2005 OBP Bi-Annual Peer Review

Feedstock Platform Analysis

Shahab Sokhansanj,

Bob Perlack,

Anthony Turhollow

November 14, 2005

Overview

Partners• ORNL & INL• In collaboration with NREL• University of Tennessee• Virginia Tech• University of British Columbia• USDA & Industry

Analysis ObjectiveDOE feedstock supply analysis:• Identifies barriers to feedstock supply. • Guides core R&D in engineering solutions to overcome barriers.• Seeks out minimum cost supply options subject to quantity and quality.

Budget: Sam discussed the budget

Targets

• Target:

– Provide data on current and future feedstock supplies from agricultural residues, forest residues, and energy crops – the one billion ton vision.

– Analyze feedstock supply systems & logistics to ensure the availability of low cost biomass to meet the $35/dry ton goal.

• Guiding documents

– Roadmap for agricultural biomass feedstock supply for the U.S. (2003)

– MYTP (2003), MYAP (2004), MYPP (2005)• Timelines

– By 2007, feedstock analysis task will demonstrate that by 2015 ample feedstock will be available at $35/dry ton

• Pathways

– Agricultural residue pathway

– Perennial grasses & woody energy crop pathway

Accomplishments Forecast and Analysis

• Joint DOE/USDA Billion ton vision report (April 2005)

– Large potential biomass resource from U.S. croplands (residues, perennial energy crops)

– Most forest resources are currently available

• Analysis of grower payments for crop residues (nutrient and site operations, grower premium)

– Complicated issue given conflicting objectives between growers and processors

– Nitrogen replacements costs have risen sharply

• Revised feedstock website with updated resource data (website reconfigured by BCS)

Current resource availability and future resource potential:agricultural crop residues and perennial energy crops

75

256

11

5225

120

0

377

0

50

100

150

200

250

300

350

400

450

Current resource availability Future resource potential

Milli

on d

ry to

ns

Corn stover Wheat straw Other crop residues Perennial energy crops

Value of removed nutrients (N,P,K) has risen sharply

0

1

2

3

4

5

6

7

8

9

10

2000 2001 2002 2003 2004 2005

$/dr

y to

n of

re

sidu

e re

mov

ed

North Central - corn North Central - corn/soybeans Northwest - wheat

Quantified the magnitude of cost reductions from current residue handling systems to more efficient single pass harvest and bulk handling systems:

Source: IBSAL

0.00

5.00

10.00

15.00

20.00

25.00

30.00

Bale system Loaf system

Co

st

($/d

T)

Grower

Shred

Bale Loaf

Stack

$24

$18

Grower

Shred

Return on Investment

Return on Investment

Accomplishments: Biomass Collection

• Bale system: multi pass, packaged load• Loaf system: single pass, bulk load

Accomplishments: Preprocessing & Transport

0

5

10

15

20

25

30

0.01 0.03 0.07 0.1 0.5 1 2

Particle size (inch)

Co

st

($/d

T)

UnloadTruck Grind

Search for reducing the cost of preprocessing and transport - Biomass densification by reducing particle size

Source: IBSAL

Accomplishments:Integration

• Integration– dry systems

Transport options ($/dT)

Bales Grinds Chops

Collection 13.70 15.45 14.26

Format $/dT Overall cost $/dT

Stover

Baling 26.02 41.77 43.79

Loafing 21.85 39.61

Chopping 37.88 54.28

Straw

Baling 29.02 44.78 46.79

Loafing 26.81 44.58

Chopping 46.51 62.91

Switchgrass

Baling 28.17 43.93 45.94

Loafing 23.31 41.07

Chopping 40.67 57.07

2005 2012 2015

Delivered cost of biomass ($/dry ton)

53 45 35

Source: IBSAL

$10 to producer15% profit to supply

Target cost

Accomplishments– publications

For 2004-2005: 11 peer reviewed journal papers, 15 conference presentations4 Forum sessions (AETC and ASABE)

• Igathinathane, C., A.R. Womac, S. Sokhansanj, L. Pordesimo. 2005.Thermodynamic properties of mold appearance on selected corn stover components. ASAE paper 056047. American Society of Agricultural and Biological Engineering (ASABE). St. Joseph, MI: ASABE.

