Advancing the Bioeconomy through Innovation and Integration
National Institute of Food and Agriculture – USDA Advancing the Bioeconomy Through Innovation and Integration National Energy Extension Summit April 8, 2015 Bill Goldner, Ph.D. [email protected] The Bioeconomy • What is the Bioeconomy? – Biofuels, Industrial Chemicals, Biopower, and Biobased Products produced from agricultural and forest biomass (including oil crops/algae) • Why does it matter? – – – – – – Create and protect jobs Enhance energy security Increase rural economic development Provide sustainable alternatives to fossil feedstock options Enhance existing agricultural/forest production systems Provide ecosystem services National Institute of Food and Agriculture Sustainable Bioenergy • Facilitate system-based approaches for development of sustainable regional biomass supply chains for the production of biofuels, biopower, and bioproducts. • >$200 M NIFA current five year investment in biomass supply chains research, development, demonstration, extension, education – – – – Agriculture and Food Research Initiative Biomass Research and Development Initiative Joint Feedstock Genomics for Bioenergy Non-competitive Regional Approaches to Bioenergy Systems – Coordinated Agricultural Projects (CAP) • Regional partnerships – Academia, industry, government, NGOs, communities • Work back from targets to develop entire supply chains • Build on existing infrastructure and previous investments • Integrate Research, Education, and Extension/Tech Transfer • Robust sustainability analysis: Impacts on … – Economics, rural communities, and the environment • Targeted Feedstocks (perennial grasses, energy cane, sorghum, woody biomass, oil crops) • 2010-2013: 7 AFRI awards totaling ~$156 M over 5 years Fund allocation to date across 7 CAPs • Research $60 M • Education $15 M • Extension $17 M AFRI CAP Regions and Feedstocks AHB Progress Toward Sustainable Transportation Fuels and Chemicals Rick Gustafson, Brian Stanton, Tim Eggeman, Kate Field, Bryan Jenkins, Jason Selwitz, Kevin Zobrist. Keys to Advanced Hardwood Biofuels • Innovation and Integration § § § § Superior poplar genetics Biomass coppice plantation production system Biomass harvest system Modular conversion technology • Chemicals • Fuels (ethanol, aviation fuel) § Workforce development § Community and landowner engagement § Sustainability Analysis hardwoodbiofuels.org Why it matters… • Rural economic development § New jobs for forest product communities § Alternative income for landowners • Products from non-petroleum renewable feedstocks • Environmental Services hardwoodbiofuels.org Laying the foundation for a renewable fuels and chemicals industry Good science Community and policy support Sound technologies & Thorough analyses Well educated work force hardwoodbiofuels.org Committed land owners AHB is building a renewable bio-based chemical and biofuel industry in the Pacific Northwest using sustainably grown hybrid poplar. 1. Demonstration of hybrid poplar production and harvesting technology • Feedstock lead GreenWood Resources 2. Production of bio-based chemicals and fuels • Conversion lead ZeaChem at their Boardman demonstration bio-refinery. 3. Assessment of sustainability and critical system metrics • Sustainability leads Universities of Washington and California, Davis. 4. Development of curricula for pre-college, community and technical college, undergraduate, and graduate levels • Education leads Oregon State University and Agriculture Center of Excellence. 5. Outreach to policy makers, community leaders, growers, equipment manufacturers, investors, regulators • Extension lead Washington State University hardwoodbiofuels.org Phase I hybrid poplar demonstration farms– crux of the feedstock program • Four farms, 20 to 40 hectares each. • Each site has many clones to assess suitability • Sites are selected for potential commercial prospect – proximity to fuel markets • Tree farms are used to assess harvester technologies, environmental impacts, etc. hardwoodbiofuels.org Feedstock production group Jefferson, OR Site 2nd growing season before harvesting on September 2013 Height mean = 19.7 ft hardwoodbiofuels.org New Holland FR Series with 130FB Coppice Header FR 9060 2012 Hybrid Poplar FR 9080 FR series Grass or grain Corn Corn Woody coppice ZeaChem’s Boardman demonstration-scale refinery hardwoodbiofuels.org The AHB sustainability program