National Institute of Food and Agriculture USDA Advancing the Bioeconomy Through Innovation and Integration

Transcription

1 National Institute of Food and Agriculture USDA Advancing the Bioeconomy Through Innovation and Integration National Energy Extension Summit April 8, 2015 Bill Goldner, Ph.D.

2 The Bioeconomy What is the Bioeconomy? Biofuels, Industrial Chemicals, Biopower, and Biobased Products produced from agricultural and forest biomass (including oil crops/algae) Why does it matter? Create and protect jobs Enhance energy security Increase rural economic development Provide sustainable alternatives to fossil feedstock options Enhance existing agricultural/forest production systems Provide ecosystem services

3 National Institute of Food and Agriculture Sustainable Bioenergy Facilitate system-based approaches for development of sustainable regional biomass supply chains for the production of biofuels, biopower, and bioproducts. >$200 M NIFA current five year investment in biomass supply chains research, development, demonstration, extension, education Agriculture and Food Research Initiative Biomass Research and Development Initiative Joint Feedstock Genomics for Bioenergy Non-competitive

4 Regional Approaches to Bioenergy Systems Coordinated Agricultural Projects (CAP) Regional partnerships Academia, industry, government, NGOs, communities Work back from targets to develop entire supply chains Build on existing infrastructure and previous investments Integrate Research, Education, and Extension/Tech Transfer Robust sustainability analysis: Impacts on Economics, rural communities, and the environment Targeted Feedstocks (perennial grasses, energy cane, sorghum, woody biomass, oil crops) : 7 AFRI awards totaling ~$156 M over 5 years

5 Fund allocation to date across 7 CAPs Research $60 M Education $15 M Extension $17 M

6 AFRI CAP Regions and Feedstocks

7 AHB Progress Toward Sustainable Transportation Fuels and Chemicals Rick Gustafson, Brian Stanton, Tim Eggeman, Kate Field, Bryan Jenkins, Jason Selwitz, Kevin Zobrist.

8 Keys to Advanced Hardwood Biofuels Innovation and Integration Superior poplar genetics Biomass coppice plantation production system Biomass harvest system Modular conversion technology Chemicals Fuels (ethanol, aviation fuel) Workforce development Community and landowner engagement Sustainability Analysis hardwoodbiofuels.org

9 Why it matters Rural economic development New jobs for forest product communities Alternative income for landowners Products from non-petroleum renewable feedstocks Environmental Services hardwoodbiofuels.org

10 Laying the foundation for a renewable fuels and chemicals industry Good science Sound technologies & Thorough analyses Community and policy support Well educated work force Committed land owners hardwoodbiofuels.org

11 AHB is building a renewable bio-based chemical and biofuel industry in the Pacific Northwest using sustainably grown hybrid poplar. 1. Demonstration of hybrid poplar production and harvesting technology Feedstock lead GreenWood Resources 2. Production of bio-based chemicals and fuels Conversion lead ZeaChem at their Boardman demonstration bio-refinery. 3. Assessment of sustainability and critical system metrics Sustainability leads Universities of Washington and California, Davis. 4. Development of curricula for pre-college, community and technical college, undergraduate, and graduate levels Education leads Oregon State University and Agriculture Center of Excellence. 5. Outreach to policy makers, community leaders, growers, equipment manufacturers, investors, regulators Extension lead Washington State University hardwoodbiofuels.org

12 Phase I hybrid poplar demonstration farms crux of the feedstock program Four farms, 20 to 40 hectares each. Each site has many clones to assess suitability Sites are selected for potential commercial prospect proximity to fuel markets Tree farms are used to assess harvester technologies, environmental impacts, etc. hardwoodbiofuels.org

13 Feedstock production group Jefferson, OR Site 2 nd growing season before harvesting on September 2013 Height mean = 19.7 ft hardwoodbiofuels.org

14 New Holland FR Series with 130FB Coppice Header FR Hybrid Poplar FR 9080 FR series Grass or grain Corn Corn Woody coppice

