2013 DOE Bioenergy Technologies Office (BETO) …...materials, chemicals) that reduce dependence on foreign oil – Seek to prove commercial feasibility (economic and technical) of

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Avello ® and Bioasphalt® are trademarks of Avello Bioenergy, Inc. Copyright © 2013 All rights reserved.

2013 DOE Bioenergy Technologies Office (BETO) Project Peer Review

Demonstration of Pyrolysis Biorefinery Concept for Biopower, Biomaterials and

Biochar

May 20, 2013

Bio-Oil Technology Area Review

Dennis S Banasiak, PhD Avello Bioenergy, Inc.

This presentation does not contain any proprietary, confidential, or otherwise restricted information

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Goals/Objective Statement

Project Goals:

• Design, Build and Operate 2.5 ton/day Integrated Pilot Plant

– Wood and corn stover feedstocks

– Make Products and Collect Engineering Data

– Demonstrate continuous operation

• Pre-Commercial Testing of Products

– Asphalt, Chemical, Fuel Oil, Transportation Fuels and Biochar Applications

Supports BETO Goals:

• Process integration and scale-up of novel Avello®FRAC fractionation technology, (Tt-E, Tt-I, Tt-K)

• Product demonstrations and R&D (including Tt-G)

– Biofuel Oil™ combustion for power

– Bioasphalt® for non-energy applications (petroleum replacement)

– Feedstocks for specialty chemicals and advanced biofuels

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Project Quad Chart Overview

Timeline • Project start date: TBD

• Project end date: 3 yrs. From start

• Percent complete: 0%

Barriers • Tt-E. Liquefaction of Biomass and

Bio-Oil Stability

• Tt-K. Bio-Oil Pathways Process Integration

• Tt-I. Sensors and Controls

Budget Total project funding: $8,967,012

• DOE: $2,500,000

• Cost share: $6,467,012

Funding received in FY 2011: $0

Funding in FY 2012 (proposed)

• DOE: $583k

• Cost share: $113.6k

Funding for FY 2013 (proposed)

• DOE: $1.917M

• Cost share: $2.53M

ARRA Funding - NO

Years the project has been funded & average annual funding -None

Partners & Roles • Avello – Lead

• ConTech – EPC

• Emerson – Engineering support

• Borregaard – Product R&D

• Cargill – Biofuel Oil demo

• Leading roofing company – Bioasphalt R&D

• Virent – Biofuels R&D

• ISU – Biomass and product R&D

• APAI, Iowa DOT, USDA – Advisors

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Project Overview

• Process integration of the entire process train including – Biomass pre-processing

– Pyrolysis conversion and fractionation of Bio-oil

– Bio-oil fraction use and upgrading as petroleum replacement products

– Front-end and back-end storage/logistics

– Bioasphalt production (not shown above)

• Main technical barriers

– Tt-E. Liquefaction of Biomass and Bio-Oil Stability

– Tt-K. Bio-Oil Pathways Process Integration

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Biomass Prep and Handling

Pyrolysis and Fractionation

Bioproduct upgrading and

testing

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1 - Approach

Demonstration of pyrolysis based biorefinery concept for biopower,

biomaterials and biochar

A. Engineering B. Procurement and Construction C. Startup, Operation D. Bioproduct testing

B.1 Site preparation

B.2 Building construction

C.1 Startup

C.2 Operation

A.1 Pre-FEED

A.2 FEED

A.3 Detailed Engineering

B.4 Equipment installation

E. Project management and reporting

E.1 Project management

E.2 Project reporting

D.1 ISU R&D

D.2 Bioproduct sampling and RD&D

B.3 Equipment procurement

Work Breakdown Structure (from PMP)

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• Leverage PDU data and experience for scale-up

• Leverage market leader expertise in product evaluation and development

• Project milestones, schedule, and risk mitigation via PMP

• 5 project tasks

• Phase reviews after subtasks

• Go/No-Go decision point after detailed engineering →

Budget Period 2

•

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2 - Technical Background and Planned Activities

