes from PE
Pilot scale (100 kg/hr) unit at Harper-Adams University
Proces s Technology
The pyrolysis-reforming reactor integrates intermediate

pyrolysis and reforming to yield high quality syngas, bio
oil & bio char
Key Advantages
fuel CHP engines

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Proces s Technology
As an additional option the pyrolysis-reforming process

can be combined with the bio-activated fuel process
Biogas digestate
Fertilizer
Organic waste & residues
Biochar
Pyrolysis-Reforming
Reactor
Thermal Power Plant
Agricultural residue
Pyrolysis
Vapors
... and many other
organic wastes
Bio Syngas
Dual fuel power generation
Crude Bio Glycerol
Bio-Activated Fuel
Reactor
or other long chain
oils & fats as well
as plastics wastes
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Bio-Aliphatic fuel
Decentral power & heat
generation
Proces s Technology
Bio-Activated Fuel reactor cracks melted plastics waste

utilizing the bio-oil contained in hot pyrolysis vapor
Key Advantages
Hot pyrolysis vapor

containing bio-oil is
flowed through heated
long chain oil or polymer
melt
Cracking of long chain
oils, waxes and waste
polymers at reduced
temperatures (200-450 C)
without catalyst
Avoids creation of chars
Yields dual fuel engine quality

fuels:
Bio-aliphatic Diesel fuel
Clean lean gas fuel rich in

H2, CO, CO2 and CH4
aqueous phase
Residues from feedstock

impurities
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BAF
Reactor
Yields engine quality bio-aliphatic fuel for

dual fuel CHP engines
The fuel is stable for storage and

transportation
High energy efficiency of the overall process
Bio-oil reduces required cracking

temperature
Avoids creation of waxes from PE
Pilot scale (100 kg/hr) unit at Harper-Adams University
Application S cenario
Our innovative pyrolysis-reforming technology offers

unique opportunities for biogas plant operators
Biogas plant
Pyrolysis-Reforming
CHP
Pyrolysis water
Substrate
Products &
Increased
Use of digestate &
added value
Bio-Gas Yield
further biomass sources
Gas
Oil
Biochar
Power
Heat
Use of digestate or biosolids deriving from bio-gas, bio-waste and purification

plants
Production of high-grade pyrolysis-gas and oil, as well as biochar using a combined

pyrolysis and reforming procedure
Direct coupling with a CHP enables local, flexible energy and heat generation
including integrated thermal use or a mobile heat storage option
Recirculation of pyrolysis water increases methane recovery in the biogas plant
Produced biochar can be used as fertilizer or for energy production
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At an ultimate scale of implementation the plant could process

over 100 000 t/a of digestate producing just under 1 MWel
Illustrative Example
6 MW Biogas
Plant
Sample plant with
approx. 136000 t/a corn
& gras silage and cattle
manure feedstock
Diges tate, w et
9% DM
107000 t/a
Py roly s is Reform ing

1100 kg/h
Water Phas e
850 t/a
Bio Oil
570 t/a
Bio S y ngas
4800 t/a
Screw Extractor
Biochar
920 t/a
Diges tate, s ep.
30% DM
19000 t/a
Heat im port
from biogas CHP
Heat
Thermal Drying
1800 kWth
1100 kWth
Diges tate, dry

80% DM
7100 t/a
Notes: Illustrative plant working at 6500

operating hours per year. Data estimated
based on preliminary test results. Further
testing required
700 kWth
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Partly utilized for proces s heat
Dual fuel CHP

