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Biofuels: An Opportunity for the GCRI

Biofuels: An Opportunity for the GCRI. Dr. Michael A. Pacheco Director of The National Bioenergy Center November 3, 2006 Future of Gulf Coast Refining Industry Symposium Houston, Texas. National Renewable Energy Laboratory.

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Biofuels: An Opportunity for the GCRI

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  1. Biofuels: An Opportunity for the GCRI Dr. Michael A. Pacheco Director of The National Bioenergy Center November 3, 2006 Future of Gulf Coast Refining Industry Symposium Houston, Texas

  2. National Renewable Energy Laboratory • Only national laboratory dedicated to renewable energy and energy efficiency R&D • Fundamental science to technology solutions • Collaboration with industry and university partners • Research programs linked to market opportunities • Originally the Solar Energy Research Institute, July 1977 • Designated a U.S. Department of Energy National Lab, Sept. 1991 • Current staff of 1100 and budget of $200 million/yr

  3. Solar <1% Geothermal 5% Nuclear 8% Natural Gas 23% Biomass 47% Renewable 6% Wind 2% Hydroelectric 45% Petroleum 40% Coal 23% U.S. Energy Supply (2004 data) Source: Renewable Energy Trends 2004; Energy Information Administration, August 2005. Note: Total U.S. Energy Supply is 100.278 QBtu; Energy Information Administration, August 2005.

  4. The “Good News” the planet’s sustainable carbon cycle dwarfs our non-sustainable use of fossil sources

  5. Biomass Strengths • Biomass is: • Abundant • Renewable • Carbon-neutral • The only sustainable source of hydrocarbons. • Biomass can: • Fill the gap between demand and availability of petroleum in the near/mid term. • Serve as a renewable source of hydrogen in the long term.

  6. How can Biofuels be an Opportunity for the Gulf Coast Refining Industry ? • Develop biofuel options that can utilize existing infrastructure: including: refineries, petrochemical facilities, channels to market • Look for technologies that create synergy with existing operations • Focus on ensuring sufficient biomass resources, avoid competition with food sources, and improve conversion efficiency to liquid fuels • Develop alternative crude oils from biomass, versus alternative products • Reduce the power foreign National Oil Co’s have over GCRI • Develop liquid biofuels that are more compatible with petroleum products, with a higher in energy density than ethanol or biodiesel • Identify and develop “game changing” technology to better position the GCRI for the long term transition to C-neutral renewable fuels

  7. Products • Fuels • Ethanol • Biodiesel • “Green” Gasoline & Diesel • Power • Electricity • Heat • Chemicals • Plastics • Solvents • Chemical Intermediates • Phenolics • Adhesives • Furfural • Fatty Acids • Acetic Acid • Carbon Black • Paints • Dyes, Pigments, and Ink • Detergents • Etc. • Food and Feed Conversion Processes • Enzymatic Fermentation • Gas/liquid Fermentation • Acid Hydrolysis/Fermentation • Gasification • Combustion • Co-firing • Trans-esterification Range of Possible Biorefinery Concepts Biomass Feedstock • Trees • Grasses • Agricultural Crops • Residues • Animal Wastes • Municipal Solid Waste • Algae • Food Oils

  8. O H O H H H O O O O O O O O O O H O H H O H H O H O O H O H O O O H H O H H H O O H O O O O O O O O H O H O O H C O C O H H 3 3 O O 7 7 O O 7 H O S H O O O O O H H H H N N N O N C N O O H N N N 3 H H H H O O O O O O H S N H N N H 2 Edible Constituents of Biomass • Starch: 70%–75% (corn) • Readily available and hydrolysable • Basis for existing U.S. “biorefineries” • Oil: 4%–7% (corn), 18%–20% (soybeans) • Readily separable from biomass feedstock • Basis for oleochemicals and biodiesel • Protein: 20%–25% (corn), 80% (soybean meal) • Key component of food • Chemical product applications

