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Results for “BIOREFINERY”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Life-cycle analysis of integrated biorefineries with co-production of biofuels and bio-based chemicals: co-product handling methods and implications: Co-product handling methods and implications of life-cycle analysis of biofuel and bio-chemical co-producing biorefineries

New integrated biorefinery (IBR) concepts are being investigated to co-produce hydrocarbon fuels and high-value bio-based chemicals to improve the economic viability of IBRs, to enhance biomass resource utilization efficiencies, and to maximize potential greenhouse gas (GHG) emission reductions. Unlike fuel-only biorefineries, IBRs may co-produce a significant amount of bio-based chemicals, whose emission implications for specific biorefinery products and the biorefinery as a whole need to be evaluated. We discuss this in principle and apply three sets of co-product handling methods to conduct life-cycle analysis (LCA) of modeled IBRs with co-production of two bioproduct examples - succinic acid and adipic acid - alongside a renewable diesel blendstock fuel product. The LCA results for the specific co-product handling methods that were examined shed light on potential artifacts of product-specific LCA with selected co-product methods. We discuss the advantages and limitations of each method and conclude that (i) a system-level or 'black-box' LCA allocation method is too simplistic to reflect appropriately the GHG burdens of distinctly different processing trains for fuels and chemicals in the IBR context, and (ii) the displacement method is the only co-product handling method that accounts fully for the emission effects of both the fuel product and the non-fuel bio-based co-products in the IBRs within the context of the existing fuel-focused GHG regulatory framework. Alternatively, biorefinery system-level LCA combines benefits of individual products to offer a complete picture. This system-level LCA approach offers a holistic LCA without somewhat arbitrary decisions either on an allocation basis or by the selection of an evaluation metric based on specific products.

09 BIOMASS FUELS↗
DOE OSTI2018

Techno-Economic Evaluation of Cellulosic Ethanol Production Based on Pilot Biorefinery Data: a Case Study of Sweet Sorghum Bagasse Processed via L+SScF

Replacing fossil fuels with renewable fuels derived from lignocellulosic biomass can contribute to the mitigation of global warming and the economic development of rural communities. This will require lignocellulosic biofuels to become price competitive with fossil fuels. Techno-economic analyses can provide insights into which parts of the biofuel production process need to be optimized to reduce cost or energy use. Here, we used data obtained from a pilot biorefinery to model a commercial-scale biorefinery that processes lignocellulosic biomass to ethanol, with a focus on the minimum ethanol selling price (MESP). The process utilizes a phosphoric acid-catalyzed pre-treatment of sweet sorghum bagasse followed by liquefaction and simultaneous saccharification and co-fermentation (L+SScF) of hexose and pentose sugars by an engineered Escherichia coli strain. After validating a techno-economic model developed with the SuperPro Designer software for the conversion of sugarcane bagasse to ethanol by comparing it to a published Aspen Plus model, six different scenarios were modeled for sweet sorghum bagasse Under the most optimistic scenario, the ethanol can be produced at a cost close to the energy-equivalent price of gasoline. Aside from an increase in the price of gasoline, the gap between ethanol and gasoline prices could also be bridged by either a decrease in the cost of cellulolytic enzymes or development of value-added products from lignin.

Biofuel↗
DOE OSTI2021

Towards cost-competitive middle distillate fuels from ethanol within a market-flexible C2 platform-based biorefinery concept

