2007 exco59 meeting 1 - ieabioenergy.com · associated study tour provided the participants with...

2007 ExCo59 Meeting 1

2 2007 ExCo59 Meeting


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SESSION A: BIOREFINERSESSION A: BIOREFINERSESSION A: BIOREFINERSESSION A: BIOREFINERSESSION A: BIOREFINERY PY PY PY PY PAAAAATH FTH FTH FTH FTH FORORORORORWWWWWARD,ARD,ARD,ARD,ARD,PILPILPILPILPILOOOOOT PLANTS, AND THE ST PLANTS, AND THE ST PLANTS, AND THE ST PLANTS, AND THE ST PLANTS, AND THE STTTTTAAAAAGE GGE GGE GGE GGE GAAAAATE PRTE PRTE PRTE PRTE PROCESSOCESSOCESSOCESSOCESS

1.1 Commercializing Biorefineries: The Path Forward1.2 Insuring Success through Stage Gate and Beyond1.3 Providing Biochemical Technologies at the Pilot Scale for Integrated

Biorefinery Development1.4 Biorefinery, The Bridge Between Agriculture and Chemistry

SESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLOGIES, IBUS,OGIES, IBUS,OGIES, IBUS,OGIES, IBUS,OGIES, IBUS,AND INTEGRAAND INTEGRAAND INTEGRAAND INTEGRAAND INTEGRATED CEREAL PRTED CEREAL PRTED CEREAL PRTED CEREAL PRTED CEREAL PRODUCTIONODUCTIONODUCTIONODUCTIONODUCTION

2.1 Pilot-Scale Thermochemical Technologies for Integrated BiorefineryDevelopment - The Thermochemical Conversion Platform

2.2 Integrated Biomass Utilization Systems: Best Basis for Biorefiners2.3 Integration of Biomass and Cereal Ethanol Production

SESSION C: BIOREFINERSESSION C: BIOREFINERSESSION C: BIOREFINERSESSION C: BIOREFINERSESSION C: BIOREFINERYYYYY: THE L: THE L: THE L: THE L: THE LONG WINDING RONG WINDING RONG WINDING RONG WINDING RONG WINDING ROOOOOADADADADAD3.1 Incorporating Conversion R&D and Testing Adaptation in an

Existing Facility3.2 Upgrading of Byproducts from Biodiesel and Sugar Industry by

Bioconversion and Chemical Catalysis3.3 Commercializing Thermochemcial R&D and Pilot-Plant Results

SESSION D: IOGEN AND DEPSESSION D: IOGEN AND DEPSESSION D: IOGEN AND DEPSESSION D: IOGEN AND DEPSESSION D: IOGEN AND DEPARARARARARTMENT OF ENERTMENT OF ENERTMENT OF ENERTMENT OF ENERTMENT OF ENERGGGGGY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICE4.1 The Iogen Story4.2 Project Management Center: Managing the The Biofuels Portfolio

TTTTTOUR: NOUR: NOUR: NOUR: NOUR: NAAAAATIONAL RENEWTIONAL RENEWTIONAL RENEWTIONAL RENEWTIONAL RENEWABLE ENERABLE ENERABLE ENERABLE ENERABLE ENERGGGGGY LABORAY LABORAY LABORAY LABORAY LABORATTTTTORORORORORYYYYY

TTTTTOUR: COORS PLANTOUR: COORS PLANTOUR: COORS PLANTOUR: COORS PLANTOUR: COORS PLANT

LISLISLISLISLIST OF PT OF PT OF PT OF PT OF PARARARARARTICIPTICIPTICIPTICIPTICIPANTSANTSANTSANTSANTS


The International Energy Agency (IEA) BioenergyImplementing Agreement provides a structurethrough which Member Country experts fromresearch, government, and industry share ideas,collaborate on research, and strategize on howto foster the growth of bioenergy worldwide.Members of IEA Bioenergy met in Golden,Colorado April 25-27, 2007 for their 59thExecutive Committee Meeting (ExCo). Part of themeeting was a workshop to provide updates oncurrent practices and to share ideas on policiesand strategies regarding research anddevelopment (R&D) that will foster thebiorefinery concept. The workshop andassociated study tour provided the participantswith opportunities to view cutting-edge bioenergytechnologies and R&D facilities. The meetingalso enabled the members to address theplanning and business administration tasksrequired to maintain the continued operation ofthe IEA Bioenergy Agreement.

Introduction

The following countries were represented at the meeting:

• Australia• Austria• Belgium• Canada• Denmark• European Commission• France• Germany• Japan• Netherlands

• New Zealand• Norway• South Africa• Republic of Korea *• Sweden• Switzerland• Turkey *• United Kingdom• United States of America

* Denotes Non-Member Countries that attended the meeting as Observers.