  9. H C O 3 H C O 3 H O O C H O 3 O O O H O C H O C H 3 O 3 H O O O H O O C H 3 O C H O H 3 O O H O O H H O O O H O O H O O H O O H O O H O H O H O O H O H H C O O C H H O 3 3 O C H O 3 O H O O H H O O H O O O H O O C H O C H O H 3 3 O O O O H H O H O O C H O H O H 3 O O O H O H O O O H O O O H O O H O O H O H O H O O H O H O O O H O H H O H O H O O H O O O H O H O O H O H H O H C O O H O O H O 3 O O O C H 3 O H O H O O O O H O H H O H O O H O O O H O H O O H O H O O O H O O H O O H O H O H O H O O H O O H H O H O O O O H O H O O H H O O H O H O O H O O O O H O H O O O O H O H H O H O O O O O H O H O O H O H O O O H O O H O O H O H O O O H O H H O H O O O H O H O O H O H O O H O O O H O H O O O H O H H O O H O O H O H O O H O O H O O H H O O H O O H O O H O O H O H Non-Edible Constituents of Biomass • Lignin: 15%–25% • Complex aromatic structure • Very high energy content • Resists biochemical conversion • Hemicellulose: 23%–32% • Xylose is the second most abundant sugar in the biosphere • Polymer of 5- and 6-carbon sugars, marginal biochemical feed • Cellulose: 38%–50% • Most abundant form of carbon in biosphere • Polymer of glucose, good biochemical feedstock

  10. Food Supplies Not a Food Supply U.S. Biomass Resource Potentials • Corn (largest volume grain and source of EtOH in U.S.) • Potential to displace 10-20% of our gasoline Soybeans, fats & greases (largest sources of biodiesel) • Potential to displace 5-10% of our diesel Over 1 billion tons/year of lignocellulosic biomass (trees, grasses, etc.) could be available in the U.S. • Potential to displace 50-70% of our gasoline Short-term: improve cost and efficiency of corn ethanol & biodiesel Mid to Long-term: focus on lignocellulose (trees, grasses, & residues)

  11. Significance of the “Billion Ton” Scenario Billion Barrel of Oil Equivalents Based on ORNL & USDA Resource Assessment Study by Perlach et.al. (April 2005) http://www.eere.energy.gov/biomass/pdfs/final_billionton_vision_report2.pdf 

  12. Ethanol is the 1st of Many Possible Biofuels Near Term • Ethanol – as a blending agent from either grain or cellulosic material from Ag and/or Forestry industry • Biodiesel – Transesterified vegetable oils blended with diesel • Green Diesel – fats, waste oils, or virgin oils converted to low-sulfur diesel in petroleum refinery • Other Fermentation Products – examples include: butanol, acetates, lactates, and other possibilities • Pyrolysis Liquids – alternative feedstock to petroleum refinery or gasification facility • Synthesis Gas – for conversion to Fischer-Tropsch liquids, methanol, dimethyl ether, or mixed alcohols • Algae-derived Fuels – alternative source of triglycerides for biodiesel or green diesel, and a carbohydrate source • Hydrocarbon Fuels – from hydrogenation of biomass constituents Long Term

  13. Ethanol Production Actual and Projected U.S. Ethanol Production 1999-2012 Billion Gallons of Production Source: December 2005 Ethanol Today Magazine • Renewable Fuels Standard mandates 7.5 billion gallons by 2012 • Total US gasoline market ~140 billion annual gallons

  14. Integrated Cellulosic Ethanol Biorefinery

  15. Energy Required to Produce Ethanol • Total Btu spent for 1 Btu available at fuel pump Fuel-to-Petroleum Ratio = 10 45% Efficiency 57% Efficiency Fuel-to-Petroleum Ratio = 0.9 Btus Required per Btu of Fuel 81% Efficiency Energy in the Fuel Based on “Well to Wheels Analysis of Advanced Fuel/Vehicle Systems” by Wang, et.al (2005).

  16. Reducing the Cost of Ethanol From Stover $6.00 State of Technology Estimates $5.00 Feed $53/ton $4.00 Enzyme Conversion Feedstock Prior DOE Cost Targets President's Initiative $3.00 Minimum Ethanol Selling Price ($/gal) Costs in 2002 Dollars Integrated large-scale BC/TC processing $2.00 2005 Yield 65 gal/ton $1.00 Feed $30/ton Yield 90 gal/ton $0.00 5 2000 2005 2010

  17. Parameters that Drive the Cost of Cellulosic Ethanol via Biochemical Path

  18. Other Near-Term Biofuel Technologies Near Term • Ethanol – as a blending agent from either grain or cellulosic material from Ag and/or Forestry industry • Biodiesel – Transesterified vegetable oils blended with diesel • Green Diesel – fats, waste oils, or virgin oils converted to low-sulfur diesel in petroleum refinery • Other Fermentation Products – examples include: butanol, acetates, lactates, and other possibilities • Pyrolysis Liquids – alternative feedstock to petroleum refinery or gasification facility • Synthesis Gas – for conversion to Fischer-Tropsch liquids, methanol, dimethyl ether, or mixed alcohols • Algae-derived Fuels – alternative source of triglycerides for biodiesel or green diesel, and a carbohydrate source • Hydrocarbon Fuels – from hydrogenation of biomass constituents Long Term

