Biochemical Conversion - University of IL · PDF fileGasification . Syngas . ... Combined Saccharification & Fermentation Time (d) 7 ; 7 . 7 ; 5 . 3 ; 3 . ... Integrated biochemical

S-1041 Symposium on Conversion Technologies for Biofuels

Biochemical Conversion at the DOE

August 3, 2010

Energy Efficiency & Renewable Energy eere.energy.gov

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• Expanding and diversifying the portfolio to include renewable hydrocarbon fuels – Leveraging bio- and thermochemical conversion technology developments from

cellulosic ethanol to other advanced biofuels as well as products and power • Deploying first-of-a-kind facilities and encouraging strong industry partnerships

• Program Targets: (At a modeled cost for mature technology) – $1.76/gallon cellulosic ethanol by 2012 – $2.85/gallon renewable gasoline by 2017 – $2.84/gallon renewable diesel by 2017 – $2.76/gallon renewable jet by 2017

Strategic Focus

Feedstock Supply

Biofuels Production

Biofuels Distribution

Biofuels End Use

Crosscutting Activities Analysis, Sustainability, Strategic Partnerships, Stakeholder Communications and Outreach


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Biomass Program Budget

$0

$50

$100

$150

$200

$250

$300

$350

$400

FY11*FY10FY09FY08FY07FY06FY05

Mill

ions

Earmarks

Cellulosic Ethanol Reverse Auction

Analysis and Sustainability

Large Scale Biopower

Integration of BiorefineryTechnologiesProducts Development

Algal Conversion

Algal Feedstocks

Biochemical Platform R&D

Thermochemical Platform R&D

Feedstock Infrastructure

*Requested

$0

$100

$200

$300

$400

$500

$600

$700

$800

ARRAFY10

Mill

ions

Mill

ions


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Recovery Act Funding and Initiatives $800 Million in Funding to Biomass Program

$509M Pilot and Demonstration-Scale Biorefineries Validate technologies for integrated production of advanced biofuels, products, and power to enable financing and replication. In 2009, DOE selected

- 12 pilot-scale projects for up to $25M each - 4 demonstration-scale projects for up to $50M - 2 research and development projects for $2.5M each $82M Commercial-Scale Biorefineries

Increase in funding for one previously awarded project to expedite construction and accelerate commissioning and start-up

$107M Fundamental Research $18M: Integrated Process Development Unit

$5M: Sustainability research with Office of Science, National Laboratory, university, and USDA partners $35M: National Advanced Biofuels Consortium to accelerate demonstration

$49M: National Alliance for Advanced (Algal) Biofuels and Biofuels Products Consortium to accelerate demonstration $20M Ethanol Infrastructure Research

Optimize flex-fuel vehicles operating on E85 Evaluate impacts of intermediate blends on conventional vehicles Upgrade existing infrastructure for compatibility with E85

$14M NREL Integrated Biorefinery Research Facility: expand the pretreatment capacity $68M SBIR and Program Direction

http://recovery.gov/


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R E

F I

N I

N G

Exploring Routes to Convert Biomass

Integrated Biorefineries

Research on multiple conversion pathways aims to improve the efficiency and economics of bioenergy production.

Feedstock Production & Logistics • Energy

crops • Forest

Residue • Agricultural

wastes • Algae

Ethanol Butanol Olefins Gasoline Diesel Others

DDGS

Lignin (for power)

Thermochemical Conversion

Fast Pyrolysis

Gasification Syngas Fischer Tropsch Alcohol Synthesis

Liquid Bio-oil

Zeolite Cracking Hydrogenolysis

Upgrading

Enzymatic Hydrolysis

Pretreatment & Conditioning

Enzyme Production

Sugars Fermentation

Distillation Biochemical Conversion

By-Products Wastes/Residue

Lipid (Oil) Extraction

Algal Oil

Transesterification Fractionation


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Biochemical Platform

• Current Target: • Reduce the estimated mature technology

processing cost of ethanol from cellulosic feedstocks to $0.92 per gallon in 2012 (modeled)

• Major Changes: • Broadened unit operations to be more inclusive.

