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Biorefinery – An Overview
Gopal C. Goyal – Manager, Fiber Technology Solutions
Zheng Tan – Senior Research Scientist
Caifang Yin – Research Fellow
Norman Marsolan – Director, Research & Development
International Paper
Loveland, OH, USA
Tom Amidon – ESPRI, SUNY College of ESF
Syracuse, NY, USA
Slide 2
Topics:
Facts and figures
Background information related to biorefinery
concepts
Various options for woody biomass conversion to
ethanol
Results on maple and Eucalyptus
• VPP concept
Conclusions
Slide 3
Drivers for Biorefinery
Bio-Product Current 2020 2090
Liquid Fuels 1-2% 10% 50%
Chemicals 10% 25% >90%
Materials 90 % 95% 99%
NRC Report - 2000
Chemicals – Petroleum-based feed stock for chemical industry
was 50% prior to WWII
Biomass Availability - 368 million tpy tree and 998 million
TPY agri-residues available for meeting 30% energy demand
(DOE/USDA “Billion Ton” study)
Reduce dependence on petroleum
Improve profits of the stagnant Paper Industry –
Slide 4
US Forest Products Industry Overview
Manufacturers of pulp, paper, paperboard, and wood products
$230 billion per year to the US economy
Employment – 1.3 million; Payroll - $50 billion
7% of US manufacturing base; top 10 manufacturing in 42 of
50 states
Converts 270 million tons/yr for products
US consumption about 210 million tons/yr
Post-consumer recovery of paper and paperboard is 50%
Copyright 2005 © Agenda 2020
Slide 5
Biorefinery Changing the Basis and Rules of Competition
A forest biorefinery is a facility that integrates
biomass conversion processes and equipment into
an existing chemical pulp mill to produce fuels,
chemicals, and/or renewable energy, in addition to
manufacturing traditional pulp products.
The purpose of biorefinery is to improve pulp mill
profitability and competitiveness.
Slide 6
Some Facts:
Hemicellulose is worth more as ethanol than as
energy
Lignin is worth more as ethanol (syngas) than as
energy from direct combustion
Cellulose is worth more as pulp than as ethanol
Slide 7
Various options for the conversion of cellulose material to ethanol
AVAP (American Value-added Pulping™) process
Biomass gasification
Conversion of cellulosic material to ethanol –
Mascoma Corporation approach
Re-purposing of an existing Kraft mill – N. C. State
Value prior to pulping
Slide 8
The AVAP Process
Produces ethanol from wood
Co-produces ethanol with pulp
Site uses all the tree
Site is energy self-sufficient
•(Transportation fuels used to deliver wood)
Cost of ethanol production by AVAP
•~$0.30 - $0.60/USG
Slide 9
AVAP Biorefinery
Fast cooking in alcohol sulfite environment
•Hemicelluloses hydrolyze to sugars
•Easily bleachable pulp produced – furnish to paper machine
•Lignin sulfonated
Sugars are fermented to ethanol
Lignin is precipitated
•Gasifier produces syngas
•Syngas is: oUsed to make heat and power in the first phase
oCan be used to make transportation fuels in the future
Process and heat integration maximized
•Reuse of chemicals and heat minimizes production costs
Start a design for 20 million gallons annual cellulosic ethanol plant for Flambeau River Paper as early as 2009
Slide 10
AVAP Process Highlights
Fast cooking (2-3 hr. batch cooks at 300°F)
Cooking liquor ethanol and SO2
Wash presses to reduce liquor losses
MVR pre-evaps/stripping to evaporate concentrated cooking chemicals
Neutralization of liquor to precipitate lignin • Filtered to high solids, gasified, and converted to
ethanol
Fermentable sugars are concentrated • Fermentation, distillation, and dehydration to
convert in fuel ethanol (100%)
Slide 11
Hemicellulose Cellulose Lignin
Pulp
Paper
Fermentable
Sugars
Ethanol
Gasification
Energy…ethanol
Fermentation Combustion
Energy
Combustion
Energy
Wood Chips Wood chips
Forest residue Bark
Combustion
Energy
Combustion
Energy
Biorefinery Revenue Streams
Trees
Slide 12