  19. Oils, Fats & Greases as Bio-renewable Petroleum Refinery Feedstocks • Co-processing of oils and greases with petroleum fractions • Utilize existing process capacity • Potential for lower conversion costs (than FAME) • Higher quality diesel blending component • G/D flexibility ISBL Petroleum Refinery Catalytic Cracker Green Gasoline & Olefins Oils and Greases Distillate Hydrotreater Green Diesel Based on Presentations at 1st International Biorefinery Workshop, Washington DC, July 20-21, 2005 - Future Energy for Mobility, James Simnick, BP - From Bioblending to Biorefining, Veronique Hervouet, Total - Opportunities for Biorenewables in Petroleum Refineries, Jennifer Holmgren, UOP

  20. Green Diesel • Hydrotreating of biorenewable oils in existing refinery units • Lower capital costs than biodiesel • Excellent fuel properties Source: U.O.P. Corp. 1st International Biorefinery Conference, August 2005

  21. Published Economic Comparison(from UOP-NREL-PNNL study) Net Present Value • Biodiesel is least competitive option in this UOP/PNNL/NREL study • All fuels from soy bean oil require fuel subsidy • “Green” fuels or olefins from greases in petroleum refinery may generate positive NPV even without subsidy Source: Arena, B. et.al., “Opportunities for Biorenewables in Petroleum Refineries”, presented at Rio Oil & Gas Conference, held Sept 11-14, 2006

  22. Mid-Term Biofuel Technologies Near Term • Ethanol – as a blending agent from either grain or cellulosic material from Ag and/or Forestry industry • Biodiesel – Transesterified vegetable oils blended with diesel • Green Diesel – fats, waste oils, or virgin oils converted to low-sulfur diesel in petroleum refinery • Other Fermentation Products – examples include: butanol, acetates, lactates, and other possibilities • Pyrolysis Liquids – alternative feedstock to petroleum refinery or gasification facility • Synthesis Gas – for conversion to Fischer-Tropsch liquids, methanol, dimethyl ether, or mixed alcohols • Algae-derived Fuels – alternative source of triglycerides for biodiesel or green diesel, and a carbohydrate source • Hydrocarbon Fuels – from hydrogenation of biomass constituents Long Term

  23. Bio-oil is is comprised of many oxygenated organic chemicals, with water miscible and oil miscible fractions Fast Pyrolysis and Bio-oil as Feed to Power Plant or Petroleum Refinery Dark brown mobile liquid, Combustible, Not 100% miscible with hydrocarbons, Modest heating value ~ 17 MJ/kg, High density ~ 1.2 kg/l, Acidic, pH ~ 2.5, Pungent odour, “Ages” - viscosity increases with time Based on research at NREL (1990 - 2006)

  24. Crude Pyrolysis Oil Cost Estimates Base Case: 550 ton/d wood chips 59% oil yield 2 MBPD oil product $ 44 million Capital Source: V. Putsche, NREL report (2004)

  25. Decentralized Biomass Liquids Scenario • Alternate Feedstock for a Petroleum Refinery or Petrolchemical Plant

  26. Mid-Term Biofuel Technologies Near Term • Ethanol – as a blending agent from either grain or cellulosic material from Ag and/or Forestry industry • Biodiesel – Transesterified vegetable oils blended with diesel • Green Diesel – fats, waste oils, or virgin oils converted to low-sulfur diesel in petroleum refinery • Other Fermentation Products – examples include: butanol, acetates, lactates, and other possibilities • Pyrolysis Liquids – alternative feedstock to petroleum refinery or gasification facility • Synthesis Gas – for conversion to Fischer-Tropsch liquids, methanol, dimethyl ether, or mixed alcohols • Algae-derived Fuels – alternative source of triglycerides for biodiesel or green diesel, and a carbohydrate source • Hydrocarbon Fuels – from hydrogenation of biomass constituents Long Term

  27. Gasification Offers Many Feed & Product Options Slide courtesy of BP Corporation

  28. Biofuels via Biomass Gasification • “SunDiesel” strongly supported by Volkswagen • Attractive LCA of high quality diesel and HCCI engine technology • Excellent overall conversion efficiency to liquid fuels • Several fuels options from SynGas Excerpted from Renewable Fuels for Advanced Powertrains RENEW, by Frank Seyfried, Volkswagen, presented at 1st International Biorefinery Workshop, July 20-21, 2005, Washington D.C.

