2005 OBP Bi-Annual Peer Review Biorefinery Project Overview
Neil P. RossmeisslU.S. Department of Energy
Energy Efficiency and Renewable EnergyOffice of the Biomass Program
Barriers for Technology
BasicR&D
Technology Development
Commercially Viable Demo
Permitting &Engineering
Proof of Concept Construction Operation
Co
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First Commercial Plant Me
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Att
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De
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Operation
80% / 20% 50% / 50% 20% / 80% Loan Guarantee Program/Risk Mitigation Pool
“A” Milestone AchievedTechnical Risk Minimized
Dev
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Co
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100% / 0%
Current BiorefineryProjects
Procurement
Private Cost-Share:OBP Cost-Share:Project Timeline:
Development Stages:Unexpected Cost:
Risk Mitigation:
Potential FutureOBP/EERE Deployment Efforts(to overcome financial barriers)
The Holistic Ethanol FacilityThe Holistic Ethanol Facility
Corn Quick Steep Scarification
Filtration Fermentation EthanolRecovery
MolecularSieves
“Fiber” HydrolysisNew DDG
Animal FeedEthanol
StarchEtOH 95%
EtOH100%EtOH
GermSeparation
Fermentation
CatalyticConversions
Gasification
Fuel/PowerEG, PG
Glycerol, Etc
ItaconicSuccinic, Etc
Oil
Value Added ProductsValue Added Products
grindcornglucose
fermentationethanol
starch enzymatichydrolysis
hemicellulose enzymatic hydrolysis
DDG(feed)
celluloseproteinLignin
Fats/oilsfilter
arabinaric acidxylaric acid
•enzymes •itaconic acid•diammonium
succinate•succinic acid
other acids/monomers
.
.
.monomers and high value solvents-butyrolactone (GBL)1,4-butanediol2-Pyrrolidinone N-methyl -2-pyrrolidinone (NMP)N-vinyl -2-pyrrolidinone3-methyl pyrrolidinone derivatives3-methyl -THF
polyhydroxyamides chelatorsmonomers
fermentationHydro -
genation
oxidation
filter
arabinosexylose
grindcornglucose
fermentationethanol
starch enzymatichydrolysis
hemicellulose enzymatic hydrolysis
DDG(feed)
celluloseproteinLignin
Fats/oilsfilter
arabinaric acidxylaric acid
•enzymes •itaconic acid•diammonium
succinate•succinic acid
other acids/monomers
.
.
.monomers and high value solvents-butyrolactone (GBL)1,4-butanediol2-Pyrrolidinone N-methyl -2-pyrrolidinone (NMP)N-vinyl -2-pyrrolidinone3-methyl pyrrolidinone derivatives3-methyl -THF
polyhydroxyamides chelatorsmonomers
fermentationHydro -
genation
oxidation
filter
arabinosexylose
ethylene glycolpropylene glycolglycerol
hydrogenationhydrogenolysis
“Generic Model”
Agricultural Sector Biorefinery Pathways
Program “A” MilestonesFeedstocksBiorefinery Pathway
Conversion Pathway Options Under
Consideration (each has a IndustrialPartners
B Milestone - cost target )•Aventine•Nature Works, LLC
Corn Grain
Residual Starch Conversion Fiber Conversion New Fractionation Process Products from C 5/C6 Sugars Products from Oils
Complete systems level demonstration and validation of
technologies to improve corn wet mill facilities using
corn grain feedstock
Residual Starch Conversion DDG Conversion New Fractionation Process Products from C 5/C6 Sugars
•Abengoa•Broin•Dupont
Complete systems level demonstration and validation of
technologies to improve corn dry mill facilities using
corn (and other ) grain feedstock
Other Grains
Complete systems level demonstration and validation of
technologies to improve natural oil processing facilities
using oil crop feedstock
Oil Crops
Products from Oils
Corn
Stover Small Grain
Straw Rice Straw
•Abengoa•Dupont•Cargill•Nature Works LLC
Complete systems level demonstration and validation of
technologies to improve processing facilities using
agricultural residue feedstocks
Biomass Sugar Production Products from C 5/C6 Sugars Products from Lignin Biomass Gasification Products from Synthesis Gas New Fractionation Processes Products from New Process
Intermediates
Complete systems level demonstration and validation of
technologies to improve processing facilities using
Perennial Crops
•Chariton Valley•Great Plains Institute•Univ. of Tennessee
Grasses Woody
Crops
Biomass Sugar Production Products from C 5/C6 Sugars Products from Lignin Biomass Gasification Products from Synthesis Gas New Fractionation Processes Products from New Process
Intermediates New Consolidated Processes
•ADM•DOW•Cargill
•ADM•NCGA•Cargill•NCGAWet
andDry Mills
Oil Crops
AgricultureResidues
Perennial Crops
•Rohm & Hass
Fund Solicitations to Overcome Barriers
Cost of LiquidTransportation Fuels
Product YieldProduction Rate
Final ConcentrationProduct Recovery
Capital Costs
OrganismDevelopment
CatalystDevelopment
1st Tier
2nd Tier
3rd Tier
Biological Chemical
Cost of LiquidTransportation Fuels
Cost of LiquidTransportation Fuels
Product YieldProduction Rate
Final ConcentrationProduct Recovery
Capital Costs
Product YieldProduction Rate
Final ConcentrationProduct Recovery
Capital Costs
OrganismDevelopmentOrganismDevelopment
CatalystDevelopmentCatalystDevelopment
1st Tier
2nd Tier
3rd Tier
Biological Chemical
Liquid Fuels
Cost of ChemicalsAnd Materials
Product YieldProduct Purity
Final ConcentrationProduct Recovery
Capital Costs