1 MWel
Pow er
6400 MWh/a
Bus ines s Cas e
In this large scale scenario the return of capital is still

estimated at approx. 13% due to lower power feed-in tarif
CAPEX
Plant Investment
Working Capital
Inputs
Wet Digestate
Bio Diesel
82 kEUR/a
for free
82 kEUR
Key As s um ptions
15 years duration
Power price of 220 /MWh
below 1000 kWel
Before financing,
subsidies and taxation
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5780 kEUR
5500 kEUR
280 kEUR
based on estimates
Outputs
Power
Bio Char
Fertilizer
Py roly s is Plant
1100 kg/h 6500 h/a
1 MWel
Other OPEX
Labor
Maintenance
Insurance
Depreciation
Depreciation
432 kEUR/a
103 kEUR/a
296 kEUR/a
33 kEUR/a
456 kEUR/a
456 kEUR/a
1402 kEUR/a
1330 kEUR/a
42 kEUR/a
28 kEUR/a
EBIT
431 kEUR/a
RoC
13%
The financial analysis is forward-looking and based upon the current expectations, estimates
and projections; are not guarantees of future performance; and are subject to certain risk,
uncertainties and other factors, many of which are beyond Fraunhofer UMSICHT control.
In this illustrative application scenario a pyrolysis-reforming

plant processes sewage sludge from a water treatment plant
Water Treatm ent

Plant
S ew age s ludge
3% DM,
75000 t/a
Py roly s is Reform ing

300 kg/h
Water Phas e
380 t/a
Bio Oil
60 t/a
Bio S y ngas
1000 t/a
Screw Extractor
Biochar
540 t/a, 55% Ash
S ludge, s ep.
30% DM
4500 t/a
Heat im port
required
Thermal Drying
400 kWth
Utilized for proces s heat
Heat
270 kWth
Dual fuel CHP

160 kWel
130 kWth
S ludge, dried
70% DM
2000 t/a
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Notes: Illustrative plant working at 6500

operating hours per year. Data estimated
based on preliminary test results. Further
testing required
Pow er
1050 MWh/a

Structure
Project partners
Funding
Sulzbach-Rosenberg / Oberhausen
20 million
Straubing / Stuttgart
System
analysis
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Chemical
storage
Bavarian State Ministry of Economy,

Infrastructure, Transport and Technology
Chemical storage
Methods/technical
implementation
Heat storage

System Analysis as a Focal Topic
System analysis
Electricity, heat, mobility
Bavaria, Germany and Europe
Period up to 2050
Storage requirements,
grid expansion
Scenario of energy industry in

Germany
Folie 243
Fraunhofer UMSICHT

Chemical Storage Systems as a Focal Topic
Development of methods and

processes
Development of catalysts and

biocatalysts
Extension and optimization of

methods
www.rp-online.de
www.uni-hannover.de
Folie 244
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www.idwf.eu
www.begerow.com

Chemical Storage Systems as a Focal Topic
Methods and
technical implementation
Procedural implementation
on pilot plant scale
Decentralized applications
Energetic and economic

evaluation
Quelle: www.bundeskanzlerin.de
Quelle: www.elektrolyse.de
Quelle: www.pressebox.de
Quelle: www.bundeskanzlerin.de
Folie 245
Fraunhofer UMSICHT

Thermal Storage Systems as a Focal Topic
Thermal energy storage
Thermal storage as a
component of compressed
air energy storage
High-temperature storage
Latent heat storage
Thermochemical storage
Optimization of CHP plants
www.heizungsfinder.de
www.dlr.de
Folie 246
Fraunhofer UMSICHT
Thermal Process Technologies

Thermal Energy Storage
High Temperature Storage
Folie 247
Fraunhofer UMSICHT
experience from comprehensive

research & development
Radial flow bulk bed storage for

dust-containing exhaust fumes
test-rig for material aging

(decomposition, formation of
dust, storage capacity)
Database on multiple storage

materials
CAD and CFD based

development and optimisation
system integration to enhance

the use of volatile waste heat

Latent Heat Storage Systems
Folie 248
Fraunhofer UMSICHT
mobile latent heat storage

systems
Heat exchanger and systems
test-rig for mobile systems as

well as for heat transmission
systems
database on suitable storage

media
Identification and qualification

of new storage media
analysis of technology, energy

and economic efficiency as well
as marketability
market potential analysis
system integration of mobile

latent heat storage systems

Thermochemical Storages
test system based on

magnesium oxide/ hydroxide
identification and analysis of

new and enhanced materials
test-bench for
Folie 249
Fraunhofer UMSICHT
material aging and

characterisation
different reactor designs

(laboratory scale)
analysis of materials concerning
surface texture
particle size
elementary composition
and crystalline structure

