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The project goal is to assess opportunities for value-adds in the supply chain through designing a feedstock logistics systems that uses moisture during the residence time in storage to protect and increase feedstock value.
The diverse portfolio of biomass sources that is available in the Southeastern U.S., including a significant supply of pine “residue”, represents a valuable strategic position for the region. Through blends formulated based on critical properties, this project will take full advantage of the range in biomass properties afforded by the portfolio to produce a consistent, high-performance feedstock for the industry, while lowering cost. Key developments being targeted to enable this potential include whole-tree transport to a state-of-the-art merchandising depot that will further access biomass from ongoing, forest industry operations. The approach will more effectively utilize the tree and distribute cost, while minimizing in-woods contamination of the woody biomass component. To implement this vision, information on the chemical composition and changes that are induced during multiple preprocessing steps (size reduction, moisture removal, densification, etc.) is needed. New NIR sensor technology will be developed for online monitoring of important biomass properties. The data will be incorporated into a statistical process control platform to improve process efficiency and meet required specifications. Advanced process models are being developed to inform the techno-economic and life-cycle assessment of the program’s impact. The new system will ultimately reduce operational risks from supply chain disruptions, and allow operation of larger-scale biorefineries.
The U.S. Department of Energy (DOE) promotes the production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the State of Technology (SOT). As part of its involvement with this mission, Idaho National Laboratory (INL) completes an annual SOT report for biomass feedstock logistics. This report summarizes supply system impacts of Bioenergy Technologies Office (BETO)-funded research and development efforts at INL and INL collaboration with external partners (e.g. Forest Concepts, Purdue University ) that lead to improvements in feedstock supply systems. These include improvements to and observed performance of innovative harvest and collection methods, storage technologies, transportation and handling approaches, and advanced preprocessing technologies. Biomass quality and variability, and the interface between feedstock quality and conversion performance are key drivers in addition to delivered feedstock cost. In this report, we estimate the benefits of R&D technology improvements to individual supply system unit operations and present the status of feedstock logistics technology development for converting herbaceous biomass into biofuels. These analyses are supported by experimental data where possible and help to align the SOT relative to the cost goals defined in the Multi-Year Plan.
Willow and poplar short rotation woody crops (SRWC) have shown promise with regards to environmental benefits and rural development but wide adoption lags due to underdeveloped markets and supply systems. High costs associated with harvesting, handling and transportation (40-60% of delivered cost) have impeded expansion. A better understanding of these systems will create opportunities to improve efficiency, reduce costs, and realize environmental benefits and impacts. The project’s goal was to lower the delivered cost of hybrid poplar in the Northwest and willow in the Northeast by optimizing harvesting and logistics supply systems while maintaining or improving biomass quality along the supply chain. Over 3,400 Mg of biomass and 300 ha of willow and poplar were monitored over a range of crop and field conditions. Feedstock quality as affected by storage and preprocessing were shown to improve or maintain feedstock quality. Modeled harvesting costs ranged from $38–61 Mg -1 dry; when including delivery and preprocessing feedstock costs ranged between $79-83 Mg -1 dry for willow and $106-116 Mg -1 dry for poplar. Costs for willow minimized when hot water extraction and high-moisture densification preprocessing were used. Models also suggest that social and regional factors could further reduce costs. Results will give guidance to feedstock growers, harvesting and logistic operations, biorefinery project developers, and policy makers developing SRWC to support a growing bioeconomy.
Abstract The state‐of‐technology for corn stover harvest is a multi‐pass system that collects the stover after grain harvest. An alternative is a single‐stream system where the grain and stover are harvested as a bulk material co‐stored and preserved by anerobic fermentation, and finally, co‐transported to a biorefinery. In the present work, four single‐pass whole‐plant bulk systems were compared with a conventional multi‐pass bale system. The single‐stream systems consisted of the harvest of corn grain and a portion of the stover fraction. Four machine configurations were simulated. This work predicted that a multi‐pass bale system would result in a material cost of 111.80 $2021 Mg –1 stover DM delivered to the biorefinery gate. Alternatively, the lowest cost single‐stream system was the self‐propelled forage harvester (SPFH) configured with the whole‐plant header, which delivered feedstock for 74.76 $2021 Mg stover DM –1 . In addition to machine configuration, a sensitivity analysis was performed to understand important drivers of feedstock cost. These analyses revealed that feedstock cost increased with moisture content, fertilizer price, and biorefinery size, and decreased with harvest season length, crop yield, and grower participation. This work demonstrated that single‐stream systems could reduce corn stover feedstock costs in comparison with state‐of‐technology systems. © 2022 The Authors. Biofuels, Bioproducts and Biorefining published by Society of Industrial Chemistry and John Wiley & Sons Ltd.
