USDA Western Regional Research Center Albany, California

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2 USDA Western Regional Research Center Albany, California Albany ~380 people ~50 in Biofuels/ & Bioproducts Known for biotechnology especially crop biotech.

3 !"#$%&'()*+,&'-$+.#/'01+"%/' Renewable Fuel Standard-2 32 billion gallons/year by 2022! ' ' '2""34*' '5##6/7),8 ' '9$)63,:)"'' 'A+)6+#/#*' ; ' 'B#**3*)/+,'>+)?3#*/' ;<' 'C71#$'46.4",#6'>+)?3#*/ '' =' '' Need 21! billion! gals/year!

4 Decreasing NPP! 100 o Meridian! Irrigation and fertilizers matter! Regions with low NPP! Region with greatest biomass production potential!

5 Partnerships: An ongoing story..!

6 ISSUES: Straw varies with seasons Aging! harvest time is once per year Moisture and storage are challenging Transportation! Low density Supply is not near highest demand.

7 CR 3 Autoclaves: Pressurized hot water treatment. Reduces volume. Isolates recyclables Fractionates components

8 Salinas Crazy Horse Landfill

9 Conveyor loading MSW to autoclave

10 MSW inside the autoclave prior to steam treatment

11 MSW in the autoclave after steam treatment

12 Post-Autoclave MSW Sorting >1 3/8! 1 Trommel Screen Side View Trommel Screen Frontal View

13 Clean fiber from MSW after centrifugal cleaners

14 Cellulose Recovery from Autoclaved MSW Processed paper from recovered fiber

15 Post-Autoclave MSW Sorting >1 3/8! 1 Trommel Screen Side View Trommel Screen Frontal View

16 Recycling Autoclaved PET Bottles - Holtman, K.H. et al. J. Appl. Polym. Sci., 2012 Virgin PET (pellets) Post-consumer PET bottles Provided by Bottling Company Reclaimed PET bottles from the Autoclave Autoclave CHIPPING CLEANING AND CHIPPING CLEANING AND CHIPPING EXTRUSION EXTRUSION EXTRUSION EXTRUSION VPET PCPET APCPET rpet

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19 Summary of Autoclaved PET Bottles - Holtman, K.H. et al. J. Appl. Polym. Sci., 2012 GPC (washed) M n M w M w /M n g mol -1 g mol -1 vpet 37,546 65, pcpet 33,228 62, apcpet 31,785 60, rpet 30,682 58, EvPET 33,133 62, EpcPET 26,075 50, EapcPET 18,913 37, ErPET 18,153 34,

20 Autoclaved PET Bottles The loss in Mw is mostly seen after extrusion This down-cycling means less value But, rpet could be used in textiles, etc.! Could explore small additions to virgin streams Can avoid the large cost of MRF s

21 Clean fiber from MSW after centrifugal cleaners

22 Enzymatic hydrolysis of hot-water 100 treated MSW % Cellulose conversion Incubation time (h) 215 C, 0 min 215 C, 4 min 215 C, 8 min 215 C, 12 min

23 Enzymatic hydrolysis of MSW Ethanol Production = ~65 gal/ton

24 MSW as a Platform for Biomass-to-Ethanol Biorefinery 35-45% paper and paperboard products Will reduce landfill volume by >40% In MSW, paper is already fractionated Can produce other co-products! Pulp! Methane = ENERGY For ethanol, though, MSW would provide <15 billion gal/yr, less than 10% of our transportation fuel needs..

25 Anaerobic digestion! Biogas Due to flexibility in cost and scale, anaerobic digestion (AD) is highly recommended in today s economic climate.! - it scales well from larger to smaller.! - smaller capital cost (can produce fertilizer for ag-use)! - fits into current engine technologies and infrastructure.! - can be used to replace electricity (coal), diesel/gasoline, LPG.! - transports well.! - reduces emissions.!

26 TS, VS, and BVS reductions with high solids, flow-through anaerobic digestion. solids reduction, % ml CH 4 /g TS reduction VS reduction BVS reduction Carbohydrate reduction 90.5 n/a

27 Plug Flow AD of autoclaved MSW 5, ,000 daily CH 4 yield (ml/d) 4,000 3,000 2,000 1,000 0 Gas production 215 ml CH 4 /g applied VS daily CH4 cumulative time (days) 80,000 60,000 40,000 20,000 0 cumulative CH 4 yield (ml)

28 One life-cycle analysis published in Science (May 8, 2008), concluded that bioelectricity produces an average 81% more transportation kilometers and 108% more emissions offsets per unit area cropland than cellulosic ethanol through either production of electric cars or through use of liquefied biomethane.!