Storage Integration
Folie 250
Fraunhofer UMSICHT
integration of thermal energy

storages into new or established
processes
evaluation of technology and

ecology of storages and
peripheral devices
validation of economic and

energy efficiency
plants and process design
optimisation and adaptation of

facilities and processes
examination of the overall

contribution of energy from
source to sink
scientific consulting
FRAUNHOFER UMS ICHT
Further Reading
Thank You v ery m uch
for y our attention!
Kontakt
Fraunhofer UMSICHT
Fraunhofer-Instituts fr Umwelt-, Sicherheitsund Energietechnik UMSICHT
Institutsteil Sulzbach-Rosenberg
An der Maxhtte 1
92237 Sulzbach-Rosenberg
E-Mail:
info-suro@umsicht.fraunhofer.de
Internet: http://www.umsicht-suro.fraunhofer.de
Folie 251
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Telefon: 09661-908 400
E-Mail: andreas.hornung@umsicht.fraunhofer.de
Fraunhofer UMSICHT
Fraunhofer Institute for Environmental, Safety, and Energy Technology UMSICHT
Institute Branch Sulzbach-Rosenberg

Director Institute Branch
Fraunhofer UMSICHT
Joseph von Fraunhofer (1787 - 1826)
Researcher
Fraunhofer-Lines
Inventor
Optical instruments
Entrepreneur
Director and Partner of a glassworks
Folie 253
Fraunhofer UMSICHT
Fraunhofer-Gesellschaft
Research and Development
Applied research in an international context, of direct

utility to private and public enterprise and of wide
benefit to society as a whole
Application-oriented basic research
Entrepreneurship
Institutes organized as profit-centers
A third of the budget are revenues

of industrial projects
Spin-offs are promote
Contracting parties/Clients
Industrial and service companies
Public sector
Daten und Fakten
More than 23 000 staff members
More than 67 research institutes
2 Mrd annual research budget
Folie 254
Fraunhofer UMSICHT
Sulzbach-Rosenberg
DIRECTORATE
ENERGY
PROCESSES
PRODUCTS
ORGANIZATION
ENERGY SYSTEMS
ENGINEERING
BIOREFINERY/
BIOFUELS
MATERIAL SYSTEMS
ADMINISTRATION
Waste Heat to Power

Compressed Air Energy
Storage
ENERGY SYSTEMS
Energy Supply Systems
Energy System
Optimization
CHEMICAL ENERGY
STORAGE
Thermochemical Storage
Catalytic Processes
Biogas
ELECTRICAL,
THERMAL ENERGY
STORAGE
Electrochemical Storage
Thermal Energy Storage and
Systems
THINK TANK ENERGY
Bio-based Chemicals
Biofuels, Hydrcarbons
Thermochemical Conversion
Specialty Chemicals,
Formulations
PROCESS
INTENSIVATION
Water Processes
Adsorption Processes
Active Surfaces
INFORMATION
TECHNOLOGY
IT-Infrastructure
IT-Services
Application Development
Modelling and Simulation
PROCESS
ENGINEERING
Environmental Biotechnology
Bioprocess Engineering and
Fluid Separation
Biomass and Residue
Utilization
Membrane and Food Technology
THINK TANK
International Projects
Urban Production
Group Environmental and
Process Technology (RUB*)
Synthesis and Functionalization

