115/22/2006

Future Opportunities for Biomass Fuels and Power

Dr. Richard L. Bain, Principal EngineerBiorefinery Analysis & Exploratory Research GroupNational Bioenergy Center

SmallWood 2006

Richmond, VA

May 16, 2006

5/22/2006 2

Disclaimer and Government License

This work has been authored by Midwest Research Institute (MRI) under Contract No. DE-AC36-99GO10337 with the U.S. Department of Energy (the “DOE”). The United States Government (the “Government”) retains and the publisher, by accepting the work for publication, acknowledges that the Government retains a non-exclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this work, or allow others to do so, for Government purposes.

Neither MRI, the DOE, the Government, nor any other agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe any privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not constitute or imply its endorsement, recommendation, or favoring by the Government or any agency thereof. The views and opinions of the authors and/or presenters expressed herein do not necessarily state or reflect those of MRI, the DOE, the Government, or any agency thereof.

5/22/2006 3

Biomass Share of U.S. Energy Supply (2004 data)

Source: Renewable Energy Trends 2004; Energy Information Administration, August 2005.Note: Total U.S. Energy Supply is 100.278 QBtu; Energy Information Administration, August 2005.

Biomass 47%

Wind 2%

Hydroelectric 45%

Geothermal 5%Solar <1%

Renewable 6%

Natural Gas 23% Nuclear 8%

Petroleum 40% Coal 23%

5/22/2006 4

United States Biomass Consumption in 2004(Quadrillion Btu)

Reference: Annual Energy Outlook 2006, Energy Information Administration, Table A17

Commercial0.09

Residential0.41

Ethanol0.28

Electric Power0.44

Industrial1.63

5/22/2006 5

U.S. Biopower Generation, 1981-2004

Year1980 1985 1990 1995 2000 2005

Gen

erat

ion

(TW

h/an

num

)

0

10

20

30

40

50

60

70

Net

Sum

mer

Cap

acity

(MW

)

0

2000

4000

6000

8000

10000

12000

Generation Capacity

5/22/2006 6

Ethanol Production

0123456789

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

Cellulosic Ethanol2005 EPACT RFS - MinimumU.S. Ethanol Production

• Renewable Fuels Standard mandates 7.5 billion gallons by 2012• Total US gasoline market ~140 billion annual gallons

Actual and Projected U.S. Ethanol Production 1999-2012Billion Gallons of Production

Source: December 2005 Ethanol Today Magazine

5/22/2006 7

U.S. Biodiesel Production

0

10

20

30

40

50

60

70

80

1999 2000 2001 2002 2003 2004 2005

U.S

. Pro

duct

ion,

m

illio

n ga

llons

per

yea

r

Total US distillate fuels market is approximately 60 billion gallons per year

5/22/2006 8

Biomass StrengthsBiomass is:

AbundantRenewableCarbon-neutralThe only sustainable source of hydrocarbons.

Biomass can:

Fill the gap between energy demand and petroleum availability in the near term.Be a renewable source of hydrogen in the long term.

5/22/2006 9

Sources of Lignocellulosic Biomass

38-50%5-13%

23-32%15-25%

Lignin

OtherCellulose(Glucose sugar)

Hemicellulose(Pentose sugars)

(“Young clean coal”)

Softwoods

Grasses

Hardwoods

Crop residues

MSW

(Extractives, ash, etc.)

5/22/2006 10

U.S. Biomass Resource Potentials Corn (largest volume grain and source of EtOH in U.S.)

Potential to displace 10-20% of our gasoline

Soybeans, fats & greases (largest sources of biodiesel)Potential to displace 5-10% of our diesel

Over 1 billion tons/year of lignocellulosic biomass (trees, grasses, etc.) could be available in the U.S.

Potential to displace 50-70% of our gasoline

Short-term: improve cost and efficiency of corn ethanol & biodieselMid to Long-term: focus on lignocellulose (trees, grasses, & residues)

FoodFoodSuppliesSupplies

Not a FoodNot a FoodSupplySupply

5/22/2006 11

U.S. Biomass Resource Assessment• Updated resource assessment - April 2005• Jointly developed by U.S. DOE and USDA• Referred to as the “Billion Ton Study”

5/22/2006 12

Based on ORNL & USDA Resource Assessment Study by Perlach et.al. (April 2005) http://www.eere.energy.gov/biomass/pdfs/final_billionton_vision_report2.pdf

The 1.3 Billion Ton Biomass ScenarioBillion Barrel of Oil Equivalents

5/22/2006 13

Chemical Conversion

Lignocellulosics (polysaccharides)