The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement with this overall mission, Idaho National Laboratory completes annual SOT reports for nth-plant biomass feedstock logistics. The purpose of the SOTs is to provide the status of feedstock supply system technology development for biomass to biofuels, based on actual data and experimental results relative to technical targets and cost goals from specific design cases. The 2020 Woody Feedstock SOT is separated into three separate pathways that utilize woody feedstocks: indirect liquefaction (IDL), catalytic fast pyrolysis (CFP), and algal-blend hydrothermal liquefaction (AHTL).
The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement with this overall mission, Idaho National Laboratory completes annual SOT reports for n th -plant biomass feedstock logistics. The purpose of the SOTs is to provide the status of feedstock supply system technology development for biomass to biofuels, based on actual data and experimental results relative to technical targets and cost goals from specific design cases.
The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for n th -plant and 1 st -plant woody biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for woody biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Conventional feedstock supply systems need to be modified to meet the demands of conversion pathways, specifically to have the ability to adjust the quality of the raw biomass materials. Advanced systems incorporate innovative methods of material handling, preprocessing and supply chain configuration. In advanced designs, variability of the raw biomass can be reduced to produce feedstocks of a uniform format, moving toward biomass commoditization. Against this backdrop, the 2022 Woody SOT for low-ash woody feedstocks utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (wood, bark, needle, and extrinsic ash) to reduce impurities and attempt to maximize the retention of usable fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in forest residues, separate out a majority of the incoming needles (which can be supplied to alternate markets), and maximize the retention of whitewood in the usable fraction. The fractionated forest residues are then mixed with clean-pine chips in a 50-50 blend to prepare the feedstock for the desired conversion pathway. The n th -plant analysis estimated the delivered cost for the feedstock at $\$$69.23/dry ton (2016$\$$) which represents a $\$$6.64/dry ton decrease compared to the cost estimate of the 2021 Woody SOT supply system for low-ash woody feedstocks. The quality requirements in the 2022 Woody SOT were identical to those of the 2021 Woody SOT at = 1.00 wt % ash and = 50.51 wt% carbon. The cost savings derive primarily from reductions in dry matter losses during air classification. The GHG emissions for the n th -plant analysis were estimated at 178.39 kg CO2e/dry ton compared to 178.71 kg CO 2 e/dry ton in the 2021 Woody SOT, a decrease of 0.32 kg CO2e/dry ton. The small change stems from an increase in emissions attributed to preprocessing and slightly larger savings in emissions from transportation. In the 1 st -plant analysis of the 2022 Woody SOT system, the average throughput was estimated to be approximately 2,128 dry tons/day or 96.51% of the name plate capacity. During the simulation the daily throughput ranged from 1,090 dry tons/day to 2,200 dry tons/day, or 49.43% to 99.75% of the daily nameplate capacity. After the year of operation 722,403 tons of processed feedstock were produced in total without regard to quality considerations (99.64% of the annual nameplate capacity). The variability in throughput was primarily caused by equipment failures in the system. Regular failures, downtime caused by routine maintenance per manufacturer guidelines, contributed to a majority 62.50% of failures and 62.60% of downtime. Failures due to wear were the other cause of disruption within the system, impacting the rotary shear and orbital screen and accounting for 37.50% of the failures and 37.40% of the total downtime. Ultimately the system was on stream for 87.84% during the simulation period, which is only 2.16 percentage points below the nth-plant assumption for on-stream time. The production cost of the system averaged $\$$71.66/dry ton. The costs ranged from a minimum of $\$$71.23/dry ton to a maximum of $\$$2,115.30/dry ton. When dry matter losses (disposed low-quality fractions as well as other losses such as in grinders) were considered the costs increased to an average of $\$$75.11/dry ton with a minimum of $\$$74.69/dry ton and a maximum of $\$$2,136.86/dry ton...
