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ISU Bio economy Initiative
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Transcript of ISU Bio economy Initiative
Impacts already……
Current Status - Ethanol
Source: RFA
1-24-08
Typical Grain Ethanol Plant
CO2Starch
Enzymes
Fermenter
Cooker
Grain
Milling
Distillation
Ethanol
WaterStarch Sugar
Dried Distillers Grains and Solubles(DDGs)
Dried Distillers Grains and Solubles(DDGs)
EthanolEthanol
ISU Extension “Conversations”96 counties, 950 respondents, March ‘2007
Optimism• Jobs
• Livestock expansion
• Improving infrastructure
• Iowa pride
• Increased tax base
• Economic development Value adding Rural revitalization
• Potential for keeping young people in Iowa
Concerns• Increased land costs, input costs, and risk
• Water quality and quantity
• Loss of wetlands and habitat
• Quality of life issues degraded by industrial growth
• Strains on physical infrastructure
• Food versus feed versus fuel
• More consolidation in farming due to higher land prices
“Biggest change for agriculture since the plow”
Facts and FiguresDecember, 2007- 7.3 billion gal/year- 2.5 billion bu. corn/year
In 2008- another 6 billion gal/year comes online- will require additional 2 billion bu/yr Total corn requirement for U.S. ethanol by end of 2008 will be 4.5 billion bu/year
2008 corn supply may not be sufficient to meet food,export, feed, and ethanol demands; corn prices may rise to the point that ethanol production is reduced by 10-15%*
Chris Hurt, Purdue University
Prediction:…….we ain’t seen nothin
yet…….
2007 Energy Bill Mandates36 Billion gallon of ethanol by 2022
21 Billion gallon must come from cellulose
Billion gallons
0
12
24
36
2000 2008 2016 2022
Biomass-based
Total
Corn-based
Source: U.S. DOE
The HUGE Challenge Before Us
• It took 30 years to reach 6 billion gallons per year of grain-based ethanol fuel (using technology known for millennia)
• The new biofuels mandate requires production of 21 billion gallons per year of advanced biofuels within 15 years (and no commercial plants currently exist) 30 years 15 years
6 billion gallons
21 billion gallons
Where will biomass come from?
DOE 1.3 Billion Ton Study*
*Could supply 66% of U.S. transportation fuel
How do we “jump start” the cellulose industry?
2007 DOE Biorefinery Awards=$385M
Source: R. Wisner, ISU
November, 2006
$76 M
$33 M
$40 M
$80 M
$80 M
$80 M
Feedstocks- corn stover- Wheat straw- Milo stubble- Yard/wood waste- landfill waste- Barley straw- Energycane
What is a feasible timeline for this transition?
Advanced Corn-to-Biofuel Biorefineries
Corn starch
Corn starch
and bran
Corn starch,
bran, and cobs
Corn starch,
bran, cobsand stover
Corn starch, bran, cobs, stover, and dedicated cellulosic
crops
Today 2010 2012 2015 2020
Vision
Source: Larry Johnson, ISU
Forest12.8%
Urban waste2.9%
Manure4.1%
Grains5.2%
Crop residues7.6%
Soy6.2%
Wheat straw6.1%Corn stover
19.9%
Perennial crops35.2%
From: Billion Ton Vision, DOE & USDA 2005
US Biomass inventory = 1.3 billion tons*
*Could supply 66% of U.S. transportation fuel
Current Sustainable Availability ofCellulosic Biomass from Agricultural Lands
75 mdt/year
6 mdt/year
11 mdt/year
6 mdt/year
21 mdt/year*
* Oil seeds, soybeans, sugar crops, root crops
Source: http://feedstockreview.ornl.gov/pdf/billion_ton_vision.pdf
Feedstocks Used in Attaining the Goal Timing and Feedstocks for 25 X ’25
How will the biomass be converted into fuels?
Three approaches to advanced biofuels
• Biologically (enzyme) based cellulosic ethanol
• Thermally based biofuels (including ethanol)
• Hybrid processing (includes both biological and thermal steps)
Source: R.C. Brown, ISU
“Next Generation” Biofuels
• corn bran• corn cobs• corn stover• dedicated energy crops
“If any one step on the value chain does not work, the entire value chain does not work.”