Hydrolysis

Sugars

Fermentation

Lignin

Pretreatment

Starches

Primary Conversion Routes for “Biomass”

Combustion

Gasification/Pyrolysis

5/22/2006 14

Chemical industry investing in higher value products from glucose

NatureWorks LLCduPont

Both corn ethanol and chemical industries are investigating biomass to extended sugar resources

Shell investing in biomass ethanol technology (Iogen, Canada)

300 dry ton/day gasifier at

Burlington Electric, VT

Cargill Dow Dedicates PLA Refinery April 2002

•Ethanol industry at 4 billion gal/yr based on corn starch•Corn mills investing in process improvements and higher value products

–ADM–Broin–Abengoa

EthanolEthanol

5/22/2006 15

The Structures are Very DifferentGlucose

Xylose

G

Lignin

Sugars:

Polysaccharides in Lignocellulosic Biomass:

X

Starches: GlucoseGlucose

5/22/2006 16

Biochemical Conversionfor Ethanol via PT/Hyd/Ferm

SSF

Simultaneous saccharification & Fermentation - SSF

Fermentationof C5 & C6

SugarsConditioning

5/22/2006 17

Cost of Ethanol via PT/Hyd/Ferm

$0.00

$1.00

$2.00

$3.00

$4.00

$5.00

$6.00

2000 2005 2010 2015 2020

Min

imum

Eth

anol

Sel

ling

Pric

e ($

/gal

)

State of Technology Estimates

Feed $53/ton

2005 Yield65 gal/ton

Feed $35/tonYield 90 gal/ton Feed $35/ton

Yield 104 gal/ton

Costs in 2002 Dollars

EnzymeConversionFeedstockCurrent DOE Cost TargetsPresident's Initiative

Integrated large-scaleBC/TC processing

5/22/2006 18

Griffin Industries, USA and Bruck Industries, Austria

BiodieselBiodiesel

Sep 2004: 60 Mil gal/yr dedicated capacity in U.S.

5/22/2006 19

Biodiesel - Basic TechnologyVegetable oils Recycled Greases

Dilute AcidEsterification

Transesterification

Crude Glycerin

Refining

Crude biodiesel

Biodiesel

Sulfur +methanol

Methanol + KOH

Glycerinrefining

Glycerin

Methanolrecovery

5/22/2006 20

Oils, Fats & Greases as Bio-renewable Petroleum Refinery Feedstocks

• Co-processing of oils and greases with petroleum fractions

• Utilize existing process capacity

• Potential for lower conversion costs (than FAME)

• Higher quality diesel blending component

• G/D flexibility

CatalyticCracker

DistillateHydrotreater

Oils andGreases

Green Gasoline& Olefins

GreenDiesel

ISBL Petroleum Refinery

Based on Presentations at 1st International Biorefinery Workshop, Washington DC, July 20-21, 2005- Future Energy for Mobility, James Simnick, BP- From Bioblending to Biorefining, Veronique Hervouet, Total- Opportunities for Biorenewables in Petroleum Refineries, Jennifer Holmgren, UOP

5/22/2006 21

Green Diesel and Biodiesel Yields

12% glycerol

83-8696% diesel

.025.05Operating cost $/gal

8.7% methanol

100

Biodiesel

12-16% water,C02

Green DieselFeed

2-5

1.5-3.8

100

% Lt HC

Products

% H2

% Oil or Grease

Marinangeli, R., et.al. (2005). “Opportunities for Biorenewables in Oil Refineries: Final Technical Report,” UOP, Des Plaines, IL; DOE Report No. DE-FG36-05GO15085.

5/22/2006 22

Diesel Properties

.78.883Density g/ml

0 to -100 to +10 % change in NOx emission

265-320340-355Distillation 10-90% pt

<10ppm<10ppmSulfur content4438Heating Value (lower) MJ/kg

011% Oxygen

-5 to -30-5 Cloud Point oC

80-9050Cetane

Green DieselBiodiesel (FAME)

Marinangeli, R., et.al. (2005). “Opportunities for Biorenewables in Oil Refineries: Final Technical Report,” UOP, Des Plaines, IL; DOE Report No. DE-FG36-05GO15085

5/22/2006 23

Gasification Cleanup Synthesis

Conversionor Collection Purification

Separation Purification

Pyrolysis

OtherConversion*

Biomass

Biomass Thermochemical Conversionfor Fuels and Chemicals PRODUCTS

• Hydrogen• Alcohols• FT Gasoline• FT Diesel• Olefins• Oxochemicals• Ammonia• SNG

