Future Opportunities for Biomass Fuels and Power Dr. Richard L. Bain, Principal Engineer Biorefinery Analysis & Exploratory Research Group National Bioenergy Center SmallWood 2006 Richmond, VA May 16, 2006 5/22/2006 1
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 2
Biomass Share of U.S. Energy Supply (2004 data) Solar <1% Geothermal 5% Nuclear 8% Natural Gas 23% Biomass 47% Renewable 6% Wind 2% Petroleum 40% Coal 23% Hydroelectric 45% 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. 5/22/2006 3
United States Biomass Consumption in 2004 (Quadrillion Btu) Commercial 0.09 Residential 0.41 Industrial 1.63 Ethanol 0.28 Electric Power 0.44 Reference: Annual Energy Outlook 2006, Energy Information Administration, Table A17 5/22/2006 4
U.S. Biopower Generation, 1981-2004 70 12000 60 10000 Generation (TWh/annum) 50 40 30 20 10 Generation Capacity 8000 6000 4000 2000 Net Summer Capacity (MW) 0 0 1980 1985 1990 1995 2000 2005 Year 5/22/2006 5
8 7 6 5 4 3 2 1 0 Ethanol Production Actual and Projected U.S. Ethanol Production 1999-2012 Billion Gallons of Production 9 Cellulosic Ethanol 2005 EPACT RFS - Minimum U.S. Ethanol Production Source: December 2005 Ethanol Today Magazine 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 Renewable Fuels Standard mandates 7.5 billion gallons by 2012 Total US gasoline market ~140 billion annual gallons 5/22/2006 6
U.S. Biodiesel Production 80 U.S. Production, million gallons per year 70 60 50 40 30 20 10 0 1999 2000 2001 2002 2003 2004 2005 Total US distillate fuels market is approximately 60 billion gallons per year 5/22/2006 7
Biomass Strengths Biomass is: Abundant Renewable Carbon-neutral The 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 8
Sources of Lignocellulosic Biomass Hardwoods Grasses Crop residues Cellulose (Glucose sugar) 38-50% 23-32% Hemicellulose (Pentose sugars) Other (Extractives, ash, etc.) 5-13% 15-25% Lignin ( Young clean coal ) MSW Softwoods 5/22/2006 9
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 Food Supplies 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 Not a Food Supply Short-term: improve cost and efficiency of corn ethanol & biodiesel Mid to Long-term: focus on lignocellulose (trees, grasses, & residues) 5/22/2006 10
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 11
The 1.3 Billion Ton Biomass Scenario Billion Barrel of Oil Equivalents 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 5/22/2006 12
Primary Conversion Routes for Biomass Lignocellulosics (polysaccharides) Starches Pretreatment Sugars Hydrolysis Lignin Fermentation Chemical Conversion Combustion Gasification/Pyrolysis 5/22/2006 13
Ethanol Ethanol industry at 4 billion gal/yr based on corn starch Corn mills investing in process improvements and higher value products ADM Broin Abengoa Chemical industry investing in higher value products from glucose NatureWorks LLC dupont 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 5/22/2006 14
The Structures are Very Different Sugars: Glucose Starches: Glucose Glucose Polysaccharides in Lignocellulosic Biomass: Lignin Xylose X G 5/22/2006 15
Biochemical Conversion for Ethanol via PT/Hyd/Ferm SSF Conditioning Fermentation of C5 & C6 Sugars Simultaneous saccharification & Fermentation - SSF 5/22/2006 16
Cost of Ethanol via PT/Hyd/Ferm Minimum Ethanol Selling Price ($/gal) $6.00 $5.00 $4.00 $3.00 $2.00 $1.00 $0.00 State of Technology Estimates Feed $53/ton 2005 Yield 65 gal/ton Feed $35/ton Yield 90 gal/ton Enzyme Conversion Feedstock Current DOE Cost Targets President's Initiative Costs in 2002 Dollars Integrated large-scale BC/TC processing Feed $35/ton Yield 104 gal/ton 2000 2005 2010 2015 2020 5/22/2006 17
Biodiesel Griffin Industries, USA and Bruck Industries, Austria Sep 2004: 60 Mil gal/yr dedicated capacity in U.S. 5/22/2006 18
Biodiesel - Basic Technology Vegetable oils Recycled Greases Dilute Acid Esterification Sulfur + methanol Methanol + KOH Transesterification Methanol recovery Crude Glycerin Crude biodiesel Glycerin refining Refining Glycerin Biodiesel 5/22/2006 19
