advanced liquid biofuels developments in the usa
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NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Advanced Liquid Biofuels Developments in the USA
James D. (Jim) McMillan, Ph.D.
Bioenergy Australia 2016 Conference
Brisbane, Queensland, Australia
November 15, 2016
2
Synopsis
• US remains world’s largest producer, producing over 50 B L ethanol and 6 B L diesel biofuels o 10% ethanol “blend wall” fracturing
o Momentum for higher blends building
• Science and technology continues to advance o Many routes and bio/catalysts
improving, increasing efficiency, reducing production costs
• Commercialization of cellulosic ethanol operations progressing o e.g., DuPont, POET-DSM and QCCP
• Paris COP21 agreement reflects growing consensus to address/mitigate climate change.
• Oil prices remain too low for most advanced biofuels to be economical o Many technology developers/ producers
are halting biofuels RD&D, redirecting efforts to higher value non-fuel products
o Abengoa, INEOS plants idled & for sale o Norway out of Task 39 (oil price impact)
• Production of cellulosic and advanced biofuels lags RFS2 targets; obligated volumes lowered for 2014-2016
• Bioenergy held to higher standard than other technologies. Concerns about: o Carbon neutrality, food vs. fuel, etc.
• Other challenges o Polarized administration and congress o No value/price on reducing carbon emissions
despite mounting global warming – Atmospheric CO2 > 400 ppm – Great barrier reef dying (bleaching) – 2016 on track to be hottest year yet
Positive Negative 2015-2016: Exciting but Challenging Times
* RFS2 = Renewable Fuel Standard
* RFS2 = Renewable Fuel Standard
* RD&D = Research, Development and Demonstration
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Outline
•Current drivers, energy landscape and production levels
•Cellulosic biofuels options, challenges and progress •Thermochemical, biochemical and hybrid routes
o2012 NREL biochemical cellulosic ethanol demonstration •Process relevant performance data that’s in the public domain
• Illustrates the power of sustained, focused, well-funded R&D
•Emerging Adv. Biofuels Technologies & New Initiatives
•Summary and outlook
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Promote use of domestic and
renewable (sustainable)
energy resources
Create a new bio-industry, foster science & engineering, and create new
jobs
Reduce carbon emissions from energy and fuel production and
consumption
Reduce
dependence on non-
renewable petroleum
supplies
The use of renewable biomass as as a feedstock for producing fuels and chemicals supports United States national priorities
Biofuels Support National Priorities
5 | Bioenergy Technologies Office
The Challenge and Opportunity in the USA
Biofuels could displace 30% of liquid transportation fuels by 2030
THE OPPORTUNITY
More than 1 billion tons of biomass could be sustainably produced in the U.S.
1 Billion tons of biomass could displace 30% of U.S. petroleum use by 2030 and reduce annual GHG emissions by 400 million tons
THE CHALLENGE
More than $1 billion is spent every three days on U.S. crude oil imports
Transportation sector accounts for 67% of petroleum consumption and 26% of GHG emissions in the U.S.
Biomass resources can help mitigate petroleum dependence and GHG emissions
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Transport Fuel is a Big Part of U.S. Energy Mix
Source: Lawrence Livermore National Laboratory, 2016. (https://flowcharts.llnl.gov)
U.S. Energy Use in 2015 (97.5 Quads) (Quadrillion Btu)
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U.S. Fuel Ethanol Production Capacity (2015)
2/29/16, 10:40 AMU.S. Fuel Ethano l Plant Product ion Capacity
Page 1 of 1ht tps: / /www.eia.gov/petroleum/ethanolcapacity/ index. c fm
U.S. Nameplate Fuel Ethanol Plant Production Capacity as of January 1,2015
PADDistrict
Numberof Plants
2015Nameplate Capacity
2014Nameplate Capacity
(MMgal/year) (mb/d) (MMgal/year) (mb/d)
PADD 1 5 464 30 260 17
PADD 2 173 13,151 858 12,504 816
PADD 3 5 442 29 442 29
PADD 4 5 190 12 190 12
PADD 5 7 510 33 285 19
U.S.Total 195 14,757 962 13,681 893
Nameplate Capacity: volume of denatured fuel ethanol that can be producedduring a period of 12 months under normal operating conditions
Source: Form EIA-819M Monthly Oxygenate Report
Petroleum & Other Liquids
U.S. Fuel Ethanol Plant Production CapacityRelease Date: June 23, 2015 | Next Release Date: June 2016
Previous Issues
Year: 2015 Go
This is the fifth release of U.S. Energy Information Administration data on fuel ethanol production capacity. EIA first reported fuel
ethanol production capacities as of January 1, 2011 on November 29, 2011. This new report contains production capacity data for all
operating U.S. fuel ethanol production plants as of January 1, 2015.
