Bionic µFuel Catalytic Microwave Depolymerisation

MWDP
REVISION 2014/2
Catalytic Microwave Depolymerization
efficient conversion of organic feedstock into fuels
4/19/2014 © 2008-2013 Bionic Fuel Knowledge Partners Inc., Oswego, NY
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µfuel

BIONICS GUIDING PRINCIPLE
Direct conversion of Biomass and Waste Materials
into Electric Power and Transportation Fuel
offer the most realistic immediate response to
 Depletion of fossil resources,
 Rising demand in the developing world and
 Over boarding mountains of Waste.
Climate Change and exploding Fuel Prices require a
bold response.
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FOSSIL FUEL RESERVES ARE LIMITED…
2007
Consumption
???
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…AND UNEQUALLY DISTRIBUTED
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CLIMATE CHANGE IS HERE
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A SOLUTIONS THAT WORKS TODAY
 Many technologies are discussed, but few are directly available.
 Many solutions proposed require a complete system change of technologies,
infrastructure, and lifestyle with severe consequences.
 The time required for that kind of change is simply not available to avert a major global disaster.
 Mankind needs solutions NOW that can later be merged with the implementation of long term plans
and technologies.
 The global fleet of traditionally powered vehicles is still increasing with a life cycle horizon of 20-25
years.
 Only a creative mix of all possibilities available short term can tackle the imminent
threats.
 It is the time NOW to initiate a first wave of change while continued preparations for a long term shift to
complete sustainability occur.
 BIONIC energy solutions stand for a fast track change with a unique, highly flexible
technology that is ready for commercial implementations.
 Technically efficient
 Environmentally clean
 Financially sound
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BTL/WTL TECHNOLOGIES
 First Generation approaches not efficient enough
 Plant oils
 Biodiesel
 Biogas
 Bioethanol
 Traditional pyrolysis
 Second Generation approaches mostly in pilot stage
 Gasification and FT proving challenging
 Direct liquefaction (Advanced pyrolysis)  Catalytic MWDP
 Synthetic fuels including bio-synthesis
 Cellulosic ethanol
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MWDP = DIRECT LIQUEFACTION = DEPOLYMERISATION
 For thousands of years it was known that under certain conditions biomass converts into gas, oil and char.
Today the process is called pyrolysis or sometimes thermal depolymerisation. It requires energy input (heat)
and an oxygen-free environment. Scientists explain the formation of fossil fuels with the natural occurrence
of a similar process.
 In the 1920s it was established, that in the presence of metal catalysts this process becomes more efficient
and controllable. For that reason we now call it thermo catalytic depolymerisation or TCDP. A similar process
is used successfully since the early forties to improve refinery yields in the production of Diesel and Petrol.
 BIONIC has, for the first time, combined TCDP with the independent depolymerisation capabilities of
advanced microwave radiation. The combination resulted in Bionic’s unique MWDP (microwave
depolymerization) process which overcomes many fundamental engineering issues of TCDP applications.
 Very efficient catalysts are available today in the form of “designer zeolites” facilitating the development of
an effective and economical MWDP process and plant design.
 Compared to other pyrolysis technologies Bionic’s MWDP design is extremely versatile converting many types
of feedstock into proven high quality liquid and solid drop-in fuels.
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Microwave Depoly-
merization (MWDP)
Catalytic
Depolymerization
Catalytic
Flash PyrolysisFlash Pyrolysis
Traditional Methods
• Very short residence time (seconds)
• High temperatures (600 – 900°C)
• Elevated pressure
Advanced Methods
• Medium residence times (45-60 min)
• Low temperatures (280 – 350°C)
• Low pressure
µfuel
Catalytic MWDP
Next Generation Hybrid
Depolymerization Method
Microwave
Fast Pyrolysis
+
MWDP WITHIN DIRECT LIQUEFACTION TECHNLOGIES