• Biological Processing • Chemical Processing


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FY10 Accomplishments

2007 2008 2009 2010 2011 2012 Minimum Ethanol Selling Price ($/gal) $2.69 $2.61 $2.40 $1.92 $1.68 $1.49 Feedstock Contribution ($/gal) $0.97 $0.90 $0.81 $0.64 $0.60 $0.57 Conversion Contribution ($/gal) $1.72 $1.71 $1.59 $1.28 $1.08 $0.92 Yield (Gallon/dry ton) 72 73 77 83 87 90 Feedstock Feedstock Cost ($/dry ton) $69.60 $65.30 $62.05 $53.70 $52.00 $50.90 Pretreatment Solids Loading (wt%) 30% 30% 30% 30% 30% 30% Xylan to Xylose (including enzymatic) 75% 75% 84% 85% 88% 90% Xylan to Degradation Products 13% 11% 6% 6% 5% 5% Conditioning Ammonia Loading (mL per L Hydrolyzate) 50 50 38 38 35 25 Hydrolyzate solid-liquid separation yes yes yes yes yes no Xylose Sugar Loss 2% 2% 2% 2% 1% 1% Glucose Sugar Loss 1% 1% 1% 1% 1% 0% Enzymes Enzyme Contribution ($/gal EtOH) $0.35 $0.35 $0.35 $0.17 $0.12 $0.12 Enzymatic Hydrolysis & Fermentation Total Solids Loading (wt%) 20% 20% 20% 20% 20% 20% Combined Saccharification & Fermentation Time (d) 7 7 7 5 3 3 Corn Steep Liquor Loading (wt%) 1% 1% 1% 1% 0.60% 0.25% Overall Cellulose to Ethanol 85% 85% 84% 85% 85% 85% Xylose to Ethanol 76% 80% 82% 82% 85% 85% Minor Sugars to Ethanol 0% 0% 51% (arab.) 80% 85% 85%

Biochemical Platform State of Technology


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High Impact Research Areas

•Barrier: Low C5 sugars conversion – Ethanologen Solicitation (up to $23 million)

• Objective: Drive to more robust to temperature and ethanol concentration organisms

• Goal: Increase microorganism productivity and use of pentose sugars

• Performers: Cargill, DuPont, Mascoma, Purdue, Verenium, NREL

•Barrier: High enzymatic conversion costs – Enzyme Solicitation (up to $33.8 million)

• Objective: Creating highly effective, inexpensive enzyme systems for commercial biomass hydrolysis

• Goal: Utilize pretreated cellulosic feedstocks and maximize production of glucose and xylose yields by developing a more robust enzyme

• Performers: Danisco (Genencor), DSM (Sandia, Las Alamos), Novozymes, Verenium, NREL


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Solids: Baseline 17.5% 17.5% 17.5% 17.5% 20% 20% 20% 20% Organism: 8b 8b ZW705 ZW705 8b 8b ZW705 ZW705 Enzyme: Enzy. A Enzy. B Enzy. A Enzy. B Enzy. A Enzy. B Enzy. A Enzy. B

Yield

Cellulose to Glucose Xylose to Ethanol Higher Cellulose Conversion w/ Enzyme B

Enzyme B Insensitive to Solids Loadings

Xylose Ferm. Improves w/new Innoc.

