2005 OBP Bi-Annual Peer Review Biorefinery Project Overview

Neil P. RossmeisslU.S. Department of Energy

Energy Efficiency and Renewable EnergyOffice of the Biomass Program

Barriers for Technology

BasicR&D

Technology Development

Commercially Viable Demo

Permitting &Engineering

Proof of Concept Construction Operation

Co

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First Commercial Plant Me

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Att

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De

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Operation

80% / 20% 50% / 50% 20% / 80% Loan Guarantee Program/Risk Mitigation Pool

“A” Milestone AchievedTechnical Risk Minimized

Dev

elo

pm

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Co

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100% / 0%

Current BiorefineryProjects

Procurement

Private Cost-Share:OBP Cost-Share:Project Timeline:

Development Stages:Unexpected Cost:

Risk Mitigation:

Potential FutureOBP/EERE Deployment Efforts(to overcome financial barriers)

The Holistic Ethanol FacilityThe Holistic Ethanol Facility

Corn Quick Steep Scarification

Filtration Fermentation EthanolRecovery

MolecularSieves

“Fiber” HydrolysisNew DDG

Animal FeedEthanol

StarchEtOH 95%

EtOH100%EtOH

GermSeparation

Fermentation

CatalyticConversions

Gasification

Fuel/PowerEG, PG

Glycerol, Etc

ItaconicSuccinic, Etc

Oil

Value Added ProductsValue Added Products

grindcornglucose

fermentationethanol

starch enzymatichydrolysis

hemicellulose enzymatic hydrolysis

DDG(feed)

celluloseproteinLignin

Fats/oilsfilter

arabinaric acidxylaric acid

•enzymes •itaconic acid•diammonium

succinate•succinic acid

other acids/monomers

.

.

.monomers and high value solvents-butyrolactone (GBL)1,4-butanediol2-Pyrrolidinone N-methyl -2-pyrrolidinone (NMP)N-vinyl -2-pyrrolidinone3-methyl pyrrolidinone derivatives3-methyl -THF

polyhydroxyamides chelatorsmonomers

fermentationHydro -

genation

oxidation

filter

arabinosexylose

grindcornglucose

fermentationethanol

starch enzymatichydrolysis

hemicellulose enzymatic hydrolysis

DDG(feed)

celluloseproteinLignin

Fats/oilsfilter

arabinaric acidxylaric acid

•enzymes •itaconic acid•diammonium

succinate•succinic acid

other acids/monomers

.

.

.monomers and high value solvents-butyrolactone (GBL)1,4-butanediol2-Pyrrolidinone N-methyl -2-pyrrolidinone (NMP)N-vinyl -2-pyrrolidinone3-methyl pyrrolidinone derivatives3-methyl -THF

polyhydroxyamides chelatorsmonomers

fermentationHydro -

genation

oxidation

filter

arabinosexylose

ethylene glycolpropylene glycolglycerol

hydrogenationhydrogenolysis

“Generic Model”

Agricultural Sector Biorefinery Pathways

Program “A” MilestonesFeedstocksBiorefinery Pathway

Conversion Pathway Options Under

Consideration (each has a IndustrialPartners

B Milestone - cost target )•Aventine•Nature Works, LLC

Corn Grain

Residual Starch Conversion Fiber Conversion New Fractionation Process Products from C 5/C6 Sugars Products from Oils

Complete systems level demonstration and validation of

technologies to improve corn wet mill facilities using

corn grain feedstock

Residual Starch Conversion DDG Conversion New Fractionation Process Products from C 5/C6 Sugars

•Abengoa•Broin•Dupont

Complete systems level demonstration and validation of

technologies to improve corn dry mill facilities using

corn (and other ) grain feedstock

Other Grains

Complete systems level demonstration and validation of

technologies to improve natural oil processing facilities

using oil crop feedstock

Oil Crops

Products from Oils

Corn

Stover Small Grain

Straw Rice Straw

•Abengoa•Dupont•Cargill•Nature Works LLC

Complete systems level demonstration and validation of

technologies to improve processing facilities using

agricultural residue feedstocks

Biomass Sugar Production Products from C 5/C6 Sugars Products from Lignin Biomass Gasification Products from Synthesis Gas New Fractionation Processes Products from New Process

Intermediates

Complete systems level demonstration and validation of

technologies to improve processing facilities using

Perennial Crops

•Chariton Valley•Great Plains Institute•Univ. of Tennessee

Grasses Woody

Crops

Biomass Sugar Production Products from C 5/C6 Sugars Products from Lignin Biomass Gasification Products from Synthesis Gas New Fractionation Processes Products from New Process