The U.S. Department of Energy promotes production of advanced liquid transportation fuels from lignocellulosic biomass by funding fundamental and applied research that advances the state of technology (SOT). As part of its involvement in this mission, Idaho National Laboratory completes an annual SOT report for nth-plant and 1st-plant herbaceous biomass feedstock logistics. The purpose of the SOT is to provide the status of feedstock supply system technology development for herbaceous biomass to biofuels relative to technical targets and cost goals from specific design cases, based on data and experimental results. Although conventional feedstock supply systems form the backbone of the emerging biofuels industry, they have limitations that restrict widespread implementation on a national scale. To meet the demands of the future industry, the feedstock supply system must shift from the conventional system to what has been termed “advanced” supply systems. In advanced designs, a distributed network of aggregation and processing centers, termed “depots,” are employed near the points of biomass production (i.e., the field or forest) to reduce feedstock variability and produce feedstocks of a uniform format, moving toward biomass commoditization. The 2022 Herbaceous SOT is part of a vision of achieving an implemented advanced feedstock supply system, which produces a stable, tradable commodity at the decentralized distributed depot. It utilizes feedstock fractionation by incorporating technologies that can separate the biomass into its anatomical fractions (leaves, husks, stems and cobs) to reduce impurities and produce fractions that satisfy downstream quality considerations. By using a series of air classification steps, this strategy can reduce the extrinsic ash in corn stover and produce enriched tissue fractions that can be blended to a conversion specification or converted individually in optimized biochemical conversion campaigns. Additionally, a majority of the leaves (which do not meet the quality specification) are separated out early and can be supplied to alternate markets. The 2022 Herbaceous SOT incorporates an advanced biomass fractionation and processing system to produce pellets enriched tissues from three-pass corn stover. The resulting enriched pellets are delivered to the biorefinery individually where they can be blended to a specification or converted in campaigns where the conditions are optimized for each tissue. Unused fractions can be sent to a a midstream market or to a different conversion process that is better suited to their properties to offset the cost of the delivered feedstock. The main benefits from the proposed system can be summarized as: (1) $6.86/dry ton (2016$) lower cost for the air classification due to elimination of the requirement to discard the high ash lights fraction; (2) $1.56/dry ton lower delivered cost by selling the unsuitable leaf fraction into the feed market as a midstream co-product (assuming a selling price that is 11% higher than their cost of production); (3) 0.98% increase in carbohydrate content (from 60.16% to 61.14%); and (4) 0.97% decrease in ash content (from 6.00% to 5.03%) compared to the 2021 Herbaceous SOT. Overall, the 2022 nth-plant Herbaceous SOT predicts a modeled delivered feedstock cost of $78.64/dry ton (2016$) if it is assumed that the enriched leaf fraction is sold at its production cost; this is a slight increase of $0.43/dry ton increase from the 2021 Herbaceous SOT nth-Supply case cost. The increased cost derived from a $0.38/dry ton increase in transportation and handling cost to procure more biomass (to replace the enriched leaf fraction that was not delivered to the biorefinery. The total preprocessing cost was $0.27/dry ton higher than the 2021 result because of updates to energy consumption, purchasing price and dry matter loss data for the rotary shear ($3.00/dry ton increase) and the pelleting mill ($4.52/dry ton increase). The data utilized were generated in pilot-scale tests in the Biomass Feedstock National User Facility (BFNUF) at INL and at Forest Concepts, including tests for rotary shear and pelleting of the air classified fractions. A greenhouse gas emissions analysis was performed by Argonne National Laboratory using the most up to date version of the Greenhouse Gases, Regulated Emissions, and Energy use in Transportation model (GREET®). The analysis showed an increase of 17.34 kg CO2e/dry ton from the 2021 SOT (67.71 kg CO2e/ton in the 2021 Herbaceous SOT to 85.05 kg CO2e/ton in the 2022 Herbaceous SOT). The net increase is primarily attributed to increased energy consumption in pelleting mill.
The U.S. Department of Energy's (DOE's) Bioenergy Technologies Office and the National Renewable Energy Laboratory (NREL) developed the BSM (Bioenergy Scenario model) to explore the development of a U.S. biofuels industry. The BSM is a system dynamics model built on the STELLA software platform. The model represents the dynamic interactions of the major sectors of the biofuels industry—feedstock production, feedstock logistics, biomass to biofuels conversion, and biofuels end use, including fuels inventory, dispensing, distribution, fuel use, and the vehicle fleet. The BSM represents contextual aspects of the developing biofuels industry, including investment in new biomass to biofuel conversion technologies, competition from petroleum fuels, vehicle demand for biofuels, and various government policies, using all of these to simulate the development of the industry. The purpose of the BSM is to generate and explore plausible scenarios for the evolution of a biofuels industry in the United States, and as a high-level system model it is not designed for precise, quantitative forecasting. Instead, it is best used to (1) analyze and evaluate alternate policies; (2) generate scenarios; (3) identify high-impact levers and bottlenecks to system evolution; and (4) seed focused discussion among policymakers, analysts, and stakeholders.