Higher Xylose Conversion w/ZW705

Strains Sensitive to Solids Loadings

Yield $/gal

Solids: Baseline 17.5% 17.5% 17.5% 17.5% 20% 20% 20% 20% Organism: 8b 8b ZW705 ZW705 8b 8b ZW705 ZW705 Enzyme: Enzy. A Enzy. B Enzy. A Enzy. B Enzy. A Enzy. B Enzy. A Enzy. B

Ethanol Yield MESP Improved Ethanol Yields in all cases

Yield Sensitive to Solids Loading

Improved MESP in all cases

Solids Loading Trade-off in MESP

20%, ZW705, Enzyme B used in SOT

Enzymatic Hydrolysis/ Fermentation Improvements


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•Barrier: Seamless process integration – Objective: Identify and address potential integration

issues at bench and pilot scale to ensure unit operations work in sequence

– Goal: Integrated biochemical conversion processes – Performers: NREL, ANL, Ethanologen and Enzyme

award winners

•Barrier: Enabling a smooth transition between fundamental and applied research activities – Objective: Fund directed fundamental activities that

directly support the research barriers identified previously

– Goal: Bridge the gap between fundamental and applied R&D

– Performers: NREL, PNNL, University and USDA/DOE Joint Solicitation awardees

High Impact Research Areas


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Integration

• Strict performance tables in Enzyme & Ethanologen contracts • Validation efforts • Biomass process integration task (NREL)

• Back end concerns (proposed switch from Lime to Ammonia Conditioning): • Much simpler process; no solid-liquid separations required and minimal sugar losses • Extra removal steps may be required for ammonium and sulfate coming from pretreatment, and potassium coming in with the feedstock

• The primary research plan is to reduce chemical usage in pretreatment and conditioning


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NABC Research Strategies

Consortium Leads: NREL, PNNL Consortium Partners: Albemarle, Amyris, ANL, BP Products, Catchlight, Colorado School of Mines, Iowa State Univ., LANL, Pall, RTI, Tesoro, UC Davis, UOP, Virent, Washington State Univ.

1 3 2 6 4 5

NABC matrix of technology and strategy teams will ensure development of complete integrated processes.

Project Objective: Develop cost-effective technologies that supplement petroleum-derived fuels with advanced “drop-in” biofuels that are compatible with today’s transportation infrastructure and are produced in a sustainable manner.

ARRA Funded: DOE Funding $33.8M/Cost Share $12.5M over 3 years


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NABC Barriers

• Each of the six strategies comprises multiple processing pathways that address key technology barriers which can be combined in innovative ways to meet the objectives of the project.

• The NABC brings together a cross-disciplinary team with a diverse skill set to carry out targeted research.

Six Initial Strategies Proposed By NABC


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Future Thrusts

• Continued pretreatment and enzyme hydrolysis integration

• Continued lowering/stabilizing enzyme costs and understanding enzyme companies' marketing strategy

• Moving beyond fermentation to ethanol technologies, requiring a need to develop: •Alternative fermentative organisms

• New routes need to be analyzed for potential research • New Targets must be developed

•Catalysts • New routes need to be analyzed for potential research • New Targets must be developed

•Other bio/chemical conversion routes


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Integrated Biorefinery (IBR) Description IBR Scale Description Feedstocks Fuel/Product

R&D 2 projects

Includes R&D and a preliminary engineering

design

Poultry Fat, Woody Biomass, Ag Residue,

Algal Oil

Renewable Fuels, Renewable Gasoline,

Renewable Diesel

Pilot Scale 12 projects

Processes a minimum of 1 dry tonne per day biomass and verifies the integrated performance of the given suite of technologies from both a technical and an

economic perspective for the first time

Algae, CO2, Woody Biomass, Sweet

Sorghum, Corn Stover, Switchgrass, Energy

Sorghum, Ag and Forestry Residue,

Hybrid Poplar

Ethanol, Cellulosic Ethanol, Renewable

Diesel, Jet Fuel, Renewable Diesel

Demonstration Scale

9 projects

Working with projects to verify technologies from a

technical and an economic perspective

at a scale sufficient for a commercial facility

Wheat Straw, Corn Stover, Poplar

Residues, Woody Biomass, Algae, Mill

Residues, MSW, Ag and Forestry Residue

Cellulosic Ethanol, Renewable Sulfur-Free Diesel Fuel, Renewable

Hydrocarbon Based Fuel, Renewable

Gasoline, Renewable Diesel, Jet Fuel,

Succinic Acid

Commercial Scale

6 projects

Processes a minimum of 700 dry tonnes per day biomass and refers to a first-of-a-kind or “beta”

commercial facility

Lignocellulosic Biomass, Corn Cobs, Woody Biomass, Mill Waste, Sorted MSW

Cellulosic Ethanol, Ethanol, Methanol


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Feedstock Conversion Intermediate Conversion Product Performer