SECOND GENERATION BIOFUELS
 Second generation biofuels overcome practically all environmental and
social issues raised the first generation.
 The complete plant or biomass waste is used instead of only extracted
plant oils. Valuable plant oils can be returned to the food chain or
higher value bio-products.
 The catalysts used are easy to produce or naturally available in
abundance across the globe.
 The new technologies have positive energy balances saving 60% -90%
of GHG emissons compared to fossil energy sources.
 In certain situations a Bionic µfuel system can become carbon negative
due to near indefinite carbon sequestration in the soil.
 New agricultural and agriforestry technologies are being developed to
supply feedstock sustainably.
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OTHER CONCEPTS COMPARABLE TO MWDP
 Main representatives of second generation biofuels:
 Fischer-Tropsch-Process
 Complex, two stage process
 Low energy efficiency, unsolved technical issues
 Various types of Pyrolysis
 Numerous technology vaiants
 Technical engineering issues, high temperatures
 Major upgrading issues of pyrolysis oil
 Thermo Catalytic Depolymerisation
 Technical engineering issues, feedstock limitations
 Cellulosic Ethanol Processes
 Not commercially ready
 Emzymatic Bioreactor technologies
 Not ready, scaling issues, no drop-in fuels
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IMPACT OF MWDP
The MWDP process modifies the moelcular composition of the energy
contained in the carbo hydrates of the feedstock by converting them into oil,
char and gases, all with an exceptionally high energy content.
In other words:
Solid fuel contained in biomass and waste is converted to liquid and coke which
are storable for an indefinite time. The resulting prooducts can be burned later
for heat or power or upgraded to transportation fuels including jet fuel.
Toxic organic materials contained in some plastic waste are mostly transformed
into salts and thus neutralized.
Minerals contained in the feedstock remain unchanged and are ready for
further processing or direct use.
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THE PRINCIPLE BEHIND MWDP
Irradiation of the feedstock with advanced
microwaves in the presence of certain catalysts
creates mechanically unstable hydrocarbon
molecules causing a vibrating movement. This
phenomenon results in the eventual breakdown
(cracking) of larger molecules. They evaporate
from the reaction mass as an oil vapour.
The oil vapours are then condensed and cleaned.
Where required, additional petrochemical
upgrading
is added to meet applicable fuel standards. The
final product is a high quality fuel with the
properties of diesel or jet fuel.
That fuel is storable and cold resistant. It can be
used as transportation fuel, heating oil or blended
with mineral oils. It is also a valuable intermediate
raw product for the petro chemical industry.
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2 x C16 H32
1 x C32 H64

KEY MWDP APPLICATION AREAS
 Biomass to bio-crude:
 Decentralized conversion of energy crops
 Forestry and agriculture waste
 Decentralized processing of press cakes
 Processing of sugar beet and molasses
 Waste materials to gasoil:
 Processing of high calorific waste fractions (HCF, RDF)
 Processing of MSW
 Processing of scrap tires
 Processing of organic hazardous waste
 Processing of fossil hydrocarbons:
 Refinery residue cleanup
 Soil decontamination and cleanup of oil spills
 Processing of tar sands and oil shale
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ENERGY FROM WASTE
Valuable energy products can be extracted
through the intelligent use of waste materials.
Typcally more than 70% of MSW (municpal solid
waste) drymass can be converted into fuel with
the MWDP process.
Instead of landfills or destroying waste
through enormously expensive and
complex incineration still producing
large amounts of greenhouse gases,
the MWDP technology allows for a
much more efficient disposal.
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ENERGY FROM BIOMASS
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Wood
Wood chips Wood pellets
Most Biomass can be chopped and pelletized
Brushes
Grasses
To achieve optimal results
most feedstock types are first
shredded or grinded. Humid
materials should be dried.
Materials are then mixed with
the catalyst and pelletized
before they are fed into the
reactor.
This approach has many advantages by standardizing size and consistency for further
processing when entering the microfuel reactor. Processing of scrap tires is the one
exception to that rule.