Corn stover is an abundant source of biomass that can be utilized for bioenergy production, representing 70% of the available crop residues in the U.S. However, recent projections estimate that over 60% of corn stover will be collected at moisture levels that exceed 20% moisture (wet basis), resulting in instability in conventional baled logistics systems due to unwanted microbial degradation. This biomass challenge can be solved with a paradigm-shifting technology or SWIFT: Single-pass, Weather Independent Fractionation Technology. SWIFT streamlines collection by eliminating multiple time-consuming, costly, non-value-added, field and weather-dependent steps that comprise the current state of the art in corn stover harvest. The unique approach envisions simultaneous harvest and collection of high, dry matter, whole-plant corn (i.e., stover plus grain) combined with anaerobic storage and fractionation as a means to positively influence the physical and chemical characteristics of corn stover biomass and the resulting feedstock.
There is a growing interest in making the overall aviation industry more environmentally-friendly by developing advanced biofuels. In this context, the main driver is establishing feedstocks with lower environmental loads and higher energy use efficiency. The objective of this study was to evaluate the energy requirement and environmental impacts of hydroprocessed renewable jet fuel (HRJ) production from pennycress. The system boundary included pennycress production, logistics, oil extraction and conversion to HRJ, wastewater treatment, and electricity and steam generation. Energy allocation method was used for the analysis. The functional unit was considered to be one GJ of HRJ, and the biorefinery size was considered to be 18.9 million l/yr (5 million gal/yr) HRJ. Energy use efficiency of pennycress-based HRJ production was estimated to be 3.9–5.5 (90% central range), which was higher than that of HRJ from other oilseeds, such as canola. Global warming potential of pennycress-based HRJ (35–49 kgCO 2 eq/GJ of HRJ (90% central range)) was also lower than those of HRJ from similar oilseeds and the commercial jet fuel baseline. Pennycress production was the main contributor to the total energy use and environmental impacts of HRJ production, mainly due to the use of nitrogen fertilizer for production, and fuel combustion for farm operations. Pennycress yield was identified as the most sensitive parameter affecting the energy use efficiency and environmental impacts of HRJ production. Furthermore, the outcomes of this study are useful for identifying the performance targets towards improving energy use efficiency and environmental performance of pennycress-based HRJ production at the commercial scale.
The Energy Independence and Security Act (EISA) of 2007 required a minimum supply of 36 million gallons of renewable fuels per year by 2022. In order to achieve these goals, the Bioenergy Technologies Office (BETO) has set cost and technology targets for producing advanced and cellulosic biofuels. One of the targets is to validate feedstock supply infrastructures and systems with 90% overall operating effectiveness and field-to-reactor throat delivered cost less than $85.51/dry ton (2016). As stated by the 2017 Multi-Year Program Plan (DOE 2017), the research and development focus of the Feedstock Technologies (FT) platform is reducing the cost, improving the supply chain logistic efficiency, improving biomass quality, and increasing the supply volume. In addition, BETO oversees annual State of Technology (SOT) report that assesses current technologies that are relevant to BETO’s targets based on actual data and experimental results. Feedstocks are essential to achieving BETO goals because the cost, quality, and quantity of feedstock available and accessible at any given time limit the maximum volume of biofuels that can be produced. In accordance with the 2016 Multi-Year Program Plan (DOE 2016a), FT focuses on (1) reducing the delivered cost of sustainably produced biomass, (2) preserving and improving the physical and chemical quality parameters of harvested biomass to meet the individual needs of biorefineries and other biomass users, and (3) expanding the quantity of feedstock materials accessible to the bioenergy industry. This is done by identifying, developing, demonstrating, and validating efficient and economical integrated systems for harvest and collection, storage, handling, transport, and preprocessing raw biomass from a variety of crops to reliably deliver the required supplies of high-quality, affordable feedstocks to biorefineries as the industry expands. The elements of cost, quality, and quantity are key considerations when developing advanced feedstock supply concepts and systems (DOE 2016a).