• Current status of technology

• Project Overview

• Project Site

• Project Workflow

• Project RD&D

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NON-FOOD

BIOMASS

NON-

CONDENSABLE

GAS

BIOCHAR

Bio-oil

PYROLYSIS OIL FRACTIONS

FAST PYROLYSIS

Conv

entio

nal

Avello™FRAC Technology Differentiation

Multiple Fractions • Separate acids and water

• Higher energy, less corrosive, more stable

Single Fraction • Corrosive, poor properties

• Complex chemical mixture

•10 - 15%

•12 - 25%

•60 - 75%

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Avello®FRAC Pilot Plant

•Liquid Product

Recovery

•Feed System

•Reactor and Cyclones

Cyclones

Char

Fluidized Bed

Reactor

FeedSystem

Nitrogen

ESP ESP ESP

To GC analysis

To flare

Glass wool filter

Fraction 1 Fraction 3 Fraction 4 Fraction 5

Condenser

Condenser Condenser

Surgehopper

Metering Hopper

Biomassfrom

hopper

Preheaters

Injection auger

Fraction 2

Gas

Hea

ter

BedScale

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Status of Technologies

Fractionation Technology

• ¼ ton/day pilot plant

• > 525 hours operation

• Multiple feedstocks

– Cornstover, Pine, Oak, Switchgrass

• Multiple 24hr/day continuous campaigns

• Strategic Partner sample evaluation •Courtesy of ISU

Bioasphalt® binder • Developed by Dr. Chris Williams (ISU) • Meets AASHTO specs • October 2010, IDOT Demo in Polk County

– 10’ x 1 mile trail – 3% additive to petroleum asphalt binder – Standard blending and paving equipment

•Waveland Trail •Franklin Ave. & 55th St., Des Moines

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Biofuel Oil™ Combustion

Property Biofuel Oil1 Conventional Pyrolysis Oil2

No. 2 Fuel Oil2

Moisture content (wt%) 7 20 - 25 < 1.0

HHV (BTU/gal) 96,000 72,000 – 80,000 138,500

1. From Red Oak feedstock. Properties shown for specific sample tested by Brookhaven National Laboratory in combustion application (May 2012). 2. Easterly, James L. "Assessment of Bio-Oil as a Replacement for Heating Oil.“ 1 Nov. 2002. Web: <http://www.nrbp.org/pdfs/pub34.pdf>.

• Fraction 3 tested as-is in conventional home heating burner by Brookhaven National Laboratory

• Acceptable performance and reduced emissions compared to ULSD

~1 gal/hr EZ-1 residential burner with Econox inline nozzle heater from Carlin Combustion Technologies

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Project Overview/Partners

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BCRF Site

* Approximate size and location shown for lease area •12

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Detailed

Engineering

(A.3)

Pre-FEED

(A.1)

FEED

(A.2)

Phase

Review

Phase

Review

Phase

Review

Building

construction

(B.2)

Phase

Review

Phase

Review

Startup

(C.1)

Equipment

procurement

(B.3)

Site prep

(B.1)

Phase

Review

Equipment

installation

(B.4)

Operation

(C.2)

Bioproduct

sampling and

RD&D

(D.2)

Project management (E.1) & Project reporting (E.2)

Notice toProceed

ProjectComplete

BUDGET PERIOD 1 BUDGET PERIOD 2

ISU R&D (D.1)

Final

Completion

Engineering Report

E.2.DL.1

A.3.ML.1

Pilot Plant Construction

ReportE.2.DL.2

B.2.ML.1

B.3.ML.1

B.4.ML.1

C.1.ML.1

C.2.ML.1

E.1.ML.1

D.2.ML.1 – D.2.ML.6

Final Project Report

E.2.DL.3

C.1.GN.1

KEY

Feedstock

Bioproducts

DataD.1.ML.1 – D.1.ML.5

Substantial

Completion

Performance

Testing

Phase

Review

A.GN.1

Level 2

TaskDeliverableMILESTONE Go/No-

Go

Avello/EPC Project controls

C.2.ML.2

Move to

Budget

Period 2

Move to

operational

status

Project Workflow

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Project RD&D

Feedstocks Bioasphalt®

binder Biofuel Oil™ Chemicals Biofuels Biochar

• ISU ABE Dept., Matt Darr • AGCO • Single pass stover

baling • Switchgrass likely • Harvest, Storage,

Transport (HST) • Pre-treatment • Torrefaction?