Agricultural Residues

biochemical

gasification

pyrolysis oil

syngas

sugar

catalysis

fermentation ethanol

diesel

Abengoa, Poet, Verenium, ADM

Ineos

REII

Forest Resources

biochemical

gasification

pyrolysis oil

syngas

sugar

catalysis

fermentation ethanol

gasoline diesel jet fuel

Lignol, Mascoma, Pacific Ethanol RSA, API, Zeachem, Blue Fire

Range Fuels

Haldor Topsoe Clear Fuels New Page, Flambeau

Energy Crops / Grasses/

biochemical

Sugar

fermentation

ethanol

diesel

ICM, Logos

Amyris

GTI, UOP

succinic acid Myriant



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Feedstock Conversion Intermediate Conversion Product Performer

Algae

open pond

Closed bioreactor

oil

ethanol

diesel jet fuel

Sapphire

Solazymes

Algenol

catalysis diesel jet fuel

catalysis

oil transesterification biodiesel

metathesis diesel jet fuel

Elevance

MSW gasification syngas catalysis ethanol Enerkem



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Integrated Biorefinery Projects

For more information visit: http://www1.eere.energy.gov/biomass/integrated_biorefineries.html

http://www1.eere.energy.gov/biomass/integrated_biorefineries.html


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Extra Slides EXTRA SLIDES


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Approach


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Department of Energy Priorities and Goals

Science & Discovery • Connecting basic and applied

bioscience • Conducting breakthrough R&D:

− Advances in enzymes and catalysts fermentation

− Engineering of new microorganisms

Clean, Secure Energy • Developing & demonstrating

cellulosic and advanced biofuels, biorefineries and systems to support the Renewable Fuels Standard

"Developing the next generation of biofuels is key to our effort to end our dependence on foreign oil and address the climate crisis -- while creating millions of new jobs that can't be outsourced. With American investment and ingenuity -- and resources grown right here at home -- we can lead the way toward a new green energy economy."

Secretary of Energy Steven Chu Advancing Presidential Objectives

Economic Prosperity • Creating 50 to 75 jobs per new biorefinery

(based on commercial-scale facilities) • Reinvigorating rural economies • Supporting the emerging U.S. bioenergy

industry and market

Climate Change • Reducing GHG emissions by 60% for

cellulosic biofuels and 50% with advanced biofuels (relative to gasoline)

• Validating and demonstrating low-carbon power generation technologies

• Influencing development of criteria and indicators for sustainable biofuel production


23 Source: Energy Information Administration, “Petroleum Explained” and AEO2009, Updated (post-ARRA), Reference Case.

• Advanced biofuels and products are needed to displace the entire barrel • Heavy duty/diesel and jet fuel substitutes are needed to displace other components of the barrel • Cellulosic ethanol displaces light duty gasoline fraction only

Displacing a Barrel of Crude


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0 5 10 15 20 25 30 35 40

2012

2015

2022Renewable Fuel Standard (RFS2)

Production Targets (Billions of Gallons)

EISA defines Advanced Biofuel as “renewable fuel, other than ethanol derived from corn starch, that has lifecycle greenhouse gas emissions…that are at least 50 percent less than baseline lifecycle greenhouse gas emissions.” This includes biomass-based diesel, cellulosic biofuels, and other advanced fuels such as sugarcane-based ethanol.

Conventional (Starch) Biofuel Biomass-based diesel Cellulosic Biofuels Other Advanced Biofuels

Advanced Biofuels (include cellulosic biofuels other

than starch-based ethanol)

EISA Mandated Biofuel Production Targets

15 BGY cap on conventional (starch) biofuel

EISA defines Cellulosic Biofuel as “renewable fuel derived from any cellulose, hemicellulose, or lignin that is derived from renewable biomass and that has lifecycle greenhouse gas emissions…that are at least 60 percent less than baseline lifecycle greenhouse gas emissions.” The EPA interprets this to include cellulosic-based diesel fuel.


