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ISU Bio economy Initiative

ISU Bio economy Initiative. Jill Euken jeuken@iastate.edu. Impacts already……. Current Status - Ethanol. Biorefineries in Producion (139) Biorefineries under Construction (62). Source: RFA 1-24-08. Distillation. Fermenter. Ethanol. Starch. CO 2. Enzymes. Water. Cooker.

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ISU Bio economy Initiative

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  1. ISUBioeconomy Initiative Jill Euken jeuken@iastate.edu

  2. Impacts already……

  3. Current Status - Ethanol Biorefineries in Producion (139) Biorefineries under Construction (62) Source: RFA 1-24-08

  4. Distillation Fermenter Ethanol Starch CO2 Enzymes Water Cooker Milling Starch Sugar Grain Dried Distillers Grains and Solubles (DDGs) Typical Grain Ethanol Plant Ethanol

  5. ISU Extension “Conversations” 96 counties, 950 respondents, March ‘2007

  6. Optimism • Jobs • Livestock expansion • Improving infrastructure • Iowa pride • Increased tax base • Economic development • Value adding • Rural revitalization • Potential for keeping young people in Iowa

  7. 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”

  8. Facts and Figures • December, 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

  9. Prediction: …….we ain’t seen nothin yet…….

  10. Total 36 2007 Energy Bill Mandates36 Billion gallon of ethanol by 202221 Billion gallon must come from cellulose Corn-based 24 Billion gallons 12 Biomass-based 0 2000 2016 2022 2008 Source: U.S. DOE

  11. The HUGE Challenge Before Us 21 billion gallons • 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) 6 billion gallons 30 years 15 years

  12. Where will biomass come from?

  13. DOE 1.3 Billion Ton Study* *Could supply 66% of U.S. transportation fuel

  14. How do we “jump start” the cellulose industry?

  15. 2007 DOE Biorefinery Awards=$385M $80 M $80 M $80 M $76 M $40 M • Feedstocks • - corn stover • Wheat straw • Milo stubble • Yard/wood waste • landfill waste • Barley straw • Energycane $33 M Source: R. Wisner, ISU November, 2006

  16. What is a feasible timeline for this transition?

  17. Today 2020 2012 2010 2015 Corn starch, bran, cobs, stover, and dedicated cellulosic crops Corn starch and bran Corn starch, bran, and cobs Corn starch, bran, cobs and stover Corn starch Advanced Corn-to-Biofuel Biorefineries Vision Source: Larry Johnson, ISU

  18. Wheat straw Corn stover 6.1% Soy 19.9% 6.2% Crop residues 7.6% Grains 5.2% Manure 4.1% Urban waste 2.9% Perennial crops 35.2% Forest 12.8% US Biomass inventory = 1.3 billion tons* *Could supply 66% of U.S. transportation fuel From: Billion Ton Vision, DOE & USDA 2005

  19. Current Sustainable Availability of Cellulosic Biomass from Agricultural Lands 6 mdt/year 21 mdt/year* 6 mdt/year 75 mdt/year 11 mdt/year * Oil seeds, soybeans, sugar crops, root crops Source: http://feedstockreview.ornl.gov/pdf/billion_ton_vision.pdf

  20. Feedstocks Used in Attaining the Goal Timing and Feedstocks for 25 X ’25

  21. How will the biomass be converted into fuels?

  22. 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

  23. “Next Generation” Biofuels • corn bran • corn cobs • corn stover • dedicated energy crops

  24. Agricultural & Bioenergy/Bioproduct Value Chain Germplasm Cultivation Harvest Transport Storage Processing Ceres Syngenta Monsanto Pioneer/DuPont Canavialis Dow Novozymes Genencor Poet ICM Iogen Verasun ConocoPhillips Lack of focus on economic & environmental drivers Additional research needed Integrated Systems Approach “If any one step on the value chain does not work, the entire value chain does not work.” Source: Jill Euken and Joe Colletti, ISU

  25. 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

  26. Why cobs? • Consistency • Farmer willingness • One pass harvest capability • Higher ethanol yield • Greater bulk density • Proven feedstock • Logical first step

  27. CO2 Simplified LIBERTY Diagram Ethanol Endosperm Centrifuge & Dry Fractionation Fermentation Distillation Grain Corn Water VA Chemicals and modified DDGs Corn Germ Bran Ethanol Distill Corn Cobs Pre-treat Hydrolysis & Ethanol Fermentation Co-product stream processed into energy for the ethanol production processes and drying DDGs Based on information supplied by POET

  28. 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

  29. ISU visit to Hurley SD

  30. Stover/cob removal concerns • How to “value” • Risk • Soil organic matter • Moisture infiltration • Lime needs • Long term soil quality parameters.

  31. 2007 Harvest Objectives To understand impact to the farmer: • economics • equipment • processes • storage • transportation • capital • logistics • speed • labor

  32. 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

  33. Cob Caddy, Ihnen farm

  34. 8010 and Cob Caddy

  35. Cob Caddy Harvest

  36. Cob Caddy

  37. On-Field Storage

  38. Cob handling

  39. 9860 CCM harvest

  40. Corn cob mix

  41. Corn cob mix

  42. Feterl cob screener

  43. Cob storage experiments • 60 experiments • Hybrids • Moisture • Storage/retrieval/ delivery

  44. Looking Ahead to “Third Generation” Bioprocessing …..harvesting stover……

  45. Biomass Harvest Logistics

  46. Harvest equipment

  47. Iowa State University Research N, P, and K Nutrient Replacement Costs: N, P, and K Nutrient Replacement costs: aAverage for fertilizer N, P, and K at Walton, NE, Kelly, IA and Boone, IA in March 2006. Nitrogen cost $0.328 lb-1Phosphate cost $0.615 lb-1 Potassium cost $0.284 lb-1 Source: Stuart Birrell, ISU

  48. 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

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