Out of the Box Carbon Feedstocks
for the Forest Biorefinery
José Meléndez & Paul R. Stuart
NSERC Environmental Design Engineering Chair
Department of Chemical Engineering, Ecole Polytechnique
Montréal, Canada
Outline
Introduction
ƒ Problem Definition
Objectives
“The Corn Biorefinery
The Forest Biorefinery
ƒ Biorefinery feedstocks
ƒ Biomass characterization & classification
ƒ Lignocellulosic feedstocks
“The Lignocellulosic Biorefinery”
Conclusions
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Problem Definition
A current high demand/low production scenario for
low cost sawmill residues caused by:
ƒ Increasing energy prices
ƒ Tariffs for Brazilian ethanol imported to the US & Canada
ƒ Implementation of Kyoto protocol & environmental policies
• Push companies & communities to search for cleaner, more
sustainable and renewable sources of energy
ƒ Decreases in demand for traditional forestry products which
have lead to mill closures (both pulp & paper and sawmills)
ƒ Costs of competing biomass (non-wood) sources are still
much higher than mill residues
[Canada Report on Bioenergy, 2009]
This shortage of traditional biomass feedstock
creates a need for new sources of carbon.
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Problem Definition
The increased usage of 1st generation biofuels such
as biodiesel & ethanol, has created instabilities in the
market supply and demand of traditional crops
ƒ Grain and crop demand for ethanol production has pushed
feedstock prices up in the past few years
ƒ 1st generation biofuels use crops which typically are used for
food (human and livestock); creating a social dilemma:
• Food VS Fuel
• Feed VS Fuel
2nd generation biofuels seek to use the residuals from
crop production (cobs & stover) among various other
feedstocks
ƒ Care must be taken not to fall into the same patterns of the
past [IEA's Report on 1st- to 2nd-Generation Biofuel Technologies, 2008]
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Problem Definition
Identification and usage of new sources of biomass
needs to be a priority for companies working to
transform into forest biorefineries
ƒ Process technologies used must allow for variation in
incoming feedstock characteristics.
Guarantee of biomass on a long term basis is
absolutely essential for financing & viability of a
biorefinery
ƒ Biomass suppliers like to work on a “First come, first served”
basis which gives no security of supply on a long term basis
Flexibility in feedstocks to a biorefinery will guarantee
biomass supply & lower costs.
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Objectives
To illustrate the impact of corn price on ethanol
production business models (single feedstock),
associated with the emergence of increased demand
for ethanol.
To determine feedstock characteristics required for
biorefinery processes (biochemical and
thermochemical).
To address a concretizing example that establishes the
economic benefits of multiple feedstock use, by
accounting for
a) feedstock types
b) feedstock availability
c) feedstock cost as a function of distance from the mill.
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The Corn biorefinery
Example of a single feedstock process
Uses biochemical process which has been optimized
for corn feedstocks only.
Main product looked at is ethanol (2.85gal/bu
conversion rate)
When the markets prices of corn and ethanol
fluctuate, the industry has no alternative but to
endure the changes.
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The Corn Biorefinery
Ethanol Bankruptcies & Acquisitions
Conference – Houston, TX [July 2009]
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The Corn Biorefinery
From the graphs we can determine that:
ƒ Market fluctuations in feedstock and product prices have had
detrimental effects on the entire corn ethanol industry (see
Earth2Tech’s biofuels deathwatch list).
ƒ A single feedstock process limits industry adaptation when
market conditions, policies and other factors affect feedstock
and product prices.
ƒ Other factors have also contributed to the industries
downturn. It’s important that companies seeking to convert to
biorefineries learn from these mistakes
Conclusion
When the process technology allows for changes in feedstocks
with minimal impact to process or products, it helps secure
feedstock supply over a long term period
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The forest biorefinery
Retrofitted (continued production of P&P plus
additional products) or repurposed mills that integrate
multiple processes for production of multiple products
Use of both biochemical and thermochemical
processes which will allow for production of multiple
products from multiple feedstocks
Biorefinery configuration and design will vary from
one location to another depending on:
ƒ Desired products
ƒ Existing processes and facilities
ƒ Feedstocks available
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Forest biorefinery Feedstocks
Ideal Feedstock: Engineered & Tailored Biomass
ƒ Tailored feedstocks for the biorefinery process (the right
components in the right amounts for the selected process)
ƒ High growth yields of biomass with increased process
selectivity to desired product
Let’s use what’s available in the best way possible
ƒ Evaluate process’s feedstock requirements
ƒ Characterize all possible feedstocks
ƒ Link your feedstock sources to your process requirements
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Biomass Classification
Analyse the process requirements first, then establish
what your feedstocks should contain
Requirements
Biochemical Technologies
Hydrolysis
Transesterification
Anaerobic Digestion
Chemical Technologies
Extraction, Separation
& Fractionation
Thermal Technologies
Gasification, Pyrolysis,
Combustion (Energy)
Sugars
Lipids/oils
Organic Material
Different components in
chemical composition
Low Moisture
High Energy density
Sugars & Starch
Feedstocks
Vegetable oils &
Animal Fats
Biodegradable
waste feedstocks
Lignocellulosic
Feedstocks
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Biomass Classification
Biomass Characterization
Sugars & Starch
Feedstocks
Vegetable oils &
Animal Fats
Biomass Classification
Sugars
Starches
Others
Sugarcane, Sugar beet
Corn, wheat, potatoes, tapioca
Industrial by-products & residues
Virgin oils
Soybeans, palm, rapeseed
Animal fats
Tallow, lard, chicken fat, etc
Others
Waste vegetable oils
Animal Wastes
Biodegradable
waste feedstocks
Lignocellulosic
Feedstocks
Municipal Solid Wastes
Others: Sludges & Biowaste
Forestry
Timber, Forestry & Sawmill
residues, Pulp and Paper residues
Agricultural
Harvesting & Processing Residues
Energy Crops
Herbaceous & Woody crops
Waste Material
Urban, Recyclables & Industrial
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Characterization Results
Sugars, starches, vegetable oils & animal fats are
better suited for biochemical pathways
ƒ 1st Generation biomasses of course present problems due to
their use in the food supply chain (Food-Feed-Fuel)
Biodegradable waste feedstocks present high
moisture content. It’s content and possible extraction
will determine if it’s better used in a biochemical or
thermochemical process.