CommerCommerCommerCommerCommercializing Biorefcializing Biorefcializing Biorefcializing Biorefcializing Biorefineries: The Pineries: The Pineries: The Pineries: The Pineries: The Path Fath Fath Fath Fath Forororororwwwwwarararararddddd Larry Russo, DOE, U.S.A.

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Insuring Success thrInsuring Success thrInsuring Success thrInsuring Success thrInsuring Success through Stage Gatough Stage Gatough Stage Gatough Stage Gatough Stage Gate and Bee and Bee and Bee and Bee and BeyyyyyondondondondondBob Wooley, National RenewableEnergy Laboratory (NREL), U.S.A.


The biorefinery concept is critical to the development andintegration of bioenergy into the world economy. However, aclear implementation path is needed. This includes R&D incritical technology areas, technology scale-up and pilot plants,and best management practices. Session A of the ExCo 59meeting was designed to provide an overview of thecommercialization of the biorefinery concept and the variousstrategies members of the Executive Committee 59 are using.Four speakers from the United States (U.S.) Department ofEnergy (DOE), the U.S. National Renewable Energy Laboratory(NREL), and the representative from the Netherlands providedinput into this session.

The ExCo member from U.S. DOE discussed the policies that theUnited States government is pursuing to promote thedevelopment of biorefineries. In particular, the discussion wasfocused on the President’s “Twenty in Ten” (20 in 10) goal toreduce twenty percent of gasoline consumption in ten years.This goal will help thrust forward the biorefinery conceptthrough increased production of biofuels by 2017. Severalfederal agencies, as well as the national laboratories includingthe U.S.-based NREL, are in the process of collaboratingon this goal.

The next presentation was led by NREL. It focused on the StageGate Process, an innovative solution to manage R&D projects.The Stage Gate Process is based on the notion that asmanagement practices improve, R&D funds will be spent moreefficiently and the technical challenges facing efforts such asthe 20 in 10 will be met more quickly. The discussion in thissession also provided an overview of NREL’s pilot scalebiochemical biorefinery and how it is a critical tool in furtheringthe commercialization of biorefinery technologies.

The presentation by the ExCo member from the Netherlandsprovided an overview of the integrated relationship betweenagricultural feedstocks for a biobased chemical industry, acritical component of the integrated biorefinery. All of thesepresentations provided an overview of how various efforts indifferent countries have been deployed to accelerate theuse of bioenergy.

1.0SESSION A: BIOREFINERSESSION A: BIOREFINERSESSION A: BIOREFINERSESSION A: BIOREFINERSESSION A: BIOREFINERY PY PY PY PY PAAAAATH FTH FTH FTH FTH FORORORORORWWWWWARD, PILARD, PILARD, PILARD, PILARD, PILOOOOOT PLANTS,T PLANTS,T PLANTS,T PLANTS,T PLANTS,AND THE SAND THE SAND THE SAND THE SAND THE STTTTTAAAAAGE GGE GGE GGE GGE GAAAAATE PRTE PRTE PRTE PRTE PROCESSOCESSOCESSOCESSOCESS


The U.S. is pursuing R&D activities that will bringcommercially viable biorefineries to the market through amulti-faceted strategy that is based on analysis, thePresidential “Twenty in Ten” Initiative, and the drive toreduce U.S. dependence on foreign oil.

In April 2005, DOE published the study entitled Biomass asFeedstock for Bioenergy and Bioproducts Industry: TheTechnical Feasibility of a Billion Ton Annual Supply, whichindicated that the U.S. has the potential to displace 30percent of current U.S. petroleum consumption using avariety of biomass feedstocks (corn stover, wheat straw,switchgrass, etc.). This analysis provided the foundation forDOE to pursue a strategy that examines multiple biomassfeedstocks. Currently, this report is being updated by theU.S. DOE Oak Ridge National Laboratory and is expected tobe published in 2008.

The U.S. biomass R&D effort was further shaped by theannouncement of the U.S. Biofuels Initiative, whichcomplements the Twenty in Ten Initiative. The U.S. BiofuelsInitiative set the goal to achieve biofuels production todisplace 30 percent of the nation’s 2004 gasoline use by2030. To achieve this goal, the U.S. structured itsgovernment-funded research portfolio along five pathways:

1) Feedstock R&D2) Biochemical R&D3) Thermochemical R&D4) Products R&D5) Balance of Plant

Through this multiple-pathway approach, the U.S. will deployintegrated biorefineries throughout the country to meet itsbioenergy objectives.

In the effort to commercialize the biorefinery concept, DOEconsiders its critical role to be the mitigation of riskassociated with the commercialization of emergingtechnologies. At present there is significant privateinvestment in biofuels development, although early failuresin R&D efforts could jeopardize further investment.Therefore, DOE looks to provide 80 to 100 percent of thefunds needed for basic R&D and technology development.

