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Technical Opportunities & Challenges
Lee R. Lynd
Thayer School of Engineering & Department of Biology
Dartmouth College, Hanover, New Hampshire, USA
1
Transformative Biomass Energy Benefits: What Could be Achieved?
Mature process & production technology, supported by results of the
Role of Biomass in America’s Energy Future (RBAEF) project
Process technology features
Production of ethanol with coproducts (diesel, gasoline, power, feed, chemicals)
High quality fuels competitive with conventional fuels from oil at < $30/barrel
Energy value of products ~ 3/4 feedstock energy
Feedstock production
High productivity (tons/acre)
Enhanced soilfertility
Very high nutrient capture efficiency, recycle of N perhaps other elements
Systemic attributes (lifecycle basis)
Nearzero net greenhouse gas emissions
Fossil fuel displacement:fossil energy inputs > 10:1
2
Responsiveness to Societal Challenges
Security
Large reductions in oil importation
The dominant energy security challenge for the coming decades
A magnet for conflict (Richard Lugar & James Woolsey)
Sustainability
Radical reduction of transportation sector greenhouse gases
Substantial improvements in the sustainability of agriculture
Rural economy
Increased demand/value for farm products
Substantially alleviate the chronic problem of agricultural overcapacity that has affli
U.S. agriculture for a century
Improvements of historic proportions in the economic health of rural communities
3
Transformative Biomass Energy Benefits Not Just I Think So
RBAEF project
“Considers & supports the possibility of biomass fuels being a primary transport
energy storage medium not a bit player, not only a transition option
Environmental community from ambivalent to champion
“Cellulosic ethanol is at least as likely as hydrogen to be an energy carrier
of choice for a sustainable transportation sector.” (NRDC, UCS)
Rocky Mountain Institute/Amory Lovins
Biofuels prominently featured in “Winning the Oil End Game”
25 x 25 group
Clearest statement to date by the farm community of the possibility &
desirability of largescale energy production
DOE “Billion tons” report
Detailed report documenting largescale biomass availability
Energy Future Coalition
Supports major biofuels push (R&D & deployment)
4
Transformative Biomass Energy Benefits What do we Need to Do?
Science & Technology Societal & Policy
Conversion Technology
Overcoming the recalcitrance
of cellulosic biomass
Biological
Nonbiological
Product diversification Commercial Application
Ascend learning curve
Highefficiency integrated processing facilities
Feedstock production
New crops & cropping systems
Feedstock storage & delivery systems
Integration with processing Vehicles
Increase MPG Keep availability of FFVs ahead of
biomass fuel availability
Consensus & Willingness to Act
Addressed in this talk
Sustainability & energy security
5 Biomass energy
Biomass Processing Research Frontiers
Feedstock Production Feedstock Activation* Product Diversification
(Sunlight Biomass) Biomass Reactive Reactive Products
intermediates intermediates
Productivity
Corn (wellestablished, low cost) Metabolic
Site range Overcoming the recalcitrance Engineering
of cellulosic biomass
Not a major research frontier (product
Logistics Cellulose (not wellestablished) focused)
Large costGasification Acid
Enzymatic
Hydrolysis Catalysis
Low inputs Major research frontier Hydrolysis (especially
aqueous)
Pretreatment Utilization of Lowcost
all sugars Hydrolysis Separation
Dilute acid
Dedicated CBP/Microbial
Aqueous cellulase cellulose utilization
production
AFEX
Hydrolysis Lowcost Recombinant Native
reactor cellulase Strategy Strategy
Fundamentals design & production
operation
Better cellulases
6
Focusing Our Attention
The cost of processing, not feedstock, is the key factor impeding
costcompetitiveness
Feedstock Representative Price $/GJ
LowCost Cellulosic Residues 0 to $30/dd ton 0 to 1.7
Cellulosic Energy Crops $35 to $50/dd ton 2 to 2.9
Crude Oil $35 to $70/bbl 6.1 to 12.2
Corn (kernels) $2.50/bu 5.0
Whether accomplished by enzymatic hydrolysis, acid hydrolysis, gasification,
or pyrolysis, conversion of cellulosic biomass to reactive intermediates:
• Represents the largest cost among process steps
• Is the least technologically mature
• Has the greatest potential for R&Ddriven improvement
7
Evolution of Biomass Processing Featuring Enzymatic Hydrolysis
Biologically Processing Strategy
Mediated (each box represents a bioreactor not to scale)
Event SSF
SHF SSCF CBP
Cellulase O2 O2 O2
production
Cellulose
hydrolysis
Hexose
fermentation
Pentose
fermentation
_____________
SHF: Separate hydrolysis & fermentation CBP: Consolidated bioprocessing
SSF: Simultaneous saccharification & fermentation
SSCF: Simultaneous saccharification & cofermentation
8
Cost Comparison: SSCF with Advanced Cellulase vs CBP
Cost of Biological Conversion
0.21
18.8
0.18
Lost Yield
(¢/gal EtOH)
5.59
0.15 Utilities
0.12 Raw materials
9.85 3.90
8.98 Capital & related
0.09 1.85
5.59 2.27
0.06 1.02
4.23
1.63 1.71
0.03
0.83 0.68
1.80 5.69 7.49 1.84
0.00
Cellulase SSCF Total CBP
Production
Plant scale, 5,000 tpd; Hydrolysis conversion, 95%; Fermentation yield, 95%; Ethanol concentration, 50 g/L; Temp, 37oC
Cellulase costs based on Wooley et al., 1999. SSCF costs from RBAEF process models, 7 day reaction time
Lynd et. al., Curr. Opin. Biotechnol., 2005
Substituting CBP for SSCF with advanced cellulase:
> 4fold reduction in cost of biological processing
> 2fold reduction in the cost of processing overall
9
HighlyEfficient Integrated Processing (mature technology, one scenario)
0.1% 0.2% 0.8% 1.6% THERMOCHEMICAL
Power 3.6%
2%
Steam Turbine
NH3
Steam 10%
1%
HRSG
8%
Feedstock Ethanol
Feed Handling
Pretreatment
Distillation
54%
CBP
100% 100% 97% 96%
7% 1%
14%
1%
0.1% 0.1%
Solids
Liquid 25%
6% 2% 9% 16%
19% Power 5%
GT
FT Synthesis
Gas Cleanup
Gasification
Drier
21% 4%
26% 22% 35%
WWT
Residue FT Gasoline 6%
Other Utilities
Cooling/Heat Loss
WWT
Sludge FT Diesel 10%
1%
Biogas 13%
POX
0.6% 0.3%
BIOLOGICAL
Ag Inputs
(Farming, feedstock transport) ~ 5 %
10
Scenario Comparison: Fuel price variable, power price constant, 5,000 tpd
2002 2003 2004 2005?