Ethanol to middle distillates (ETMD) is a promising pathway to produce sustainable liquid fuels to decarbonize the hard-to-electrify transportation sectors due to (1) the abundant sugar/starch and lignocellulosic biomass, (2) the existing deployment scale of fuel ethanol production (similar to 29 billion gallons per year globally), and (3) emerging opportunities in C2+ alcohol synthesis from CO2. Here we report a conceptual market-responsive biorefinery centered around a new ETMD pathway based on one-step ethanol to butene-rich olefins (ETO) over a Cu-Zn-Y/Beta catalyst. Specifically, this ethanol conversion pathway comprises one-step ETO, oligomerization, and hydrotreating. This ETO is distinct from that in the conventional ethanol-to-jet process which is based on two-step ethanol to ethylene and ethylene oligomerization to butenes. Butene-rich olefins can be shifted to butadiene-rich products by simply changing the reaction atmosphere from hydrogen to inert gas over the same ETO catalyst. Leveraging the experimental results, baseline techno-economic analysis (TEA) and sensitivity analysis indicate that the ethanol conversion cost is $0.60 per gallon gasoline equivalent (GGE), with opportunities for further cost reduction via improving the liquid hydrocarbon yield and space velocities, and process optimization on balancing dewatering of ethanol feed prior to the ETO step. The minimum fuel selling price (MFSP) of liquid hydrocarbons derived from corn starch ethanol with butadiene as coproduct is $1.64 per GGE, in the range that is cost competitive with petroleum kerosene-type jet fuel. Projected MFSP for cellulosic ethanol (corn stover) derived hydrocarbons is below $3.00 per GGE and co-production of butadiene further reduces the MFSP to $1.70 per GGE. The Well-to-Wake life-cycle analysis indicates that 85% greenhouse gas emission reduction can be achieved when using corn stover compared to petroleum reference and the associated carbon credits will provide significant economic incentives to favor the cellulosic ethanol-derived hydrocarbon fuels. This study demonstrates a low-cost pathway to middle distillate fuels leveraging existing ethanol infrastructure, where catalysis innovation drives the reduction of process complexity and flexible coproduction of a value-added chemical product.

Zhang, Junyan↗
DOE OSTI2021

The nth-plant scenario for blended feedstock conversion and preprocessing nationwide: biorefineries and depots

The sustainability of the biofuel industry depends on the development of a mature conversion technology on a national level that can take advantage of the economies of scale: the nth-plant. Defining the future location and supply logistics of conversion plants is imperative to ultimately transform the nation’s renewable biomass resources into cost-competitive, high-performance feedstock for production of biofuels and bioproducts. Since the US has put restrictions on production levels of conventional biofuels from edible resources, the nation needs to plan for the widespread accessibility and development of the cellulosic biofuel scenario. Conventional feedstock supply systems will be unable to handle cellulosic biomass nationwide, making it essential to expand the industry with an advanced feedstock supply system incorporating a distributed network of preprocessing depots and conversion plants, or biorefineries. Current studies are mostly limited to designing supply systems for specific regions of the country. We developed a national database with potential locations for depots and biorefineries to meet the nation’s target demand of cellulosic biofuel. Blended feedstock with switchgrass and corn stover (harvested by either a two- or three-pass method) are considered in a Mixed Integer Linear Programming model to deliver on-spec biomass that considers both, a desired quantity and quality at the biorefinery. A total delivered feedstock cost that is less than $79.07/dt (2016$) is evaluated for years 2022, 2030, and 2040. In 2022, 124 depots and 59 biorefineries could be supplied with 42.8 million dt of corn stover and switchgrass. In 2030 and 2040, the total accessible biomass could increase to 215% and 393% respectively when compared to 2022. However, an $8/dry tons reduction in targeted delivery cost could reduce total accessible biomass by 67%. Kansas, Nebraska, South Dakota and Texas were identified as potential states with a strong biofuel economy given that they had six or more biorefineries located in all scenarios. In some scenarios, Colorado, Alabama, Georgia, Minnesota, Mississippi and South Carolina would greatly benefit from a depot network as these could only deliver to a biorefinery in a nearby state. To elaborate the impact of a nationwide consideration, the findings were compared with existing literature for different US regions. We also present results for biorefinery capacities that are double, triple, and quadruple in size.

09 BIOMASS FUELS↗
DOE OSTI2016

Recovery Act: Alpena Biorefinery and Alpena Biorefinery Lignin Separation Final Technical Report