As the technologies mature and the proof-of-concept andcommercial viability are demonstrated, the U.S. governmentshare of the funding is reduced and more of the financialburden is shifted to the commercial sector. This is the casewith the U.S. DOE 942 solicitation, which aims to provide

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loan guarantees for the development of commercialbiorefineries. These loan guarantees mitigate the financialburden on lending institutions because the U.S. governmentis held responsible should the recipient default on the loan.

To avoid early failures in R&D projects, DOE uses the StageGate Process. It is an advanced management system whichtracks the progress of R&D projects within its technologydevelopment portfolio. The Stage Gate process enablesevaluation of a project’s performance in bringing scienceand technology to commercial applications quicker, at lowercosts, and with improved probability of success. This isaccomplished by tracking the project at the beginning of theR&D stage and providing a framework for each project to gothrough a series of Stage Gate reviews before receivingsupport to continue to the next stage. R&D starts withsignificant government investment and as a project ortechnology progresses, industry takes on a greater rolethrough each stage. Commercialization is the end goal inthis process. It is structured so that it incorporates stepssuch as exploratory research, development research, andtechnical support to address problems that will arise whenmoving to the commercialization phase.

In the Stage Gate Process, it is important to evaluate whathas been done throughout each project stage. During aStage Gate review, it may be determined that a projectshould be stopped. The process may reveal that there areshortcomings and more work is needed in a particular area,or that the project should proceed to the next stage. Thefinal assessment is critical to making sure that the rightprojects are being pursued.

Independent Project Analysis, Inc. (IPA) originated the StageGate Process under the Rand Corporation in the 1970’s,and has applied it to a variety of research portfolios,including those within the synfuels industry. IPAindependently measures the performance of capitalprojects, evaluates risk factors and unknowns, and predictsthe success of a project to guide the research process andmitigate potential barriers. The Stage Gate Process providessuggestions on how outcomes of commercial projects canbe improved. DOE has enlisted the services of IPA to help

Although a large portion of U.S policy aimed at reducing thenation’s dependence on foreign oil is centered on biofuels,the U.S. recognizes the need for a balanced approach toachieving its goal. The U.S. has begun to examine the needfor more flexible fuel vehicles and improvements in thefueling infrastructure.

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implement the Stage Gate Process for the DOE BiorefineryDevelopment projects to ensure maximum value is gainedfrom project investments.

NREL’s pilot scale biochemical biorefinery in the U.S. is acritical tool in furthering the commercialization of biorefinerytechnologies. This facility was constructed to generatecritical data on the behavior of the system for use in thedesign of larger commercial demonstration facilities.

NREL’s pilot plant can be used to test the feasibility ofproposed processes and implement process changes. It alsocan be used to research solutions to potential processbottlenecks and problems that can occur whenimplementing a new technology or process. Because pilotscale plants are less expensive to build and operatecompared to commercial scale facilities, this testingarrangement is much more cost effective thandemonstrating new technologies and processes at acommercial facility. Another benefit of NREL’s pilot plant isthe ability to provide design data on a variety of topics suchas chemical reactions, mass and heat balances, material forconstruction, control strategies, and operating costs for a fullscale plant. The pilot plant allows NREL to gather metricsassociated with competing technologies in terms of cost andproductivity to provide the commercial sector withindependently verified data needed by industry to make theappropriate business decisions.

NREL is in the process of adding new capabilities to its pilotplant to enable it to handle a wider range of pretreatmentchemistries. NREL is also adding new unit operations andexpanding instrument and control capabilities. Theseexpansions will enable NREL to provide more usefulinformation to the commercial sector and facilitate thedeployment of more technologies into the market place.

BIOREFINERBIOREFINERBIOREFINERBIOREFINERBIOREFINERYYYYY, THE BRIDGE BET, THE BRIDGE BET, THE BRIDGE BET, THE BRIDGE BET, THE BRIDGE BETWEENWEENWEENWEENWEENAAAAAGRICULGRICULGRICULGRICULGRICULTURE AND CHEMISTURE AND CHEMISTURE AND CHEMISTURE AND CHEMISTURE AND CHEMISTRTRTRTRTRYYYYY

The relationship between agricultural feedstocks and abiobased chemical industry is extremely important to thebiorefinery. For each country, the bridge between agricultureand chemistry is different. In many countries, efforts havebeen enacted to ensure that biomass feedstocks are usedin finished products. In Holland, a number of initiatives havebeen established to increase development of bioenergy,specifically a goal of 30 percent from biomass by 2030.

To tackle these issues, many countries realize theimportance of supply chains and co-production ofalternative products through biomass. The role of farmers inthe supply chain is also important because producing andselling biomass needs to make economic sense for farmers.A combination of different products both from the farmerand from the chemical industry will increase the potentialrevenue and provide stronger incentives. The importance ofco-products is exemplified in a pilot plant established innorthern Holland 10 years ago, which converted grass intothree major products with multiple applications.

