Presentation of Andy Aden for the "Workshop Virtual Sugarcane Biorefinery" Apresentação de Andy Aden realizada no "Workshop Virtual Sugarcane Biorefinery " Date / Data : Aug 13 - 14th 2009/ 13 e 14 de agosto de 2009 Place / Local: ABTLus, Campinas, Brazil Event Website / Website do evento: http://www.bioetanol.org.br/workshop4

1. NREL Biomass and Biofuels Experience
Andy Aden, PE
Senior Research Engineer
Nation Renewable Energy Laboratory
August 16, 2009
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1

2. Energy Efficiency & Renewable Energy
Technology Development Programs
NREL R&D Portfolio
L P o
Efficient Energy Use Renewable Resources Energy Delivery &
• Vehicle Technologies • Wind Storage
• Building Technologies
g g • Solar
So a • Electricity
• Industrial Transmission &
• Biomass
Technologies Distribution
• Geothermal
• Alternative Fuels
• Hydrogen Delivery
and Storage
Foundational Science

3. Biomass F d t k
Bi Feedstocks Intermediates
I t di t Transportation Fuels
Fermentation
Ethanol &
Catalytic synthesis
Mixed Alcohols
FT synthesis
Lignocellulosic Gasification
g Syn Gas
y ese
Diesel*
Biomass (wood, agri, MeOH synthesis
Methanol
waste, grasses, etc.) MTG
Pyrolysis & Gasoline*
Liquefaction Bio-Oils HydroCracking/Treating
Diesel*
Ag residues,
(stover, bagasse) Catalytic upgrading
Lignin Gasoline* & Diesel*
APP
Diesel*
Sugar/Starch Crops Catalytic pyrolysis
Gasoline*
Hydrolysis Sugars
(corn, sugar cane, etc.) APR
Hydrogen
Fermentation Ethanol, Butanol,
Hydrocarbons
Transesterification Biodiesel
Natural Oils
(plants, l
( l t algae)
)
Hydrodeoxygenation Green diesel
* Blending Products
National Renewable Energy

4. Biomass Program Mission and Objectives
Program Mission
Develop and transform our renewable and abundant,
non-food,
non food biomass resources into s stainable cost
reso rces sustainable, cost-
competitive, high-performance biofuels.
Focus on targeted research, development, and
demonstration
• Support through public and private partnerships
• Deploy in integrated biorefineries
Program Performance Goals
• Make cellulosic ethanol cost competitive at
a modeled cost for mature technology:
$1.76/gallon
$1 76/gallon by 2012
• Help create an environment conducive to
maximizing production and use of biofuels,
21 billion gallons of advanced biofuels per
year by 2022 (EISA)

5. U.S. Biomass Resource Assessment
• Updated resource assessment - April 2005
• Jointly developed by U.S. DOE and USDA
• Referred to as the “Billion Ton Study”
Taken from ORNL & USDA Resource Assessment Study by Perlach et.al. (April 2005)
http://www.eere.energy.gov/biomass/pdfs/final_billionton_vision_report2.pdf

6. In 2008, the Biomass Program, Sun Grant Initiative universities, and USDA selected, and in
some cases established the first round of replicated field trials of corn stover removal
and dedicated herbaceous energy crops.
This map shows
the selected
locations and
types of crops.

7. Commercial development

8. Appropriate Level of Analysis for Project Stage of Development
Early Stage: Simple spreadsheet,
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back of the envelope estimates  Early Stage: Simple cash
Mid Stage: Industry-relevant flow analysis
ASPENPlus™ process simulation  Mid Stage: Discounted cash
Kinetic modeling and regression flow rate of return analysis
fl t f t l i
analysis tools
R&D
Conceptual Capital and
Material and Economic
Process Project Cost
Energy Balance Analysis
Design Estimates
Environmental /
Sustainability
Analysis
National Renewable Energy 8

9. Biochemical Conceptual Design Report
Drives R&D Direction
Enzyme
Production (Currently being updated)
Co-
Enzymatic
E ti fermentation
f t ti Product
P d t
Pretreatment Conditioning Ethanol
Hydrolysis of C5 & C6 Recovery
Sugars
Hybrid Saccharification & Fermentation - HSF
Residue
By-products
Processing
• Conceptual design of a 2,000 tonnes/day commercial plant –
one possible tech package, not optimized
• NREL pilot plant based on this process
• Basis for connecting R&D targets to cost targets
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• Has undergone rigorous peer review
• Basis for comparison against other technology options