The Alpena Biorefinery (AB) was constructed in Alpena, Michigan, at the Decorative Panels International hardboard manufacturing facility. The goal of the AB was to demonstrate a modular, technically successful, and financially viable process of making cellulosic ethanol from woody biomass extract at wood processing facilities. At full capacity, the AB can produce 894,200 gallons per year of cellulosic ethanol and 696,000 gallons per year of aqueous potassium acetate, using extract from northern hardwood and aspen woodchips feedstock. The project objectives and the value proposition of AB promote the national goals of energy independence, greenhouse gas reduction, and green job creation and retention. A successful outcome of the Alpena Biorefinery project has been commercial sales of the first ever cellulosic ethanol RINS generated from woody biomass in the US, under the EPA’s Renewable Fuels Standard Program. We believe that American Process is also likely the first company in the world to produce commercial quantities of cellulosic ethanol from mixed forest residue. Life Cycle Analysis performed by Michigan Institute of Technology found that the entire life cycle greenhouse gas emissions from the plant’s cellulosic ethanol were only 25 percent that of petroleum-based gasoline. They found the potassium acetate runway de-icer coproduct generates up to 45 percent less greenhouse gases than the production of conventional potassium acetate. The Alpena Biorefinery project created 31 permanent jobs for direct employees and helped retain 200 jobs associated with the existing Decorative Panels International facility, by increasing its economic viability through significant savings in waste water treatment costs. The AB project has been declared a Michigan Center of Energy Excellence and was awarded a $4 million State of Michigan grant. The project also received New Market Tax Credit financing for locating in an economically distressed community. All other equity funds were contributed by American Process Inc. The facility will remain operational after the demonstration period. It will also be available as a pilot-plant “for hire,” where third parties can perform trials on emerging biorefinery technologies. Additional capital projects are underway outside of the scope of DOE project.

09 BIOMASS FUELS↗
DOE OSTI2016

Cellulosic biorefinery portfolio and diversification: Strategies to mitigate cellulosic biorefinery risks in US Corn Belt

Several studies have highlighted that one of the largest risks with cellulosic biorefinery investments are year-to-year variability in cellulosic biomass quantity available. Yet, strategies to mitigate these risks in biofuel development are less understood. In the absence of strategies to minimize the impact due to these variations, both biorefineries and farmers venturing into the cellulosic biofuel arena will be significantly exposed. Studies have been done on using engineering approaches, such as biomass pre- treatment and storage to address biomass supply variations. Recent studies have provided market structure and contracting strategies to manage biomass supply risks. However, storage, pre-treatment and similar engineering approaches lead to higher costs and has other limitations such as additional infrastructural requirements. There is a gap in understanding the use of feedstock (biomass) diversifi- cation and portfolio strategies to mitigate such risks. In this study a portfolio approach is developed and applied to the case of the US Corn Belt, considering various types of cellulosic biomass including corn stover, wheat straw, and switchgrass. It is found that feedstock diversification mitigates up to 40% of feedstock supply variations, while biorefinery diversification can mitigate up to 70% of feedstock supply variations although it is constrained by current cropland use patterns in the region. Altogether, diversification and portfolio strategies present an effective way for mitigating risks associated with feedstock supply variations.

09 BIOMASS FUELS↗
DOE OSTI2020

Techno-Economic Analysis and Global Warming Potential of a Novel Offshore Macroalgae Biorefinery

The success of a large scale macroalgae-based biorefinery is dependent on the demonstration of favorable system economics and environmental sustainability. This study uses detailed process modeling to quantify the mass and energy flows through the various unit operations required for a novel free-floating macroalgae biorefinery concept. The modular process model served as the foundation for the techno-economic and global warming potential analyses used to quantify the sustainability of the proposed concept. This work includes detailed techno-economic results for a complete macroalgae cultivation and conversion system with multiple hatchery configurations and several emerging technologies. System optimization was achieved through the evaluation of various technology options for each unit operation. Technologies considered include traditional twine and textile substrate hatchery configurations, drone assisted seeding and biomass transport, mechanized line seeding and harvesting, adhesive spore mixtures that simplify seeding operations and improve hatchery energetics, and hydrothermal liquefaction to produce upgradable biocrude. Outputs from the system include renewable diesel (R100), naphtha, biochar, nitrogen and phosphorus fertilizers, and aqueous/solid waste streams. Three different system pathways were explored, yielding a biomass production cost ranging from $210 to $565 per dry metric ton and a minimum fuel selling price from $1.35 to $2.91 per liter of gasoline equivalent. Stochastic manipulation of the process model and sensitivity analyses support these results. The global warming potential analysis shows net greenhouse gas emissions ranging from 14 to 29 gCO2-eq MJ-1, supported by stochastic and sensitivity analyses. The recommendations from this work highlight critical areas for research and development investment such that a sustainable macroalgae cultivation and conversion system can be realized.