There is renewed interest from the chemical industry andthe pulp and paper industry because of rising prices oftraditional feedstocks, and pulp and paper waste streamsare now a more economically feasible feedstock. Chemicalscan be made from biomass without major inputs. Also, whenconverting biomass to ethanol, the co-products are almostequal in value to the ethanol produced.

There are advantages of small-scale processing such asharvesting in the fields with lower transport costs andreduced water; however, the lacking economies of scale is adisadvantage of small-scale processing. Majordevelopments needed for the biorefinery include lower rawmaterial costs and better refinery efficiencies, separationtechnologies, and downstream processes.

The integrated biorefinery increases the value of individualbiomass components, as well as co-products. Thebiorefinery bridges the gap between agriculture and thechemical industries by providing a demand for biomassfeedstocks and producing a menu of finished chemicalproducts. When these products are produced from non-fossilfuel feedstock, they also promote strategic national goals forrenewable energy production.

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2.0SESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLSESSION B: THERMOCHEMICAL TECHNOLOGIES, IBUS,OGIES, IBUS,OGIES, IBUS,OGIES, IBUS,OGIES, IBUS,AND INTEGRAAND INTEGRAAND INTEGRAAND INTEGRAAND INTEGRATED CEREAL PRTED CEREAL PRTED CEREAL PRTED CEREAL PRTED CEREAL PRODUCTIONODUCTIONODUCTIONODUCTIONODUCTION

Thermochemical technologies are key components of theintegrated biorefinery concept. Biorefineries must be able toutilize various feedstocks and integrate multiple conversionprocesses.

One of the challenges faced by biorefineries is to developthermochemical technologies that are technically and economi-cally feasible at the appropriate scale for reasonably availablebiomass resources. NREL’s pilot plant facility attempts toaddress this challenge by measuring the technical and eco-nomic feasibility of a pre-commercial scale facility.

Presenters described the goal of most biorefineries, which is toproduce cost-competitive biofuels at approximately one U.S.dollar per gallon, and to produce gasoline-ethanol blends thatmeet industry, federal, and state specifications. To achieve this,biorefineries need to integrate bioethanol and electricitycombined with heat to achieve processing efficiencies.


Biorefineries utilize two main processes, biochemical andthermochemical, in converting raw biomass feedstocks intofinished products such as ethanol. Thermochemicalconversion utilizes heat and pressure to convert carbon intofinished products.

There are several barriers for thermochemical conversion inbiorefineries: feedstock analysis, conversion, gas clean-upand conditioning, and integration of operations. Multiplefeedstocks necessitate multiple conversion processes whichcan complicate integration in a biorefinery. Moreover,gasification of feedstocks is a complex function which needsto incorporate varied types of equipment. Clean-up of wastestreams from thermochemical processing affect theeconomics of the process.

At NREL, most of the thermochemical work is focused onparticulate removal and to consolidate as many processes aspossible. NREL’s recent focus has been on fuel synthesis toproduce biofuels from clean syngas. NREL can generatesyngas to test unit operations and look at integration andcatalyst performance issues. Once these technicalchallenges are addressed and the goals are achieved, majorbreakthroughs in biorefinery production will ensure that theU.S. will have the means to produce finished products fromrenewable resources.

Integrated Biomass Utilization System (IBUS) began byseeking alternative uses for straw. As the conceptdeveloped, it became clear that ethanol was a goodalternative use to animal feed. The key activity of IBUS is theintegrated utilization of sugar/starch and lignocellulosicfeedstocks. Most crops contain both sugar and starch, andlignocellulose, which are separated at the biorefinery.

In an integrated production of bioethanol and electricity, 55to 65 percent of the input energy is lost as heat. This energycan be captured during the co-production and utilization offuel ethanol and heat energy. The IBUS concept utilizes thesurplus steam to produce high-quality solid biofuels. TheIBUS system requires less energy and therefore has lowerenergy costs. Use of low pressure steam from electricity

Abengoa is a biorefinery technology company whichintegrates starch-hybrids and biomass. It has strategicinterests in producing fuels for future technologies such ashydrogen, and it anticipates its ethanol production will formthe basis for hydrogen fuels.

Abengoa is currently working on the development of athermochemical pathway for conversion of anycarbonaceous feedstock to ethanol. Current projects includea biorefinery pilot plant in York, United Kingdom sponsoredby the U.S. DOE, which converts 1.5 tons/day of biomassfeedstocks from corn stover, wheat straw, and switchgrass.Abengoa also has a commercial biomass ethanoldemonstration plant in Salamanca, Spain supported by theEuropean Commission, which uses 70 tons/day wheat strawas a feedstock and produces 5 million liters/year of ethanol.Abengoa has various gasification, catalyst development, andethanol reforming projects. One such project is a hybridstarch and biomass commercial plant in a conceptualdesign phase. Its output will be 700 tons/day integratedwith a cereal ethanol plant.