Processing and Testing
Prototype, Design, Interaction
BIO-BASED
PLASTICS
Polymer Chemistry
Material Development
Processing and Applications
Production Scale-Up and Testing
Projects
Controlling
Human Resources
Adminstration
Travel and Central Services
PUBLIC RELATIONS
Press and Media Relations
Events
Internal Communications
Leather Technology
High Pressure Impregnation
Product Design by Pressure
(RUB*)
RESSOURCES AND
INNOVATION
MANAGEMENT
Sustainaiblilty Assessment
and Management
Material Flow Systems
EU, IPR, Strategy
THINK TANK
FUTURE PRODUCTS
Further Academic
Education
Human Resources
Development
Catalytic Conversion
Processes
Energy Efficiency and
System Analysis
THERMAL PROCESS
TECHNOLOGIES
RECYCLING
MANAGEMENT
NEW MATERIALS
Corrosion and Wear
Protection
Surface Engineering
Metallurgical Processes
TECHNICS
BIO. PROCESS
TECHNOLOGIES
R&D-Workshop
Construction and Facility
Management
OCCUPATIONAL
SAFETY AND
ENVIRONMENTAL
PROTECTION
LIBRARY
ENERGY SYSTEMS
Waste Management and

Recycling Technologies
ANALYTICS
Additive Manufacturing, FabLab

Sustainable Polymer Products
SULZBACH-ROSENBERG
Energy from Biomass

Thermal Storages
UMSICHT ACADEMY
LEATHERANDHIGH
PRESSURETECHNOLOGY
INSTITUTE BRANCH
Biogas Technologies
Wastewater Treatment and
Phosphorous Recovery
System analysis
INFRASTRUCTURE
Administration
Public Relations and Marketing
Central Technical Services
* Ruhr University Bochum As of: 24/4/2013
Fraunhofer UMSICHT
Our Organisation
Director: Prof. Dr. rer. nat. Dipl.-Ing.
Deputy Director: Dipl.-Ing.
Andreas Hornung
Gerold Dimaczek

Dr. James R. Gasson
Renewable
Energy
Business Development
Dipl.-Ing. Thorsten Hornung, MBA
Thermal Process
Technologies
Recycling
Management
Biological
Process
Technologies
New Materials
Dipl.-Ing.
Dr.-Ing.
Dr.-Ing.
Dipl.-Wi.-Ing.
Dr. HDR
Samir Binder
Michael Jakuttis
Matthias Franke
Fabian Stenzel
Patrick J. Masset
Catalytic
Conversion
Processes
Energy Efficiency
and System
Analysis
Energy from
Biomass
Thermal
Storages
Waste Management and

Recycling
Technologies
Biogas Technologies
Wastewater
Treatment and
Phosphorous
Recovery
System analysis
Corrosion and
Wear Protection
Surface
Engineering
Metallurgical
Processes
Infrastructure
Dipl.-Ing. Gerold Dimaczek
Administration
Dipl.-Bw. Brigitte Herbst
Folie 256
Fraunhofer UMSICHT
Corporate Communications
Matthias Herms, M. A.
Central Technical Services

Helmut Heinl
Our sites
New building 2015
Haus 3
Haus 1
Haus 5
Haus 2
Haus 4
Folie 257
Fraunhofer UMSICHT
Our services
Consulting &
Studies
From the
idea
Construction
to the
product
Pilot plant
operation
Processimplementation
Development &
Design
Feasibility
Folie 258
Fraunhofer UMSICHT
Economy
Ecology
Safety
Legal / Political Framework
Our portfolio
Energy from biomass
and waste
Furnace technology
& development
CHP and incineration / RDF plants
Filter developement for emissions-reduction
Resource management
and recycling
Chemical energy storage

Thermochemical conversion
(BioPyroEnergy)
Conversion of H2 and CO2
Synthesis of short- and long chained alkanes and
alcohols
Thermal energy storage