THE MICROFUEL PROCESS WITH WOOD CHIPS
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Wood chips are first
pressed into pellets
MWDP Conversion
* µcrude is a ready blendstock, a direct fuel for CHP use or upgradable into standard Diesel fuel products
** µchar is a highly valuable product for long term soil improvement and carbon sequestration or as a solid fuel
Conversion of wastewood into Diesel and Biochar
(Plus distilled water and light gases for internal use)
Products:
Bionic µcrude* & µchar**

MWDP VS. TYPICAL PYROLYSIS TECHNIQUES
 MWDP and typical pyrolysis are building on a similar chemo-physical
principle:
- Thermal decomposition of hydrocarbons under absence of oxygen -
 Significant differences are setting MWDP apart:
 Very low temperature requirement of around 280°C, equal to torrefaction (which does
not produce any liquid phase) implies a high energy efficiency of MWDP.
 Significantly higher energy content of µcrude and µchar than any fast/flash pyrolysis
technology known (crude: 40-45 MJ/kg, char: 25-30 MJ/kg).
 MWDP bio-crude quality greatly supersedes any typical pyrolysis oil even from flash
pyrolysis, thus making it usable directly for heavy oil applications and as a blendstock
while also upgradable to ASTM diesel and bio jetfuel (SPK).
 MWDP yields (crude: 30-35%wt, char: 30-50%wt, gas: 10-30%wt) are incomparable with
pyrolysis yields, due to factors like water and energy content and chemical composition.
 MWDP oil yields for comparable feedstock are always better than those from other
pyrolysis processes.
 MWDP char quality is superior for technical applications.
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CURRENT MICROFUEL REACTOR PROGRAM
Bionic currently offers 4 reactor lines:
 The standard continuous reactor model MF480 has an output capacity of
up to 1200 l/h.
 A reduced version of the standard reactor MF192 with an output volume of
approx. 500 l/h (upgradable to MF480).
 A downscaled continuous MF60 with an output capacity of up to 150 l/h.
 Semi-mobile, mountable in container frames
 Intended for special applications and as a demonstrator and test bed
 A lab batch reactor for feedstock testing and analysis, R&D, scientific use
and small demonstrations.
(NB: Above mentioned output volumes are approximate and exemplary for common, dry biomass feedstock.
They can vary widely depending on feedstock properties like energy content)
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COMPLEMENTARY R&D ACTIVITIES
The following additional developments are close to approaching their
commercialization status:
 µCTL - A microwave driven process for clean liquefaction of coal and char.
 Innovative petrochemical processes for µcrude upgrading with the
distinct capability for economical conversion of smaller quantities of
crude feeds into clean fuels meeting the highest clean fuel standards like
ultra low sulfur diesel.
 µsoil - An integrated organic soil enhancer and fertilizer production
system based on a patented process licensed by Bionic to be used to
upgrade the bionic char product with plant nutrients.
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A MICROFUEL LAB REACTOR
Inside
First Distillation
Raw Distillate4/19/2014 © 2008-2013 Bionic Fuel Knowledge Partners Inc., Oswego, NY
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CONTINUOUS REACTOR (PRINCIPLE DETAIL)
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PILOT REACTOR COMPONENTS
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FULLY OPERATIONAL MF60 PROTOTYPE
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The status in March 2014 At Brno industry fair receiving an award: “innovative product of the year”
• Since August 2013 this µfuel prototype is under rigorous testing directly
at the manufacturing site.
• Many modifications and upgrades have been implemented.
• Extended test runs further increase operational robustness.
• External certification is being performed.

THE LATEST MF480 DESIGN
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A 4xMF480 CLUSTER
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MICROFUEL PLANT 4X CLUSTER
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MICROFUEL PLANT PROCESS FLOW
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FROM ORGANIC WASTE TO FUEL AND CHAR
Market
Diesel Fuel
Vegetable Oil
Crude Oil
Refined Oil
catalyst
5000 Ltr/hr
capacity
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µchar
Making efficient use of palm oil milling waste

FROM MUNICIPAL SOLID WASTE TO FUEL
Diesel fuel
municipal waste
Bionic µfuel plant >60% efficiency
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CONTACT INFORMATION
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Bionic Laboratories GmbH
Helwigstr. 41
64521 Gross-Gerau, Germany
+49 1525 33 40 500
info@bionic-lab.de
Visit our website at www.bionic-world.net

Bionic µFuel Catalytic Microwave Depolymerisation

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