15 ZeaChem s Boardman demonstration-scale refinery hardwoodbiofuels.org

16 Sustainability University of California, Davis University of Washington The AHB sustainability program integrates data from the feedstock and conversion teams to: 1. Study the optimum locations for regional refineries 2. Estimate local economic impact 3. Techno-economic assessment of conversion processes 4. Conduct life cycle assessments 5. Produce an integrated model for evaluating system capability

17 Techno-economic modeling jet fuel is challenging at current prices ASPEN process modeling as a function of hydrogen source 3.5 Economies of scale Natural gas steam reforming Lignin gasification 3 Cash cost ($/gal) Cash cost ($/gal) Gasification Reforming Capacity (MMGal/yr) Reforming $ Gasification $ Jet fuels sells ~ $3.00/gal at refinery gate hardwoodbiofuels.org

18 Techno-economic modeling acetic acid looks much better ASPEN process modeling of poplar to acetic acid Operating costs $/ton Feedstock 121 Cellulase 69 Fermentation nutrients 3 Other raw materials 32 Natural gas 210 Waste disposal 2 Electricity credit -172 Fixed Manufacturing Costs 111 Cash production cost $376/ton Acetic acid sells ~ $650-$800/ton hardwoodbiofuels.org

19 Extension Washington State University Proactive on bioenergy information Provides research-based information o Social impact assessment Helps with informed decision making Facilitates technology transfer to Extension professionals Policy makers Potential growers Environmental groups Business community Interested citizens

20 Poplar growers manual Growing Poplar for Bioenergy: A Grower s Manual Work with GWR Feedstock Production Report

21 Northwest Advanced Renewables Alliance A new vista for Green Fuels, Chemicals, & Environmentally Preferred Products Michael Wolcott Regents Professor Project Co-Director Ralph Cavalieri Associate Vice-President for Alternative Energy Project Director Washington State University Northwest Advanced Renewables Alliance

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24 Isobutanol to Jet Fuel Demonstration Demonstration unit at South Hampton Resources, Silsbee, TX is fully functional USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA 2012 Gevo, Inc.

25 USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Keys to NARA Innovation and Integration Robust project management Feedstock Logistics Pre-processing (mild bisulfite, milled wood) Sustainability Analysis (TEA) Novel conversion technologies Isobutanol to AJF, lignosulfonates, activated carbon Workforce development Community and landowner engagement

26 USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Why it matters Rural economic development New jobs in rural communities Protected jobs in the pulp industry through diversification Alternative income for landowners Products from non-petroleum renewable feedstocks Ecosystem services

27 NARA: Feedstock to Fuels USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Completed Year 3 of 5

28 NARA Team USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Catchlight Energy CLH Cosmo Specialty Fiber Facing the Future Gevo, Inc. Gevan Marrs, LLC. Montana State University Oregon State University Pennsylvania State Univ. Salish Kootenai College Steadfast Management TSI Inc. University of Idaho University of Minnesota University of Montana University of Washington University of Wisconsin USFS Forest Products Lab USFS PNW Research Sta. University of Utah Washington State University Western Washington Univ. Weyerhaeuser

29 Teams vs Goals Process vs Outcomes USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Sustainable Biojet Valuable Co-Products Regional Supply Chains Energy Literacy Rural Econ Development Feedstock Conversion Sustainability Outreach Education

30 NARA Techno-Economic Analysis USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Source: TSI Chemicals & Biomass Products and Processes

31 Value Chain: Route to Cost Parity for Fuels USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

32 Sustainability Assessment USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Environmental Economic Social Sustainable Feedstock Weyerhaeuser, OSU, UW, WSU Life Cycle Assessment UW Economic Analysis TSI, Weyerhaeuser, UW Social & Market Assessment Penn State, WSU, UIdaho

33 Milestone: NARA Long Term Soil Productivity Site

34 Siting Analysis for Integrated Biorefinery Potential Biomass Depot Locations Inventory of Assets on Sites Site Designs Biomass Supply Scenarios (quantity and transportation) Community Impact Analysis Scenarios for Life Cycle Analysis Developed by Education and Outreach Teams Assessed by Regional Stakeholders REGIONAL SUPPLY CHAINS USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

