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NREL is a na*onal laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.
Cellulosic Biofuels Development and Commercializa6on Progress in the
United States of America
James D. (Jim) McMillan, Ph.D.
Bioenergy Australia Webinar
NREL, Golden, Colorado, USA
21 July, 2015 (20 July in Golden)
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Outline • Task 39 overview • Cellulosic biofuels op6ons and barriers • Progression of cellulosic ethanol technology development and commercializa6on o An example of the powerful results sustained research focus and funding can achieve
• Status of hydrocarbon biofuels development • Summary and outlook
3
IEA Bioenergy Task 39 – Objectives § “To facilitate commercialization of conventional and advanced liquid
biofuels from biomass”
§ Collaboration between 15 countries § Analyze policy, markets and sustainable biofuel implementation § Catalyze cooperative research and development § Ensure information dissemination & outreach with stakeholders § Focus on Technical and Policy issues
POLICY AND IMPLEMENTATION TECHNICAL ANALYSIS AND ASSESSMENT
Catalyze Cooperative
Research
State of Technology &
Trends Analysis
Policy, Market and
Deployment Analysis
Biofuel Deployment
and Information Sharing
IEA Bioenergy Task 39 Liquid biofuels focus 15 member countries 2013-‐2015 www.Task39.org
4
Norway -‐ Karin Oyass, Judit Sandquist, Gisle Johansen, Berta Guell
Denmark -‐ Michael Persson, Claus Felby, Henning Jorgensen, Anders Kristoffersen
Germany -‐ Franziska Mueller-‐Langer, Nicholaus Dahmen
The Netherlands -‐ John Nee\
South Korea – Jin Suk Lee, Kyu Young Kang, Seonghun Park
Canada -‐ Jack Saddler, Warren Mabee, Stan Blade
United States -‐ Jim McMillan
Australia -‐ Les Edye
Austria – Dina Bacovsky
Japan -‐ Shiro Saka, Kazumichi Uchida
South Africa -‐ Emile van Zyl, Bernard Prior
Sweden – Alice Kempe, Maria Nyquist, Jonas Lindmark
Italy – David Chiaramon6, Alessandra Fra`ni, Stefania Pescarolo
New Zealand – Ian Suckling
Brazil – Paulo Barbosa, Antonio Bonomi, Eduardo Plaae
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Outline • Task 39 overview Ø Cellulosic biofuels op-ons and barriers • Progression of cellulosic ethanol technology development and commercializa6on o An example of the powerful results sustained research focus and funding can achieve
• Status of hydrocarbon biofuels development • Summary and outlook
Cellulosic Biomass to Biofuels Conversion Op6ons, Technical Barriers, and Demonstra6on
and Commercializa6on Progress
7
Thermochem
Cellulosic Biofuels Technology Routes Biochem, Thermochem & Hybrid Approaches
Product Recovery/ Purifica6on, Storage & Distribu6on
Feedstock Supply Logis6cs,
Prepara6on & Handling
Syngas Fermenta6on
Aqueous Phase
Reforming
Biomass Sugars Hydrolysate
Condi6oning / Detoxifica6on
Pretreatment & Enzyma6c Hydrolysis/
Saccharifica6on
Biomass Sugar
Fermenta6on
Biochem
Syngas Cleanup &
Condi6oning/ Tar Reforming
Thermochemical Synthesis Gas Produc6on/ Gasifica6on
Syngas Cataly6c
Upgrading/ Product Synthesis
Gasification
Bio-‐oil Stabiliza6on Pyrolysis
Bio-‐oil Upgrading To Fuel
Pyrolysis
Hybrid ?
8
Alcohols Among Many Biofuels Options Biomass Feedstocks
Lignocellulosic Biomass (wood, agricultural residues, grasses, etc.)
Sugar/Starch Crops (sugar cane, sugar beet, corn, wheat, etc.)