NOMAD seaweed cultivation, techno-economic analysi↗
DOE OSTI2021

Multiobjective Modular Biorefinery Configuration under Uncertainty

With increasing interest in using biomass as a raw material for fuel, the development of biorefineries is an active area of research. However, increasing market competition, uncertainty, and environmental concerns are a few of the challenges that need to be addressed. In this work, mathematical optimization formulations are proposed to address these challenges simultaneously. A multiobjective deterministic optimization framework is proposed to address economic and environmental objectives. A two-stage stochastic optimization framework is proposed to account for uncertainties in material flow and product yields. To model the environmental objective, an environmental risk metric is proposed. Finally, as modularization is gaining popularity in the process industry due to its ability to save capital cost because of standardization and reduce time to market, a formulation for simultaneously achieving modular process design and biorefinery configuration is proposed. Furthermore, the results demonstrate the efficacy of the proposed approach.

09 BIOMASS FUELS↗
DOE OSTI2016

Peracetic Acid Depolymerization of Biorefinery Lignin for Production of Selective Monomeric Phenolic Compounds

Lignin is the largest source of renewable material with an aromatic skeleton. However, due to the recalcitrant and heterogeneous nature of the lignin polymer as well as its complex side chain structures, it has been a challenge to effectively depolymerize lignin and produce high value chemicals with high selectivity. In this study, a highly efficient lignin-to-monomeric phenolic compounds (MPC) conversion method based on peracetic acid (PAA) treatment was reported. PAA treatment of two biorefinery lignin samples, diluted acid pretreated corn stover lignin (DACSL) and steam exploded spruce lignin (SESPL), led to complete solubilization and production of selective hydroxylated monomeric phenolic compounds (MPC-H) and monomeric phenolic acid compounds (MPC-A) inclduing 4-hydroxy-2-methoxyphenol, p-hydroxybenzoic acid, vanillic acid, syringic acid, and 3,4-dihydroxybenzoic acid. The maximized MPCs yields obtained were 18% and 22% based on the initial weight of the lignin in SESPL and DACSL respectively. However, we found that the addition of niobium pentoxide catalyst to PAA treatment of lignin can significantly improve the MPC yields up to 47%. The key reaction steps and main mechanisms involved in this new lignin-to-MPC valorization pathway were investigated and elucidated.

Ma, Ruoshui↗
DOE OSTI2019

Determination of hydroxyl groups in biorefinery resources via quantitative 31 P NMR spectroscopy [Determination of hydroxyl groups in biorefinery resources via quantitative 31 P Nuclear Magnetic Resonance Spectroscopy]

The analysis of chemical structural characteristics of biorefinery product streams (such as lignin and tannin) has advanced substantially over the past decade, with traditional wet-chemical techniques being replaced or supplemented by NMR methodologies. Quantitative 31 P NMR spectroscopy is a promising technique for the analysis of hydroxyl groups because of its unique characterization capability and broad potential applicability across the biorefinery research community. This protocol describes procedures for (i) the preparation/solubilization of lignin and tannin, (ii) the phosphitylation of their hydroxyl groups, (iii) NMR acquisition details, and (iv) the ensuing data analyses and means to precisely calculate the content of the different types of hydroxyl groups. Compared with traditional wet-chemical techniques, the technique of quantitative 31 P NMR spectroscopy offers unique advantages in measuring hydroxyl groups in a single spectrum with high signal resolution. Furthermore, the method provides complete quantitative information about the hydroxyl groups with small amounts of sample (~30 mg) within a relatively short experimental time (~30–120 min).

31P NMR↗
DOE OSTI2026

Data for Optimization of Pre-Commercial Enzymes Dosage for a Potential Lignocellulosic Biorefinery

