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NREL is a na*onal laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC. Cellulosic Biofuels Development and Commercializa6on Progress in the United States of America James D. (Jim) McMillan, Ph.D. Bioenergy Australia Webinar NREL, Golden, Colorado, USA 21 July, 2015 (20 July in Golden)

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Page 1: CellulosicBiofuelsDevelopmentand ...€¦ · 8 Alcohols Among Many Biofuels Options Biomass Feedstocks Ethanol Lignocellulosic Biomass (wood, agricultural residues, grasses, etc.)

NREL  is  a  na*onal  laboratory  of  the  U.S.  Department  of  Energy,  Office  of  Energy  Efficiency  and  Renewable  Energy,  operated  by  the  Alliance  for  Sustainable  Energy,  LLC.  

 Cellulosic  Biofuels  Development  and  Commercializa6on  Progress  in  the  

United  States  of  America  

James  D.  (Jim)  McMillan,  Ph.D.  

Bioenergy  Australia  Webinar  

NREL,  Golden,  Colorado,  USA  

21  July,  2015  (20  July  in  Golden)  

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Outline • Task  39  overview  • Cellulosic  biofuels  op6ons  and  barriers  • Progression  of  cellulosic  ethanol  technology  development  and  commercializa6on  o An  example  of  the  powerful  results  sustained  research  focus  and  funding  can  achieve  

• Status  of  hydrocarbon  biofuels  development  • Summary  and  outlook  

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IEA Bioenergy Task 39 – Objectives §  “To facilitate commercialization of conventional and advanced liquid

biofuels from biomass”

§  Collaboration between 15 countries §  Analyze policy, markets and sustainable biofuel implementation §  Catalyze cooperative research and development §  Ensure information dissemination & outreach with stakeholders §  Focus on Technical and Policy issues

POLICY AND IMPLEMENTATION TECHNICAL ANALYSIS AND ASSESSMENT

Catalyze Cooperative

Research

State of Technology &

Trends Analysis

Policy, Market and

Deployment Analysis

Biofuel Deployment

and Information Sharing

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IEA  Bioenergy  Task  39  Liquid  biofuels  focus  15  member  countries  2013-­‐2015  www.Task39.org    

4  

Norway  -­‐  Karin  Oyass,  Judit  Sandquist,  Gisle  Johansen,  Berta  Guell  

Denmark  -­‐  Michael  Persson,  Claus  Felby,  Henning  Jorgensen,    Anders  Kristoffersen  

Germany  -­‐  Franziska  Mueller-­‐Langer,    Nicholaus  Dahmen  

The  Netherlands  -­‐  John  Nee\  

South  Korea  –  Jin  Suk  Lee,  Kyu  Young  Kang,  Seonghun  Park  

Canada  -­‐  Jack  Saddler,  Warren  Mabee,  Stan  Blade  

United  States  -­‐  Jim  McMillan  

Australia  -­‐  Les  Edye  

Austria  –  Dina  Bacovsky  

Japan  -­‐  Shiro  Saka,  Kazumichi  Uchida  

South  Africa  -­‐  Emile  van  Zyl,  Bernard  Prior    

Sweden  –  Alice  Kempe,  Maria  Nyquist,  Jonas  Lindmark    

Italy  –  David  Chiaramon6,  Alessandra  Fra`ni,  Stefania  Pescarolo  

New  Zealand  –  Ian  Suckling  

Brazil  –  Paulo  Barbosa,  Antonio  Bonomi,  Eduardo  Plaae    

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Outline • Task  39  overview  Ø Cellulosic  biofuels  op-ons  and  barriers  • Progression  of  cellulosic  ethanol  technology  development  and  commercializa6on  o An  example  of  the  powerful  results  sustained  research  focus  and  funding  can  achieve  