Oils, Fats & Greases as Bio-renewable Petroleum Refinery Feedstocks Oils and Greases ISBL Petroleum Refinery Catalytic Cracker Distillate Hydrotreater Green Gasoline & Olefins Green Diesel 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 Based on Presentations at 1 st 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 20
Green Diesel and Biodiesel Yields Feed Biodiesel Green Diesel % Oil or Grease % H2 % methanol Products % water,c02 % Lt HC % diesel % glycerol Operating cost $/gal 100 8.7 96 12.05 100 1.5-3.8 12-16 2-5 83-86.025 Marinangeli, R., et.al. (2005). Opportunities for Biorenewables in Oil Refineries: Final Technical Report, UOP, Des Plaines, IL; DOE Report No. DE-FG36-05GO15085. 5/22/2006 21
Diesel Properties % Oxygen Density g/ml Sulfur content Heating Value (lower) MJ/kg Biodiesel (FAME) 11.883 <10ppm 38 Green Diesel 0.78 <10ppm 44 % change in NOx emission Cloud Point o C Distillation 10-90% pt Cetane 0 to +10-5 340-355 50 0 to -10-5 to -30 265-320 80-90 Marinangeli, R., et.al. (2005). Opportunities for Biorenewables in Oil Refineries: Final Technical Report, UOP, Des Plaines, IL; DOE Report No. DE-FG36-05GO15085 5/22/2006 22
Biomass Thermochemical Conversion for Fuels and Chemicals PRODUCTS Hydrogen Gasification Cleanup Synthesis Alcohols FT Gasoline FT Diesel Olefins Oxochemicals Ammonia SNG Biomass Pyrolysis Conversion or Collection Purification Hydrogen Olefins Oils Specialty Chem Other Conversion* Separation Purification Hydrogen Methane Oils Other 5/22/2006 23
Fuels from Syngas Fischer Tropsch Fuels Wax Alpha-olefins Mixed Alcohols Refineries Hydrogen Ammonia Syngas CO + H 2 Acetic Acid Formaldehyde MTBE Diesel Additives Urea SYNGAS High/Low Pressure Gasifier Cyclone (Optional) Methanol Ethanol Freeboard Disengaging Zone DME Fluidized Bed Injector BARK & Screws SLUDGE AIR/O2 Olefins O2/AIR / STEAM Polypropylene Bottom Ash Acrylonitrile Removal Polyethylene 5/22/2006 24 Ethylene Glycol l h l f
Thermochemical Conversion for Ethanol via Gasification Mixed Alcohol Synthesis Scrubbed Syngas Syngas Compression High P Syngas 260-350 C 30-175 bar Alkali promoted MoS 2 catalyst Crude Products Preliminary Separation Mixed Alcohols Product Separation C3 + Alcohols Ethanol Methanol Recycle 5/22/2006 25
Cost of Ethanol via Gasification Minimum Ethanol Selling Price ($ per gallon) $2.50 $2.00 $1.50 $1.00 $0.50 State of Technology Estimates Forest Resources 56 gal/ton Biorefinery Residues 67 gal/ton Conversion Feedstock Previous DOE Cost Targets President's Initiative Costs in 2002 Dollars Integrated with Biochemical Processing 104 gal/ton total yield $0.00 5/22/2006 2000 2005 2010 2015 2020 26
Fast Pyrolysis of Biomass Fast 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 transported Has been developed in many configurations At present is at relatively early stage of development. 5/22/2006 27
Applications of Bio Oils Boiler Bio -oil Upgrade Extract Heat Chemicals Electricity Transport Fuel 5/22/2006 28
Fast Pyrolysis and Bio-oil as Feed to Power Plant or Petroleum Refinery 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 Based on research at NREL (1990-2000), Colin Schaverien presentation 5/22/2006 29
Variation of Pyrolysis-based Biorefinery Lignin Derivatives Aromatic Chemicals and/or Gasoline Blending Fast Pyrolysis Of Biomass Fractionation and/or Deoxygenation Other Products of Interest: Heating oil PF resins FCC feed DDU feed Carbohydrate Derivatives Fermentation or Hydrogenation of Aqueous Phase (Carbohydrates) 5/22/2006 30
DOE Goal: 30 by 30 - Replace 30% of Today s Gasoline in 2030 with Biofuels 5/22/2006 31
Integrated Biorefinery Elements 5/22/2006 32
Integrated Biorefinery Ethanol yield = 113 gal/dry ton stover MESP = $0.60/gal EtOH Ethanol 1,035,000 gpd Corn Stover 10,000 dmt/day Lignin-rich Residue 2,932 dmt/day Ethanol via bioconversion Steam & Power Coal-Fired CHP Plant Coal Ethanol 1,250,400 gpd 438.0 MM gal/yr Gasification Syngas Chemical Alcohols Alcohol Synthesis Ethanol 215,400 gpd gpd (gal/dry ton lignin) 7,900 Methanol (2) 39,100 n-propanol (12) 15,100 n-butanol (5) 5/22/2006 6,900 n-pentanol (2) 33
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 5/22/2006 34