integrates data from the feedstock and conversion teams to: Sustainability 1. Study the optimum locations for regional refineries 2. Estimate local economic impact University of California, Davis University of Washington 3. Techno-economic assessment of conversion processes 4. Conduct life cycle assessments 5. Produce an integrated model for evaluating system capability Techno-economic modeling – jet fuel is challenging at current prices ASPEN process modeling as a function of hydrogen source Economies of scale 3.5 Cash cost ($/gal) 3 2.5 Natural gas steam reforming Gasification Reforming 2 0 50 100 150 Capacity (MMGal/yr) Lignin gasification Cash cost ($/gal) 25 50 100 150 Reforming $2.94 2.69 2.52 2.45 Gasification $3.24 2.85 2.67 2.57 Jet fuels sells ~ $3.00/gal at refinery gate hardwoodbiofuels.org Techno-economic modeling – acetic acid looks much better ASPEN process modeling of poplar to acetic acid Operating costs Feedstock Cellulase Fermentation nutrients Other raw materials Natural gas Waste disposal Electricity credit Fixed Manufacturing Costs Cash production cost $/ton 121 69 3 32 210 2 -172 111 $376/ton Acetic acid sells ~ $650-$800/ton hardwoodbiofuels.org Extension Washington State University Proactive on bioenergy information • Provides research-based information o Social impact assessment • Helps with informed decision making Facilitates technology transfer to • Extension professionals • Policy makers • Potential growers • Environmental groups • Business community • Interested citizens Poplar growers manual Work with GWR Feedstock Production Report Growing Poplar for Bioenergy: A Grower’s Manual Northwest Advanced Renewables Alliance A new vista for Green Fuels, Chemicals, & Environmentally Preferred Products Michael Wolcott Regents Professor Project Co-Director Ralph Cavalieri Associate Vice-President for Alternative Energy Project Director Washington State University Northwest Advanced Renewables Alliance Isobutanol to Jet Fuel Demonstration Demonstration unit at South Hampton Resources, Silsbee, TX is fully functional © 2012 Gevo, Inc. USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Keys to NARA • Innovation and Integration – Robust project management – Feedstock Logistics – Pre-processing (mild bisulfite, milled wood) – Sustainability Analysis (TEA) – Novel conversion technologies • Isobutanol to AJF, lignosulfonates, activated carbon – Workforce development – Community and landowner engagement USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Why it matters… • Rural economic development – New jobs in rural communities – Protected jobs in the pulp industry through diversification – Alternative income for landowners • Products from non-petroleum renewable feedstocks • Ecosystem services NARA: Feedstock to Fuels USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Completed Year 3 of 5 USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA NARA Team Catchlight Energy CLH Cosmo Specialty Fiber Facing the Future Gevo, Inc. Gevan Marrs, LLC. Montana State University Oregon State University Pennsylvania State Univ. Salish Kootenai College Steadfast Management TSI Inc. University of Idaho University of Minnesota University of Montana University of Washington University of Wisconsin USFS – Forest Products Lab USFS – PNW Research Sta. University of Utah Washington State University Western Washington Univ. Weyerhaeuser Teams vs Goals | Process vs Outcomes Sustainable Biojet Valuable Co-Products Regional Supply Chains Energy Literacy Rural Econ Development Feedstock Conversion Sustainability Outreach Education USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA NARA Techno-Economic Analysis Source: TSI Chemicals & Biomass Products and Processes USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Value Chain: Route to Cost Parity for Fuels USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Sustainability Assessment Environmental Sustainable Feedstock ----------------Weyerhaeuser, OSU, UW, WSU Life Cycle Assessment ----------------UW Economic Economic Analysis ----------------TSI, Weyerhaeuser, UW Social Social & Market Assessment ----------------Penn State, WSU, UIdaho Milestone: NARA Long Term Soil Productivity Site USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA • • • • • • • Siting Analysis for Integrated Biorefinery Potential Biomass Depot Locations Inventory of Assets on Sites Site Designs Biomass Supply Scenarios (quantity and transportation) Community Impact Analysis Scenarios for Life Cycle Analysis Developed by Education and Outreach Teams Assessed by Regional Stakeholders REGIONAL SUPPLY CHAINS Western Montana Corridor (WMC) USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Overall Impact in WMC USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Mid Cascade to Pacific (MC2P) USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Demonstrate Integrated Production of BioJet USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Regional Corporate Member NARA Affiliate Member Market Studies Retrofit Options Techno-Econ Studies USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA Regional Tribes 1. 2. 3. 4. 5. TOP 5 Tribal Landowners In Commercial Acres Colville ~ 660,000 Yakama ~ 449,000 Salish & Kootenai ~ 300,000 Warm Springs ~ 256,000 Quinault ~ 174,000 Collaborations with Salish & Kootenai – Completed Warm Springs -- John Bailey (OSU) Developing Collaborations Yakama Quinault DOE Tribal Energy Program DOE awarded $807,000 to CSKT for engineering work Bioenergy Project Beck Group Harris Group NARA Biomass Assessment Leveraging NARA for New Projects USDA NIFA Sustainable Bioenergy PD Meeting October 29-30, 2014 in Arlington, VA If its going to burn…. … it might as well be in a jet engine John Bailey, OSU NARA Member Sustainable Production and Distribution of Bioenergy for the Central USA CenUSA Bioenergy is supported by Agriculture and Food Research Initiative Competitive Grant No. 2011-68005-30411 from the National Institute of Food and Agriculture Our vision is to create a regional system for producing advanced transportation fuels and other biobased products from perennial grasses grown on land that is either unsuitable or marginal for row crop production. In addition to producing advanced biofuels, the proposed system will improve the sustainability of existing cropping systems by reducing agricultural runoff of nutrients and soil and increasing carbon sequestration. Midwest Sustainable Biofuels Vision Keys to CenUSA • Innovation and Integration • • • • • Superior perennial grass genetics Low input marginal land production systems Feedstock logistics Sustainability analysis Distributed pyrolysis conversion concept • Chemicals • Fuels • Biochar • Workforce development • Community, farmer, and landowner engagement Why it matters… • Enhancement of existing crop production systems • Ecosystem services • Water quality improvement (protecting the Gulf of Mexico) • Wildlife habitat • Alternative farm income • Products from non-petroleum renewable feedstocks 47 Commercialization: ADM Fiber Platform Biomass Cooked biomass Consumer products Pulp Food ingredient: ADM Chemical pulp: ADM cellulose Lignin and Hemicellulose Lignin External Partners Finding the best value proposition for the three products Lignin, pulp, hemicellulose Hemicellulose Furfural External Partners Commercialization: CenUSA Vermeer Field-scale Site Liberty Switchgrass 29 July, 2014 Commercialization: Field Scale Plots in Eastern Nebraska Feedstock 2012 Yield 2013 Yield 2013 Transported Yield Liberty Switchgrass (Mg/ha) 7.6 18.5 11.4 Big bluestem (Mg/ha) 2.7 12.7 9.2 LD Mixture (Mg/ha) 4.3 14.5 11.2 103 (1.4 tons) 149 (1.9 tons) ----- Corn (bu/acre) Transported Yield = baled, transported off the field, and weighed to estimate loss Transport Improvements and Impacts Transport Improvements and Impacts 8 – 10 lbs DM/ft3 10 – 13 lbs DM/ft3 Feedstock Readiness Level Fuel Readiness Level (FRL) 1 2 3 4.2 4.1 5.1 5.2 5.3 5.4 6.1 6.2 6.3 7 8 9 Biochar Product Readiness Level 1 2 3 4.1 4.2 5.1 5.2 5.3 5.4 6.1 6.2 6.3 7 8 9 4.2 5.1 5.2 5.3 5.4 6.1 6.2 6.3 7 8 9 5.2 5.3 5.4 6.1 6.2 6.3 7 8 9 ADM Acetosolv Pulping Readiness Level 1 2 3 4.1 Renmatix C5 and C6 Sugar Production Readiness Level 1 2 3 4.1 4.2 5.1 Corn Stover Feedstock Production 1 2.1 2.2 2.3 2.4 3.1 3.2 4.1 4.2 4.3 5.1 5.2 5.3 5.4 6.1 6.2 7 8 9 4.3 5.1 5.2 5.3 5.4 6.1 6.2 7 8 9 Herbaceous Perennial Feedstock Production 1 2.1 2.2 2.3 2.4 3.1 3.2 4.1 4.2 Education and Outreach: • Problem-oriented, research-based transdisciplinary hands-on learning for a wide cross-section of students • Specific activities include: • Creating learning modules on bioenergy-relevant topics • Offering week-long intensive programs for graduate students to understand the interactions between research areas • Offering 10-week summer internship programs to students