The Potentially Promising Technologies for Conversion Woody Biomass to Sugars for Biofuel Production: Technology and Energy Consumption Evaluation

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The Potentially Promising Technologies for Conversion Woody Biomass to Sugars for Biofuel Production: Technology and Energy Consumption Evaluation

1 The Potentially Promising Technologies for Conversion Woody Biomass to Sugars for Biofuel Production: Technology and Energy Consumption Evaluation J.Y. Zhu US Forest Service, Forest Products Laboratory, Madison, WI 2009 TAPPI International Bioenergy and Bioproducts Conference October 13, 2009

2 Barriers to Biobased Economy Can we do it technologically? Can we do it economically? Can we do it sustainablly? Can we do it ENERGY efficiently?

3 Biorefinery Economic Analysis $$ Capital What about net energy output? Biorefinery $$$ Value $$ Processing

4 Chemicals Enzymes Yeast Engineering Analysis Energy How much is net energy output? Biofuel

5 Material and Energy Analysis Energy Mixing energy Energy Heat A A Glucan: Mannan: Xylan: Lignin: Ethanol: Lignin: Energy C Energy Energy 1000 Glucan: Mannan: Xylan: Lignin: B B+C Glucan: Mannan: Xylan: Lignin: Ethanol: Lignin: Energy

6 Process Performance Evaluation Total Sugar Yield Pretreatment Process Efficiency ηpretreatment = Total sugar yield / Energy Input

7 Process Performance Evaluation Total Ethanol Yield Ethanol Production Energy Efficiency ηenergy = Net energy output / Energy Input

8 Feedstock Comparison Wh/kg 50 Wh/kg 1.3 cents/liter ~50 Wh/kg Cornstover

9 Two Key Barriers to Woody Biomass Conversion Size reduction energy consumption Recalcitrance Low cellulose conversion, especially softwoods

10 Size reduction Energy Consumption in Pretreatment Nonwoody: 50 Wh/kg = 0.18 MJ/kg Woody: Wh/kg = MJ/kg Thermal energy Temperature L/S Ratio o C L/S = 3 ~ MJ/kg Biomass ~ o C L/S = 5 ~ MJ/kg Biomass ~ o C L/S = 1 ~ MJ/kg Biomass ~ 1.8

11 Energy Consumption in Pretreatment Total energy Non-woody o C L/S = 3 ~1.48 MJ/kg o C L/S = 5 ~2.28 MJ/kg o C L/S = 1 ~1.80 MJ/kg Woody o C L/S = 3 ~ MJ/kg o C L/S = 5 ~ MJ/kg o C L/S = 1 ~1.80 MJ/kg 20% 32% 25% 28-48% 40-60% 25% Biomass ethanol Energy ~80 gallon/ton of biomass (OD); Ethanol HHV = 90 MJ/gallon Biomass ethanol energy = 7.2 MJ/kg

12 CAFI-II Study Biomass Refining Consortium for Applied Fundamentals and Innovations (CAFI) CAFI II: Poplar wood pass ¼ mesh Process studied: Dilute acid + steam explosion (NREL) Acid Catalyzed steam explosion (UBC) Lime (TX A&M) Ammonia recycle percolation-arp (Auburn) Ammonia fiber expansion-afex (Michigan State) Controlled ph (Purdue)

13 CAFI-II (Poplar) Findings Pretreatment Glucose Xylose Total Wt % Theoretical Theoretical Dilute acid Steam Explosion Controlled ph AFEX ARP Lime

14 CAFI-II (Poplar) No energy data for wood size-reduction to pass ¼ mesh No liquor/solid ratio in pretreatment No solids loading in SSF No fermentation of hemicellulose sugar stream Cannot calculate ethanol yield/ton wood!! Cannot determine process energy efficiency!! 4 of the 6 process are not suited for woody biomass!!

15 Cellulosic Ethanol Technology Status Few carried out the complete process study to produce data for economic analysis Few reports ethanol productivity?? gallons / ton biomass

16 Pretreatment Technologies Steam Explosion Oganosolv Dilute Acid (including hot-water) Alkaline (Ammonia, AFEX, lime, NaOH) SPORL

17 Steam Explosion Pretreatment SO 2 Concentration = % T = o C Steam explosion A lot of steam lost Pre-Steam Scale-up facility not commercially proven Extractor Hemicellulose Low conversion for softwood Substrate Hydrolysis Fermentation

Organosolv Pretreatment Ethanol = 50% (v/v) ph = 2-3.

18 Organosolv Pretreatment Ethanol = 50% (v/v) ph = T = o C Lignin Pre-Steam Extractor Recovery Hemicellulose Cellulose Hydrolysis Fermentation

19 SPORL Technology Platform

20 SPORL Pretreatment Biomass T ( o C) Reaction time (min) L/S Acid charge (wt% DM) Bisulfite charge (wt% DM) Agricultural residue Hardwoods Softwoods Typical size reduction energy: KWh/ton wood Typical enzymatic glucose yield: 85-90% theoretical Overall sugar recovery: >85% theoretical Typical energy efficiency: 0.4 kg/mj

21 SPORL Substrate Digestibility Enzymati cellulose conversion (%) Acid Bisulfite Enzymatic saccharification time (h)

22 1024 Disk-Milling Energy and Substrate Digestibility Disk-milling energy (Wh/kg od untreated wood) Pretreatment ph(t=0) Untreated Hot water 5.0 Dilute acid 1.1 SPORL 4.2 SPORL Milling solid consistency (%) EHGY ( wt% of wood) Theoretical glucose 43 wt % wood 85-90% theoretical Pretreatment ph(t=0) Untreated Hot water 5.0 Dilute acid 1.1 SPORL 4.2 SPORL Milling solids consistency (%)