Lignocellulosic feedstocks contain a wide variety of
sources. Each sources contains different amounts of
desired components.
ƒ So how do we determine which feedstocks go with which
process?
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Lignocellulosic Feedstocks
Composed mainly of 3 distinct structural components:
Hemicellulose
Cellulose
Lignin
ƒTogether, these components
give structure and strength to
the plant
ƒIndividually, each component
has differences in it’s structure
which allow for separation from
the others.
[CERES, www.ceres.net]
ƒAll 3 components are of
industrial value for production of
paper, chemicals, energy, etc.
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Lignocellulosic biomass survey
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Lignocellulosic biomass survey
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Lignocellulosic biomass survey
(Results)
Survey analysed the 3 main biochemical components
of lignocellulosic biomass to determine which were
are best suited for type of biorefinery process.
High cellulose & hemicellulose content is favourable
for biochemical processes:
ƒ Hardwoods
ƒ Energy crops (both SRWC and Herbaceous)
ƒ Agricultural harvesting residues
High lignin content might have better use in
thermochemical processes or chemical separation
ƒ Softwoods
ƒ Barks
ƒ Agricultural processing residues*
• These have very high variation in composition
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The Lignocellulosic Biorefinery
Supply of multiple feedstocks to a mill biorefinery
Concretizing example which establishes the
economic benefits of multiple feedstock use, by
accounting for
a) feedstock types
b) feedstock availability
c) feedstock cost as a function of distance from the mill.
Data of available biomass was collected and
originally analysed to produce biomass supply curves
by E. Hytönen [Pulp & Paper Canada, Vol. 110, No.5/6]
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The Lignocellulosic Biorefinery
(Mill example case)
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The Lignocellulosic Biorefinery
Numerical Example 1: Quality
100 mi radius
Hardwood
Hardwood
Softwood
Corn Stover
Total
Quantity Avg. Price
[bdt]
[$/bdt]
1,000,000
98.26
500,000
92.34
250,000
87.89
250,000
47.53
1,000,000
Total
[$]
98,260,000
98,260,000
46,171,083
21,973,561
11,881,684
80,026,328
Numerical Example 2: Energy
Quantity
[bdt]
Forestry Residues 1,000,000
Forestry Residues 300,000
Corn Stover
700,000
100,000
Mill Residues
600,000
Total
1,000,000
150 mi radius
100
Price
[$/bdt]
58.63
42.13
52.41
44.86
15.30
Total
[$]
58,630,000
58,630,000
12,639,000
36,687,000
4,486,000
9,180,000
49,326,000
26,305,000
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Conclusions
Flexibility of biomass supply will better secure the
feedstock supply for a biorefinery process over the
long term.
The literature concerning feedstocks classification
and characterization & their the link with process
requirements indicates that
ƒ For Biochemical processes, use feedstocks with high
amounts of sugars, starches, vegetable oils, animal fats,
cellulose and hemicellulose
ƒ For Thermochemical processes, use feedstocks with low
moisture and high lignin content, plus feedstocks with high
composition variability
Having biorefinery technologies that can employ
multiple feedstocks will lower feedstock costs.
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Conclusion cont.
Two frameworks for biomass supply should be
considered for the biorefinery at the early design
stage:
1. Bringing the maximum forest and other biomass to the
biorefinery gate at the lowest cost, accounting for flexibility
in the type of biomass for the biorefinery processes.
2. Bringing a targeted quantity of biomass to the mill gate that
satisfies biorefinery process capacities and market needs,
at the lowest cost and accounting for flexibility in type of
biomass for the biorefinery processes.
To define a product driven approach for the biorefinery that
accounts for supply chain efficiency (on time when the customer
wants it) and effectiveness (low cost)
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Acknowledgements
Funding
ƒ Natural Sciences Engineering and Research
Council of Canada (NSERC) Environmental
Design Engineering Chair
Data & models for lignocellulosic biorefinery
ƒ Eemeli Hytönen (NSERC Design Chair)
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Out of the Box Carbon Feedstocks for
the Forest Biorefinery
THANK YOU
Questions?
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