Project Independence: Construction of an Integrated Biorefinery for Production of Renewable Biofuels at an Existing Pulp and Paper Mill
Project Independence proposed to construct a demonstration biomass-to-liquids (BTL) biorefinery in Wisconsin Rapids, isconsin. The biorefinery was to be co-located at the existing pulp and paper mill, NewPage Wisconsin System Incorporated’s Wisconsin Rapids Mill, and when in full operation would both generate renewable energy for Wisconsin Rapids Mill and produce liquid fuels from abundant and renewable lignocellulosic biomass. The biorefinery would serve to validate the thermochemical pathway and economic models for BTL production using forest residuals and wood waste, providing a basis for proliferating BTL conversion technologies throughout the United States. It was a project goal to create a compelling new business model for the pulp and paper industry, and support the nation’s goal for increasing renewable fuels production and reducing its dependence on foreign oil. NewPage Corporation planned to replicate this facility at other NewPage Corporation mills after this first demonstration scale plant was operational and had proven technical and economic feasibility. An overview of the process begins with biomass being harvested, sized, conditioned and fed into a ThermoChem Recovery International (TRI) steam reformer where it is converted to high quality synthetic gas (syngas). The syngas is then cleaned, compressed, scrubbed, polished and fed into the Fischer-Tropsch (F-T) catalytic reactors where the gas is converted into two, sulfur-free, clean crude products which will be marketed as revenue generating streams. Additionally, the Fischer-Tropsch products could be upgraded for use in automotive, aviation and chemical industries as valuable products, if desired. As the Project Independence project set out to prove forest products could be used to commercially produce biofuels, they planned to address and mitigate issues as they arose. In the early days of the Project Independence project, the plant was sized to process 500 dry tons of biomass per day but would generate a blend of synthesis gas for the lime kiln and a minimum of Fischer-Tropsch liquids for sale. This was to be done using a single stage of Fischer-Tropsch reaction at roughly a 70% yield. The capability of the Wisconsin Rapids Mill lime kiln to run on the relatively low heating value of the product synthesis gas was problematic. The design was then changed to maximize Fischer-Tropsch liquids production using a two stage Fischer-Tropsch process. Project Independence progressed with the design of the mill as ThermoChem Recovery International worked on the technical details of the project as well as develop information from their pilot plant. The pilot plant work uncovered several problems with the synthesis gas clean-up that solutions. ThermoChem Recovery International found these solutions and developed a very good path forward on the technical side. The technical solutions were demonstrated in the pilot plant to everyone’s satisfaction. In July 2010, NewPage Corporation had been severely affected by the downturn in the economy and actively went to find a strategic partner. By April 2011 the Abell Foundation entered the picture as this strategic partner. The Abell Foundation would join forces as Project Independence Inc. to build the 500 dry ton per day Project Independence plant. The design of this facility progress even after NewPage Corporation declared Chapter 11 Bankruptcy protection in September, 2011. This continued until April 2012 when NewPage Corporation determined that continued work on Project Independence Inc. presented too much risk with little reward for NewPage Corporation. The project was terminated at this point.
- Research Organization:
- NewPage Wisconsin System Inc.
- Sponsoring Organization:
- USDOE Office of Energy Efficiency and Renewable Energy (EERE)
- Contributing Organization:
- AMEC
- DOE Contract Number:
- FC36-08GO18049
- OSTI ID:
- 1254304
- Report Number(s):
- DOE-NPWS-18049
- Country of Publication:
- United States
- Language:
- English
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