Biomass Program Overview
- 1. DOE/EE/OBP Biomass Program Overview and Products R&D Western Regional Sun Grant Initiative Dr. Todd Werpy PNNL/DOE August 16, 2004
- 2. Mission of OBP “ The mission of OBP is to partner with U.S. industry to foster research and development on advanced technologies that will transform our abundant biomass resources into clean, affordable, and domestically-produced biofuels, biopower and high-value products. The result will be improved economic development, expanded energy supply options, and increased energy security”
- 3. Program Goals Develop biorefinery-related technologies to the point that they are cost and performance competitive and are used by the nation’s transportation, energy, chemical, and power industries to meet their market objectives 2005: Demonstrate an integrated process for fuels production from biomass 2007: Complete technology development necessary to enable start-up demonstration of a biorefinery producing fuels, chemicals, and power 2010: Help U.S. industry to establish the first large-scale integrated biorefinery based on agricultural residues
- 4. Strategy: Remove Technical Barriers Thermo-Chemical Platform Sugar Platform Biomass CO, H 2 , Bio-oils Sugar Feedstocks & Lignin Residues Advanced Biomass Process R&D Technology Validation and Systems Integration “The Integrated Biorefinery” Mixed Sugars Syngas, Pyrolysis-oils Fuels, Chemicals, Materials, Heat & Power
- 5. Program Strategy Analysis is used to identify major cost barrier areas in each element of the program Research is dedicated to overcoming these barriers and reducing the cost of each process as well as the final integrated biorefinery Program is driven by private public partnerships to ensure integrity of the program Regular reviews are undertaken to ensure progress and fiduciary responsibility Program is based on both near term and long R&D objectives
- 6. Program Structure $6MM $5MM $16.9 MM $20 MM $21.7 MM Congressional Mandates - $41MM
- 7. Biomass Program Funding Three-fold increase in earmarks since 2000 EWD Earmarks have grown from 18% to over 47% of the total funding Real decline in the available funds used in support planned R&D 13 18 39 30 41 81 94 74 61 80 Earmarks Total Funds for Planned R&D Legend Earmarks and Total Funding Millions of Dollars per Year
- 8. Building the Bio-refinery Maximize the value from the existing infrastructure Bring lignocellulosics into those existing facilities Build stand alone lignocellulosic facilities
- 9. An Example of a Grains Bio-refinery Corn Wet Mill starch corn oil corn gluten meal corn gluten feed food & industrial starches hydrolysis glucose fuel ethanol high fructose corn syrup fermentation sorbitol • foodstuffs • pharma . polyols isosorbide hydrogenation other citric acid lysine xanthan gums itaconic acid & other fermentation products industrial oils lactic acid PLA polymers • resins & plastics applications • polyesters • surfactants • pharmaceuticals deicers solvents coatings glycerol food oils feed oils Corn Wet Mill starch corn oil corn gluten meal corn gluten feed food & industrial starches hydrolysis glucose fuel ethanol high fructose corn syrup fermentation sorbitol foodstuffs pharma . polyols isosorbide hydrogenation Other sweeteners citric acid lysine xanthan gums itaconic acid & other fermentation products industrial oils lactic acid PLA polymers resins & plastics applications polyesters surfactants pharmaceuticals deicers solvents coatings glycerol food oils feed oils Phytochemicals C-5 Products Xylitol & polyols Bio-diesel Di-acids Epoxides Diols Diacids Polymers Vinyl Monomer Other Products Of Fermentation
- 10. Building the Biorefinery Current Portfolio Biomass Feedstock Starch Cellulose Lignin Hemi-Cellulose Oil Industrial Starches Protein Xylose Arabinose Glucose Liquid Fuels (EtOH) Lactic Acid PLA Xylitol Arabinitol Succinic Acid Itaconic Acid PG and EG 1,3-PDO Esters Isosorbide PG and EG 3-HP (Acrylic Acid) Liquid Fuels (EtOH) Polyols Pyrolyis Oil Gasification Animal Feed
- 11. Current Status of Ethanol Dry Mills Economics can be difficult Current ethanol facilities are limited to only two products, ethanol and DDG Economics are highly dependent of value of the co-product DDG Significant energy costs are associated with the drying of DDG Markets for DDG are not always favorable and will deteriorate as additional ethanol facilities come on line