Natural Oils (plants, algae)
Ag residues, (stover, straw, bagasse)
Intermediates
Syn Gas
Bio-Oils
Lignin
Sugars
Gasifica6on
Pyrolysis & Liquefac6on
Hydrolysis
* Blended Products
Transportation Fuels Ethanol &
Mixed Alcohols
Diesel*
Methanol
Gasoline*
Diesel*
Gasoline* & Diesel*
Diesel*
Gasoline*
Hydrogen
Ethanol, Butanol(s), Hydrocarbons
Biodiesel
Green diesel (a.k.a renewable diesel)
Catalytic synthesis
FT synthesis
MeOH synthesis
HydroCracking/ HydroTreating
Aqueous Phase Reforming (APR)
Catalytic pyrolysis
APR
Fermentation or
Biological Conversion
Catalytic upgrading
MTG
Transesterifica6on
Hydrodeoxygena6on
Fermentation
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Interacting Process Steps - Biochemical
Biomass Sugar
Fermentation
Enzymatic Cellulose
Saccharification
Biomass Pretreatment
Amount of cellulose Cellulose crystallinity Available surface area
Amount and nature of lignin Type/amount of hemicellulose
Biomass Feedstock
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Technical Barriers – Biochemical 1. Plant cell wall recalcitrance
Deconstruct secondary cell wall sugar-‐based polymers to fermentable sugars (and lignin?) at high yield and low cost (low energy and other inputs)
2. Carbohydrate heterogeneity Ferment all biomass sugars to ethanol at high yield, i.e., both hexoses (glucose, galactose, fructose and mannose) and pentoses (arabinose and xylose)
3. Process integra*on and scale up Cost effec*vely test/qualify process op*ons; close mass balance; demonstrate process robustness, scalability
Design-Expert® Software
Ethanol Yield
X1 = B: Conditioning X2 = D: Strain
Actual FactorsA: Hydrolysate Strenght = 65.00C: Added Glucose = 100
Neutralization
Ov erliming S.c. D5A
Broin S.c .
Z. m. 8b
P.s.
0
25
50
75
100
E
than
ol Y
ield
(%
)
34
16
47
27
84
82 77
11
USA’s CE Development Timeline (40+ Years!) 1970s – Oil shocks spur search for renewable fuel supply 1990s – Sugars cofermen*ng microbes developed (ethanol) 2000s – Hydroly*c enzyme cost reduced 10-‐20-‐fold 2006 – US admits it’s addicted to oil; aggressively funds cellulosic
ethanol (CE) Integrated BioRefineries (IBRs)
2010s – Scaled up commercial produc*on begins…
12
Cellulosic Ethanol Development Timeline (2) 1970s – Oil shocks spur search for renewable fuel supply 1990s – Sugars cofermen*ng microbes developed (ethanol) 2000s – Hydroly*c enzyme cost reduced 10-‐20-‐fold; 2006 – US admits it’s addicted to oil; aggressively funds cellulosic
ethanol (CE) Integrated BioRefineries (IBRs)
2010s – Scaled up commercial produc*on begins… 2012
- NREL pilots BC (and TC) CE processes, achieving performance consistent with a modeled produc*on cost of $2.15/gallon
Opera-ng condi-ons for NREL’s BC pilot CE demonstra-on – Feedstock: Corn stover (i.e., the agricultural residue a5er harves6ng the corn grain) – Pretreatment: 160°C, 10 minutes, ~0.35% (w/w) H2SO4 acid in aqueous reac6on, in some cases a5er first applying an NaOH alkaline washing “deacetyla6on” step
– Enzyma-c hydrolysis: Novozymes CTec2 cellulase, 20% total solids loading (~12% insoluble solids), 50°C, pH 4.8-‐5.2 controlled with NH4OH
– Fermenta-on: DuPont’s cofermen6ng Zymomonas mobilis A7, 33°C, pH 5.8 controlled with NH4OH, 10% (v/v) inoculum (~0.5 g/L ini6al cell density, dry basis)
13
0
20
40
60
80
100
0.0 24.0 48.0 72.0 96.0 120.0 144.0
Concen
tration (g
/L) Glucose
XyloseArabinoseEthanol
Pilot Process - SHF Concentration Data
Enzyme: Ctec2 loaded at 19 mg cellulase/g cellulose; substan6ally lower w/ Ctec3
24 0 0 48 72 24 48
Enzyma*c Hydrolysis Fermenta*on
Time (h)
SHF mode ≥ 1000 L scale
14
$0.00
$1.00
$2.00
$3.00
$4.00
$5.00
$6.00
$7.00
$8.00
$9.00
$10.00
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Min
imum
Eth
anol
Sel
ling
Pric
e (2
007$
per
gal
lon)
Conversion Feedstock
