2005 OBP Bi-Annual Peer Review

Thermochemical Processing Effort

Dr. Don J. Stevens, PNNLThermochemical Platform

November 14, 2005

Overview

Budget (K)

NRELPNNLBioengineering ResourcesAntaresEastman ChemicalWeyerhaeuser University of Utah

Partners

Work Objective:Promote efficient conversion of lignin-rich biomass to useful intermediates including syngas

0

500

1000

1500

2000

2500

3000

2004 2005 2006 (planned)

Industrial Partners Core R&D

Relevant Pathways: Agricultural Residues, Energy Crops, Forest Products, Pulp and Paper

Feed Processing & Handling

Thermochemical Processing

Clean-Up & Conditioning

Fuels & Chemicals

Heat & Power

Biomass ResiduesDedicated Crops

BiorefineryResidues

Fuels Production

Sensors & Control

Technical Barrier Areas

Addressing technical barriers:• Handling varying biorefinery residues, lignin-rich feedstocks, and

“off-specification” biomass• Efficiently converting biomass with low tar production• Achieving desired syngas composition• Handling/recovering inorganic material

ThermochemicalR&D

FeedstockR&D

BiochemicalR&D

ProductsR&D

IntegratedBiorefinery

Corn Wet Mill Improvements

Corn Dry Mill Improvements

Agricultural Residue

Processing

Energy Crops

Pulp & Paper Mill

Improvements

Forest Products Mill

Improvements

Corn

Other Grains

Corn StoverWheat StrawRice Straw

Perennial GrassesWoody Crops

Mill WastesWood

Mill WastesWood

Fiber Conversion

DDG Conversion

Biomass & Lignin Gasification

Biomass & Lignin Gasification

Black Liquor, Biomass, & Lignin Gasification

Biomass Gasification& Pyrolysis

Systems-level demonstration & validation of technologies to

improve corn wet milling facilities using corn grain feedstock by

2008

Systems-level demonstration & validation of technologies to

improve corn dry milling facilities using corn grain feedstock by

2008

Systems-level demonstration & validation of technologies to

utilize agricultural residue feedstocks in existing or new

facilities by 2009

Systems-level demonstration & validation of technologies to

utilize perennial crops in existing or new facilities by 2012

Systems-level demonstration & validation of technologies to

improve pulp & paper mill facilities and/or produce

additional products from wood by 2012

Systems-level demonstration & validation of technologies to improve forest products mill

facilities and/or produce additional products by 2012

Strategy and Pathways –Intermediate to Long Term

Impact of Thermochemical Platform R&Don A and B Milestones in the Agricultural Residues

and Perennial Crops Pathways

Complete systems level demonstration and validation of all key technologies to utilizeAgricultural residues feedstocks and perennial crops in existing or new facilities

Demonstrate and validate lignin gasification

to produce syngas for $0.xx/MM Btu by 20xx

Demonstrate and validate biomass gasification

to produce syngas for $4.89/MM Btu by 2020

Demonstrate and validate combined heat and power from

lignin intermediates/residues

Demonstrate and validate products (i.e. ethanol from mixed alcohols)

from lignin or biomass derived syngas for $0.60/gal by 2025

Impact of Thermochemical Platform R&Don A and B Milestones in the Pulp and Paper and

Forest Products Pathway

Complete systems level demonstration and validation of technologies to improvepulp and paper mill facilities and/or produce additional products (fuels, chemicals and /or power)

from wood feedstock in pulp and paper and forest product mills environment

Demonstrate and validate gas cleanup and

process chemical recovery and recyclefrom spent pulping liquor syngas

Demonstrate and validate cost-effective biomass gasification of wood residues

and other process residues and synthesis gas cleanup

in a pulp and paper orforest products mill environment

Demonstrate and validate production of DME/mixed alcohols/FT liquids

or other products from syngasin a pulp or forest products mill

at a price competitive with current commercial practice

Demonstrate and validate reliable and economic gasification of spent pulping liquor and recycle liquor causticization in a pulp mill

Demonstrate and validatesyngas utilization

in a pulp or forest products millfor CHP and direct fuel gas including clean cold gas

