S-1041 Symposium on Conversion Technologies for Biofuels
Biochemical Conversion at the DOE
August 3, 2010
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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
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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
Integrated Biorefineries
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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
Integrated Biorefineries
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Integrated Biorefinery Projects
For more information visit: http://www1.eere.energy.gov/biomass/integrated_biorefineries.html
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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
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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)
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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