($24/bbl) ($29/bbl) ($37/bbl) ($50/bbl)
($0.81/gal) ($0.98/gal) ($1.27/gal) ($1.58/gal)
70% EtOH/Rankine
65% EtOH/GTCC
Internal Rate of Return (%)
EtOH/FT/GTCC
60% EtOH/FT (1X)/CH4
55% EtOH/FT (w/recycle)/CH4
50% EtOH/H2
EtOH/Protein/Rankine
45% EtOH/Protein/GTCC
40% EtOH/Protein/FT
EtOH/SA/Rankine
35% FT/GTCC
30% DME/GTCC
H2/GTCC
25%
Rankine
20% GTCC
15%
10%
5% $0.04/kWh
0% $0.20/lb protein
$5 $6 $7 $8 $9 $10 $11 $12 $13 $14 $15 40/60 D/E
7.5% loan rate
Fuel Price ($/GJ gasoline equiv.)
11
Scenario Comparison: Fuel price variable, power price constant, 5,000 tpd
2002 2003 2004 2005?
($24/bbl) ($29/bbl) ($37/bbl) ($50/bbl)
($0.81/gal) ($0.98/gal) ($1.27/gal) ($1.58/gal)
70%
65%
Internal Rate of Return (%)
60%
55%
50%
45%
e ls)
40% xf u ing
m a e ss
35% a n ol ( p roc
i o eth l + TC
B
30% t hano
e
Bi o
25%
20%
uels
15% TC F
10%
Power
5% $0.04/kWh
0% $0.20/lb protein
$5 $6 $7 $8 $9 $10 $11 $12 $13 $14 $15 40/60 D/E
7.5% loan rate
Fuel Price ($/GJ gasoline equiv.)
12
New Crops & Cropping Systems
Land use is usually either held constant or extrapolated in analyses of the role of
biomass energy production.
However, demand for cellulosic feedstocks due to costcompetitive processing
technology would very likely result in large changes.
Feed protein/feedstock coproduction
Winter cover crops
Agricultural residue removal, enhanced by appropriate crop rotations
New crops developed for bioenergy, integration into agriculture
Increase production on underutilized land (e.g. hay, pasture)
Feedlot pretreatment to make calories more accessible
Reimagining agriculture to accommodate large scale energy production
We have barely scratched the surface in terms of both vision & realization
13
Let’s Think Big
Miscanthus, One Season’s Growth
Courtesy Steve Long, University of Illinois
14
Integrating Feedstock Production & Processing
Observations
The most attractive mature configurations for biomass processing feature
biological conversion followed by gasification
Gasification features a reducing chemical environment in which nitrogen originating
from biomass feedstocks, microbial cells, or enzymes exists primarily as ammonia
Nrecovery already practiced industrially SASOL recovers most of the nitrogen
present in coal as ammonia
This suggests
15
Reimagining BiomassBased Mobility Chains as if Sustainability &
Energy Security Challenges Were Important to Solve
CRP Land U.S. Cropland
(30 MM) (400 MM)
Advanced
processing 90 gal Geq/ton 400
Efficient 160 LDV
vehicles (2.5x)
HDV
Agricultural integration
I. Soy > switchgrass Earlycut switchgrass produces more feed protein/acre
or large biomass soy 86 than soy; similar benefits from “large biomass soy”
II. Corn stover (72%) 45 Feasibility of stover utilization enhanced by rotation
III. Other Winter cover crops, other residues, increased productivity
of food crops, increased production on underutilized land…
2. Extrapolate current trends.
3. Hope for a miracle (e.g. Hoffert et al., Science, 2002).
• Acknowledge the importance of sustainable and secure energy supplies
• Dismiss foreseeable options as inadequate to provide for the world’s energy needs
• Call for “disruptive” advances in entirely new technologies whose performance
cannot be foreseen.
4. Innovate & change.
• Define sustainable futures based on mature but foreseeable technologies
in combination with an assumed willingness of society to change in ways that increase
resource utilization efficiency
• Work back from such futures to articulate transition paths beginning where we are now
#1 and #2 do not offer solutions to sustainability and security challenges.
#3 should be pursued but is too risky to rely on.
#4 is the most sensible choice if it is assumed that challenges associated with
17
sustainability and security are important to solve.