Detailed nameplate and maximum sustainable capacities of fuel ethanol plants by Petroleum Administration for Defense District (PAD
District) are available in XLS.
Source: US EIA. https://www.eia.gov/petroleum/ethanolcapacity/index.cfm
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US Commercial Ethanol Production Plants
Source: Renewable Fuels Association (RFA), 2016: http://www.ethanolrfa.org/resources/biorefinery-locations/
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U.S. Diesel Biofuels Production 2003-2013
Sources: National Biodiesel Board (NBB) and EIA Annual Energy Outlook 2014 (AEO 2014), NBB: http://www.biodiesel.org/production/production-statistics
AEO: Table 11. Petroleum and Other Liquids Supply and Disposition http://www.eia.gov/forecasts/aeo/tables_ref.cfm
Biodiesel (FAME & HEFA) production levels reached 1.2 - 1.8 and 1.4 billion gallons in 2013 and 2014, respectively, with NBB estimates much higher than EIA’s.
Annual production levels highly constrained feedstock supply. Need alternative
feedstocks to enable major growth
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Cellulosic Biofuels Options, Challenges and Progress
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Thermochem
Cellulosic Biofuels Technology Routes Biochem, Thermochem & Hybrid Approaches
Product Recovery/
Purification, Storage &
Distribution
Feedstock Supply
Logistics, Preparation & Handling
Syngas Fermentation
Aqueous Phase
Reforming
Biomass Sugars Hydrolysate
Conditioning / Detoxification
Pretreatment & Enzymatic Hydrolysis/
Saccharification
Biomass Sugar
Fermentation
Biochem
Syngas Cleanup &
Conditioning/ Tar Reforming
Thermochemical Synthesis Gas Production/ Gasification
Syngas Catalytic
Upgrading/ Product
Synthesis
Gasification
Bio-oil Stabilization
Pyrolysis Bio-oil
Upgrading To Fuel
Pyrolysis
Hybrid
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Biochemical Conversion Flow Diagram
Pretreatment Conditioning
Co- fermentation
of C5 & C6 Sugars
Product Recovery Products
By-products
Enzyme Production
Enzymatic Hydrolysis
Residue Processing
Simultaneous Saccharification and Co fermentation
Ethanol Yields
Ethanol Concentration
Xylose Yield Xylose Degradation
Reactor Costs Solids Loading
Sugar Losses
Glucose Yield
Solids Loading (titer)
Feedstock Variation
Feedstock Quality Enzyme Cost
Rate Hydrolyzate Toxicity
Feedstock Cost
How can research reduce cost?
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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 integration and scale up Cost effectively test/qualify process options; 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.
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USA’s CE Development Timeline (40+ Years!) 1970s – Oil shocks spur search for renewable liquid fuels supply
1990s – Sugars cofermenting microbes developed (ethanol)
2000s – Hydrolytic 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 production begins…
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Cellulosic Ethanol Development Timeline (2) 1970s – Oil shocks spur search for renewable fuel supply
1990s – Sugars cofermenting microbes developed (ethanol)
2000s – Hydrolytic 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 production begins… 2012
- NREL pilots BC (and TC) CE processes, achieving performance consistent with a modeled production cost of US $2.15/gallon
Operating conditions for NREL’s BC pilot CE demonstration – Feedstock: Corn stover (i.e., the agricultural residue after harvesting the corn grain)
– Pretreatment: 160°C, 10 minutes, ~0.35% (w/w) H2SO4 acid in aqueous reaction, in some cases after first applying an NaOH alkaline washing “deacetylation” step
– Enzymatic hydrolysis: Novozymes CTec2 cellulase, 20% total solids loading (~12% insoluble solids), 50°C, pH 4.8-5.2 controlled with NH4OH
– Fermentation: DuPont’s cofermenting Zymomonas mobilis A7, 33°C, pH 5.8 controlled with NH4OH, 10% (v/v) inoculum (~0.5 g/L initial cell density, dry basis)
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g/L
) Glucose
Xylose
Arabinose
Ethanol
Pilot Process - SHF Concentration Data
Enzyme: Ctec2 loaded at 19 mg cellulase/g cellulose; substantially lower w/ Ctec3
24 0 0 48 72 24 48
Enzymatic Hydrolysis Fermentation
Time (h)
SHF mode ≥ 1000 L scale
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2007$ p
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gallo
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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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Commercial CE Plants (partial list)
COMPANY LOCATIONCELLULOSICFEEDSTOCK
TECHNOLOGYPLATFORM
SIZE(MGY)
Abengoa Hugoton,Kansas,USAAg.residues,energycrops
Biochem 23
Chemtex Crescentino,ItalyWheatstraw,
ArundodonaxBiochem 20
DuPont Nevada,Iowa,USA Cornstover Biochem 25
Enerkem*Edmonton,Alberta,Canada
Municipalsolidwaste
Thermochem 10
Fiberight Blairstown,Iowa,USAMunicipalsolidwaste
Biochem 6
GranBioSãoMigueldosCampos,Alagoas,Brazil
Sugarcanebagasse
Biochem 20
IneosBioVeraBeach,Florida,USA
Municipalsolidwaste
TC-BCHybrid 8
POET-DSM Emmetsburg,Iowa,USA Cornstover Biochem 20
QuadCountyCornProcessors
Glava,Iowa,USA Cornkernelfiber Biochem 2
Raízen(Iogen)Piracicaba,SãoPaulo,Brazil
Sugarcanebagasse
Biochem 10
Total 144113
*Markettargetisethanolalbeitneartermfocusismethanol;MeOHàEtOHinprogress.