• Status  of  hydrocarbon  biofuels  development  • Summary  and  outlook  

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Cellulosic  Biomass  to  Biofuels  Conversion  Op6ons,  Technical  Barriers,  and  Demonstra6on  

and  Commercializa6on  Progress    

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7  

Thermochem  

Cellulosic Biofuels Technology Routes Biochem, Thermochem & Hybrid Approaches

Product  Recovery/  Purifica6on,  Storage  &  Distribu6on  

Feedstock  Supply  Logis6cs,  

Prepara6on  &  Handling  

Syngas  Fermenta6on  

Aqueous    Phase  

Reforming  

Biomass  Sugars  Hydrolysate  

Condi6oning  /  Detoxifica6on  

Pretreatment  &  Enzyma6c  Hydrolysis/  

Saccharifica6on  

Biomass  Sugar  

Fermenta6on  

Biochem  

Syngas  Cleanup  &  

Condi6oning/  Tar  Reforming  

Thermochemical  Synthesis  Gas  Produc6on/  Gasifica6on  

Syngas  Cataly6c  

Upgrading/  Product  Synthesis  

Gasification  

Bio-­‐oil  Stabiliza6on  Pyrolysis  

Bio-­‐oil  Upgrading  To  Fuel  

Pyrolysis  

Hybrid   ?  

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Alcohols Among Many Biofuels Options Biomass Feedstocks

Lignocellulosic Biomass (wood, agricultural residues, grasses, etc.)

Sugar/Starch Crops (sugar cane, sugar beet, corn, wheat, etc.)

Natural Oils (plants, algae)

Ag residues, (stover, straw, bagasse)

Intermediates

Syn Gas

Bio-Oils

Lignin

Sugars

Gasifica6on  

Pyrolysis  &  Liquefac6on  

Hydrolysis  

*  Blended  Products  

Transportation Fuels Ethanol &

Mixed Alcohols

Diesel*

Methanol

Gasoline*

Diesel*

Gasoline* & Diesel*

Diesel*

Gasoline*

Hydrogen

Ethanol, Butanol(s), Hydrocarbons

Biodiesel

Green diesel (a.k.a renewable diesel)

Catalytic synthesis

FT synthesis

MeOH synthesis

HydroCracking/ HydroTreating

Aqueous Phase Reforming (APR)

Catalytic pyrolysis

APR

Fermentation or

Biological Conversion

Catalytic upgrading

MTG

Transesterifica6on  

Hydrodeoxygena6on  

Fermentation

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Interacting Process Steps - Biochemical

Biomass Sugar

Fermentation

Enzymatic Cellulose

Saccharification

Biomass Pretreatment

Amount of cellulose Cellulose crystallinity Available surface area

Amount and nature of lignin Type/amount of hemicellulose

Biomass Feedstock

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Technical Barriers – Biochemical 1.  Plant  cell  wall  recalcitrance  

Deconstruct  secondary  cell  wall  sugar-­‐based  polymers  to  fermentable  sugars  (and  lignin?)  at  high  yield  and  low  cost  (low  energy  and  other  inputs)  

 

2.  Carbohydrate  heterogeneity  Ferment  all  biomass  sugars  to  ethanol  at  high  yield,  i.e.,  both  hexoses  (glucose,  galactose,  fructose  and  mannose)  and  pentoses  (arabinose  and  xylose)  

3.  Process  integra*on  and  scale  up  Cost  effec*vely  test/qualify  process  op*ons;  close  mass  balance;  demonstrate  process  robustness,  scalability  

Design-Expert® Software

Ethanol Yield

X1 = B: Conditioning X2 = D: Strain

Actual FactorsA: Hydrolysate Strenght = 65.00C: Added Glucose = 100

Neutralization

Ov erliming S.c. D5A

Broin S.c .

Z. m. 8b

P.s.

0

25

50

75

100

E

than

ol Y

ield

(%

)

34

16

47

27

84

82 77

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USA’s  CE  Development  Timeline  (40+  Years!)    1970s  –  Oil  shocks  spur  search  for  renewable  fuel  supply  1990s  –  Sugars  cofermen*ng  microbes  developed  (ethanol)  2000s  –  Hydroly*c  enzyme  cost  reduced  10-­‐20-­‐fold    2006  –  US  admits  it’s  addicted  to  oil;  aggressively  funds  cellulosic  

ethanol  (CE)  Integrated  BioRefineries  (IBRs)    

2010s  –  Scaled  up  commercial  produc*on  begins…  

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Cellulosic  Ethanol  Development  Timeline  (2)  1970s  –  Oil  shocks  spur  search  for  renewable  fuel  supply  1990s  –  Sugars  cofermen*ng  microbes  developed  (ethanol)  2000s  –  Hydroly*c  enzyme  cost  reduced  10-­‐20-­‐fold;    2006  –  US  admits  it’s  addicted  to  oil;  aggressively  funds  cellulosic  

ethanol  (CE)  Integrated  BioRefineries  (IBRs)    