Intermediates New Consolidated Processes

•ADM•DOW•Cargill

•ADM•NCGA•Cargill•NCGAWet

andDry Mills

Oil Crops

AgricultureResidues

Perennial Crops

•Rohm & Hass

Fund Solicitations to Overcome Barriers

Cost of LiquidTransportation Fuels

Product YieldProduction Rate

Final ConcentrationProduct Recovery

Capital Costs

OrganismDevelopment

CatalystDevelopment

1st Tier

2nd Tier

3rd Tier

Biological Chemical

Cost of LiquidTransportation Fuels

Cost of LiquidTransportation Fuels

Product YieldProduction Rate

Final ConcentrationProduct Recovery

Capital Costs

Product YieldProduction Rate

Final ConcentrationProduct Recovery

Capital Costs

OrganismDevelopmentOrganismDevelopment

CatalystDevelopmentCatalystDevelopment

1st Tier

2nd Tier

3rd Tier

Biological Chemical

Liquid Fuels

Cost of ChemicalsAnd Materials

Product YieldProduct Purity

Final ConcentrationProduct Recovery

Capital Costs

Organism DevelopmentFermentation DevelopmentEnzyme DevelopmentSeparations

Catalyst DevelopmentSeparations

1st Tier

2nd Tier

3rd Tier

Biological Chemical

Cost of ChemicalsAnd Materials

Cost of ChemicalsAnd Materials

Product YieldProduct Purity

Final ConcentrationProduct Recovery

Capital Costs

Product YieldProduct Purity

Final ConcentrationProduct Recovery

Capital Costs

Organism DevelopmentFermentation DevelopmentEnzyme DevelopmentSeparations

Catalyst DevelopmentSeparations

1st Tier

2nd Tier

3rd Tier

Biological Chemical

Chemicals and Materials

FY2002 Solicitation

Industries Engaged: •Dry Mills•Wet Mills•Chemicals

Technologies Being Developed: •Fractionation•Pretreatment•Hydrolysis•Strain Development •Fermentation •Catalysis•Various Separation Technologies•Harvesting •Storage

Pathways: •Corn Dry Mill Improvements Pathway•Corn Wet Mill Improvements Pathway•Agricultural Residue Pathway

Expected Outcomes: •Chemicals•Fuel•Value-added products

Relevance to Pathways

• Broin: A Second Generation Dry Mill Biorefinery• ADM/NCGA: Separation of Corn Fiber and Conversion to

Fuels and Chemicals• Cargill: New Biorefinery Platform Intermediate Project• Cargill: Making the Industrial Biorefinery Happen• Cargill/MAT: Collection, Commercial Processing and Utilization

of Corn Stover• DuPont: Integrated Corn Based Biorefinery Project• Abengoa: Advanced Biorefining of Distiller’s Grain and Corn

Stover Blends

Congressionally Directed

Industries Engaged: •Dry Mills•Pulp & Paper•Chemicals

Technologies Being Developed: • Pretreatment• Hydrolysis• Gasification • Fermentation • Catalysis• Harvesting • Storage

Pathways: •Corn Dry Mill Improvements Pathway• Pulp and Paper Pathway•Agricultural Residue Pathway• Forest Residue

Expected Outcomes: •Chemicals•Fuel•Value-added products

Relevance to Pathways

• GTI: Commercial Demo of Thermodepolymerization (TDP) Technology, Nevada• MBI: Biorefinery• GTI: Ag Waste Biorefinery using TDP• Mississippi Ethanol Gasification• Iroquois Bioenergy: Corn Dry Mill to Ethanol Plant• AgraPure: Fibrowatt• University of ND: EERC Center for Biomass Utilization• Brazos River: North Central Texas Dairy Waste• Farm Power: Small Scale Waste Energy Demo• Louisiana State: Improved Biorefinery From Sugar Cane• Mount Wachusett: Modular Biopower Micro-Cooling and Power• North Country Hospital: Biomass Cogeneration Project• Georgia Pacific: Demo of Black Liquor Gasification• Sealaska Corp: Southeast Alaska Ethanol Project• Changing World: Ag Mixed Waste Biorefinery • City of Gridley: City of Gridley Biofuels Project

Platform Budget

0%

20%

40%

60%

80%

100%

2004 2005 2006(planned)

Yearly Budget

EarmarksProgramIndustrial Partners

Platform Barriers

Barrier Solution Responsibility

End-to-End ProcessIntegration

Develop methods of collecting, storing, transporting and processing diverse feedstocks

OBP/Industry

Integrate biochemical and thermochemical technologiesOBP

Commercial-scaleDemonstration

Sustained integrated performance Industry

Demonstrated technical, economic, safety and environmental targets OBP

Improved existing and new biorefineriesPolicy/Legislation

Sensors and controls DOE Labs

Technical Risk

Pretreatment Options DOE/USDA Labs

Feedstock Development USDA

ToolsOBP

Commercialization Risk

Probability of failure in new facilities due to unproven technologies Policy/LegislationDOE HQ

Financial investment is high, plants must achieve design capacity quicklyPolicy/LegislationDOE HQ

Goals & Approach

• Complete technology development necessary to enable start-up demonstration of a biorefinery producing fuels, chemicals and power by 2012 at an existing or new corn dry mill.

• Help U.S. industry establish the first large-scale sugar biorefinery based on agricultural residues by 2018.

• Complete technology integration to demonstrate a minimum sugar selling price of $0.64/lb resulting in a minimum ethanol selling price of $1.09/gal by 2020 from ag residues or dedicated perennial energy crops.

• Complete the technology integration of thermochemical processes into a sugar biorefinery to produce syngas at $3.84/MMBtu by 2030 from lignin or wood feedstocks.

Key Accomplishments

• Development and demonstration of a new front-end pretreatment operation for a dry mill by Broin that increases the ethanol yield and produces more valuable high protein animal feed.

• Demonstrated a pilot plant by ADM and the NCGA at NREL to scale-up bench results to define operating parameters involved in integrating processes into existing corn wet mills.

Presentation Agenda

• Integrated Biorefinery Analysis: Bob Wallace, NREL• Integrated Corn-Based Biorefinery: Bill Provine, DuPont• Making Industrial Biorefinery Happen:Bob Wooley, NatureWorks LLC

Break• Collection of Corn Stover: David Glassner, NatureWorks LLC• New Biorefinery Platform Intermediate: Jim Millis, Cargill Inc.• Second Generation Dry Mill: Steve Lewis, Broin & Associates

Lunch• Advanced Biorefining of DDG and Corn Stover: Patrick Mulvihill, Abengoa

Bioenergy• Separation of Corn Fiber and Conversion to Fuels and Chemicals: Nathan

Fields, NCGABreak

• Demonstration of BLG at Big Island: Larry Rath, NETL• Southeast Alaska Ethanol: Fran Ferraro, Merrick• City of Gridley Biofuels: Dennis Schuetzle, TSS Consultants