Emerging Technologies & New Initiatives
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Emerging Technologies & New Initiatives
• Current RD&D focused on “drop-in” infrastructure compatible biofuels; higher ethanol blends also in the mix
• Science and process technology are improving, but economics remain challenging given market conditions
•Highlight developments: • Pyrolysis oil coprocessing in
petroleum refineries (Ensyn)
• Gasification + Fischer-Tropsch synthesis (Fulcrum)
• Combined optimization of advanced fuels and advanced engines (USDOE’s Co-optima initiative)
Schematic of Petrobras’ demo-scale FCC unit. Source: A.R. Pinho et al. Fuel 188 (2017)
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Refinery Co-processing Pathway Advancing
Source: A.R. Pinho et al. Fuel 188 (2017) 462–473
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Co-Optimization of Fuels and Engines
• better fuels. better vehicles. sooner.
Crosscutting project tackling fuel and engine innovation to co-optimize performance, maximize transport efficiency.
Advancing R&D to: • Bring affordable, scalable advanced
biofuels and advanced engine solutions to market more quickly
• Improve fuel economy 15%–20% beyond targets of BAU R&D efforts
• Reduce petroleum use, achieve massive cost savings annually via improved fuel economy
• Dramatically decrease transport sector pollutants and GHG emissions
Co-Optimization of Fuels and Engines
Draws on collaborative expertise of two DOE research offices, nine national
laboratories, and numerous industry and academic partners.
http://energy.gov/eere/bioenergy/co-optimization-fuels-engines
Summary and Outlook
24
Commercialization Status
Cellulosic Ethanol oAbengoa, DuPont, INEOS Bio and POET-DSM
progressing CE plant start ups; production remains well below design capacity oDuPont seeks to license to China and Macedonia; no
licenses yet but agreements in place to enable this o Technology robustness and economic viability remain to be fully
demonstrated for ag. residue and woody feedstocks
o Corn ethanol dry mills now implementing production of CE from corn fiber (cellulosic fraction of DDGs)
FAME and Renewable Diesel oVO, FOG-based FAME and HEFA production growing
however volumes constrained by feedstock supply
Other advanced routes also progressing but performance info proprietary, not public) o Syngas fermentation (e.g., LanzaTech)
oGasification + Fisher-Tropsch (e.g., Fulcrum)
o Pyrolysis + Refinery Coprocessing (e.g., Ensyn)
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Situation and Outlook
• Terrestrial and aquatic biomass remains our only renewable source of carbon; it can also be carbon neutral or carbon sequestering.
• CE technologies progress shows power of sustained, focused R&D, with multiple feedstock x conversion process options now being commercialized o Sugar platform approaches dominate but hybrid and
thermochemical gasification routes also progressing
o Economics challenged by low oil price & policy uncertainty
o Market success needed to re-frame biofuels’ image and demonstrate that advanced biofuels “can be done right”
• Commercialization of drop-in hydrocarbon biofuels at earlier stage, with TC routes now predominant
• Supportive policies like U.S.’s RFS2 and CARB LCFS are key to expanding advanced biofuels deployment - Needed to ensure a market and foster investment
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More Information
• National Renewable Energy Laboratory www.nrel.gov
• USDOE’s Bioenergy Technologies Office (BETO) http://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 Initiative www.biomassboard.gov
• Alternative Fuels Data Center www.afdc.doe.gov
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Thanks for Your Attention! Questions?
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Funding: US DOE EERE BioEnergy Technologies Office (BETO)
Data: NREL’s Biochemical Cellulosic Ethanol Demonstration Project Team (Daniel Schell et al.)
Refinery Coprocessing: NREL’s Helena Chum & Michael Talmadge
Acknowledgments
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