from across the US and a wide variety of academic and socioeconomic backgrounds Growing a Sustainable Bioenergy Industry for the Northeast Tom Richard Penn State University University and Federal Partners Partner Organizations Penn State University Cornell University SUNY ESF West Virginia University Delaware State University Ohio State University Rutgers University Drexel University USDA ARS ERRC DOE Oak Ridge National Laboratory DOE Idaho National Laboratory Keys to NewBio • Innovation and Integration – Superior perennial genetics (switchgrass, willow, Miscanthus) – Low input marginal land production systems – Feedstock logistics – Sustainability Analysis – Diverse conversion options • Chemicals • Absorbents • Fuels (ethanol, aviation fuel) – Workforce development – Community, farmer, landowner engagement Why it matters… • Enhancement of existing crop production systems • Ecosystem services – Water quality improvement (protecting the Chesapeake Bay) – Wildlife habitat • Alternative farm income • Products from non-petroleum renewable feedstocks 60 Conversion Partner: Delta Sustainability Partner: Chesapeake Bay Commission Extension Willow DoubleAWillow Switchgrass Ernst Miscanthus Aloterra Harvest Store Densify Transport Case New Holland, Aloterra Ernst TerraGreen Education Biochemical Mascoma Renmatix Thermochemical Praxair Primus Green Energy Biofuel Markets American Refining Group Bio-electricity ReEnergy Harvest, Feedstock Human Systems Preprocessing Human Systems Improvement & Logistics Safety and Health Sustainability Systems Leadership and Evaluation Extension Willow DoubleAWillow Switchgrass Ernst Miscanthus Aloterra Biochemical Harvest Store Densify Transport Mascoma Renmatix Thermochemical Case New Holland, Aloterra Ernst TerraGreen Praxair Primus Green Energy Biofuel Markets American Refining Group Bio-electricity ReEnergy Short Courses Webinars Fact Sheets and Tools Equipment Access Program Demonstration Site Field Days eXtension Target: regionally appropriate biomass feedstocks Questions to be Answered The deep south states can to produce 50% of the biofuels in the future because they have the most available land with adequate water and sun. Agricultural What crops suitable for production in underutilized agricultural areas (Cold tolerance)? Industrial Are the products (syrups) suitable for use by industrial partners? Financial-Environmental What is the financial baseline for producing biofuels from these crops and what are the environmental costs associated with the production? KEYS TO SUBI Innovation and Integration §Superior energy cane and sweet sorghum genetics §Cold tolerant energy cane to move cane production away from the coast §Low input production systems §Feedstock logistics §Sustainability Analysis §Diverse conversion options §Chemicals, bioplastic §Fuels (butanol, aviation fuel) §Workforce development §Community and landowner engagement WHY IT MATTERS… • Rural economic development •Jobs in an area that sorely needs them •Potential for greater farm income than current cropping systems • Products from non-petroleum renewable feedstocks YEAR ROUND FEEDSTOCK SUPPLY Month Sorghum Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec E-cane Commercial sugar Other Bagasse Bagasse Bagasse Winnsboro Ho 02-113 1st stubble crop (Sept. 2014). White PVC pole is 10’ long. Courtesy of Chris Adams. SWEET SORGHUM Annual crop Contains, a sugar containing juice, starch containing seed heads and fiber 90-120 day crop cycle, can be grown across target region Gross structure similar to sugarcane Can be widely grown across Southern US About 6,000 acres required to sustain processing plant for 3 months CROP COMPARISON Energycane Harvest time(months) Ag Inputs Planting Sweet sorghum 7 none perennial Harvest time(months) Ag Inputs 3 None* Planting annual Acres/1000t/day factory 8,000 Acres/1000t/day factory 6,000 Growth in nontraditional regions yes Growth in nontraditional regions yes Dry ton/acre 10 Dry ton/acre 1 -9 *fallow with clover Process Outline Sustainable Production Feedstock development Sustainability Harvest analyze Deliver Technology development Sugar Cane Gasoline ZSM-5 Biomass APR Kerosene Jet Fuel Condensation Corn Starch Hydrotreating Diesel Conversion to Fuel Value to Consumer Intermediate Product Process Economic feasibility Process Indeterminate Technology development Biomass PROCESSING Bioenergy Alliance Network of the Rockies