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Biomass-to-Bioenergy Supply Chain

Cross-cutting Life cycle analysis of water consumption and greenhouse gas emissions; land use change modeling; water quality analysis of biofuels

Environmental Sustainability

Economic Sustainability

Social Sustainability

Feedstock Supply

Conversion Distribution End Use

Field-based research to

evaluate nutrient and carbon

cycling

Collecting biomass physical

and chemical properties

impacting land use sustainability

Monitoring and improving the

carbon footprint of new

facilities; promoting co-

product utilization and fully integrated

systems

Ensuring minimal

greenhouse gas emissions and avoidance

of negative impacts on

human health

Minimizing water consumption and

air pollution, maximizing efficiency

Our Commitment to Sustainability

Develop and invest in the resources, technologies, and systems needed for biofuels to grow in a way that enhances the health of our environment and protects our planet.


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Biomass Research and Development Board • Created by Congress in 2000 to coordinate and maximize benefits

of federal R&D programs that promote biofuels and bioproducts • Has issued several reports and plans, including National Biofuels

Action Plan, as a result of interagency collaborations to identify RD&D challenges, and make recommendations to mitigate them

• Has identified several new areas for further collaboration, including genetic modification of feedstocks, logistics, anthropogenic carbon cycle, and conversion technologies

Members

• Department of Agriculture (co-chair) • Department of Energy (co-chair) • National Science Foundation • Environmental Protection Agency • Department of the Interior • Office of Science and Technology Policy • Department of Transportation • Department of Defense

Draft and Issued Reports

National Biofuels Action Plan

Occasional Paper No. 1 - Economics of Biomass Feedstocks in the US: Review of the Literature

Increasing Feedstock Production for Biofuels: Economic Drivers, Environmental Implications,

and the Role of Research

Sustainable and Adequate Biofuel Feedstock Production: Recommendations for Federal Research and Development

Feedstock Logistics: Recommendations for Research and Commercialization

Conversion: Challenges for Federal Research and Commercialization

Pipeline Feasibility Analysis

• Synopsis on GIS Inventory • Synopsis on Multi-Modal Analysis


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Feedstock Supply R&D Regional Feedstock Bioenergy Crop Trials

http://www1.eere.energy.gov/biomass/pdfs/field_trials_map2v2.pdf


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Feedstock Logistics

• Deployable Process Demonstration Unit (PDU) to bridge gap between producers and refineries

– The PDU will allow biorefinery partners to test supply system concepts and reduce feedstock supply risks and allow equipment partners to test new designs and deploy new technologies in the context of an integrated supply system.

– Will produce engineered feedstocks that meets commodity-scale performance metrics and advanced conversion characteristics.

• Ongoing feedstock logistics projects are developing systems to better handle and deliver high tonnage biomass feedstocks (August 2009 awards)

– Agco Corporation of Duluth, GA (up to $5 million) for agricultural residues – Auburn University of Auburn, Alabama (up to $4.9 million) for woody biomass – FDC Enterprises Inc. of Columbus, Ohio (up to $4.9 million) for energy crops – Genera Energy, LLC of Knoxville, Tennessee (up to $4.9 million) for energy crops – The SUNY College of Environmental Science and Forestry of Syracuse, New York (up to

$1.3 million) for woody biomass


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Algal Biofuels: Range of Feedstocks, Systems, Processes, and Products


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Conversion and End-use

• Process optimization • Thermochemical • Biochemical

• Fuels characteristics • Co-Products

• Energy efficient harvesting and dewatering systems

• Biomass extraction and fractionation

• Product purification

• Cultivation system design • Temperature Control • Invasion and fouling

•Cultures • Growth, stability, and resilience

• Input requirements •CO2, H2O sources, energy •Nitrogen and phosphorous

•Siting and resources

Algal Biofuel Systems: Technical Challenges

Biology and Cultivation

Biomass Harvesting and

Recovery

A nano-membrane filter being developed by a NAABB partner.