10. Technical Achievements Translate into Cost Savings

11. FY08 Biochemical State of Technology
Bi h i l St t f T h l
$7.00
(yr $2007 actual)
$6.47
$6.00 Feedstock Conversion
Minimum Ethanol Sellin Price (2007$ per gallon)
$5.00
$4.00
ng
$3.00 $2.85
$2.69 $2.61
FY06 Included in FY07 $2.36
$1.98
$2.00
d
m
$1.68
$1 68
$1.49
$1.00
$0.00
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012

12. NREL Pilot Plant Capabilities
1 ton per day biochemical
batch & continuous
pretreatment
enzymatic hydrolysis
fermentation (9000L)
Distillation
Separations
0.5 ton per day thermochemical
Gasification
Pyrolysis
Tar Reforming
Syngas cleanup
Fuel synthesis
National Renewable Energy

13. Thermochem Conceptual Design
Feed Report Drives R&D Targets
Processing Products
and Handling
Gasification Gas Cleanup Gas Conditioning Fuel Synthesis Heat
&
Indirect
I di t High T
Collection/Fractionation Upgrading Power
Separation
Indirect Gasification and Mixed Alcohol Synthesis
• Conceptual design of a 2000 tonnes/day commercial plant
• NREL pilot plant based on this process
• B i f connecting R&D t
Basis for ti targets t cost t
t to t targets
t
• Has undergone rigorous peer review

14. Fast Pyrolysis and Bio-oil as Feed to
Power Plant or Petroleum Refineryy
Bio-oil is is comprised of many oxygenated organic
chemicals, with water miscible and oil miscible fractions
Dark brown mobile liquid,
Combustible,
Not
N t 100% miscible with hydrocarbons,
i ibl ith h d b
Modest heating value ~ 17 MJ/kg,
High density ~ 1.2 kg/l,
Acidic, H 2 5
A idi pH ~ 2.5,
Pungent odour,
“Ages” - viscosity increases with time
Based on research at NREL (1990 - 2006)

15. Stage of Development of Biofuels Technologies
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Compared to Penetration of Conventional Fuels
Demonstration Market Market
Biofuel R&D Initial System Refined Commercial Entry
y Penetration
Prototypes Prototypes Prototypes
Ethanol from
Corn/Sugarcane
Ethanol from 2012 – few 700 tons/day
http://www1.eere.energy.gov/biomass/
htt // 1 /bi /
lignocellulosics start commercial operation
Biodiesel
Renewable Conventional
Diesel
Bio Syn-Gas Heat & Power
Liquid Fuels
Bio-Oil Chemicals
Fuels
Ren. Diesel Specialties
from Algae
Sugars to
Hydrocarbons
National Renewable Energy

16. Key challenges facing the biofuels industry
1. The “Blend Wall”
 E10 market will soon be saturated and E85 market is very small
and stagnant
 Even if E20 blends are allowed, market is limited
 Advanced biofuels key for expanding markets and achieving
societal benefits
2. Cost Competitive Cellulosic Biofuels
 Current “credit crunch” affects entire industry
3. Sustainability
 Land use change / availability
 Water use / water quality
 GHG / Climate change
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17. Life Cycle Assessment
+ Water Use/Recycley
A H li ti and Rigorous Approach
Holistic d Ri A h + Land Use
+ Land Use Change
to Answer Sustainability Questions + Direct/Indirect Impacts
+ Biodiversity…
waste materials Waste
emissions
emissions disposal
Extraction
process energy net emissions
energy
non-
renewable raw materials energy emissions energy emissions
energy
Intermediate Intermediate Process
Process feedstock Process feedstock of
final product
Interest
Intermediate
energy energy
non- feedstock emissions
renewable
emissions energy Extraction
materials Process raw materials
emissions p
process
Life cycle system boundary

18. GHG Impacts
Relative Emissions Impacts
CO Plants
Wet DGS
Reduction
36%
Greenhouse gas emissions of fuels vary by feedstock
and by type of energy used for processing.

19. Algae
Microalgae
60%
Triglyceride
CO2
40% Jet Fuel (JP-8)
Carbohydrates
and
Cultivation Ponds Protein
• Ethanol
• Power Green Diesel
• F d
Food
National Renewable Energy

20. Thank You for the
Opportunity
Are there any Questions ?