Latent- and thermochemical
storage units
Utilization of residual materials

Recycling and resource concepts
Sustainability analysis
Components for compressed
Materials for
energy technology
Energy storage
system analysis
Corrosion and
Energy
Raw materials
Storage demand
abrasion protection
Functional coatings
Recycling of high-tech metals
Folie 259
Fraunhofer UMSICHT
air storage units

Storage systems for CHP plants
Selected Technology Portfolio
The Biobattery
Anaerobic Digestion
Extended bioenergy- and plastics recycling concept
Recycling Concepts and Technologies for E-Scrap
Thermal Energy Storage Systems
New Materials
Fraunhofer UMSICHT
Anaerobic digestion
Residues 2 biogas
Focus:
Material flows of inferior and/or contaminated
production residues in different industrial sectors
Glue stock
Purposes:
Exploitation of the economic value through
anaerobic digestion
Additional generation of heat and electricity
Solution of disposal problems
Approach:
Identification of material flows
Quantification of potentials
Process engineering and optimization of the
anaerobic digestion
Techno-economic and socio-ecologic assessment
of the system
Concepts for the digestate utilization
Folie 261
Fraunhofer UMSICHT
Deinking sludges
(phenol, cyanide)
Residues from citrus friut

processing industry
(phenol, biocide)
Residues from the

olive oil production
(phenolrich waste water)
Anaerobic digestion
Sustainable digestate management
Biogas plants
Relief of regions with nutrient oversupply
Reduction of disposal costs for digestate
Production of tradable fertilizer products
Avoidance of emissions
Folie 262
Fraunhofer UMSICHT
Digestate as fertilizer
(surplus of nutrients)
The Biobattery concept
Folie 263
Fraunhofer UMSICHT
The Biobattery concept
Us e of peak
electricity
Energy and
m aterial products
Flex ible technology pool

Us e of
res idues
Intelligent
integration
Folie 264
Fraunhofer UMSICHT
Anaerobic digestion
Sustainable digestate management
Oil
Power
Gas
Heat
Biomass /
biogenic residues
Folie 265
Fraunhofer UMSICHT
Pretreatment
Fermentation
Dewatering
TCR
Liquide phase
Solid phase
N-removal
Biochar
CHP

Innovative & economical biomass-to-energy solution
The Challenges
The Solution
Large volumes of biomass wastes available

globally
Fraunhofer UMSICHT offers an innovative

Thermal Catalytic Reforming technology for
a broad range of residual biomass
Significant opportunities for rural areas and

industries in decentralized smaller scale
energy solutions
A number of technologies is competing in
the biomass waste-to-energy market
including anaerobic digestion,
fermentation, gasification, pyrolysis
However for many biomass wastes these
technologies are limited in feedstock and
product options or do not maximize the
primary energy utilization
Folie 266
Fraunhofer UMSICHT
Producing quality fuels for power

generation in CHP engines and valuable bio
char as soil enhancer
Cost effective solution for decentral
applications

Feedstock and application
Biogas digestate
Syngas
Power
Dual Fuel Engine*

* Oil blended withbio diesel
Sewage sludge
Agricultural residues
Oil
Heat
Bunker Fuel
Fertilizer*
Industrial biowastes
Biochar*
* Dependent on
Feedstock
Use of all Products

Municipal biowastes
Folie 267
Fraunhofer UMSICHT
Thermal Use

Key components
Key Advantages

fuel CHP engines

Folie 268
Fraunhofer UMSICHT

Conventional biowaste treatment process
biowaste
Plastics from
biowaste
digestate
Incinerator
Gas
compost
Pre-Treatment
Fermentation
CHP
Composting
Separation of plastics from biowaste

Fermentation and subsequent composting of biowaste
Incineration of high calorific plastic waste (gate fee)
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Utilization

Optimized biowaste treatment process
biowaste
digestate
Plastic waste
biochar
Gas
Gas
oil
Pre-Treatment
Fermentation
CHP
TCR-Reactor
Gas
BAF-Reactor
Energy storage
Separation of plastics from biowaste