Reasons for biomass gasification
Biomass cost - $1-2/MM BTU
Burned biomass to replace steam - $4/MM
BTU
Biomass gasification generation of
syngases to replace natural gas – 6-10/MM
BTU
B. Thorp – Solutions Magazine
Slide 13
Biomass gasification: background
Potlatch is proposing potential site for industry biorefinery demonstration
Fully integrated agric/forest biorefinery using both biochemical (VPP) and thermochemical conversion (biomass gasification)
Driver is finding low cost ways to reduce or eliminate the mill’s dependency on natural gas while developing new products from the forest residuals
Potlatch interest is to support whatever will “get this done” on behalf of the industry
Copyright 2005 © Agenda 2020
Slide 14
Key Participants (as of January 15, 2005)
Potlatch Corporation
Winrock International
State of Arkansas
Agenda 2020 Technology Alliance
• Weyerhaeuser
• Stora Enso
• Others pending
Potential Partners: local refinery and energy utility
Copyright 2005 © Agenda 2020
Slide 15
Arkansas IFPB: Raw Materials
Large quantities of low cost Bio-mass are available:
• From the Forest: about 2/3 of the trees are left in the forest
• From Farming: We believe up to 2/3 of the plants are left
on the ground
• Pulping
o Lignin (black liquor): Virtually all the lignin in the chips
(about ½) is removed and burned in a recovery boiler
o Hemicellulose: Makes up 20 to 30% of the chips and is lost in
the pulping process
• Selected Manufacturing and Municipal Waste: There may
be opportunities to recover a portion of these waste
streams
• Ethanol Plants: If a conventional ethanol plant was close
by its waste stream could also be processed
Copyright 2005 © Agenda 2020
Slide 16
Conversion of lignocellulosic material to ethanol from an existing mill
Two main schools of thought:
• Repurposing an existing mill with the purpose of
making ethanol only
• Extracting hemis prior to pulping and still making
unchanged pulp and paper products (VPP)
Slide 17
Mascoma
Established August 2005 in Cambridge, MA
Found from many years of leading cellulosic ethanol research
by Dr. Lee Lynd and Dr. Wyman at Dartmouth college
Venture capital funded for technology development and
commercialization
Dedicated to converting biomass cellulose to low-cost
renewable fuels
Converting biomass (paper sludge, wood chips, switch grass,
corn stover, etc.) to ethanol by hydrolysis, saccharification,
fermentation in a separate or combined process
Announced a plan to build a $20 million 15,000 square foot
cellulosic biomass ethanol demonstration facility in New York
State
Slide 18
Evolution of Biomass Processing Featuring Enzymatic Hydrolysis
Mascoma Focus
Increasing process simplification SHF: Separate hydrolysis & fermentation SSF: Simultaneous saccharification & fermentation
SSCF: Simultaneous saccharification & co-fermentation CBP: Consolidated bioprocessing
O2 O2 O2
Processing Strategy (each box represents a unit operation)
SHF SSF/SSCF tSSF/tSSCF (elevated temperature)
CBP
Process
Cellulase
Production
Cellulose
Hydrolysis
Hexose
Fermentation
Pentose
Fermentation
Slide 19
North Carolina State University
Repurpose an uneconomical pulp mill to a wood-ethanol plant
Redeploy the supply chain, equipment, and people assets
The proposed technology consists of prehydrolysis, high yield pulping, and
separate or simultaneous saccharification/fermentation
Prehydrolysis of wood chips and residuals (tops and limbs) in digester for
hemicelluloses fermented to ethanol
Cook the prehydrolysed wood to 10% lignin content, exiting the digester as
single fibers
Subject the cooked (high yield) fibers to hydrolysis enzymes for sugars
followed by fermentation to ethanol
Spent liquor after prehydrolysis (along with other biomass) can be
concentrated and burned in the existing chemical recovery for energy or
processed for the value of lignin
The carbohydrate hydrolysis and fermentation yields being the key to the