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generation means energy can be obtained without additionalCO2 emissions. The process can recycle byproducts, does notproduce waste water, and does not emit volatile organiccompounds.


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3.0SESSION C: BIOREFINERSESSION C: BIOREFINERSESSION C: BIOREFINERSESSION C: BIOREFINERSESSION C: BIOREFINERYYYYY: THE L: THE L: THE L: THE L: THE LONG WINDING RONG WINDING RONG WINDING RONG WINDING RONG WINDING ROOOOOADADADADAD

Bio-cascading is a term which describes processing that utilizesthe feedstock material in its entirety, helping to make effectiveuse of limited biomass resources. The integrated biorefineryattempts to utilize the entire feedstock stream to producebiofuels and valuable co-products.

Some technical challenges for biorefineries include:

* Hydrolysis degradation of products, fibers in corn ethanol products;

* Incorporating new conversion R&D in existing biorefinery facilities;

* Upgrading byproducts resulting from biodiesel and the sugar industry to be more efficient; and

* More efficient transportation.


Ethanol is used as a fuel additive (E5 and E10) as well as astand alone product (E85), and can help achieve the U.S.Presidential “Twenty in Ten” goal to reduce dependence onimported oil. Corn is the major feedstock for ethanolproduction, although only 13 percent of all corn produced inthe U.S. is used in ethanol production. The majority of cornis used for animal feed and export; however, the increasingdemand for corn has created a conflict known as the “foodvs. fuel” debate. Therefore, other feedstocks, such ascellulosic materials, are needed for maximum ethanolproduction. However, corn will continue to be the keyfeedstock until cellulosic ethanol becomes cost competitive.

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Biomass transport, pretreatment, conversion, product, andenergy costs are all barriers which must be overcome inorder to upgrade byproducts from biodiesel and the sugarindustry through bioconversion and chemical catalysis.Some important steps for biorefineries are to addressreduction costs for combined pretreatment, andconservation and separation costs such as in sugar andstarch refineries. Cost reduction in the biorefinery is themajor challenge facing the biofuels industry. There is alsosignificant potential for cost reduction through greatertransportation efficiency and cheaper and moreefficient feedstocks.

Biofuels have had an increasingly important role in theglobal energy supply, exhibiting 12-15 percent annualgrowth. There are two major biobased transport fuels:ethanol and biodiesel. The U.S. and Brazil are the primarycenters for ethanol production, and Europe is the primarycenter for biodiesel production. As an emerging technology,biofuels markets today are supported by subsidies to helpcompete with petroleum-based fuels. If the mandatesproposed by the U.S. and European Union are adopted, theywill create an additional demand for about 3 million barrelsper day of renewable transport fuels by 2020.

UOP is a supplier and licensor of processing technologywhich it applies to renewable feedstocks to help the majorbiorefinery centers in the world. UOP’s approach to biofuelsproduction uses direct conversion and pyrolysis. Theavailability of cellulosic biofuels will make a significantimpact on the amount of biofuels. Typical biomass iscomposed of cellulose, hemicellulose, lignin, and sugars/oils. Because of the various compounds which make upbiomass, it is difficult to process. A significant impact on thetransportation fuel market will also require the use oflignocellulosic material for biofuels. UOP and NREL havepartnered to pursue research together and to provide afoundation for the development of biofuels economically.

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AND CHEMICAL CAAND CHEMICAL CAAND CHEMICAL CAAND CHEMICAL CAAND CHEMICAL CATTTTTALALALALALYYYYYSISSISSISSISSIS


The Iogen StThe Iogen StThe Iogen StThe Iogen StThe Iogen StorororororyyyyyMaurice Hladik, Marketing Director, Iogen

PrPrPrPrProject Management Centoject Management Centoject Management Centoject Management Centoject Management Center: Managinger: Managinger: Managinger: Managinger: Managingthe Biofuels Pthe Biofuels Pthe Biofuels Pthe Biofuels Pthe Biofuels PororororortftftftftfolioolioolioolioolioJim Spaeth, U.S. Department of EnergyGolden Field Office


4.0SESSION D: IOGEN AND THE DEPSESSION D: IOGEN AND THE DEPSESSION D: IOGEN AND THE DEPSESSION D: IOGEN AND THE DEPSESSION D: IOGEN AND THE DEPARARARARARTMENT OF ENERTMENT OF ENERTMENT OF ENERTMENT OF ENERTMENT OF ENERGGGGGY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICEY’S GOLDEN FIELD OFFICE

This session discussed the demonstration commercial plantfunded by the DOE Biomass Program with Iogen. The Iogenplant uses straw as feedstock and will demonstrate thecellulose ethanol making process.