Fermentation and subsequent thermo-catalytic reduction (TCR) of biowaste
Cracking of plastic waste in a bio-activated fuel reactor (BAF)
Energetic utilization of pyrolysis-oil and gas from biowaste and plastics
Energetic optimization of the process by utilization of surplus electricity from
solar- and wind power (energy storage)
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Biogas
In Total: 7772
Elektrical capacity: 3530 MWel
digestate
storage
fertilizer
Biogasplants in Germany
(2013)
Biomethane
slurry
processing
plant
Biogas
energy
crops
Power
Methane
fermentation
Heat
Heat
CHP plant
organic
waste
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Fraunhofer UMSICHT

Conventional E-Scrap treatment process
E-Scrap
Dust and
Residues
Incinerator
Sanitary
Landfill
Hazardous
Comp.
Pre-Treatment
Sorting
Smelters
EoL-Treatment
Mechanical treatment of E-Scrap

Manual and automatically sorting of hazardous components
Delivery of metal fractions to centralized smelters
Incineration or landfill of huge amounts of waste fractions like dust and solid
residues
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Fraunhofer UMSICHT

Optimized E-Scrap treatment process
E-Scrap
Dust and
Residues
Oil
Gas
Hazardous
Established
Comp.
Recycling Routes
Pre-Treatment
Sorting
Coke
Pyrolysis
& CHP
Residue
Utilization
Metal
Alloy
Energy storage
Manual and mechanical treatment of E-Scrap

Manual and automatically sorting of hazardous components and fractions like waste
printed circuit boards
Pyrolysis of sorted fractions and waste fractions
Energetic utilization of pyrolysis-oil and -gas from organic compounds
Energetic optimization of the process by utilization of surplus electricity from
solar- and wind power (energy storage)
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Fraunhofer UMSICHT

High Temperature Storage
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Fraunhofer UMSICHT
experience from comprehensive

research & development
Radial flow bulk bed storage for

dust-containing exhaust fumes
test-rig for material aging

(decomposition, formation of
dust, storage capacity)
Database on multiple storage

materials
CAD and CFD based

development and optimisation
system integration to enhance

the use of volatile waste heat

Latent Heat Storage Systems
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Fraunhofer UMSICHT
mobile latent heat storage

systems
Heat exchanger and systems
test-rig for mobile systems as

well as for heat transmission
systems
database on suitable storage

media
Identification and qualification

of new storage media
analysis of technology, energy

and economic efficiency as well
as marketability
market potential analysis
system integration of mobile

latent heat storage systems

Thermochemical Storages
test system based on

magnesium oxide/ hydroxide
identification and analysis of

new and enhanced materials
test-bench for
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Fraunhofer UMSICHT
material aging and

characterisation
different reactor designs

(laboratory scale)
analysis of materials concerning
surface texture
particle size
elementary composition
and crystalline structure

Storage Integration
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Fraunhofer UMSICHT
integration of thermal energy

storages into new or established
processes
evaluation of technology and

ecology of storages and
peripheral devices
validation of economic and

energy efficiency
plants and process design
optimisation and adaptation of

facilities and processes
examination of the overall

contribution of energy from
source to sink
scientific consulting
New Materials Technologies

Developments and patents
Centrifugal atomization
Thermal spraying
Hot gas atomisation
Folie 278
Fraunhofer UMSICHT
Corrosion facilities

Wear resistance of densified oxide coatings
Material properties improve: lower porosity, higher hardness
Densification of mixed ceramics YSZ / Al2O3 50:50 as well
YSZ / Al2O3
50:50
untreated
Fraunhofer UMSICHT
YSZ / Al2O3
50:50
untreated
Temperature [C]
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Hardness [HV]
Porosity [%]
Max. 67 % lower porosity, max. 50 % higher hardness
Temperature [C]