technology’s success
Slide 20
Woodyard
Wood + Forest Residues
Kraft mill re-purposed to biochemicals
Fibrous Solids Storage
Hydrolysis Units
Hydrolysis Units
Fibrous Solids Storage
Fermentation Feed
Rectification
Chlorine Dioxide
Generation
Primary Clarifier
Biological Treatment
Enzyme Hydrolysis
Lignin Lignin Removal
Biomass Washers
Biomass Washers
Liquor Combustion
Liquor Evaporation
Biomass Pretreater
Biomass Pretreater
Power Generation
Bark/Gas Combustion
Uncoated Paper Machine
Uncoated Paper Machine X
X
Drying
Distillation
Ethanol
Lime Kiln Calcining
Recaustic
Fermenters Fermenters
Fermenters
Power Fiber
Energy
Chemicals
Biorefinery
Products
Legend
Slide 21
Chemical Pathway (Fermentation)
Hemicellulose makes up about 20 to 30% of the
wood used in the pulping process and is
considered a waste product
We believe the hemicellulose can be extracted prior
to pulping chips without damaging the fiber
Once extracted and concentrated the hemicellulose
can be fermented, then distilled into ethanol –
yielding about 35 gallons per ton of paper (possibly
more)
Copyright 2005 © Agenda 2020
Slide 22
Value Prior to Pulping
Bio Refinery (fermentation, others)
Ethanol
Acetic Acid (from HW)
Bio - Plastics /Polymer/Fibers
Wood Chips Extracting
Hemicelluloses Pulping
Pulps Paper
Chemical Celluloses MCC
A Simple Flow Diagram For The Value Prior To Pulping
Slide 23
New Value Streams from Wood
0
2
4
6
8
10
12
14
16
18
Kra
ft P
ulp
Wood a
s Fuel
Total
Kra
ft P
ulp
Eth
anol
Ren
ewab
le F
T Fuel
Total
ce
nts
/lb
od
wo
od
Bio-RefineryCurrent Pulp Mill
Biorefinery could potentially increase the value of wood by 41%.
Slide 24
VPP Consortium
Outgrowth of unfunded proposal to DOE
Goal – Demonstrate feasibility of concept
Be ready for demonstration plant in 2008
Participants • 7 paper companies
• 2 enzyme companies
• 3 universities
• NREL
• FPL
• CTT
• State of Wisconsin
Copyright 2005 © Agenda 2020
Slide 25
Pre-extraction Curves for Maple and Eucalyptus
0
5
10
15
20
25
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Time @ temperature, min
% m
ass
re
mo
val
maple 140 C
maple 150 C
maple 160 C
Euca,170 C, 90min to temperature
Effect of time and temperature on mass removal for maple and Eucalyptus chips
Slide 26
Yield vs. kappa relationship for control and extracted maple and Eucalyptus chips
Yield vs. Kappa for Maple and Eucalyptus
40
42
44
46
48
50
52
54
56
5 10 15 20 25 30 35
Kappa
% T
ota
l Y
ield
MapleControl
Maple 8% Removal
Maple 12% Removal
Euca-Control
Euca 5.3% Removal
Euca 11% Removal
Euca 16.5% Removal
Slide 27
H FACTOR/COOKING TIME AS A FUNCTION OF PULP KAPPA
STUDY CONDUCTED BY CONSORTIUM AT ESF
16% AA AND 90 MIN TO 165 C
Control chips Biorefined Chips
8% Removal 12% removal
Kappa
Cooking time at 165 C
H Factor
18
90
986
18
45
531
18
45
531
25
30
248
TI MAPLE PULP LAB BLEACHING RESULTS
STUDY CONDUCTED BY CONSORTIUM AT ESF
ODEPD BLEACHING
Pulp Control pulp 12% biorefined pulp 12% biorefined pulp
Projected
Kappa
Kappa factor
Total ClO2, %
Brightness, %
18
0.154
1.45
87.4
17
0.12
1.2
89.8
25
0.12
1.54
88-89
Other bleaching chemicals – 2% NaOH, 0.25% H2O2, 0.8% H2SO4
PROPOSED BIOREFINING BUSINESS CASE FOR TI MAPLE CHIP
STUDY CONDUCTED BY CONSORTIUM AT ESF
16% AA AND 90 MIN TO 165 C
Control Biorefining @ 12% removal
Kappa
Cooking time at 165 C
H factor
Projected ClO2 usage, %
Projected brightness, %
18
90
983
1.45
87.4
25
30
248
1.55
88-89
Cooking & Bleaching of Ti Maple
Slide 28
Pulping extracted chips to the same kappa results
in a 2% lower pulp yield. For a 1,000 TPD mill the
wood demand would go up by 365 tons/day
(assuming 12% extraction and 48% yield from the
extracted chips).
Pulping to higher kappa, compared to control, the
bleaching cost would be neutral due to easier
bleachability of the pulp. The wood consumption
would go up 272 TPD (assuming 12% extraction and
50% pulp yield from extracted chips.)