Organism DevelopmentFermentation DevelopmentEnzyme DevelopmentSeparations
Catalyst DevelopmentSeparations
1st Tier
2nd Tier
3rd Tier
Biological Chemical
Cost of ChemicalsAnd Materials
Cost of ChemicalsAnd Materials
Product YieldProduct Purity
Final ConcentrationProduct Recovery
Capital Costs
Product YieldProduct Purity
Final ConcentrationProduct Recovery
Capital Costs
Organism DevelopmentFermentation DevelopmentEnzyme DevelopmentSeparations
Catalyst DevelopmentSeparations
1st Tier
2nd Tier
3rd Tier
Biological Chemical
Chemicals and Materials
FY2002 Solicitation
Industries Engaged: •Dry Mills•Wet Mills•Chemicals
Technologies Being Developed: •Fractionation•Pretreatment•Hydrolysis•Strain Development •Fermentation •Catalysis•Various Separation Technologies•Harvesting •Storage
Pathways: •Corn Dry Mill Improvements Pathway•Corn Wet Mill Improvements Pathway•Agricultural Residue Pathway
Expected Outcomes: •Chemicals•Fuel•Value-added products
Relevance to Pathways
• Broin: A Second Generation Dry Mill Biorefinery• ADM/NCGA: Separation of Corn Fiber and Conversion to
Fuels and Chemicals• Cargill: New Biorefinery Platform Intermediate Project• Cargill: Making the Industrial Biorefinery Happen• Cargill/MAT: Collection, Commercial Processing and Utilization
of Corn Stover• DuPont: Integrated Corn Based Biorefinery Project• Abengoa: Advanced Biorefining of Distiller’s Grain and Corn
Stover Blends
Congressionally Directed
Industries Engaged: •Dry Mills•Pulp & Paper•Chemicals
Technologies Being Developed: • Pretreatment• Hydrolysis• Gasification • Fermentation • Catalysis• Harvesting • Storage
Pathways: •Corn Dry Mill Improvements Pathway• Pulp and Paper Pathway•Agricultural Residue Pathway• Forest Residue
Expected Outcomes: •Chemicals•Fuel•Value-added products
Relevance to Pathways
• GTI: Commercial Demo of Thermodepolymerization (TDP) Technology, Nevada• MBI: Biorefinery• GTI: Ag Waste Biorefinery using TDP• Mississippi Ethanol Gasification• Iroquois Bioenergy: Corn Dry Mill to Ethanol Plant• AgraPure: Fibrowatt• University of ND: EERC Center for Biomass Utilization• Brazos River: North Central Texas Dairy Waste• Farm Power: Small Scale Waste Energy Demo• Louisiana State: Improved Biorefinery From Sugar Cane• Mount Wachusett: Modular Biopower Micro-Cooling and Power• North Country Hospital: Biomass Cogeneration Project• Georgia Pacific: Demo of Black Liquor Gasification• Sealaska Corp: Southeast Alaska Ethanol Project• Changing World: Ag Mixed Waste Biorefinery • City of Gridley: City of Gridley Biofuels Project
Platform Budget
0%
20%
40%
60%
80%
100%
2004 2005 2006(planned)
Yearly Budget
EarmarksProgramIndustrial Partners
Platform Barriers
Barrier Solution Responsibility
End-to-End ProcessIntegration
Develop methods of collecting, storing, transporting and processing diverse feedstocks
OBP/Industry
Integrate biochemical and thermochemical technologiesOBP
Commercial-scaleDemonstration
Sustained integrated performance Industry
Demonstrated technical, economic, safety and environmental targets OBP
Improved existing and new biorefineriesPolicy/Legislation
Sensors and controls DOE Labs
Technical Risk
Pretreatment Options DOE/USDA Labs
Feedstock Development USDA
ToolsOBP
Commercialization Risk
Probability of failure in new facilities due to unproven technologies Policy/LegislationDOE HQ
Financial investment is high, plants must achieve design capacity quicklyPolicy/LegislationDOE HQ
Goals & Approach
• Complete technology development necessary to enable start-up demonstration of a biorefinery producing fuels, chemicals and power by 2012 at an existing or new corn dry mill.
• Help U.S. industry establish the first large-scale sugar biorefinery based on agricultural residues by 2018.
• Complete technology integration to demonstrate a minimum sugar selling price of $0.64/lb resulting in a minimum ethanol selling price of $1.09/gal by 2020 from ag residues or dedicated perennial energy crops.
• Complete the technology integration of thermochemical processes into a sugar biorefinery to produce syngas at $3.84/MMBtu by 2030 from lignin or wood feedstocks.
Key Accomplishments
• Development and demonstration of a new front-end pretreatment operation for a dry mill by Broin that increases the ethanol yield and produces more valuable high protein animal feed.
• Demonstrated a pilot plant by ADM and the NCGA at NREL to scale-up bench results to define operating parameters involved in integrating processes into existing corn wet mills.
Presentation Agenda
• Integrated Biorefinery Analysis: Bob Wallace, NREL• Integrated Corn-Based Biorefinery: Bill Provine, DuPont• Making Industrial Biorefinery Happen:Bob Wooley, NatureWorks LLC
Break• Collection of Corn Stover: David Glassner, NatureWorks LLC• New Biorefinery Platform Intermediate: Jim Millis, Cargill Inc.• Second Generation Dry Mill: Steve Lewis, Broin & Associates
Lunch• Advanced Biorefining of DDG and Corn Stover: Patrick Mulvihill, Abengoa
Bioenergy• Separation of Corn Fiber and Conversion to Fuels and Chemicals: Nathan
Fields, NCGABreak
• Demonstration of BLG at Big Island: Larry Rath, NETL• Southeast Alaska Ethanol: Fran Ferraro, Merrick• City of Gridley Biofuels: Dennis Schuetzle, TSS Consultants