2010s  –  Scaled  up  commercial  produc*on  begins…  2012      

- NREL  pilots  BC  (and  TC)  CE  processes,  achieving  performance  consistent  with  a  modeled  produc*on  cost  of  $2.15/gallon  

Opera-ng  condi-ons  for  NREL’s  BC  pilot  CE  demonstra-on  –  Feedstock:  Corn  stover  (i.e.,  the  agricultural  residue  a5er  harves6ng  the  corn  grain)  –  Pretreatment:  160°C,  10  minutes,  ~0.35%  (w/w)  H2SO4  acid  in  aqueous  reac6on,  in  some  cases  a5er  first  applying  an  NaOH  alkaline  washing  “deacetyla6on”  step  

–  Enzyma-c  hydrolysis:  Novozymes  CTec2  cellulase,  20%  total  solids  loading  (~12%  insoluble  solids),  50°C,  pH  4.8-­‐5.2  controlled  with  NH4OH  

–  Fermenta-on:  DuPont’s  cofermen6ng  Zymomonas  mobilis  A7,  33°C,  pH  5.8  controlled  with  NH4OH,  10%  (v/v)  inoculum  (~0.5  g/L  ini6al  cell  density,  dry  basis)  

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13  

0

20

40

60

80

100

0.0 24.0 48.0 72.0 96.0 120.0 144.0

Concen

tration    (g

/L) Glucose

XyloseArabinoseEthanol

Pilot Process - SHF Concentration Data

Enzyme:  Ctec2  loaded  at  19  mg  cellulase/g  cellulose;  substan6ally  lower  w/  Ctec3  

24  0   0  48   72   24   48  

Enzyma*c  Hydrolysis   Fermenta*on  

Time  (h)  

SHF  mode  ≥  1000  L  scale  

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14  

$0.00

$1.00

$2.00

$3.00

$4.00

$5.00

$6.00

$7.00

$8.00

$9.00

$10.00

2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

Min

imum

Eth

anol

Sel

ling

Pric

e (2

007$

per

gal

lon)

Conversion Feedstock

$3.85 $3.64 $3.57

$3.18 $2.77

$2.56 $2.15

$4.27

$5.33

$6.90

$9.16

Bench  Scale  -­‐  Enzymes  

Scale  Up  Pretreatment  

Scale  Up  Enz  Sacch/Ferm  

History of CE Technology Improvement

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15  

Commercial CE Plants (partial list) COMPANY( LOCATION( CELLULOSIC(

FEEDSTOCK(TECHNOLOGY(PLATFORM(

SIZE((MGY)(

Abengoa( Hugoton,(Kansas,(USA( Ag.(residues,(energy(crops( Biochem( 23(

Chemtex( Crescentino,(Italy( Wheat(straw,(Arundo'donax( Biochem( 20(

DuPont( Nevada,(Iowa,(USA( Corn(stover( Biochem( 25(

Enerkem*( Edmonton,(Alberta,(Canada(

Municipal(solid(waste( Thermochem( 10(

Fiberight( Blairstown,(Iowa,(USA( Municipal(solid(waste( Biochem( 6(

GranBio( São(Miguel(dos(Campos,(Alagoas,(Brazil(

Sugarcane(bagasse( Biochem( 20(

Ineos(Bio( Vera(Beach,(Florida,(USA(

Municipal(solid(waste( TCTBC(Hybrid( 8(

POETTDSM( Emmetsburg,(Iowa,(USA( Corn(stover( Biochem( 20(Quad(County(

Corn(Processors( Glava,(Iowa,(USA( Corn(kernel(fiber( Biochem( 2(

Raízen((Iogen)( Piracicaba,(São(Paulo,(Brazil(

Sugarcane(bagasse( Biochem( 10(

( ( ( ( (

Total( ( ( ( 144((*(Market(target(is(ethanol(albeit(near(term(focus(is(methanol;(MeOH(!(EtOH(in(progress.(

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Renewable  Hydrocarbon  (non-­‐oxygenated)  Biofuels  

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Historical focus on research, development, demonstration and deployment (RDD&D) for ethanol production from lignocellulosic biomass.