Another presentation was on the Project Management Center,part of DOE’s Golden Field Office. This Center manages $1.2billion in R&D funding for a variety of energy efficiency andrenewable energy projects, including biomass projects. Thepresenter provided an overview of the role of this office inmanaging the DOE biomass projects.


Iogen is a leader in producing enzymes, and has been activein producing ethanol since the 1970’s. Its businessobjectives are to be a world leader in the development anddeployment of cellulose ethanol technology, and to expandupon its existing strategies and partnership alliances.Iogen’s demonstration plant exclusively uses straw and is asuccessful operation of a semi-works demonstration facility.The plant demonstrates a cellulose ethanol process andintegrates all key unit operations into one continuousprocess. Iogen believes that cellulosic ethanol could displacemore than 30 percent of the U.S.’s present petroleumconsumption.

The U.S. DOE Office of Energy Efficiency and RenewableEnergy (EERE) has a dedicated field Project ManagementCenter (PMC) at its Golden Field Office (GFO) in Golden,Colorado. The PMC function is to manage EERE’s R&Dportfolio, which is approximately $1.2 billion annually. Thisincludes the Biomass Program research funds awarded tolaboratories, industry, and academia.

GFO uses common practices and business processes tomanage projects from basic R&D to commercialization. Animportant activity of GFO is enacting sections of the EnergyPolicy Act of 2005: Section 932 Commercial IntegratedBiorefinery; Section 941 Revisions to Biomass R&D Act of2000; Section 942: Cellulosic Ethanol Reverse Auction; andLoan Guarantees.

THE IOGEN STTHE IOGEN STTHE IOGEN STTHE IOGEN STTHE IOGEN STORORORORORYYYYY PRPRPRPRPROJECT MANAOJECT MANAOJECT MANAOJECT MANAOJECT MANAGEMENT CENTER:GEMENT CENTER:GEMENT CENTER:GEMENT CENTER:GEMENT CENTER:MANAMANAMANAMANAMANAGING THE BIOFUELS PORGING THE BIOFUELS PORGING THE BIOFUELS PORGING THE BIOFUELS PORGING THE BIOFUELS PORTFTFTFTFTFOLIOOLIOOLIOOLIOOLIO


5.0TTTTTOUR: NOUR: NOUR: NOUR: NOUR: NAAAAATIONAL RENEWTIONAL RENEWTIONAL RENEWTIONAL RENEWTIONAL RENEWABLE ENERABLE ENERABLE ENERABLE ENERABLE ENERGGGGGY LABORAY LABORAY LABORAY LABORAY LABORATTTTTORORORORORYYYYY

One of the premier research and development facilitiesfocusing on renewable energy in the United States is theNational Renewable Energy Laboratory. NREL has state of theart facilities where it performs research and development ofrenewable energy technologies. NREL also provides researchexpertise for DOE’s Office of Science, and the Office ofElectricity Delivery and Energy Reliability. The ExCo 59 Meetingtoured the facilities at NREL and the National Bioenergy Centerto get a better understanding of NREL’s capabilities.


The Biomass Surface Characterization Lab (BSCL) at NREL isdesigned to give scientists insights into the chemical andbiological reactions which can transform renewable plantand waste materials into useful sources of energy. BSCLfeatures electron and optical microscopes and otherresearch tools to probe biomass-to-energy processes atatomic and molecular levels. Computer hardware andsoftware systems are available for researchers using the labto capture, record, and analyze the data they obtain. Thehighly sensitive instruments used in the lab must operate ina strictly controlled environment. The BSCL includes systemsto monitor and maintain temperature, humidity, acousticalvibration, and cleanliness.

Biochemical conversion involves the following three steps:

(1) Converting biomass to sugar or other fermentation feedstock (NREL’s process design uses dilute acid pretreatment followed by enzymatic hydrolysis);

(2) Fermenting these biomass intermediates using biocatalysts (microorganisms including yeast and bacteria); and

(3) Processing the fermentation product to yield fuel-grade ethanol and other fuels, chemicals, heat, and/or electricity.

Researchers at the Biochemical Conversion ProcessDevelopment Unit (PDU) are working to improve theefficiency and economics of the biochemical conversionprocess technologies by focusing their efforts on improvingpretreatment technology, breaking hemicellulose down tocomponent sugars, and developing more cost-effectivecellulase enzymes for breaking cellulose down to itscomponent sugar.