Slide 29
Refining energy response for control and the pulp made from maple extracted chips
Maple - Freeness vs. PFI Refining
0
100
200
300
400
500
600
0 1000 2000 3000 4000 5000 6000
PFI Revs
Fre
en
ess, m
L C
SF
Control
8% Removal
12% Removal
Slide 30
Tensile index vs. freeness for control and the pulp made from extracted chips for maple
Maple - Tensile Index vs. Freeness
0
10
20
30
40
50
60
70
80
90
200 250 300 350 400 450 500 550
Freeness, csf mL
Ten
sil
e in
dex, N
-m/g
Control
8% Removal
12% Removal
Slide 31
Tensile index vs. freeness for control and the pulp made from extracted chips for Eucalyptus
Eucalyptus - Tensile Index vs. Freeness
0
10
20
30
40
50
60
70
80
0 100 200 300 400 500 600 700
Freeness, csf mL
Tn
esil
e In
dex, N
-m/g
Control-Eucalyptus
5.3% Removal
11% Removal
16.5% Removal
Slide 32
Tear index vs. freeness for control and the pulp made from extracted chips for maple
Maple - Tear Index vs. Freeness
0
2
4
6
8
10
12
200 250 300 350 400 450 500 550
Freeness, csf mL
Tear
ind
ex,
mN
m^
2/g
Control
8% Removal
12% Removal
Slide 33
Tear index vs. freeness for control and the pulp made from extracted chips for Eucalyptus
Eucalyptus - Tear Index vs. Freeness
0
2
4
6
8
10
12
14
0 100 200 300 400 500 600 700
Freeness, csf mL
Tear
Ind
ex, m
N m
^2/g
Control
5.3% Removal
11% Removal
16.5% Removal
Slide 34
TI Maple Biorefinery Business Model
Acetic Acid
(Dilute)
Extracted
Chips Digester Pulp
Membrane
Separation Step
Heat Exchanger Steam
Hydrolysate
4% Solids
Hydrolysate
10% Solids
Concentration
Step
(Reverse Osmosis)
Acetic Acid
Purification Lignin
Sugars
Shipped for
Offsite
Fermentation Sewer
Biorefinery
Acid Extraction Chips
Water
Slide 20
Fermentation
Distillation
Ethanol
Slide 35
IFPB: Forest Products Industry Advantages
Forest-based materials as feedstock
• Forest-based materials represent 30% of resources needed to
support emerging bio-industries
• Ethanol production from wood-based hemicellulose uses
significantly less fossil fuel than production from other biomass
resources
• Managed forests have positive ecological impacts that are not
mirrored in other biomass feedstocks
Industry has infrastructure and expertise
• Industry owns and manages operations for feedstock harvesting
• Raw material already is being supplied to mills
• Industry has experience in chemical processing and handling in
compliance with related standards and regulations
• Location of facilities in rural areas can realize important
synergies between agricultural and forest-based feedstocks
Copyright 2005 © Agenda 2020
Slide 36
Challenges:
Biomass gasification technology and conversion to
higher value chemicals is new
Technical and financial risk are high
No individual company is likely to take the risk of
being first. Therefore we need:
• Financial resources
• Partners
Copyright 2005 © Agenda 2020
Slide 37
Benefits if Successful
Technology can be implemented at any manufacturing site
that has access to bio-mass and a use for the waste heat
Provides new products from untapped resources
Market for bio-fuels and chemical is vase (room for many
players)
If implemented industry-wide the State’s and nation’s
dependency on fossil fuel would be reduced
Agricultural and Forest products industries would be more
viable
Creates new high-paying jobs (direct and indirect added to the
economy)
Increased tax revenue for the State
Copyright 2005 © Agenda 2020
Slide 38
Conclusions
The VPP option is by far the most extensively investigated so far. If the yield disadvantages can be overcome so that the same amount of wood is required to keep the same pulp production level, then this could be a very attractive option.
Repurposing a Kraft mill and gasification of biomass have their own merits, but commercial success of both these approaches is yet to be seen.
Pulps made from extracted maple and Eucalyptus chips exhibited very different characteristics in terms of pulping, bleaching, and strength properties. Pulp with satisfactory strength properties from extracted maple chips could be made, whereas Eucalyptus pulps were significantly lower in tear and tensile properties.
A thorough business case analysis needs to be done for any of the options because return on investment is very site-specific depending on wood and energy cost.
Slide 39
Questions?