Cellulosic Ethanol

Since 2010, focus expanded to include other advanced biofuels such as biobutanol and hydrocarbons from algae and lignocellulosic biomass (e.g., gasoline, diesel and jet biofuels).

Alternative Light-Duty, Diesel and

Aviation Replacement

Fuels

U.S. Department of Energy Bioenergy

Technologies Office

(BETO)

The  US  DOE  forms  cost-­‐share  partnerships  with  stakeholders  to  develop,  demonstrate,  and  deploy  produc6on  technologies  for  advanced  biofuels.    

USDOE’s Advanced Biofuels Strategy

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Source: Energy Information Administration, “Oil: Crude Oil and Petroleum Products Explained” and AEO2009, Updated July 2012, Reference Case. American Petroleum Institute.

•  The  U.S.  spends  $400  $200  billion/year  on  imported  oil,  of  which  about  75%  finds  its  way  into  foreign  treasuries  as  profit:  >$1  $0.5  billion/day  

•  U.S.  transporta*on  relies  almost  exclusively  on  refined  petroleum  products—95%  of  U.S.  transporta*on  energy  is  derived  from  crude  oil  

• Only  about  40%  of  a  barrel  of  crude  oil  goes  toward  light  duty  gasoline  (i.e.,  the  main  frac*on  ethanol  can  displace)  

•  Reducing  dependence  on  oil  also  requires  developing  technologies  to  replace  diesel,  jet,  heavy  dis*llates,  and  a  range  of  industrial  chemicals  and  products.  Click here for interactive Barrel Widget

Displacing the Whole Barrel of Oil

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19  

COMPANY( USA(LOCATION(( FEEDSTOCK( TECHNOLOGY( SIZE((KGY)(

Renewable(Energy(Institute(International(

Toledo,(Ohio( Rice(Hulls(and(Forest(Residues( TC<Gasification( 625(

Haldor(Topsoe( Des(Plaines,(Illinois(

Wood(Waste(and(Non<Merchantable(Wood(

TC<Gasification( 345(

Rentech(ClearFuels(Technology(

Commerce(City,(Colorado(

Woody(waste(and(bagasse( TC<Gasification( 151(

(inactive)(

Amyris(Biotechnologies(

Emeryville,(California( Sweet(sorghum( Biochemical( 1.37(

(inactive)(Gas(Technology(

Institute(Des(Plaines,(Illinois(

Wood(waste,(corn(stover,(and(algae( TC<Pyrolysis( NA(

(inactive)(

Sapphire(Energy( Columbus,(New(Mexico( Algae( Algae(+(TC( 1000(

Solazyme( Peoria,(Illinois( Algae( Algae(+(TC( Pilot(Elevance(Renewable(Sciences(

Bolingbrook,(Illinois(

Algae(Oil,(Plant,(and(Animal(Oils( Chemical( NA(

(inactive)(( ( ( ( (

Total( ( ( ( 2122((

USDOE IBR Hydrocarbon Projects

Source:  hip://www.energy.gov/eere/bioenergy/integrated-­‐biorefineries      

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Summary  and  Outlook  

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More  than  33  projects  awarded  since  2007  covering  many  feedstocks  and  conversion  technologies.  These  include  6  commercial  scale/TRL,  9  demonstra6on  scale,  16  pilot  scale  and  2  bench  scale  R&D  projects.  

–  19  ac*ve  in  2013,  including  11  biochemical,  5  thermochemical  and  3  algal  technologies.  –  16  on  cellulosic  ethanol,  12  on  renewable  hydrocarbons,  3  on  algal  oil,  2  on  bioproducts  –  5  completed  and  5  terminated  for  lack  of  technical  progress  or  cost  share  

Leveraging Industry thru IBR Projects

INEOS IBR Groundbreaking (April, 2011)  

33  Projects   Products   DOE  Funds  

16   Cellulosic  Ethanol   $  694  M  

12   Hydrocarbons   $  152  M  

3   Algae  Oil   $  76  M  

2   Bioproducts   $  75  M  

Public-­‐Private  Partnership  Leveraging:  US  DOE’s  ≥  $1.1B  public  investment  has  achieved  ≥  $1.7B  industry  cost  share  and  helped  catalyze  several  ini*al  public  offerings  (IPOs)  (2  issued,  3  planned),  venture  capital  and  equity  investments  (>$344MM),  joint  ventures  (JVs),  and  mul*ple  joint  development  agreements  (JDAs).  