  29. Well to Wheels Analysis (Volvo Study) Excerpted from Automotive Fuels from Biomass, by Anders Roj, Volvo, presented at 1st International Biorefinery Workshop, July 20-21, 2005, Washington D.C.

  30. Overall gas conditioning reactions Reforming: CxHyOz + H2O(g) H2 + xCO Water gas shift: H2O + CO CO2 + H2 Gasification: C + H2O(g) COx + H2 Thermochemical Route to Alcohols Biomass Dried Biomass Crude Syngas Scrubbed Syngas Feed Handling and Conditioning Gasification Tar Reforming And Scrubbing Syngas Compression High P Syngas Mixed Alcohol Synthesis Crude Products Methanol Preliminary Separation Mixed Alcohols • 2012 Targets for Tar Reforming: • - Promoted metal/support catalyst • - CH4< 3 vol% • - Benzene < 10 ppmv • - Heavy tars < 1 g/nM3 Product Separation Ethanol C3 + Alcohols

  31. Parameters that Drive the Cost of Cellulosic Ethanol (Mixed Alcohols) via Thermochem Path D. Dayton

  32. Thermochemical Ethanol Cost Targets D. Dayton

  33. 2030 Target Scenario for a Large Cellulosic Biorefinery to Integrate BC & TC Ethanol Paths Ethanol 1,035,000 gpd Lignocellulosic Feedstock 10,000 ton/day Steam & Power Lignin CHP Plant Ethanol via Bioconversion Ethanol 1,168,000 gpd 409 MM gal/yr Lignin-rich Residue 1,400 ton/day Yield: 117 gal/ton Lignin-rich Residue 1,500 ton/day Alcohol Synthesis Gasification Syngas Ethanol 133,500 gpd Higher Alcohols 29,700 gpd S. Phillips and J. Jechura

  34. Longer Term Biofuel Technologies Near Term • Ethanol – as a blending agent from either grain or cellulosic material from Ag and/or Forestry industry • Biodiesel – Transesterified vegetable oils blended with diesel • Green Diesel – fats, waste oils, or virgin oils converted to low-sulfur diesel in petroleum refinery • Other Fermentation Products – examples include: butanol, acetates, lactates, and other possibilities • Pyrolysis Liquids – alternative feedstock to petroleum refinery or gasification facility • Synthesis Gas – for conversion to Fischer-Tropsch liquids, methanol, dimethyl ether, or mixed alcohols • Algae-derived Fuels – alternative source of triglycerides for biodiesel or green diesel, and a carbohydrate source • Hydrocarbon Fuels – from hydrogenation of biomass constituents Long Term

  35. Algae as a Source of Biofuels • Source of additional lipids and/or carbohydrates • Complements terrestrial biomass production • Reduces pressure on land use • Avoids food vs fuel debate • Option to utilize large waste CO2 resource • Potential for greater productivity than their terrestrial biomass • Up to 50 times more productive than traditional oilseed crops • Very large resource potential for producing biodiesel or “green diesel” Based on Aquatic Species Program at NREL, from 1978-1996

  36. Challenge of Making Fuels From Algae:- A “Biological” Challenge • The biochemistry of lipid and carbohydrate synthesis • Two main forms of carbon storage: • Triacylglycerides (lipids) • Chrysolaminarin (glucan) • Goal: Control “lipid triggers” that turn on lipid synthesis pathway

  37. Diesel/Jet Fuel From Algae

  38. Possible Approaches for the Gulf Coast Industry to Partner with NREL on Biofuels • Contract R&D: Develop biofuel concepts that are uniquely suited to one company. Several already in-progress at NREL. Results are proprietary and protected. • Program direction funding from DOE: Rare. Example is UOP project on “Biorenewables in Petroleum Refining.” Low funding level. Results become public. Company’s IP can be protected. • Vertically integrated team: Biomass resource, conversion technology, fuel blending and marketing. Good strategy for competitive solicitations and industry-DOE cost sharing. • Industry sector consortium CRADA: Industry partners cost-share R&D on biofuel concepts that benefit all partners in that sector. Investment protected through a mix of patents and other barriers to entry.

  39. Summary & Conclusions • Biomass is the only renewable option for liquid transportation fuels • Resource base sufficient to supply a large fraction of demand, with good potential to increase the resource base • A sustainable solution to meet the supply-demand “gap” to be caused by peaking world oil production and rising demand • On-going R&D will create many opportunities that beyond today’s biopower, ethanol, and biodiesel

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