• Hydrogen• Olefins• Oils• Specialty Chem

• Hydrogen• Methane• Oils• Other

5/22/2006 24

Fuels from Syngas

SyngasCO + H2

Bottom Ash Removal

InjectorScrews

High/Low PressureGasifier

Cyclone(Optional)

AIR/O2

BARK & SLUDGE

O2/AIR / STEAM

Fluidized Bed

Freeboard Disengaging Zone

SYNGAS

Bottom Ash Removal

InjectorScrews

High/Low PressureGasifier

Cyclone(Optional)

AIR/O2

BARK & SLUDGE

O2/AIR / STEAM

Fluidized Bed

Freeboard Disengaging Zone

SYNGAS

Acetic Acid

Formaldehyde

MTBE

PolypropyleneAcrylonitrile

PolyethyleneEthylene Glycoll h l f

Ammonia Diesel Additives

Ethanol

Mixed Alcohols

Methanol

Olefins

Refineries

Hydrogen

Urea

Fischer Tropsch FuelsWaxAlpha-olefins

DME

5/22/2006 25

PreliminarySeparation

C3 +

Alcohols

Mixed AlcoholSynthesis

260-350°C30-175 bar

Alkali promotedMoS2 catalyst

SyngasCompression

CrudeProducts

High PSyngas

ScrubbedSyngas

EthanolMixed

Alcohols

MethanolRecycle

ProductSeparation

Thermochemical Conversionfor Ethanol via Gasification

5/22/2006 26

Cost of Ethanol via Gasification

$0.00

$0.50

$1.00

$1.50

$2.00

$2.50

2000 2005 2010 2015 2020

Min

imum

Eth

anol

Sel

ling

Pric

e ($

per

gal

lon)

ConversionFeedstockPrevious DOE Cost TargetsPresident's Initiative

State of Technology Estimates

Integrated with Biochemical Processing

104 gal/ton total yield

Biorefinery Residues67 gal/ton

Costs in 2002 Dollars

ForestResources56 gal/ton

5/22/2006 27

Fast Pyrolysis of BiomassFast pyrolysis is a thermal process that rapidly heats biomass to a carefully controlled temperature (~500°C) and then very quickly (<2 sec) cools the volatile products formed in the reactor.Fast pyrolysis:

Offers the unique advantage of producing a liquid that can be stored and transportedHas been developed in many configurationsAt present is at relatively early stage of development.

5/22/2006 28

Electricity Transport Fuel

Heat

Bio -oil

Extract

UpgradeBoiler

Applications of Bio Oils

Chemicals

5/22/2006 29

Bio-oil is water miscible and is comprised of many oxygenated organic chemicals.

• Dark brown mobile liquid,• Combustible,• Not readily miscible with hydrocarbons,• Heating value ~ 17 MJ/kg,• Density ~ 1.2 kg/l,• Acid, pH ~ 2.5,• Pungent odour,• “Ages” - viscosity increases with time

Fast Pyrolysis and Bio-oil as Feed to Power Plant or Petroleum Refinery

Based on research at NREL (1990 - 2000), Colin Schaverien presentation

5/22/2006 30

Other Productsof Interest:• Heating oil• PF resins• FCC feed• DDU feed

Variation of Pyrolysis-based Biorefinery

Aromatic Chemicals and/or

Gasoline Blending

Fermentation orHydrogenation ofAqueous Phase (Carbohydrates)

Fast Pyrolysis Of Biomass

Fractionation and/or

Deoxygenation

LigninDerivatives

CarbohydrateDerivatives

5/22/2006 31

DOE Goal: 30 by 30 - Replace 30% of Today’s Gasoline in 2030 with Biofuels

5/22/2006 32

Integrated Biorefinery Elements

5/22/2006 33

Ethanol via bioconversion

Corn Stover 10,000 dMT/day

Ethanol1,035,000 gpd

Lignin-rich Residue 2,932 dMT/day

Steam &Power

Coal-FiredCHP Plant

GasificationAlcohol

Synthesis

Chemical Alcohols

SyngasEthanol

215,400 gpd

Ethanol1,250,400 gpd

438.0 MM gal/yrCoal

MESP = $0.60/gal EtOH

gpd (gal/dry ton lignin)7,900 Methanol (2)

39,100 n-Propanol (12)15,100 n-Butanol (5)6,900 n-Pentanol (2)

Ethanol yield = 113 gal/dry ton stover

Integrated Biorefinery

5/22/2006 34

For More Information About

The National Renewable Energy Laboratory: www.nrel.gov

DOE’s Biomass Program:

http://www.eere.energy.gov/biomass/

Alternative Fuels:

www.afdc.doe.gov