29 Compressed Biomethane vs. Ethanol Ethanol Achieve 65 gallons per mt of autoclave pulp product (dry basis). Biomethane Achieve 428 ml CH 4 /g VS with MSW pulp. 99 diesel equivalent gallons per mt of autoclave pulp product (dry basis). 155 ethanol equivalent gallons per mt of autoclave pulp product (dry basis). 11/5/12! Kevin M. Holtman, USDA!

30 State of the Art Ethanol Plant - Philip W. Madson, President, Katzen International

31 Ag-Derived biomass works about as well as MSW! Co-mingled waste.

32 Why Co-mingle MSW with Crops and Ag-Residues? WE NEED HERBACEOUS CROPS TO MEET THE VOLUME! MSW reduces the risk to biorefinery developers Tipping Fees! In California it s > $50/ ton Consistent feed supply Consistent supplier contracts Transportation and handling infrastructure exists Funding is often more stable (municipal bonds)

33 Plastics from Biogas

34 PHA from Biogas PHA = bacterial fat! PHA is produced when excess carbon is present and/or when a key nutrient is limiting! Balanced growth conditions! Carbon excess and/or nutrient deficiency; PHA granules begin to form! Daniel et al (1992)!

35 Plastics:

36 Cost of Carbon Substrate per unit PHA $Carbon/lb PHA $0.60 $0.50 $0.40 $0.30 $0.20 $0.10 $0.00 -$0.10 Price of methane = $3/MMBtu! Natural gas: $0.14/lb PHA! Minimum cost for sugar substrate: $0.30/lb PHA! Natural Gas 100% methane 1066 Btu/ft 3 Biogas 60% methane 650Btu/ft 3 Biogas:! $0 $2 $0.09/lb $4 PHA! $6 $8 $10 $12 Methane Price ($/MMBtu) Mango Materials is cost competitive, even when using pipeline natural gas!

37 !"#$%&'()*+,&'-$+.#/'01+"%/' Renewable Fuel Standard-2 32 billion gallons/year by 2022! ' ' '2""34*' '5##6/7),8 ' '9$)63,:)"'' 'A+)6+#/#*' ; ' 'B#**3*)/+,'>+)?3#*/' ;<' 'C71#$'46.4",#6'>+)?3#*/ '' =' '' Need 21! billion! gals/year!

38 Section 9002: Biobased Market Program! Section 9003: Biorefinery Assistance Program! Section 9004: Repowering Assistance! Section 9005: Bioenergy Program for Advanced Biofuels! Section 9006: Biodiesel Fuel Education Program! Section 9007: Rural Energy for America Program! Section 9008: Biomass Research and Development Initiative! Section 9009: Rural Energy Self-Sufficiency Initiative! Section 9010: Feedstock Flexibility for Bioenergy Producers! Section 9011: Biomass Crop Assistance Program! Section 9012: Forest Biomass for Energy!

39 Partnerships: An ongoing story..!

40 William Orts Dominic Wong Rick Offeman Kevin Holtman Charles Lee Kurt Wagschal Gregory Glenn Bor-Sen Chiou Syed Imam George Robertson De Wood

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42 Flow scheme for flexible biorefinery MSW/ agderived fibers Autoclaving Trommel screen Soluble organics Saccharification/ Fermentation/ Distillation Ethanol Unreacted solids Anaerobic Digestion Unreacted solids Gasification Biogas for combustion Energy

43 Summary of Autoclaved PET Bottles - Holtman, K.H. et al. J. Appl. Polym. Sci., 2012 # of Heat Cycles T m ( o C)!H m (J g -1 ) " c (%)!H m /" c Appearance vpet clear pcpet clear apcpet clear rpet partially opaque EvPET clear EpcPET clear EapcPET partially opaque ErPET opaque

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45 Biomass Composition

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47 Torrefaction: Conversion of Biomass to Biocoal Reactor! Energy! combustion and recovery! Densify!

48 Torrefaction: Conversion of Biomass to Biocoal USDA-ARS and RFT are teaming up to build a portable 8 tons/day unit to produce BioCoal on location. The 28 unit is mounted on an 18-wheel trailer Reactor! To be deployed in late 2012 at Sierra Pacific Industries El Dorado National Forest Almond hullers processing plant, Los Banos, CA Wheat straw is an ideal substrate! Energy! combustion and recovery! Densify!