A gasifier being used by a NAABB partner to convert algal biomass to fuels


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Biopower

Launch a new DOE initiative to accelerate, develop and deploy advanced biopower technologies over the next six years. Initiative will establish partnerships with industry and support efforts to:

• Conduct R&D on advanced pretreatment and conversion technologies by 2013

• increase overall efficiency • improve environmental performance • decrease cost of biopower electricity

• Support pilot scale projects up to 10 MGW

• Demonstrate utility scale, biomass repowering and high percentage co-firing (up to 25% biomass) with coal by 2016 up to 100 MGW


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Key Stakeholder Relationships DOE Bioenergy Research Centers (BRCs)

Targeting breakthroughs in biofuel technology to make abundant, affordable, low-carbon biofuels a reality by:

− Developing novel enzymes for switchgrass degradation at the Joint BioEnergy Institute (LBNL)

− Reducing the cost of pretreatment requirements through the use of thermophilic microbes and/or enzymes for the conversion of biomass at the Bioenergy Science Center (ORNL)

− Understanding soil microbial community structure for biomass crop growth on marginal lands at the Great Lakes BioEnergy Research Center (Univ. of WI)

http://www.news.wisc.edu/bioenergy/images/GL-Research-center-model-graphic.jpg


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Biofuels Interagency Working Group

• President Obama established the

Working Group in 2009 • Coordinate existing policies, and

identify new policies, to support the development of sustainable next-generation biofuels production

• Developed Growing America’s Fuel strategy, issued February 2010

• In the process of further developing key objectives and beginning to conduct interagency assessment of existing biofuels and transportation policy framework to make recommendations for future action

• Co-chaired by DOE, EPA, USDA


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Infrastructure

*Task Force on Biofuels Infrastructure, National Commission on Energy Policy, April 14, 2009.

Distribution Patterns – Gasoline and Ethanol* Working with DOE Vehicle Technologies, and various offices at DOT, Infrastructure activities include:

• Research on the effects of Intermediate Ethanol Blends (E15 and E20)

• Deploying E85/Blender Pumps at retail stations nationwide

• Testing pipeline compatibility issues and analyzing the feasibility of a new dedicated pipeline

• Research on the testing, certification, and approval for commercial use of new biofuels and biofuels blends

Whereas petroleum infrastructure is designed largely to transport gasoline from the Gulf Coast toward the interior of the country, ethanol must be transported from the Midwest to major product demand centers along East and West Coast of the United States.


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Recent Funding Opportunities

Upgrading of Biomass Fast Pyrolysis Oil (Bio-oil) Funding: Up to $11,000,000 total Close Date: 07/09/2010, Applications under review This funding is to develop integrated upgrading processes of bio-oil.

Biomass Research and Development Initiative Funding: up to $33 million Close Date: 07/13/2010, Applications under review This is a joint effort between the U.S. Department of Agriculture and the U.S. Department of

Energy to support funding for research and development of technologies and processes to produce biofuels, bioenergy and high-value biobased products

Development of Methodologies for Determining Preferred Landscape Designs for

Sustainable Bioenergy Feedstock Production Systems at a Watershed Scale Funding: Approximately $5,000,000 Close Date: 07/16/2010, Applications under review This funding is for research focused on sustainable production of large quantities of non-food

biomass for bioenergy

Upcoming announcements are expected on biopower and additional broad bioenergy areas of focus in 2011

For More Information visit: www.fedconnect.net/FedConnect or www.grants.gov

https://www.fedconnect.net/FedConnect

http://www.grants.gov/

Documents

Biochemical Conversion - University of IL · PDF fileGasification . Syngas . ... Combined Saccharification & Fermentation Time (d) 7 ; 7 . 7 ; 5 . 3 ; 3 . ... Integrated biochemical