Demonstrate and validatebio-oil production

to a stable intermediate

Achieve cost-effective conversion of bio-oil intermediate into product(s)

in a forest products mill

3.0Thermochemical Platform R&D

3.1 Feed Processing and Handling

3.2 TC Processing3.3 Cleanup and

Conditioning3.5 TC Platform

Analysis

3.1.1.2.Feed Improvement

3.2.1.Biomass Gasification

3.2.2.3.2.2.PyrolysisPyrolysis

3.2.3Black Liquor Gasification

3.2.4Innovative Gasification

3.3.1. Cleanup and Conditioning Core R&D

3.3.2. Cleanup and Conditioning Partnerships

3.5.1. TC Platform Analysis

3.5.2. BLG for Fuels/Chemical in at Kraft Mills

Thermochemical Platform

Thermochemical Platform

3.2. TC Processing

3.2.1. Biomass Gasification

3.2.1.2. Gasification of Corn Stover andBiorefinery Residues

3.2.1.3. Wet Gasification of Biorefinery Residues

3.2.3. Black Liquor Gasification

3.2.3.1.3. Adv. High Temp BLG Tech.

3.2.4. InnovativeGasification

3.2.4.2. TC Conversion of Corn Stover

3.2.4.3. Catalytic Hydrothermal Conversion

3.2.4.4. Innovative Membranes/Gasification Technologies

Thermochemical Processing

• Thermal gasification using oxygen-blown or indirectly heated gasifiers for medium-energy syngas

• Hydrothermal gasification for medium-energy syngas

• Current focus is on producing syngas, suitable with conditioning, for liquid fuels production

Current Program Includes:

TC Processing Technical Areas

Project Areas Description

Biomass Gasification

(NREL, PNNL)

Core R&D to better understand gasification processes and guide process improvements, with particular emphasis on agricultural biorefinery residues

Black Liquor Gasification

(Weyerhaeuser)Process R&D to assist with integrated gasification of black liquor to syngas in a forest biorefinery

Innovative Gasification

(Antares/Eastman, Bioengineering Resources, PNNL/NREL)

R&D on innovative, higher risk thermal conversion approaches that will, if successful, provide advantages for biorefineries.

TC Processing: Biomass Gasification

Task 3.2.1. Biomass Gasification of Biorefinery Residues

Objective: Obtain basic data on thermochemical gasification of selected feedstocks to facilitate production of liquid fuels

Technical Approach:• Conduct benchmark studies using NREL and PNNL

gasification systems• Focus specifically on corn stover and biorefinery residues• Collect detailed data on solids conversion, tar and char yields,

gas compositions, N and S release, and other parameters

Needs: Basic data on gasification of corn stover and biorefinery residues is not available. Reliable data is needed to ensure compatibility with industry goals for liquid fuels

Milestones Relevance: Data assists meeting programmatic milestones on TC conversion to syngas

Projects and Participants:• NREL – Basic studies of gasifying corn stover and biorefinery

residues• PNNL – Parametric studies of wet gasification of biorefinery

residues

NREL TCPDU Gasifier System

TC Processing: Biomass Gasification

Task 3.2.1. Biomass Gasification of Biorefinery Residues (Continued)

Accomplishments & Plans:

• NREL Basic Gasification Studies• Work conducted in NREL TCPDU gasification system• 20+ corn stover gasification conditions studied to

provide data for crucial for development of technical validation model

• Work proceeding as scheduled, milestones met• FY06 work to focus on fermentation based lignin-rich

biorefinery residues

• PNNL Parametric Wet Gasification Study• Work conducted in PNNL wet gasification reactor

system• Hydrothermal catalytic process at 350°C, 200

atm• Produces methane-rich gas

• Data collection on gasification of biorefinery residues underway as scheduled

• All work complete in early FY06, project will end as planned PNNL Wet Gasification System

TC Processing: Black Liquor Gasification

Task 3.2.2. Gasification for fuels/chemicals in a pulp mill

Objective: Conduct process R&D to assist with integrated gasification of black liquor to syngas in a paper mill

Technical Approach:• Conduct research on q high temperature gasification concept• Focus on black liquor feedstock• Recognize BL gasification must be integrated with heat and chemical recovery• Collect process data to assist industry

Needs: Black Liquor is a difficult feedstock to handle with high sulfur content. Process must also provide integration of heat use and chemical recovery.

Milestones: Prior analysis shows BL Gasification has the potential to be more cost effective than current combustion systems. Project technical milestones support the syngas cost goal.

Projects and Participants:• Weyerhaueser – High temperature BL gasification

TC Processing: Black Liquor Gasification

Task 3.2.2. Gasification for fuels/chemicals in a pulp mill (continued)

Accomplishments & Plans:Weyerhaeuser – Advanced High Temperature

Gasification• Project began in 2005

• Utilizing CHEMREC New Bern gasifier as a test-bed facility

• Conducting long-term continuous trials under real process conditions

• Combining fundamental chemistry and modeling to address issues

• FY06 work will continue tests and modeling

• Project has clear milestones and go/no-go decision points

New Bern Gasifier

TC Processing: Innovative Gasification

Task 3.2.3. Innovative Gasification

Objective: Conduct research on innovative thermal conversion approaches that will, if successful, provide advantages for biorefineries

Technical Approaches:• Industry-led R&D on the hydrothermal gasification of wet biomass (Antares/Eastman

Chemical/PNNL)• Industry-led R&D to determine the feasibility of gasification systems followed by fermentation of

syngas (Bioengineering Rseources)• Assess the feasibility of ceramic membranes inside or close-coupled to biomass gasifiers for

producing improved syngas for producing liquid transportation fuels (NREL/PNNL)

Needs: The innovative nature of these projects entail higher technical and economic risks, but they offer potential for significant improvement if successful. In most cases, Industry is providing cost-sharing.