23 512 Disk-Milling Energy and Substrate Digestibility Disk-milling energy (Wh/kg od untreated wood) Pretreatment ph(t=0) Hot water 5.0 Dilute acid 1.1 SPORL 4.2 SPORL Disk-plate gap (mm) EHGY (wt% of wood) Theoretical glucose 43 wt % wood 85-90% theoretical Pretreatment ph(t=0) SPORL 1.9 y = x, r 2 = 0.76 SPORL 4.2 y = x, r 2 = 0.97 Dilute acid 1.1 y = x, r 2 = 0.36 Hot water 5.0 y = x, r 2 = Disk-plate gap (mm)

24 Pretreatment Evaluation Steam Explosion, Soderstrom et al. 2004, Biotech Prog. 20:744 Organosolv, Pan et al., 2008, Biotech Bioeng. 101:39 SPORL, Zhu et al., 2009, Biores Techno, 100:2411

25 Pretreatment Energy Consumption L/W T ( o C) Net thermal energy 1 Wood chipping energy Chip milling energy Total size reduction energy 1 Total energy 1 Steam explosion / /0 1.98/28 Organosolv / /0 1.78/25 SPORL / / / / /27

26 Pretreatment Sugar Yield Evaluation Measure Unit Steam Exp 1 Organosolv 2 SPORL 3 Species Glucan Mannan Xylan Sum Spruce 53.2% 11.9% 4.3% 69.4% Lodgepole pine 43.2% 11.6% 7.1% 61.9% Spruce 43.2% 11.5% 5.7% 60.4% Wood chipping energy MJ(kWh)/ton wood 180(50) 180(50) 180(50) Chemical pretreatment conditions: Temperature L/W 215 o C 170 o C 180 o C / Chemical pretreatment energy MJ/ton wood chips / Wood chip size-reduction energy MJ(kWh)/ton wood (150) / 180(50) Total energy consumption MJ/ton wood / / 1503 Pretreatment soluble sugar yield kg/ton wood Mannose Glucose Xylose Cellulase loading FPU/cellulose Enzymatic hydrolysis glucose yield kg/ton wood Total monomeric sugar 65% carbohydrate equivalent kg/ton wood Sugar recovery % theoretical Pretreatment energy efficiency, 65% carbohydrate equivalent kg/mj / / 0.43

Preliminary Ethanol Yield Evaluation K Lignin Arabinan Galactan Rhamnan Glucan Xylan Mannan G+M 1 Total 270.1 15.6 22.3 7 425.5 69.3 109.9 535.4 941.

27 Preliminary Ethanol Yield Evaluation K Lignin Arabinan Galactan Rhamnan Glucan Xylan Mannan G+M 1 Total Sample Label h 1 SSF Ethanol 2 SSF fermentation efficiency 3 Hydrolysate glucose + mannose 1 Hydrolysate Ethanol 2 Hydrolysate fermentation efficiency 3 Total glucose+ mannose 4 1-A2B Total Ethanol yield 5 1-A2B / / A2B / / A2B / / A2B / / A1B / / A1B / / A0B / / A0B / / 43.5

Material and Energy Analysis 0.41 (113 Wh/kg) NA 0.18 (50 wh/kg) 1.

28 Material and Energy Analysis 0.41 (113 Wh/kg) NA 0.18 (50 wh/kg) A Glucan: 385 Mannan: 4 Xylan: 8 Lignin: 195 Ethanol: 209 Lignin: 195 NA C NA NA Ethanol 1000 Glucan: 426 Mannan: 110 Xylan: 69 Lignin: 271 B 397 Glucan: 32 Mannan: 86 Xylan: 27 Lignin: 76 Ethanol: 57 Lignin: Liters 4.31 GJ/ton wood

Conclusions Both total sugar/ethanol yield and process energy efficiency should be used in technology evaluation Limited process and yield data are available for good economics analysis We report

29 Conclusions Both total sugar/ethanol yield and process energy efficiency should be used in technology evaluation Limited process and yield data are available for good economics analysis We report ethanol production from lodgepole pine, softwood at 266 liters/ton wood Net energy out put of 4.31 GJ/ton wood before distillation SPORL pretreatment appears the best process for woody biomass in terms of energy efficient, sugar yield, scalability, lignin co-products potential

30 Contributors and Collaborators Visiting Scholars and Students Dr. Gaosheng Wang Tianjin Univ. of Sci. Technology Mr. Wenyuan Zhu South China Univ. Technology 2008-present Mr. Hao Liu South China Univ. Technology 2008-present Dr. Shen Tian Capital Normal University 2009-present Mr. Xiaolin Luo South China Univ. Technology 2009-present Technical Staff Rollie Gleisner Tim Scott Fred Matt Diane Dietrich Collaborators Dr. Xuejun Pan, University of Wisconsin, Madison, WI Dr. Andy Youngblood, US Forest Service, Pacific Northwest Station Dr. Jose Negron, US Forest Service, Rocky Mountain Station Dr. Don Rockwood, University of Florida, Gainsville, FL Dr. Bruce Dien, USDA ARS NCAUR, Peoria, IL Dr. Lewis Liu, USDA ARS NCAUR, Peoria, IL Dr. Masood Ahtar, Biopulping International Dr. Thomas Jeffries, US Forest Service, Forest Products Laboratory

Bioresource Technology

Bioresource Technology 101 (2010) 2782 2792 Contents lists available at ScienceDirect Bioresource Technology journal homepage: www.elsevier.com/locate/biortech On energy consumption for size-reduction