35 Western Montana Corridor (WMC) USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

36 Overall Impact in WMC USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

37 Mid Cascade to Pacific (MC2P) USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

38 Demonstrate Integrated Production of BioJet USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

39 Regional Corporate Member USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA NARA Affiliate Member Market Studies Retrofit Options Techno-Econ Studies

40 Regional Tribes TOP 5 Tribal Landowners In Commercial Acres 1. Colville ~ 660, Yakama ~ 449, Salish & Kootenai ~ 300, Warm Springs ~ 256, Quinault ~ 174,000 USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Collaborations with Salish & Kootenai Completed Warm Springs -- John Bailey (OSU) Developing Collaborations Yakama Quinault DOE Tribal Energy Program DOE awarded $807,000 to CSKT for engineering work Bioenergy Project Beck Group NARA Biomass Assessment Harris Group

41 Leveraging NARA for New Projects USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA

42 If its going to burn.

43 it might as well be in a jet engine John Bailey, OSU NARA Member

44 Sustainable Production and Distribution of Bioenergy for the Central USA CenUSA Bioenergy is supported by Agriculture and Food Research Initiative Competitive Grant No from the National Institute of Food and Agriculture

45 Our vision is to create a regional system for producing advanced transportation fuels and other biobased products from perennial grasses grown on land that is either unsuitable or marginal for row crop production. In addition to producing advanced biofuels, the proposed system will improve the sustainability of existing cropping systems by reducing agricultural runoff of nutrients and soil and increasing carbon sequestration. Midwest Sustainable Biofuels Vision

46 Keys to CenUSA Innovation and Integration Superior perennial grass genetics Low input marginal land production systems Feedstock logistics Sustainability analysis Distributed pyrolysis conversion concept Chemicals Fuels Biochar Workforce development Community, farmer, and landowner engagement

47 Why it matters Enhancement of existing crop production systems Ecosystem services Water quality improvement (protecting the Gulf of Mexico) Wildlife habitat Alternative farm income Products from non-petroleum renewable feedstocks 47

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49 Commercialization: ADM Fiber Platform Biomass Consumer products Food ingredient: ADM Cooked biomass Pulp Chemical pulp: ADM cellulose Lignin and Hemicellulose Lignin External Partners Finding the best value proposition for the three products Lignin, pulp, hemicellulose Hemicellulose Furfural External Partners

50 Commercialization: CenUSA Vermeer Field-scale Site Liberty Switchgrass 29 July, 2014

51 Commercialization: Field Scale Plots in Eastern Nebraska Feedstock 2012 Yield 2013 Yield 2013 Transported Yield Liberty Switchgrass (Mg/ha) Big bluestem (Mg/ha) LD Mixture (Mg/ha) Corn (bu/acre) 103 (1.4 tons) 149 (1.9 tons) Transported Yield = baled, transported off the field, and weighed to estimate loss

52 Transport Improvements and Impacts

53 Transport Improvements and Impacts 8 10 lbs DM/ft lbs DM/ft 3

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55 Feedstock Readiness Level Fuel Readiness Level (FRL) Biochar Product Readiness Level ADM Acetosolv Pulping Readiness Level Renmatix C5 and C6 Sugar Production Readiness Level Corn Stover Feedstock Production Herbaceous Perennial Feedstock Production

56 Education and Outreach: Problem-oriented, research-based transdisciplinary hands-on learning for a wide cross-section of students Specific activities include: Creating learning modules on bioenergy-relevant topics Offering week-long intensive programs for graduate students to understand the interactions between research areas Offering 10-week summer internship programs to students from across the US and a wide variety of academic and socioeconomic backgrounds