• ISU CCEE Dept., Chris Williams • Performance

testing & verifications

• Coordinate up to 4 demo paving projects with IA DOT and APAI

• Roofing Company • Roofing asphalt

formulations • Analysis, blending,

modifying, performance testing

• ISU ME Dept., Terry Meyer & Song-

C. Kong • Goodrich Engine

Components • John Deere Power

Systems • Non-transport

biofuel blends • Combustion testing:

furnace (heat) and stationary engine (power)

• Emissions analysis

• Cargill • Co-fire test burn • Renewable power &

reduced CO2 profile for biofuels

• Borregaard LignoTech

Analysis, characterization, screening, modifying

• Specialty, high-value chemical applications

• Virent • Feasibility study • Bench and pilot

scale testing • Utilize BioForming

to convert Biooil fractions to drop in fuels.

• Proof-of-concept completed

• ISU ABE Dept., Matt Darr • Post-production

handling and processing

• Investigate densification methods

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3 - Relevance

• Project focuses on petroleum replacement products (fuels, materials, chemicals) that reduce dependence on foreign oil – Seek to prove commercial feasibility (economic and technical) of products

– Seek to demonstrate compatibility within existing infrastructure (fuel, transportation, chemical)

– Remove water and acid from bio-oil for new downstream processing schemes

• Joint development with public and private partnerships to leverage expertise, cut cost

• Evaluate various biomass feedstocks to quantify risk (feedstock supply critical risk)

• Test high performance separation technology (conversion critical risk)

• Test biopower demonstration and deployment (demonstration and deployment risk)

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4 - Critical Success Factors

• Critical success factors (managed using PMP): – Process Scale-up, product performance and compatibility with existing

infrastructure (technical) – Market acceptance, product cost (market) – Project Management

• Top Challenges: – Process scale-up: uniting solid feedstock processing with liquid processing; using

commercial equipment for bio-oil applications – Product/Markets: demonstration petroleum product replacement viability

• Successfully advancing technology: – Prove process scalability – Prove commercial end-use applications, market acceptance, compatibility

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Future Work

• Assumes July 1 kick-off

• Budget Period 1 • Budget Period 1

• Expected plant startup:

• Q4 2014

Year

Quarter

Task Month Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun

A. Engineering

A.1 Pre-FFED

A.2 FEED

A.3 Detailed engineering

A.G.N.1 "Go/No-Go"

B. Procurement, Construction

B.1 Survey, site-prep

B.2 Building construction

B.3 Equipment procurement

B.4 Equipment installation

C. Startup, Operation

C.1 Plant startup

C.1.ML.1. "Plant startup"

C.2 Operation

D. Bioproduct testing

D.1 ISU R&D

D.2 Bioproduct sampling, RD&D

E. Project Reporting and MGMT

Q2

2016

Q1

2013 2014 2015

Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4

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Summary

• Large integrated pilot scale plant and commercial product testing will build upon previous developmental scale work, refine economics and prepare for commercial scale up

• Public and private partnerships to leverage expertise, cut costs, increase probability of successful project

• Management team, advisors, and partnerships to manage critical success factors and solve/minimize challenges

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Additional Slides

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Avello Bioenergy Fast Pyrolysis Technology Platform

SOIL

AMENDMENT

RENEWABLE

HEAT AND

POWER

ADVANCED

BIOFUELS

SUSTAINABLE

CHEMICALS

NEXT

GENERATION

PAVEMENT

NON-FOOD

BIOMASS

END-USEPRODUCTSFEEDSTOCK PROCESS

PROPRIETARY

500°C, 1 ATMOxygen free

Rapid heating2 s res. time

< 10% moisture< ¼”

Crop residues, forest and mill

residues

PROPRIETARYFAST

PYROLYSIS

PRODUCT

RECOVERY

SYSTEM

BIOFUEL OIL™

CHEMICAL

FEEDSTOCKS

BIOASPHALT™

BIOCHAR

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Documents

2013 DOE Bioenergy Technologies Office (BETO) …...materials, chemicals) that reduce dependence on foreign oil – Seek to prove commercial feasibility (economic and technical) of