Lignocellulolytic enzymes remain one of the primary cost constraints in second-generation (2G) ethanol biorefineries. Achieving efficient hydrolysis of structural carbohydrates with minimal enzyme dosage, maintaining slurry fermentability for industrially relevant ethanol titers, and maximizing ethanol yield per ton of biomass are among the major challenges in 2G processes. In this study, we optimized the dosages of pre-commercial cellulase (NS22257) and hemicellulase (NS22244) on pilot-scale, hydrothermally pretreated lignocellulosic substrates. Enzyme dosages were evaluated at three levels: 20 mg of cellulase with 7.25 mg of hemicellulase (ED-1), 40 mg with 14.5 mg (ED-2), and 60 mg with 21.75 mg (ED-3). As expected, the highest sugar yields were obtained with ED-3; however, for sweet sorghum, oilcane, and miscanthus, sugar yields from ED-2 and ED-3 were not significantly different (p < 0.05). For example, sweet sorghum produced 123.78 ± 1.54 g L−1 and 125.76 ± 0.46 g L−1 of total sugars (glucose and xylose) with ED-2 and ED-3, respectively. Although energycane exhibited a statistically significant difference between ED-2 and ED-3, the incremental gain with ED-3 was modest, increasing sugar release by only 9.02 g L−1 relative to ED-2. Importantly, ED-1 resulted in sugar yields of 88.88 ± 3.64 to 106.86 ± 1.21 g L−1, sufficient to achieve ethanol titers ≥40 g L−1, the threshold required for industrial relevance. A semi-integrated bioprocess validated this outcome, producing 42.09 ± 2.38 g L−1 ethanol and an estimated yield of 213.38 L of ethanol per dry ton of pretreated biomass, requiring only 20.83 L of cellulase and 6.25 L of hemicellulase per ton. Remarkably, these enzyme dosages were approximately tenfold lower than those reported in prior studies.

Energycane↗
DOE OSTI2018

Impacts of feedstock properties on the process economics of fast-pyrolysis biorefineries

Feedstock properties are an important factor affecting process yields and economics of fast pyrolysis biorefineries. Here, this study develops a fast pyrolysis process model sensitive to feedstock properties based on the experimental results. 64 simulations are run to evaluate the impacts of carbon, ash and moisture content in biomass feedstocks on process yields and energy consumptions. An economic analysis is conducted for each run to quantify process economics under different feedstock properties. With biomass feedstocks of 48% carbon and 15% moisture, Minimum Fuel Selling Price (MFSP) increases from 0.97/L to 1.06/L when ash content increases from 1% to 7%, due to reduced hydrocarbon yields. With biomass feedstocks of 48% carbon and 3% ash content, MFSP increases from 1.03/L to 1.08/L when feedstock moisture increases from 15% to 45% as a consequence of increased energy demand for feedstock drying. Finally, the impact of feedstock ash content decreases gradually as ash content increases. Feedstock carbon content has less significant impacts on process economics in this study.

09 BIOMASS FUELS↗
DOE OSTI2021

Biorefinery Ethanol Upgrading: Opportunities and Challenges

The production of drop-in replacements for biofuels is a grand challenge. Lignocellulosic biomass is considered a promising feedstock for producing fuel ethanol because of its great availability. Restrepo-Flórez et al. systematically study the upgrading of ethanol toward advanced fuels with tailored properties and with consideration of process synthesis.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2018

Using steam explosion or AFEX™ to produce animal feeds and biofuel feedstocks in a biorefinery based on sugarcane residues: Using Steam Explosion or AFEX™ to Produce Animal Feeds and Biofuel Feedstocks in a Biorefinery Based on Sugarcane Residues

Sustainable integration of biofuel (primarily bioethanol) and highly digestible livestock feed in production systems is a potential way to increase the economic returns to agriculture and simultaneously promote energy security, particularly in developing countries. In this work we evaluated the efficacy of steam explosion (StEx) and ammonia fiber expansion (AFEX™) as potential processes for improving the in vitro rumen digestibility, metabolizable energy, and ethanol yields from sugarcane crop residues (bagasse and cane leaf matter, CLM). Ammonia fiber expansion pretreatment enhanced the in vitro true digestibility and metabolizable energy content of sugarcane crop residues by 69% and 26%, respectively compared to untreated controls. On the other hand, StEx increased the true digestibility and metabolizable energy content of the sugarcane residues by 54% and 7%, respectively. Ammonia fiber expansion also increased the total nitrogen content of both sugarcane bagasse and CLM to more than 20.2 g kg -1 dry forage, a more than 230% improvement relative to untreated controls. High solid-loading enzymatic hydrolysis and fermentation of StEx- and AFEX™-pretreated sugarcane crop residues generated yields of up to 3368 and 4360 L of ethanol per hectare of sugarcane cultivated, respectively, at a biomass-degrading enzyme dosage of 20 mg protein per gram glucan. This research strongly suggests that the use of suitably pretreated sugarcane crop residues in integrated sugarcane biofuel-livestock production systems can increase the total per hectare agricultural output without increasing the area of sugarcane cultivated. In effect, this integrated approach promotes more sustainable biofuel production and increased food production while avoiding the potential for indirect land use change.

09 BIOMASS FUELS↗