NREL’s one ton per day PDU is an integrated pilot plant forconverting biomass to ethanol at a rate of 900 kg (1 ton)per day of dry biomass. It was designed to provide a userfacility to accelerate the development of processes for theconversion of a wide variety of lignocellulosic biomass types

NREL’s biomass conversion program produces productssuch as ethanol fuel from corn stalks, develops gasificationprocesses that use wood chips to generate electricity, andmore. The Thermochemical Process Development Unit canbe operated in either gasification or pyrolysis mode. Thehalf-ton-per-day thermochemical process development unitis based on a fluidized-bed reactor coupled with a thermalcracker (tubular reactor). This configuration is very flexibleand can handle a range of process conditions to reflectproduct gas compositions of interest to NREL’s industrialpartners.

Particulate removal, secondary catalytic conversion, andcondensation equipment are also available. The modulardesign of the facilities allows it to readily accommodateequipment supplied by research partners. Process massbalances are continuously computed from online data.Products and intermediates can be analyzed by severalmethods, including:

* Gas chromatography;* Molecular beam mass spectrometry;* Non-dispersive infrared spectrometry;* Residual gas analysis; and* Fourier-transform-infrared spectrometry.

Raw synthesis gas and pyrolysis vapors can be upgradedusing the fluidized-bed catalytic reforming reactor. Theintegration of power generation applications with biomassgasification processes can be evaluated, for example, bytesting product gas usage in internal combustion engines ormicroturbines. So can the production of fuels and chemicalsin microcatalytic reactors. These capabilities add up to aunique research and development facility for optimizing andintegrating thermochemical biomass conversion processes.

BIOMASS SURFBIOMASS SURFBIOMASS SURFBIOMASS SURFBIOMASS SURFAAAAACE CHARACE CHARACE CHARACE CHARACE CHARACTERIZACTERIZACTERIZACTERIZACTERIZATION LABTION LABTION LABTION LABTION LAB

BIOCHEMICAL CONVERSION PRBIOCHEMICAL CONVERSION PRBIOCHEMICAL CONVERSION PRBIOCHEMICAL CONVERSION PRBIOCHEMICAL CONVERSION PROCESSOCESSOCESSOCESSOCESSDEVELDEVELDEVELDEVELDEVELOPMENT UNITOPMENT UNITOPMENT UNITOPMENT UNITOPMENT UNIT

THERMOCHEMICAL CONVERSION PILTHERMOCHEMICAL CONVERSION PILTHERMOCHEMICAL CONVERSION PILTHERMOCHEMICAL CONVERSION PILTHERMOCHEMICAL CONVERSION PILOOOOOT FAT FAT FAT FAT FACILITIESCILITIESCILITIESCILITIESCILITIES

to ethanol. The objective of this project is to perform routinemaintenance and calibration activities to maintain thefacility in a state of operational readiness for both internaland external customers. In addition, this project implementsan activity that significantly improves the operability of thepilot plant and enhances its capability to supply necessaryprocess performance data for customers. Unit operationsinclude feedstock washing and milling, pretreatment,enzymatic hydrolysis, fermentation, distillation, andsolid-liquid separation.


The Alternative Fuels User Facility is the most widely usedfacility at NREL. Its pilot plant allows testing anddevelopment of complete production processes.Fermentation trials can be performed with aerobic oranaerobic microorganisms in batch, fed-batch, orcontinuous mode. The fermentation portion can also beused to further using sugar or other intermediate biomasscomponents rather than cellulosic feedstocks.

ALALALALALTERNATERNATERNATERNATERNATIVE FUELS USER FATIVE FUELS USER FATIVE FUELS USER FATIVE FUELS USER FATIVE FUELS USER FACILITCILITCILITCILITCILITYYYYY


6.0TOUR: COORS PLANTTOUR: COORS PLANTTOUR: COORS PLANTTOUR: COORS PLANTTOUR: COORS PLANT

The Coors Brewery in Golden, Colorado producesapproximately 87,000 tons per year of brewer’s grains on a dry-matter basis from the brewing process. The feed is currentlysold as cattle feed in a wet and dry form. There are nine otherbyproducts of the brewing process that contain fermentablestarches or concentrations of ethanol. Coors developed abiomass conversion plant to convert these various biomassfeedstocks into higher value-added products and provide atest-bed to commercialize emerging enzymatic technologies.

The biomass conversion plant, which began operation in 2005,uses the synergies of an existing building and equipment thatwas currently not in use at the site to incorporate the designinto the four-stage evaporator system at the facility. The plantproduces in excess of 4MMgpy of 200 proof ethanol throughconventional processes which include: low temperature cooksection, enzymatic conversion of starches to fermentablesugars, yeast fermentation (two 250,000-gallon fermenters),stripping of ethanol from the mash, distillation, and molecularsieve dehydration of the alcohol. The wet distillers grain andsolubles are then consumed by the cattle feeding and dairyoperations in northeastern Colorado. There are two watertreatment facilities on the premises.