$3.85 $3.64 $3.57
$3.18 $2.77
$2.56 $2.15
$4.27
$5.33
$6.90
$9.16
Bench Scale -‐ Enzymes
Scale Up Pretreatment
Scale Up Enz Sacch/Ferm
History of CE Technology Improvement
15
Commercial CE Plants (partial list) COMPANY( LOCATION( CELLULOSIC(
FEEDSTOCK(TECHNOLOGY(PLATFORM(
SIZE((MGY)(
Abengoa( Hugoton,(Kansas,(USA( Ag.(residues,(energy(crops( Biochem( 23(
Chemtex( Crescentino,(Italy( Wheat(straw,(Arundo'donax( Biochem( 20(
DuPont( Nevada,(Iowa,(USA( Corn(stover( Biochem( 25(
Enerkem*( Edmonton,(Alberta,(Canada(
Municipal(solid(waste( Thermochem( 10(
Fiberight( Blairstown,(Iowa,(USA( Municipal(solid(waste( Biochem( 6(
GranBio( São(Miguel(dos(Campos,(Alagoas,(Brazil(
Sugarcane(bagasse( Biochem( 20(
Ineos(Bio( Vera(Beach,(Florida,(USA(
Municipal(solid(waste( TCTBC(Hybrid( 8(
POETTDSM( Emmetsburg,(Iowa,(USA( Corn(stover( Biochem( 20(Quad(County(
Corn(Processors( Glava,(Iowa,(USA( Corn(kernel(fiber( Biochem( 2(
Raízen((Iogen)( Piracicaba,(São(Paulo,(Brazil(
Sugarcane(bagasse( Biochem( 10(
( ( ( ( (
Total( ( ( ( 144((*(Market(target(is(ethanol(albeit(near(term(focus(is(methanol;(MeOH(!(EtOH(in(progress.(
Renewable Hydrocarbon (non-‐oxygenated) Biofuels
17
Historical focus on research, development, demonstration and deployment (RDD&D) for ethanol production from lignocellulosic biomass.
Cellulosic Ethanol
Since 2010, focus expanded to include other advanced biofuels such as biobutanol and hydrocarbons from algae and lignocellulosic biomass (e.g., gasoline, diesel and jet biofuels).
Alternative Light-Duty, Diesel and
Aviation Replacement
Fuels
U.S. Department of Energy Bioenergy
Technologies Office
(BETO)
The US DOE forms cost-‐share partnerships with stakeholders to develop, demonstrate, and deploy produc6on technologies for advanced biofuels.
USDOE’s Advanced Biofuels Strategy
18
Source: Energy Information Administration, “Oil: Crude Oil and Petroleum Products Explained” and AEO2009, Updated July 2012, Reference Case. American Petroleum Institute.
• The U.S. spends $400 $200 billion/year on imported oil, of which about 75% finds its way into foreign treasuries as profit: >$1 $0.5 billion/day
• U.S. transporta*on relies almost exclusively on refined petroleum products—95% of U.S. transporta*on energy is derived from crude oil
• Only about 40% of a barrel of crude oil goes toward light duty gasoline (i.e., the main frac*on ethanol can displace)
• Reducing dependence on oil also requires developing technologies to replace diesel, jet, heavy dis*llates, and a range of industrial chemicals and products. Click here for interactive Barrel Widget
Displacing the Whole Barrel of Oil
19
COMPANY( USA(LOCATION(( FEEDSTOCK( TECHNOLOGY( SIZE((KGY)(
Renewable(Energy(Institute(International(
Toledo,(Ohio( Rice(Hulls(and(Forest(Residues( TC<Gasification( 625(
Haldor(Topsoe( Des(Plaines,(Illinois(
Wood(Waste(and(Non<Merchantable(Wood(
TC<Gasification( 345(
Rentech(ClearFuels(Technology(
Commerce(City,(Colorado(
Woody(waste(and(bagasse( TC<Gasification( 151(
(inactive)(
Amyris(Biotechnologies(
Emeryville,(California( Sweet(sorghum( Biochemical( 1.37(
(inactive)(Gas(Technology(
Institute(Des(Plaines,(Illinois(
Wood(waste,(corn(stover,(and(algae( TC<Pyrolysis( NA(
(inactive)(
Sapphire(Energy( Columbus,(New(Mexico( Algae( Algae(+(TC( 1000(
Solazyme( Peoria,(Illinois( Algae( Algae(+(TC( Pilot(Elevance(Renewable(Sciences(
Bolingbrook,(Illinois(
Algae(Oil,(Plant,(and(Animal(Oils( Chemical( NA(
(inactive)(( ( ( ( (
Total( ( ( ( 2122((
USDOE IBR Hydrocarbon Projects
Source: hip://www.energy.gov/eere/bioenergy/integrated-‐biorefineries
Summary and Outlook
21
More than 33 projects awarded since 2007 covering many feedstocks and conversion technologies. These include 6 commercial scale/TRL, 9 demonstra6on scale, 16 pilot scale and 2 bench scale R&D projects.