Milestones: Projects have clear technical milestones, and industry projects are reviewed regularly against go/no-go decisions.

Projects and Participants:• Antares/Eastman Chemical/PNNL – Catalytic hydrothermal gasification of biosludge• Bioengineering Resources – Thermochemical conversion of corn stover• NREL/PNNL – Evaluation of membrane systems for biomass gasification

TC Processing: Innovative Gasification

Task 3.2.3. Innovative Gasification (continued)

Accomplishments & Plans: Competitive, industry cost-shared projects

• Antares/Eastman Chemical/PNNL – Catalytic Hydrothermal Gasification

• Low temperature catalytic wet gasification of biosludge, 350 °C, 200 atm

• FY05: Feedstock characterization and conversion studies in bench-scale units

• FY06: Go/no-go decision on conducting larger scale gasification tests at the Eastman Chemical site. Critical success factor: catalyst lifetimes

• Bioengineering Resources – Thermochemical Conversion of Corn Stover

• Pilot scale gasification/fermentation process to convert corn stover to ethanol

• Utilizes oxygen-enriched gasification in a Consutech gasifier

• Syngas converted to ethanol by anaerobic fermentation

• Gasifier constructed and operated in 2005• FY06 will include studies to convert syngas to ethanol.

Critical success factor: 50 g/l-day must be achieved

TC Processing: Innovative Gasification

Task 3.2.3. Innovative Gasification (continued)

Accomplishments & Plans:

• NREL/PNNL – Evaluation of Membrane Systems for Biomass Gasification

• Evaluation of high-temperature membranes located in or closely coupled to a biomass gasifier

• Focus on systems producing liquid transportation fuels

• Includes technical and economic feasibility

• “One-time” study to be completed in FY06

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Stage Placement & Portfolio Alignment Review

DOE Office of the Biomass Program FY05 Thermochemical Portfolio Alignment Review

June 7-8, 2005“Stage placement” of all new and existing projects (16) in the Thermochemical Platform.

Evaluations based on: Program Relevance, Approach, Progress, Success Factors, and Future Plans

• 7 core R&D projects (NREL, PNNL) primarily focused on developing biomass gasification and gas clean-up technology that can applied many different biomass feedstocks.

• 9 subcontracted industrial/cost-shared R&D projects selected by competitive solicitations or directed by Congress to develop/commercialize gas cleanup technology, black liquor gasification, and other thermochemical processes.

Reviewers• Professor Robert Brown, Iowa State University• Professor Esteban Chornet, Université de Sherbrooke• Viorel Duma, Abengoa Bioenergy R&D, Inc.• John Scahill, DOE Golden Field Office• David Turpin, MeadWestvaco Research

Stage Placement & Portfolio Alignment Review

General Comments on Thermochemical Program• Thermochemical Program has clear goals which support the overall program• Technical barriers are clearly identified• R&D is good fit with the program and there is good balance• Funding may be inadequate to meet program goals

Specific Reviewer Comments on TC Processing:

• Reviewers offered many detailed technical suggestions: Response: DOE provided technical feedback to PI’s

• High level BL Gasification milestones may not be met at current budget levels Response: Current funding availability is limited

• Several projects have high risk – enforce stage gate Response: DOE agrees, reviews will be held as scheduled

• Pyrolysis should be supported in the TC Processing AreaResponse: Given current budget levels and priorities, DOE is currently unable to fund pyrolysis

to bio-oil R&D

Summary and Future Work

TC Processing: Work In FY06

Biomass Gasification:• Core R&D on gasification of stover and biorefinery residues will

continue at the NREL TCPDU gasifier• Other projects will end as scheduled

Pyrolysis:• Future projects on biocrude as a refinery feedstock will depend on

industry interest and OBP funding availability

Black Liquor Gasification:• R&D work will continue in the larger-scale facility with industry cost-

sharing• Progress will be tracked and reviewed

Innovative Gasification:• Two industry-led projects will continue• Go/no-go decision in FY06 for Antares/Eastman project• Ongoing reviews for Bioengineering Resources syngas fermentation