57 Growing a Sustainable Bioenergy Industry for the Northeast Tom Richard Penn State University

58 University and Federal Partners Partner Organizations Penn State University Cornell University SUNY ESF West Virginia University Delaware State University Ohio State University Rutgers University Drexel University USDA ARS ERRC DOE Oak Ridge National Laboratory DOE Idaho National Laboratory

59 Keys to NewBio Innovation and Integration Superior perennial genetics (switchgrass, willow, Miscanthus) Low input marginal land production systems Feedstock logistics Sustainability Analysis Diverse conversion options Chemicals Absorbents Fuels (ethanol, aviation fuel) Workforce development Community, farmer, landowner engagement

60 Why it matters Enhancement of existing crop production systems Ecosystem services Water quality improvement (protecting the Chesapeake Bay) Wildlife habitat Alternative farm income Products from non-petroleum renewable feedstocks 60

61 Conversion Partner: Delta

62 Sustainability Partner: Chesapeake Bay Commission

63 Extension Education Willow DoubleAWillow Switchgrass Ernst Miscanthus Aloterra Feedstock Improvement Human Systems Harvest Store Densify Transport Case New Holland, Aloterra Ernst TerraGreen Harvest, Preprocessing & Logistics Sustainability Systems Biochemical Mascoma Renmatix Thermochemical Praxair Primus Green Energy Bio-electricity ReEnergy Safety and Health Biofuel Markets American Refining Group Human Systems Leadership and Evaluation

64 Extension Willow DoubleAWillow Switchgrass Ernst Miscanthus Aloterra Harvest Store Densify Transport Case New Holland, Aloterra Ernst TerraGreen Biochemical Mascoma Renmatix Thermochemical Praxair Primus Green Energy Bio-electricity ReEnergy Biofuel Markets American Refining Group Short Courses Webinars Fact Sheets and Tools Equipment Access Program Demonstration Site Field Days extension

65 Target: regionally appropriate biomass feedstocks Questions to be Answered The deep south states can to produce 50% of the biofuels in the future because they have the most available land with adequate water and sun. Agricultural What crops suitable for production in underutilized agricultural areas (Cold tolerance)? Industrial Are the products (syrups) suitable for use by industrial partners? Financial-Environmental What is the financial baseline for producing biofuels from these crops and what are the environmental costs associated with the production?

66 KEYS TO SUBI Innovation and Integration Superior energy cane and sweet sorghum genetics Cold tolerant energy cane to move cane production away from the coast Low input production systems Feedstock logistics Sustainability Analysis Diverse conversion options Chemicals, bioplastic Fuels (butanol, aviation fuel) Workforce development Community and landowner engagement

67 WHY IT MATTERS Rural economic development Jobs in an area that sorely needs them Potential for greater farm income than current cropping systems Products from non-petroleum renewable feedstocks

68 YEAR ROUND FEEDSTOCK SUPPLY Month Sorghum E-cane Commercial sugar Other Jan Feb Mar Apr Bagasse May Bagasse Jun Bagasse Jul Aug Sept Oct Nov Dec

69 Winnsboro Ho st stubble crop (Sept. 2014). White PVC pole is 10 long. Courtesy of Chris Adams.

70 SWEET SORGHUM Annual crop Contains, a sugar containing juice, starch containing seed heads and fiber day crop cycle, can be grown across target region Gross structure similar to sugarcane Can be widely grown across Southern US About 6,000 acres required to sustain processing plant for 3 months

71 CROP COMPARISON Energycane Harvest time(months) 7 Ag Inputs Planting Acres/1000t/day factory Growth in nontraditional regions none perennial 8,000 yes Dry ton/acre 10 Sweet sorghum Harvest time(months) 3 Ag Inputs Planting Acres/1000t/day factory Growth in nontraditional regions None* annual 6,000 yes Dry ton/acre 1-9 *fallow with clover

72 Process Outline Sustainable Production Harvest analyze Deliver Feedstock development Technology development Sustainability Sugar Cane ZSM-5 Gasoline Biomass APR Kerosene Jet Fuel Condensation Hydrotreating Corn Starch Diesel Conversion to Fuel Value to Consumer Intermediate Product Process Indeterminate Process Economic feasibility Technology development Biomass