– 19 ac*ve in 2013, including 11 biochemical, 5 thermochemical and 3 algal technologies. – 16 on cellulosic ethanol, 12 on renewable hydrocarbons, 3 on algal oil, 2 on bioproducts – 5 completed and 5 terminated for lack of technical progress or cost share
Leveraging Industry thru IBR Projects
INEOS IBR Groundbreaking (April, 2011)
33 Projects Products DOE Funds
16 Cellulosic Ethanol $ 694 M
12 Hydrocarbons $ 152 M
3 Algae Oil $ 76 M
2 Bioproducts $ 75 M
Public-‐Private Partnership Leveraging: US DOE’s ≥ $1.1B public investment has achieved ≥ $1.7B industry cost share and helped catalyze several ini*al public offerings (IPOs) (2 issued, 3 planned), venture capital and equity investments (>$344MM), joint ventures (JVs), and mul*ple joint development agreements (JDAs).
22
Recent Developments • Cellulosic Ethanol o Abengoa, DuPont, and POET-‐DSM are progressing their USA commercial CE plant start ups; INEOS Bio restar*ng their plant aoer retrofipng to improve syngas quality.
o DuPont licensing its CE technology to China and Macedonia; no licenses yet announced but agreements to enable this are in place.
• Hydrocarbon Biofuels o Major focus is avia*on biofuels; major route is thermochemical; companies include: – AltAir Fuels (Honeywell UOP’s fast pyrolysis technology) – Fulcrum Bioenergy (gasifica*on of MSW) – Ensyn, Cool Planet
o Technology robustness at scale and economic viability remain to be fully demonstrated.
23
Current Situation • Terrestrial and aqua*c biomass remain our only renewable source of organic carbon; they can also be carbon neutral and even carbon sequestering.
• CE technologies progress shows power of sustained, focused R&D, with mul*ple feedstock x conversion process op*ons now being commercialized o Sugar plasorm approaches dominate but hybrid and thermochemical gasifica*on routes also progressing
• Hydrocarbon biofuels commercializa*on at earlier stage, with algae and TC routes predomina*ng o Compe**ve economics challenged by low petroleum prices
• 2015-‐2016 crucial period to prove CE technology can be successfully commercialized, can reliably operate to achieve techno-‐economic targets o Posi*ve outcomes needed to re-‐frame biofuels’ image and demonstrate that advanced biofuels “can be done right”
24
Outlook • Growth of alcohol and other biofuels technologies requires suppor*ve policies like U.S.’s RFS2 - Needed to ensure a market and encourage investment.
• The cellulosic sugar-‐ethanol plasorm, if it can be proven economical, provides big opportuni*es for developing mul*-‐product biorefineries - What will the higher value/larger volume coproducts be?
• Successes needed to build advocacy for biofuels - Must show that projected “triple boiom line” economic, social, and environmental benefits are real.
• On-‐going drivers and possible game changers - Price of petroleum, value of reducing GHG emissions - Compe**on for feedstock, e.g., for power or products - Availability of lower cost natural gas and hydrogen - Market demand for biofuels, especially ethanol - USA: Changes in ethanol blend limit for non-‐FFVs - USA: E85 pricing / ability to make it a preferred fuel op*on
25
More Information • Na6onal Renewable Energy Laboratory
www.nrel.gov • USDOE’s Bioenergy Technologies Office (BETO)
hap://www1.eere.energy.gov/bioenergy/
• USDOE BETO Peer Reviews (2011, 2013, 2015) www.energy.gov/eere/bioenergy/2015-‐project-‐peer-‐review
• USDOE-‐USDA Biomass R&D Ini6a6ve www.biomassboard.gov
• Alterna6ve Fuels Data Center www.afdc.doe.gov
26
Funding: USDOE EERE BioEnergy Technologies Office (BETO), IEA Bioenergy Task 39 (Liquid Biofuels)
Acknowledgments
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