7.0LISLISLISLISLIST OF PT OF PT OF PT OF PT OF PARARARARARTICIPTICIPTICIPTICIPTICIPANTSANTSANTSANTSANTS

S. SchuckS. SchuckS. SchuckS. SchuckS. Schuck Australia

I. SpitzerI. SpitzerI. SpitzerI. SpitzerI. Spitzer Austria

J. SpitzerJ. SpitzerJ. SpitzerJ. SpitzerJ. Spitzer Austria

YYYYY. Schenk. Schenk. Schenk. Schenk. Schenkelelelelel Belgium

E. HoganE. HoganE. HoganE. HoganE. Hogan Canada

J. PJ. PJ. PJ. PJ. Passmoreassmoreassmoreassmoreassmore Canada

J. SaddlerJ. SaddlerJ. SaddlerJ. SaddlerJ. Saddler Canada

M. HladikM. HladikM. HladikM. HladikM. Hladik Canada

PPPPP. Hall. Hall. Hall. Hall. Hall Canada

VVVVV. Hall. Hall. Hall. Hall. Hall Canada

B.H. ChristB.H. ChristB.H. ChristB.H. ChristB.H. Christensenensenensenensenensen Denmark

K. ManiatisK. ManiatisK. ManiatisK. ManiatisK. Maniatis European Commission

M. AarnialaM. AarnialaM. AarnialaM. AarnialaM. Aarniala Finland

J-C PJ-C PJ-C PJ-C PJ-C Poueoueoueoueouettttt France

B. KB. KB. KB. KB. Kerererererckckckckckooooowwwww Germany

TTTTT. Willk. Willk. Willk. Willk. Willkeeeee Germany

N. HaraN. HaraN. HaraN. HaraN. Hara IEA Headquarters

N. AsamiN. AsamiN. AsamiN. AsamiN. Asami IEA Headquarters

PPPPP. Nair. Nair. Nair. Nair. Nair Japan

TTTTT. Miura. Miura. Miura. Miura. Miura Japan

M.J. BaikM.J. BaikM.J. BaikM.J. BaikM.J. Baik Korea

S.C. PS.C. PS.C. PS.C. PS.C. Parararararkkkkk Korea

AAAAA. T. T. T. T. Tustinustinustinustinustin New Zealand

J. GifJ. GifJ. GifJ. GifJ. Gifffffforororororddddd New Zealand

J. TJ. TJ. TJ. TJ. Tustinustinustinustinustin New Zealand

O. GislerudO. GislerudO. GislerudO. GislerudO. Gislerud Norway

M. PhagoM. PhagoM. PhagoM. PhagoM. Phago South Africa

B. TB. TB. TB. TB. Teleniuseleniuseleniuseleniuselenius Sweden

AAAAA. W. W. W. W. Wellingerellingerellingerellingerellinger Switzerland

AAAAA. F. F. F. F. Faaijaaijaaijaaijaaij The Netherlands

E. de JongE. de JongE. de JongE. de JongE. de Jong The Netherlands

K. KwK. KwK. KwK. KwK. Kwantantantantant The Netherlands

S. vS. vS. vS. vS. van Looan Looan Looan Looan Loo The Netherlands

S. OzdoganS. OzdoganS. OzdoganS. OzdoganS. Ozdogan Turkey

Z. OzdoganZ. OzdoganZ. OzdoganZ. OzdoganZ. Ozdogan Turkey

AAAAA. Br. Br. Br. Br. Brooooownwnwnwnwn United Kingdom

G. ShanahanG. ShanahanG. ShanahanG. ShanahanG. Shanahan United Kingdom

K. RicharK. RicharK. RicharK. RicharK. Richardsdsdsdsds United Kingdom

C. CohnC. CohnC. CohnC. CohnC. Cohn U.S.A.

D. DaD. DaD. DaD. DaD. Daytytytytytononononon U.S.A.

D. SchellD. SchellD. SchellD. SchellD. Schell U.S.A.

J. HolmgrenJ. HolmgrenJ. HolmgrenJ. HolmgrenJ. Holmgren U.S.A.

J. SpaeJ. SpaeJ. SpaeJ. SpaeJ. Spaeththththth U.S.A.

L. NealL. NealL. NealL. NealL. Neal U.S.A.

Q. NguyQ. NguyQ. NguyQ. NguyQ. Nguyenenenenen U.S.A.

R. NaranjoR. NaranjoR. NaranjoR. NaranjoR. Naranjo U.S.A.

R. WR. WR. WR. WR. Wooleooleooleooleooleyyyyy U.S.A.

S. BabuS. BabuS. BabuS. BabuS. Babu U.S.A.

L. RL. RL. RL. RL. Russoussoussoussousso U.S.A.

M. LadischM. LadischM. LadischM. LadischM. Ladisch U.S.A.

PPPPP. Grabo. Grabo. Grabo. Grabo. Grabowskiwskiwskiwskiwski U.S.A.

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