Agricultural & Bioenergy/Bioproduct Value Chain
Source: Jill Euken and Joe Colletti, ISU
Germplasm Cultivation Harvest Storage
Ceres
Syngenta
Monsanto
Pioneer/DuPont
Canavialis
Dow
Processing
Novozymes
Genencor
Poet
ICM
Iogen
Verasun
ConocoPhillips
Lack of focus on economic & environmental drivers
Additional research needed
Integrated Systems Approach
Transport
The first “Advanced” Biofuels Project in Iowa: Project LIBERTY
• Converting Emmetsburg, IA plant to an integrated biorefinery
• Over $300 million capital investment
• Will produce 125 million gallons of ethanol
– 25 million from cellulosic feedstock
• Cellulosic feedstocks are cobs and corn fiber
• Multiple synergies with corn and cellulose model
Why cobs?• Consistency
• Farmer willingness
• One pass harvest capability
• Higher ethanol yield
• Greater bulk density
• Proven feedstock
• Logical first step
Based on information supplied by POET 29
Simplified LIBERTY DiagramEthanol
Fractionation
Grain Corn
Corn Germ
Endosperm
CO2
Fermentation
Distillation
Centrifuge& Dry
Pre-treat Hydrolysis &Ethanol Fermentation
Distill
Corn Cobs
Bran
Ethanol
Co-product stream processed into energy
for the ethanol production processes
and drying DDGs
Water VA Chemicals
and modifiedDDGs
Project LIBERTY Delivers:
• 11% more ethanol from a bushel of corn
• 27% more ethanol from an acre of corn
• Significant reduction in fossil fuel consumption
• Replicable model for multiple plants
ISU visit to Hurley SD
Stover/cob removal concerns
• How to “value”• Risk• Soil organic matter• Moisture infiltration• Lime needs• Long term soil quality parameters.
2007 Harvest Objectives
To understand impact to the farmer:– economics– equipment– processes– storage – transportation– capital– logistics – speed– labor
2007 Cob Harvest
• Harvested 4,000 acres of cobs in South Dakota • Tested multiple harvest methods• Collaborating with major equipment
manufacturers• Conducting over 60 storage experiments
Cob Caddy, Ihnen farm
8010 and Cob Caddy
Cob Caddy Harvest
Cob Caddy
On-Field Storage
Cob handling
9860 CCM harvest
Corn cob mix
Corn cob mix
Feterl cob screener
Cob storage experiments
• 60 experiments• Hybrids• Moisture• Storage/retrieval/
delivery
Looking Ahead to “Third Generation”
Bioprocessing…..harvesting stover……
Biomass Harvest Logistics
Harvest equipment
N, P, and K Nutrient Replacement costs:
Harvest Scenario
Nitrogen Phosphates Potassium Total
Lb/ac $/ac Lb/ac $/ac Lb/ac $/ac $/ac
high-cut top 30.6 11.16 3.4 2.34 30.5 9.75 23.34
high-cut bottom 12.3 4.53 0.9 0.62 29.9 9.55 14.69
low cut 42.0 15.46 3.7 2.52 38.9 12.42 30.40
normal cut 37.5 13.78 3.6 2.45 30.6 9.77 26.01aAverage for fertilizer N, P, and K at Walton, NE, Kelly, IA and Boone, IA in March 2006.Nitrogen cost $0.328 lb-1
Phosphate cost $0.615 lb-1
Potassium cost $0.284 lb-1
Iowa State University Research
N, P, and K Nutrient Replacement Costs:
Source: Stuart Birrell, ISU
New Cropping Systems Could Provide Biomass
Feedstocks and Environmental Protection
• Using double-crop sequences
• Using herbaceous and woody perennials
• Recycling nutrients between biorefineries and crop fields
Focus on Iowa: A 2006 Corn Grower Survey…
Survey data collected post harvest 2006. Corn Price at time of survey ≈ $3.40/ Bushel
Source: John Tyndall, ISU
Map from NASS, 2004
Survey: Regionally Stratified Random Sample
12 3
4
Farmer Knowledge of Corn Stover Market
How knowledgeable are farmers about harvesting & marketing of corn stover?
• 41% are “not knowledgeable at all”
• 28% were “a little knowledgeable”
• 20% feel “somewhat knowledgeable ”.
• Only 4% feel “very informed”.
Interestingly, 6% of the respondents were harvesting & selling corn stover in 2006 (mostly in W and NC Iowa).
Therefore by and large Iowa’s farmers are still in the learning phase of this potential market.
(n = 602)
Source: John Tyndall, ISU
• increase in capital investment • additional managerial knowledge • a well-developed support infrastructure.
Farmers believe that harvesting stover will require:
Source: John Tyndall, ISU
Farmer Interest in Supplying Stover, 2006
(n= 602)
Source: John Tyndall, ISU
New Century Farm at Iowa State University
• The first-in-the-nation integrated research and demonstration farm devoted to biomass production, processing and utilization
• Will be a model for American biorenewable energy and bioproducts development
Crop Production, Harvest, Storage & Transportation Research
Harvest
Storage
Production
EnsureProducer Profitability
+Sustainable Supply
For Biorefineries
2008 Growing the Bioeconomy Conference
September 8-9
SAVE THE DATE
Jill EukenDeputy Director, ISU Bioeconomy Institute
Project Manager, Biobased Products, ISU Extension/CIRAS53020 Hitchcock Ave
Lewis, IA 51544Phone: 712-769-2600
Email: [email protected]