Reclaimed municipal wastewater is a crucial component in biofuel production, especially in regions experiencing increasing freshwater scarcity. However, accurately estimating the potential for fuel production is challenging because of the uneven distribution of biofuel feedstock regions and wastewater treatment plants (WWTPs). This study assesses the viability of using reclaimed municipal water for algal biomass production in pond systems co-located with WWTPs under scenarios driven by biomass production and based on water transport logistics. We performed state- and county-level analysis of reclaimed water resources throughout the United States based on WWTP facility data. We overlaid these data onto estimated algae facility sites and examined the temporal resource availability to address seasonal variations in cultivation demand. Our findings reveal that 2694 billion liters per year of reclaimed water could potentially be used to produce 42.2 million metric tons (ash-free dry weight) of algal biomass, equivalent to 29.2 billion liters of renewable diesel equivalent (RDe). The use of reclaimed water would double current national water reuse and expand such reuse significantly in 455 counties across the United States. However, when we limit the construction of algae facilities to counties that can fully meet their water demand in order to minimize water transport burdens, the available supply decreases by 80%, to 512 billion liters, resulting in annual production of 12.2 billion liters of RDe, which still doubles current biodiesel production. Our analysis highlights the degree to which the location and flow of WWTPs and water transport affect the deployment of algae biofuel facilities and tradeoffs. These findings underscore the importance of improving the current WWTP infrastructure for reclaimed water reuse, especially in southern states.
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.
This unique and highly effective project catalyzed collaboration among government, university, and private sector partners through a multi-state research and technology transfer project designed to support continuous improvement of bioenergy feedstock supply systems. Conceived and built upon the foundation created by prior DOE investments in the Billion Ton Study, Sun Grant Regional Project, and many other feedstock production, harvest, storage and transportation studies, this project addressed seven tasks with more than 29 subtasks. All goals were met with key accomplishments being: (1) on-farm establishment of potential perennial plant mixtures that could not only become sustainable feedstock sources but also enhance soil health, (2) a reduction in potential wind and water erosion by improving corn stover harvest techniques and incorporating cover crops into current row-crop production systems, (3) reduced potential for surface and groundwater contamination while also increasing potential biodiversity and sustainability of Midwestern USA landscapes, and (4) development of site-specific land management, data visualization, and sustainability assessment tools. Twenty-two Case Studies highlighting accomplishments and lessons learned through this public-private partnership investment are incorporated into this final report. On-farm and replicated field plot studies were used to provide the real-world data needed to verify baseline assumptions for extensive feedstock logistic modeling and greenhouse gas (GHG) assessments needed to develop sustainable bioenergy and bio-product industries at national and international scales.
Brassica carinata or Ethiopian mustard, a non-edible oilseed brassica, is a low carbon, purpose-grown, and none-to-low indirect land-use change bioenergy feedstock for the production of drop-in sustainable aviation fuel, biodiesel, renewable diesel, and a suite of value-added coproducts. Carinata oil converted to drop-in fuel using an American Society for Testing and Materials approved Catalytic Hydrothermolysis process has been successfully tested in commercial and military aviation. Carinata meal, the residue after oil extraction, is a high-protein feed supplement for livestock, poultry, and swine, and can also yield specialty products. The Southeast Partnership for Advanced Renewables from Carinata (SPARC) is a public–private partnership formed with a twofold mission: (1) Removing physical, environmental, social, and economic constraints that prevent regional intensification of carinata production as a low-carbon feedstock for renewable fuel and coproducts and (2) demonstrating enhanced value across the entire value chain by mitigating risk to farmers and other stakeholders. The partnership's goal is to energize the US bioeconomy through sustainable agriculture and thus contribute to energy security and economic diversification. SPARC relies on a combination of cutting-edge multidisciplinary research and active industry engagement to facilitate adoption of the crop. This involves informing stakeholders along the entire supply chain, from producers to end-users, policymakers, influencers, and the public, about the opportunities and best practices related to carinata. This article provides context and background concerning carinata commercialization as a winter cash crop in the Southeast US for renewable fuels and bioproducts. The advances made to date in the areas of feedstock development, fuel and coproduct development, meal valorization, supply chain logistics, and stakeholder engagement are outlined.
Worldwide, aviation accounts for 2% of all manmade carbon dioxide emissions and 12% of all transportation CO2 emissions. In 2023, the U.S. accounted for 27% of the world jet fuel consumption. The aviation industry has set sustainability goals, and mandates. Sustainable aviation fuel (SAF), made from nonpetroleum feedstocks, significantly reduces aviation emissions. SAF must be blended with petroleum-based jet fuel prior to its use in aircraft. Jet fuel quality standards and certification documents are essential to fuel performance, operability, and safety and are the primary driver in determining locations for blending. Several locations were evaluated including terminals, airports, refineries, and greenfield/brownfield sites. While all the locations evaluated are technically capable of blending fuel, there are practical considerations that make terminals the optimal location for blending. The report includes background on jet fuel and SAF use, fuel quality standards, modes of transport for both conventional jet fuel and SAF, and terminal information.