- 12. Strategies for Creating Additional Value Modify dry mills to include a quick steeping process that allows germ recovery Add an intermediate filtration process to recovery non-starch derived sugars (hemicellulose) Develop new fermentations for utilization of five carbon sugars (itaconic acid, succinic acid, etc) Develop new chemistry to produce value added products from hemi-cellulose (sugar alcohols, polyols) Include an energy component-gasify “DDG or modified DDG” to produce fuel gas
- 13. Current Ethanol Process Corn Dry Grind Liquefaction Scarification Fermentation Primary Distillation Distillation Rectifier Molecular Sieves Centrifuge Triple Effect Evaporator DDG Dryer DDG Animal Feed Ethanol Solids 50% EtOH 95% EtOH 100% EtOH Liquids Water Recycle Solids
- 14. The Holistic Ethanol Facility Corn Quick Steep Scarification Filtration Fermentation Ethanol Recovery Molecular Sieves “ Fiber” Hydrolysis New DDG Animal Feed Ethanol Starch EtOH 95% EtOH 100% EtOH Germ Separation Fermentation Catalytic Conversions Gasification Fuel/Power EG, PG Glycerol, Etc Itaconic Succinic, Etc Oil
- 15. The New Ethanol Bio-Refinery Build a bio-refinery based on creating the maximum value from each component associated with the feedstock Includes a fuel component, energy component, and value added products component Will allow for expansion of ethanol utilization based on solid economics Energy independence for the facilities could be critical to financial stability Be the model to build future lignocellulosic facilities
- 16. Chemicals and Materials Analysis Used the current petrochemical refinery as a model Surveyed over 350 chemical/material opportunities Reduced initial 350 to 30 Reduced 30 to 12 based primarily on the following: Economic considerations Technical considerations Building block strategies
- 18. 5-Carbon Building Blocks C5 Itaconic acid Furfural Levulinic acid Glutamic acid Xylonic acid Xylitol/Arabitol Methyl succinate derivatives (see above), unsaturated esters Many furan derivatives -aminolevulinate, 2-Methyl THF, 1,4-diols, esters, succinate EG, PG, glycerol, lactate, hydroxy furans, sugar acids Amino diols, glutaric acid,substituted pyrrolidones Lactones, esters
- 19. Itaconic Acid Itaconic acid 3-Methyl THF 2-Methyl-1,4-BDO 3- & 4-Methyl-GBL 2-Methyl-1,4-butaneiamine Itaconic diamide 3 - & 4-Methyl NMP And other pyrrolidones 3-Methylpyrrolidine Styrene-butadiene copolymers
- 20. Chemicals and Materials ‘Top Ten” Analysis Mapping the potential for chemicals and materials from platform outputs ChemicalsFutureDiagram . ppt Future activities will include working with industry to identify areas of needed R&D Includes solicitations Includes core R&D activities
- 21. Value-Added Building Blocks Derived From Sugars xylitol/arabinitol sorbitol glycerol 3-hydroxybutyrolactone levulinic acid itaconic acid glutamic acid glucaric acid aspartic acid 3 hydroxy propionic acid 2,5 furan dicarboxylic acid 1,4 succinic, fumaric and malic acids Building Blocks
- 22. Key Technology Hurdles for Products Fuels Improved fermentation of five carbon sugars More robust fermentations that withstand the impurities from pretreatment Mixed fermentations Fermentation rates
- 23. Key Technology Hurdles for Products Chemicals and Materials Fermentations Reduce the cost of both aerobic and anaerobic fermentations Robustness of fermentations needs to be improved Increase productivity of organisms New engineering solution for aerobic fermentations
- 25. Key Technology Hurdles for Products Chemicals and Materials Catalysis More selective catalysts are required Aqueous phase catalysis Catalyst robustness-improved resistance to fouling Overall rates need to be improved
- 26. Key Technology Hurdles for Products Combined Heat and Power Integration is key driver How does excess power get transferred to the existing grid system
- 27. On the DOE Horizon Major solicitations in FY04 University led solicitation for fundamental research—up to 5 million dollars Industry led solicitation for products—up to 10 million dollars Major planned solicitations for FY05 Focused on a forest products biorefinery Funding level TBD