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DOE OBP Pretreatment Core R&D Gate Review Meeting June 9-10, 2005
Charles E. Wyman, Dartmouth College Y. Y. Lee, Auburn University Mohammed Moniruzzaman, Genencor International Bruce E. Dale, Michigan State University Richard T. Elander, National Renewable Energy Laboratory Michael R. Ladisch, Purdue University Mark T. Holtzapple, Texas A&M University John N. Saddler, University of British Columbia Biomass Refining CAFI
Presentation Outline Project background Technical feasibility and risks Biomass Refining CAFI Competitive advantage History and accomplishments Project overview Plan/Schedule and recent results Critical issues and show stoppers Summary and caveats Plans and resources for next stage
High cellulose accessibility to enzymes High sugar yields from hemicellulose Low capital cost low pressure, inexpensive materials of construction Low energy cost Low degradation Low cost and/or recoverable chemicals
Biomass Refining CAFI
Dilute acid pretreatment is often favored based on more extensive development Many other options have been studied, but only a few are promising Pretreatment is most expensive single operation Difficult to compare leading pretreatments based on data available Limited knowledge of pretreatment mechanisms slows commercial use of all options
Biomass Refining CAFI
Competitive Advantage
Developing data on leading pretreatments using:
Common feedstocks Shared enzymes Identical analytical methods The same material and energy balance methods The same costing methods
Goal is to provide information that helps industry select technologies for their applications Also seek to understand mechanisms that influence performance and differentiate pretreatments
Provide technology base to facilitate commercial use Identify promising paths to advance pretreatment technologies
Biomass Refining CAFI
Hydrolysis Stages
Cellulase enzyme
Biomass Chemicals
Stage 1 Pretreatment
Ammonia
Stover
101.0 lb
Solids washed out
2 lb
39.2 lb
Very few solubles from pretreatmentabout 2% of inlet stover 95.9% glucan conversion to glucose, 77.6% xylan conversion to xylose 99% mass balance closure includes: (solids + glucose + xylose + arabinose )
Completed in 2004
Biomass Refining CAFI
Pretreatment system
Stage 1
62.3
Stage 2
62.3
Stage 1
100.0
Stage 2
100.0
Combined total
100.0
37.7
32.1/31.2
3.2
35.3/34.4
3.9
53.2
57.1
36.0/35.1
56.4
92.4/91.5
Increasing pH
36.3/1.7 21.8/0.9
0.6/0.5 9.0
36.9/2.2 30.8/9.9
4.5/4.4 3.5/0.2
55.2 52.9
59.7/59.6 56.4/53.1
40.8/6.1 25.3/1.1
55.8/55.7 61.9
96.6/61.8 87.2/63.0
34.6/29.3
34.6/29.3
59.8
59.8
94.4/89.1
94.4/89.1
ARP
17.8/0
15.5
33.3/15.5
56.1
56.1
17.8/0
71.6
89.4/71.6
Lime
9.2/0.3
19.6
28.8/19.9
1.0/0.3
57.0
58.0/57.3
10.2/0.6
76.6
86.8/77.2
*Cumulative soluble sugars as total/monomers. Single number = just monomers. Biomass Refining CAFI
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
Dilute acid
St ag e2 St ag e1
Flowthrough
Controlled pH
St ag e2 St ag e1
AFEX
ARP
St ag e2
Lime
Maximum possible
Oligoxylose Monoxylose Oligoglucose Monoglucose
75
50
25
0
gh AF EX pH P cid e ea ed Li m AR ou th r Di lu t oll po M ax ss ib le
Fl ow
Co
nt r
Enzymes
CO2
Water
Stover
Feed Handling
Different Pretreatments
Hydrolysis + Fermentation
Recovery
Syrup + Solids
EtOH
Chemicals
Water
Different Pretreatments
Boiler + Generator
Steam Power
1.50
1.25
1.00
0.75
MESP
0.50
Cash Cost
Plant Level
0.25
Hot Water
AFEX
ARP
Depreciation
Lime
Income Tax
Ideal
Return on Capital
Other Variable
1.50
1.25
1.00 Dilute Acid Hot Water w/o Oligomer Credit AFEX ARP w/ Oligomer Credit Lime
Added University of British Columbia to team through funding from Natural Resources Canada to
Capitalize on their expertise with xylanases for better hemicellulose utilization Evaluate sulfur dioxide pretreatment along with those previously examined: dilute acid, controlled pH, AFEX, ARP, lime
Quang Nguyen, Abengoa Bioenergy Mat Peabody, formerly Applied CarboChemicals Gary Welch, Aventinerei Greg Luli, BC International Paris Tsobanakis, Cargill Robert Wooley, Cargill Dow James Hettenhaus, CEA Lyman Young, ChevronTexaco Kevin Gray, Diversa Paul Roessler, Dow Susan M. Hennessey, DuPont Michael Knauf, Genencor
13. Don Johnson, GPC (Retired) 14. Dale Monceaux, Katzen Engineers 15. Kendall Pye, Lignol 16. Farzaneh Teymouri, MBI 17. Richard Glass, National Corn Growers Association 18. Bill Cruickshank, Natural Resources Canada 19. Joel Cherry, Novozymes 20. Ron Reinsfelder, Shell 21. Carl Miller, Syngenta 22. Carmela Bailey, USDA 23. Don Riemenschneider, USDA
CAFI 2 Stover
2nd pass harvested corn stover from Kramer farm (Wray, CO)
Collected using high rake setting to avoid soil pick-up No washing Milled to pass inch round screen