In-field corrosion tests
Test duration: >1600 h, air-cooled corrosion probes
Significant lower attack (flue side) for modified samples
Treated samples
Duration: 1900 h, T = 450C
YSZ:Al2O3 75/25
YSZ: Al2O3 75/25
Alloy 625
YSZ:Al2O3 = 50:50
250 m
Untreated samples
Duration: 1630 h, T = 430C
Pure YSZ
YSZ
Alloy 625
YSZ:Al2O3 = 50:50
250 m
100 mm
Folie 280
Fraunhofer UMSICHT

Surface modification of glass fiber clothes
Folie 281
Fraunhofer UMSICHT
Our Partners
Bayerisches Staatsministerium fr
Wirtschaft und Medien, Energie
und Technologie
Bayerisches Staatsministerium fr
Umwelt und Verbraucherschutz
Folie 282
Fraunhofer UMSICHT
FRAUNHOFER UMSICHT
Thank You very much for

Your Attention
Contact
Fraunhofer UMSICHT
Fraunhofer Institute for Environmental, Safety,
and Energy Technology UMSICHT
E-Mail:
Internet:
info-suro@umsicht.fraunhofer.de
http://www.umsicht-suro.fraunhofer.de
Folie 283
Fraunhofer UMSICHT

Director Institute Branch
Telefon: 09661-908 403
E-Mail: andreas.hornung@umsicht.fraunhofer.de

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Renewable Energy and Energy

Prof. Dr. Andreas Hornung

Fraunhofer is Europes largest application-oriented

International research with focus on direct use for both

Application-orientated fundamental research

Institutes organized as profit-centers

A third of the budget are revenues

Spin-offs are promoted

Contracting parties/ clients

Industrial and service companies

Facts and figures

> 22,000 staff members

> 66 research institutes

1.9 bn annual research budget

10 Offices & Project Centers in Asia Pacific

Center for Energy Storage

Bavarian State Ministry of Economy,

Center for Energy Storage

Center for Energy Storage

Components of compressed air energy storage

Storage of CHP plants

Fraunhofer UMSICHT can offer end-to-end innovative

Feasibility Economy Ecology Safety Legal / Political Framework

The German Energiew ende

1. Fraunhofer-UMSICHT, Institute Branch Sulzbach-Rosenberg

3. European energy market

Soft brown coal

Clim ate politics

1. Fraunhofer-UMSICHT, Institute Branch Sulzbach-Rosenberg

3. European energy market

Estimated world wood pellet production trends

World wood pellet production in ktonnes

Australasia + South Africa

Other Europe & Russia

Wood pellet trade streams above 10 ktonnes (2010)

EU wood pellet markets

Large s cale pow er generation

Current energy m ix ture of s om e EU-m em bers

Renew able energy potential

UK, Northern Germany and France

Climate and Energy Package 2009:

A 20 % reduction in EU greenhouse gas emissions from 1990

Raising the share of EU energy consumption produced from

20 % improvement in the EUs energy efficiency

EU directives 2003/30/EC & 2009/30/EC

10 % share of renewable energy in the transportation sector

1. Fraunhofer-UMSICHT, Institute Branch Sulzbach-Rosenberg

3. European energy market

Germany some facts

Conv entional pow er plants

Expansion of conventional plants

Renew able Energies

Inversity of supply and demand

Challenges for the future energy s upply

Grid 0,083 x 0,083

C.Doetsch: Future Electric Energy Storage/Balancing Demand, IEA, Paris, 23.01.13

Basis BMU leadscenarios 2010

C.Doetsch: Future Electric Energy Storage/Balancing Demand, IEA, Paris, 23.01.13

ca. 27,7 TWh

C.Doetsch: Future Electric Energy Storage/Balancing Demand, IEA, Paris, 23.01.13

ca. 27,7 TWh

ca. 3,3 TWh

C.Doetsch: Future Electric Energy Storage/Balancing Demand, IEA, Paris, 23.01.13