73 PROCESSING

74 Bioenergy Alliance Network of the Rockies Researching Sustainable Bioenergy from Beetle-Kill Wood in the Rockies Keith Paustian Project Director Department of Soil & Crop Sciences Colorado State University

75 Project members Colorado State University University of Idaho Montana State University University of Montana Oregon State University University of Wyoming USFS Rocky Mtn Res. Station Cool Planet Energy Systems Affiliates National Renewable Energy Lab Michigan State University USFS Forest Products Lab BANR Team Project advisory board Greg Aplet Wilderness Society Pat Connell Montana State Senate Rob Davis Forest Energy Corp. Angela Farr USFS, Region 1 Steve Hamburg Environmental Defense David Hiller Colorado Clean Energy Jim Neiman Neiman Enterprises

76 Keys to BANR Innovation and Integration Sustainability Analysis Feedstock logistics Modular/mobile conversion technology Biochar Fuels (gasoline, aviation fuel) Workforce development Community and landowner engagement

77 Why it matters Wildfire mitigation in part of 42 million acres Ecosystem services Water quality improvement Wildlife habitat Rural Economic Development Products from non-petroleum renewable feedstocks 77

78 Background Beetle infestation is a major ecological and resource management issue in the Rocky Mountains 17 Mha (42 Ma) of forest in US impacted by bark beetles 52% of total area is in CO, ID, MT & WY New infestations are occurring on millions of acres annually Several 100s of millions of tonnes of dead wood are a potential biofuel feedstock source Removal of beetle-kill wood and forest restoration have been proposed to meet various management objectives: Reduce risk of catastrophic wildfire Enhance safety for roads, trails, structures Enhance regeneration, diversity, habitat US Forest Service (2011) Wood from thinning for fire control & forest restoration is currently a disposal problem!

79 Can beetle-kill and other wood residues be a viable biofuel feedstock? Opportunities Large quantities of wood potentially available as a feedstock No displacement of productive lands (no indirect land use change) Minimal competing uses for other wood products Synergies with other land management objectives (e.g., fire mitigation, forest restoration, timber production) Existing forest infrastructure can be leveraged in many areas Challenges Constrained accessibility in many areas (e.g., roads, topography) Large fraction of the area is Federal and State owned Policy issues Multiple use issues Feedstock creation is unmanaged, episodic and patchy (major constraint against large, fixed location biorefineries) Potential adverse environmental impacts (e.g., erosion, water quality)

80 Overarching Objective To provide the science-based underpinnings through targeted research, education, training and extension to support the development of sustainable biofuel/bio-products from beetle-killed and residual wood feedstocks.

81 Project Task Overview RS & Field sampling campaign Feedstock supply atlas Forecasting of future infestation Enterprise partner engagement Harvest, transport & processing studies Pretreatment & CPES technology trials Field-scale impact analysis Ecosystem C/GHG modeling & LCA Socioeconomic & policy analysis K-12 science units Teacher prof. development Multidisciplinary grad. training Workshops & community meetings Stakeholder engagement Health & safety standards & training

82 BANR in perspective Softwood conifer feedstock Similar to NARA, IBSS Thermochemical conversion with biochar co-production Similar to CenUSA, IBSS Feedstock very different from other CAP s, analogous to corn stover Already exists, doesn t require dedicated cultivation (similar to NARA) DOES require additional equipment & processes to collect Maximum removal rate constrained by environmental sustainability, social acceptance and economic viability Land-ownership is mixed (Federal, State, Tribal, private) and is a key factor affecting feedstock supply 82

83 BANR activities: Modeling & optimizing harvest operations Harvest equipment slash piles from forest restoration Cost and productivity study 83

84 Contact Information BRDI: Daniel Cassidy, AFRI: Bill Goldner, Mobile SBIR: Bill Goldner Joint DOE/USDA Feedstock Genomics for Bioenergy: Bill Goldner