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Recent Developments • Cellulosic  Ethanol  o Abengoa,  DuPont,  and  POET-­‐DSM  are  progressing  their  USA  commercial  CE  plant  start  ups;  INEOS  Bio  restar*ng  their  plant  aoer  retrofipng  to  improve  syngas  quality.  

o DuPont  licensing  its  CE  technology  to  China  and  Macedonia;  no  licenses  yet  announced  but  agreements  to  enable  this  are  in  place.  

• Hydrocarbon  Biofuels  o Major  focus  is  avia*on  biofuels;  major  route  is  thermochemical;  companies  include:  – AltAir  Fuels  (Honeywell  UOP’s  fast  pyrolysis  technology)  – Fulcrum  Bioenergy  (gasifica*on  of  MSW)  – Ensyn,  Cool  Planet  

o Technology  robustness  at  scale  and  economic  viability  remain  to  be  fully  demonstrated.  

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Current Situation •  Terrestrial  and  aqua*c  biomass  remain  our  only  renewable  source  of  organic  carbon;  they  can  also  be  carbon  neutral  and  even  carbon  sequestering.  

•  CE  technologies  progress  shows  power  of  sustained,  focused  R&D,  with  mul*ple  feedstock  x  conversion  process  op*ons  now  being  commercialized  o Sugar  plasorm  approaches  dominate  but  hybrid  and  thermochemical  gasifica*on  routes  also  progressing  

•  Hydrocarbon  biofuels  commercializa*on  at  earlier  stage,  with  algae  and  TC  routes  predomina*ng  o Compe**ve  economics  challenged  by  low  petroleum  prices  

 

•  2015-­‐2016  crucial  period  to  prove  CE  technology  can  be  successfully  commercialized,  can  reliably  operate  to  achieve  techno-­‐economic  targets  o Posi*ve  outcomes  needed  to  re-­‐frame  biofuels’  image  and  demonstrate  that  advanced  biofuels  “can  be  done  right”  

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Outlook • Growth  of  alcohol  and  other  biofuels  technologies  requires  suppor*ve  policies  like  U.S.’s  RFS2  - Needed  to  ensure  a  market  and  encourage  investment.  

• The  cellulosic  sugar-­‐ethanol  plasorm,  if  it  can  be  proven  economical,  provides  big  opportuni*es  for  developing  mul*-­‐product  biorefineries  - What  will  the  higher  value/larger  volume  coproducts  be?  

• Successes  needed  to  build  advocacy  for  biofuels  - Must  show  that  projected  “triple  boiom  line”  economic,  social,  and  environmental  benefits  are  real.  

 

• On-­‐going  drivers  and  possible  game  changers  - Price  of  petroleum,  value  of  reducing  GHG  emissions  - Compe**on  for  feedstock,  e.g.,  for  power  or  products    - Availability  of  lower  cost  natural  gas  and  hydrogen  - Market  demand  for  biofuels,  especially  ethanol  - USA:  Changes  in  ethanol  blend  limit  for  non-­‐FFVs  - USA:  E85  pricing  /  ability  to  make  it  a  preferred  fuel  op*on  

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More Information •  Na6onal  Renewable  Energy  Laboratory  

 www.nrel.gov  •  USDOE’s  Bioenergy  Technologies  Office  (BETO)  

hap://www1.eere.energy.gov/bioenergy/    

•  USDOE  BETO  Peer  Reviews  (2011,  2013,  2015)  www.energy.gov/eere/bioenergy/2015-­‐project-­‐peer-­‐review    

•  USDOE-­‐USDA  Biomass  R&D  Ini6a6ve    www.biomassboard.gov  

•  Alterna6ve  Fuels  Data  Center    www.afdc.doe.gov  

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Funding:    USDOE  EERE  BioEnergy  Technologies  Office  (BETO),      IEA  Bioenergy  Task  39  (Liquid  Biofuels)    

Acknowledgments

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Thanks  for  Your  Aaen6on!  Ques6ons?