Component Sucrose Glucan Xylan Arabinan Mannan Galactan Lignin Protein Acetyl Ash Uronic Acids Extractives Composition (wt %)
2.2 34.4 22.8 4.2 0.6 1.4 11.0 2.3 5.6 6.1 3.8 8.5
CAFI 2 Poplar
Feedstock: USDA-supplied hybrid poplar (Alexandria, MN)
Debarked, chipped, and milled to pass inch round screen
Component Glucan Xylan Arabinan Mannan Galactan Lignin Protein Acetyl Ash Uronic Acids Extractives Composition (wt %) 43.8 14.9 0.6 3.9 1.0 29.1 nd 3.6 1.1 nd 3.6
Pretreatment/Substrate
Dilute Acid/Corn Stover Dilute Acid/Poplar (Bench Scale) Dilute Acid/Poplar (Pilot Plant) SO2/Corn Stover Controlled pH/Poplar SO2/Poplar Ammonia Fiber Explosion/Poplar Ammonia Recycled Percolation/Poplar Flowthrough/Poplar Lime/Poplar
Biomass Refining CAFI
Expected Date
September 2004 October 2004 December 2004 March 2005 May 2005 August 2005 September 2005 October 2005 March 2006 April 2006
Pretreatment/Substrate
Dilute Acid/Corn Stover Dilute Acid/Poplar (Bench Scale) Dilute Acid/Poplar (Pilot Plant) SO2/Corn Stover Controlled pH/Poplar SO2/Poplar Ammonia Fiber Explosion/Poplar Ammonia Recycled Percolation/Poplar Flowthrough/Poplar Lime/Poplar
Biomass Refining CAFI
Expected Date
September 2004 October 2004 December 2004 March 2005 May 2005 August 2005 September 2005 October 2005 March 2006 April 2006
Corn stover
36.1 g glucan 21.4 g xylan
Liquid phase
Sugars
1.2 g glucose 8.7 g xylose
Pretreatment
(190oC, 5min, 3% SO2)
Solid phase
Hydrolysis
(60FPU/g of glucan)
Sugars
36.9 g glucose 6.8 g xylose
95% conversion of glucan to glucose 64% conversion of xylan to xylose 83% overall yield of sugars
Glucose yield, %
70 60 50 40 30 20 10 0 0 10 20 30
POP-1-Severity -3.01 POP-3-Severity -3.31 POP-2-Severity -3.25 POP-4-Severity -3.55
Time, hours
40
50
60
70
80
NM, 5 FPU/gm
Cellulose conversion, %
80 70 60 50 40 30 20 0 10 20 30 40 50 60
Phillipidis et al.
South et al.
Holtzapple et al.
60 50 40 30 20 10 0 0 5 10 15
60 50 40 30 20 10 0 0 5 10 15
21%
60 50 40 30 20 10 0 0 5 10 15
12%
Time (hours)
Time (hours)
Time (hours)
25
15
10
120
144
0 168
Control
54.1
42.4
44.5
41.3
76.8
63.4
79.0
72.0
CAFI Presentations/Publications
Team presentations at
2004 Annual Meeting of the American Institute of Chemical Engineers, Austin, Texas, November 11 2003 Annual Meeting of the American Institute of Chemical Engineers, San Francisco, California, November 20 25th Symposium on Biotechnology for Fuels and Chemicals, Breckenridge, Colorado, May 7, 2003 2002 Annual Meeting of the American Institute of Chemical Engineers, Indianapolis, Indiana, November 4 24th Symposium on Biotechnology for Fuels and Chemicals, Gatlinburg, Tennessee, April 28, 2002
Mosier N, Wyman CE, Dale B, Elander R, Lee YY, Holtzapple M, Ladisc1 M. 2005. Features of Promising Technologies for Pretreatment of Lignocellulosic Biomass, BioResource Technology 96(6): 673-686 Special issue of Bioresource Technology in progress to report USDA IFAFS findings in several papers including joint papers to introduce project and summarize results
Critical Issues and Show Stoppers Must assure that all pretreatments realize near maximize possible yields Include both pretreatment and subsequent enzymatic hydrolysis Evaluate effect of enzymes on yields of both xylose and glucose Characterize well hydrolyzate fermentability and conditioning demands Biggest concern is unknown challenges that prove too time consuming to resolve
Caveats
The yields can be further increased for some pretreatments with enzymes a potential key Mixed sugar streams will be better used in some processes than others Oligomers may require special considerations, depending on process configuration and choice of fermentative organism The conditioning and fermentability of the sugar streams must be characterized Initial results are for corn stover, and performance with other feedstocks will likely be different as initially shown for poplar
Biomass Refining CAFI
The results from this project will provide a basis for industry to select technologies to commercialize Results should also suggest new enzyme and organism strategies Further research is important to understand reasons for performance differences Consideration should be given to taking advantage of differences among pretreatment options
Acknowledgments US Department of Agriculture Initiative for Future Agricultural and Food Systems Program, Contract 00-52104-9663 US Department of Energy Office of the Biomass Program, Contract DE-FG3604GO14017 Natural Resources Canada Our team from Dartmouth College; Auburn, Michigan State, Purdue, and Texas A&M Universities; the University of British Columbia; Genencor International; and the National Renewable Energy Laboratory
Biomass Refining CAFI