• Kumar, A. and S. Sokhansanj. 2005. Switchgrass (Panicum vigratum, L.) Delivery to a Biorefinery Using Integrated Biomass Supply Analysis and Logistics (IBSAL) Model. ASAE Paper No. 056143. American Society of Agricultural and Biological Engineering (ASABE). St. Joseph, MI: ASABE

• Mani, S., S. Sokhansanj, X. Bi, and L. Tabil. 2005. Modeling of biomass densification processes. ASAE Paper No. 056144. American Society of Agricultural and Biological Engineering (ASABE). St. Joseph, MI: ASABE

• Sokhansanj, S. and A. Turhollow. 2004. cubing operations and costs. Applied Engineering in Agriculture 20(4): 495-499.

Interim Stage Gate Overview

March 14-15, 2005

Overview of the material covered and the approach:

• Supply Forecast and Analysis – Bob Perlack– Resource estimates, grower payments, revised feedstock website

• Billion Ton Feedstock Vision – Bob Perlack (ORNL)– Results of the joint DOE/USDA feedstock supply analysis

• Biomass Supply Systems and Logistics – S. Sokhansanj (ORNL)– Integrated Biomass Supply Analysis and Logistics Model (IBSAL)

• Feedstock Harvest & Collection Assembly Systems – Reed Hoskinson (INL)

- Straw collection options and costs (IBSAL application example)

Reviewer Comments

What did the reviewers have to say about on-going analysis work?

• Supply forecast and analysis – Important task but funding was lacking. – Data development needs coordination and validation with

modeling.

• Billion ton vision ─ Need for an implementation plan and timeline.

• Biomass Supply Systems and Logistics ─ Model useful for integrating and evaluating various steps in

feedstock supply. ─ Model needs validation and peer review

DOE Response

Response to the reviewers comments

• Supply forecast and analysis – Will make new resource data and reports available on

reconfigured website. – No plans for additional activities in the Supply Forecast and

Analysis Task; related activities will be completed under Feedstock Assembly Core R&D and Feedstock Analysis.

• Billion ton vision – Will develop availability for cropland resources.

DOE ResponseActions

• Biomass supply systems and logistics

– Will accelerate validating IBSAL using existing and emerging USDA/DOE projects on straw, stover, and switchgrass over the next 3 years.

– Will collaborate with INL’s core and applied research

– Will incorporate emerging preprocessing and supply depot concepts.

• Actions taken

– Developed joint milestones between ORNL and INL

– Incorporated field data in IBSAL from USDA/Producers/INL wheat straw harvest project in Idaho.

– Incorporated data in IBSAL from Chariton switchgrass project.

– Initiated work with Imperial NE on corn stover supply logistics.

– Manuscripts for publication in Biomass & Bioenergy and Applied Engineering in Agriculture are peer-reviewed.

SIZE REDUCTION

MIXING FORMULATION

DENSIFICATION GRANULATION

SORTINGSEPARATION

DRY

BIOREFINERYPRETREATMENT

CELLULOSIC BIOMASSVARIOUS

INGREDIENTS

WET STORAGE

Summary & Future Work

Completed:

• Analysis of billion ton biomass supply• Analysis of grower payment• Integrated Biomass Supply Analysis & Logistics – Low

cost dry systems options

Planned R&D: Wet systems Model – collection, storage, transport.

Preprocessing (dry & wet) – Multiple biomass blending, sorting, & densification, bulk transport & handling.

FY06 Plans

• ORNL / INL – A framework for wet storage model and optimization is outlined and the baseline cost for wet storage of corn stover is established.

RAIN SNOW

SOLAR RADIATION

TEMPERATUREHUMIDITY

MICROBIAL INTERACTIONS

BIOCHEMICAL REACTIONS

HEAT & MASS TRANSFER PROCESS

O2 CO2

t

FY06 Plans

• INL / ORNL – Development first draft of the dry feedstock supply design report to demonstrate the integration of biomass supply and preprocessing operations that would result in overall cost reductions by increasing the value of biomass.

BIOMASS PRODUCTION

COLLECTION

BIOMASS PREPROCESSING

INSTORE PRE

PROCESSING

BIOREFINERY

BIO PRODUCTS CHARACTERISTICS

QUANTITIESPRICE

SCHEDULE

BIOMASS TYPESQUANTITIES

COSTFORMAT

TRANSPORTPRE TREATMENT

Profitability

Acknowledgement

The analysis team

• ORNL: Mark Downing, Jonathan Mielenz, Bob Perlack, Shahab Sokhansanj, Anthony Turhollow

• INL: Richard Hess, Reed Hoskinson, Kevin Kenney, Corey Radtke, Chris Wright