Researching Sustainable Bioenergy from Beetle-Kill Wood in the Rockies Keith Paustian – Project Director Department of Soil & Crop Sciences Colorado State University BANR Team Project members Colorado State University University of Idaho Montana State University University of Montana Oregon State University University of Wyoming USFS – Rocky Mtn Res. Station Cool Planet Energy Systems Affiliates National Renewable Energy Lab Michigan State University USFS – Forest Products Lab Project advisory board Greg Aplet – Wilderness Society Pat Connell – Montana State Senate Rob Davis – Forest Energy Corp. Angela Farr – USFS, Region 1 Steve Hamburg – Environmental Defense David Hiller – Colorado Clean Energy Jim Neiman – Neiman Enterprises Keys to BANR • Innovation and Integration – Sustainability Analysis – Feedstock logistics – Modular/mobile conversion technology • Biochar • Fuels (gasoline, aviation fuel) – Workforce development – Community and landowner engagement Why it matters… • Wildfire mitigation in part of 42 million acres • Ecosystem services – Water quality improvement – Wildlife habitat • Rural Economic Development • Products from non-petroleum renewable feedstocks 77 Background Beetle infestation is a major ecological and resource management issue in the Rocky Mountains § 17 Mha (42 Ma) of forest in US impacted by bark beetles – 52% of total area is in CO, ID, MT & WY § New infestations are occurring on millions of acres annually § Several 100s of millions of tonnes of dead wood are a potential biofuel feedstock source Removal of beetle-kill wood and forest restoration have been proposed to meet various management objectives: § Reduce risk of catastrophic wildfire § Enhance safety for roads, trails, structures § Enhance regeneration, diversity, habitat Wood from thinning for fire control & forest restoration is currently a disposal problem! US Forest Service (2011) Can beetle-kill and other wood residues be a viable biofuel feedstock? Opportunities § Large quantities of wood potentially available as a feedstock § No displacement of productive lands (no indirect land use change) § Minimal competing uses for other wood products § Synergies with other land management objectives (e.g., fire mitigation, forest restoration, timber production) § Existing forest infrastructure can be leveraged in many areas Challenges § Constrained accessibility in many areas (e.g., roads, topography) § Large fraction of the area is Federal and State owned § Policy issues § Multiple use issues § Feedstock ‘creation’ is unmanaged, episodic and patchy (major constraint against large, fixed location biorefineries) § Potential adverse environmental impacts (e.g., erosion, water quality) Overarching Objective To provide the science-based underpinnings – through targeted research, education, training and extension – to support the development of sustainable biofuel/bio-products from beetle-killed and residual wood feedstocks. Project Task Overview • • • • RS & Field sampling campaign Feedstock supply atlas Forecasting of future infestation • • Enterprise partner engagement Harvest, transport & processing studies Pretreatment & CPES technology trials • Field-scale impact analysis • Ecosystem C/GHG modeling & LCA • Socioeconomic & policy analysis • K-12 science units • Teacher prof. development • Multidisciplinary grad. training • Workshops & community meetings • Stakeholder engagement • Health & safety standards & training BANR in perspective • Softwood conifer feedstock – Similar to NARA, IBSS • Thermochemical conversion with biochar co-production – Similar to CenUSA, IBSS • Feedstock very different from other CAP’s, analogous to corn stover – Already exists, doesn’t require dedicated cultivation (similar to NARA) – DOES require additional equipment & processes to collect – Maximum removal rate constrained by environmental sustainability , social acceptance and economic viability – Land-ownership is mixed (Federal, State, Tribal, private) and is a key factor affecting feedstock supply 82 BANR activities: Modeling & optimizing harvest operations Harvest equipment slash piles from forest restoration Cost and productivity study 83 Contact Information • BRDI: Daniel Cassidy, [email protected] • AFRI: Bill Goldner, [email protected] – 202-445-3470 Mobile • SBIR: Bill Goldner • Joint DOE/USDA Feedstock Genomics for Bioenergy: Bill Goldner
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