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A Primer on the

Technology of Biofuel
Production
A Primer on the Technology of Biofuel Production

Biodiesel
Bioethanol
Fuel Pellets
Biodiesel Production as an
Alternative Energy Source from the
Farm
"Biodiesel Basics"

"A Case Study in Building a Biodiesel Plant-Business"


Biodiesel Basics

• What is biodiesel…
• How is it used…
• What is it made from…
Biodiesel Basics
• Biodiesel = Fuel (similar to diesel)
• Can be used in any diesel engine
– 18-wheeler, combine, pickup truck, rice well
pump, locomotive, home heating system, boat, etc
• Normally used as a "blend" with petro-diesel
– B2, B5, B20, etc….B = % biodiesel to petro-diesel
• Made from vegetable oil or fat—not petroleum
– soybean, cotton, sunflower, canola, poultry fat,
pork fat, beef fat, used cooking oil, etc….
("all come from the farm")
Biodiesel Basics

• What are the advantages of biodiesel…


– Why would you use biodiesel vs petro-diesel

• What are the disadvantages of biodiesel…


– Why might you not use biodiesel vs petro-
diesel
Biodiesel Basics

• Advantages of Biodiesel
– Reduces dependence on foreign oil
– Supports U.S. economy
– Supports Agri economy
– Cleaner Burning Fuel—Better for the Environment
– Reduced particulates, hydrocarbons, sulfur dioxide,
carbon monoxide, etc
– Non-toxic (1/10th toxicity of table salt) and
biodegradable
– Provides lubricity to engines
Biodiesel Basics

• Potential Disadvantages of Biodiesel


– Currently costs more (slightly) than petro-
diesel
– Acts as a solvent—may need to change your
filter after early use
– Potential to "gel" in extended periods of
extreme cold temperatures
– Engine warranty issues
Biodiesel Production Facilities (105) in U.S.
From NBB Web Site
Biodiesel Production Facilities (105) in U.S.
From NBB Web Site

Avg. Plant Size ~ 6M gal/year (67% < 5M and 10% > 20M)
Feedstock = Soy (34), Multiple (11), Used Cooking Oil (6), Cotton (1), & Beef (1)
Annual Production: 2004 = 25M gal…2005 = 75M gal…2006 = 150M gal
FutureFuel's Biodiesel Project
• Feasibility study began in May 2005
• Commercial production of B100 began in late October 2005
• Feedstock
– Soy oil (primary— current production)
– Rendered oil (secondary—current production)
– Used Cooking Oil (on hold)
• Market
– Arkansas (primary)
– Beyond Arkansas (as opportunities arise)
– Internal (using B20 in our own fleet)
• Production capability (all with existing equipment)
– Initially: ~ 3M gallons/year rate
– Presently: ~ 24M gallons/year rate
• Rail & Truck shipment capabilities
• BQ-9000 Accredited Producer (4th in U.S.)
• Soon to introduce "Biodiesel Services" business
Biodiesel Business Model…Soybean Oil

Biodiesel
Feedstock Biodiesel
Marketing &
Soybean Oil Production
Distribution

Soybean
Supply

Soybean Rendered
Fat
Glycerin
Meal

Alternative
Animal
Products or
Feed
Fuel
Biodiesel Business Model…Soybean Oil

Biodiesel
Feedstock Biodiesel
Marketing &
Soybean Oil Production
Distribution
1—1.4 gallons 1 gallon
Soybean
Supply
1 Bushel

Soybean
Rendered Glycerin
Meal
Fat 1 Lb.
48—52 lbs

Alternative
Animal
Products or
Feed
Fuel
Triglyceride
Methanol
Catalyst

Glycerin/Methanol/Catalyst

Water Biodiesel

Water/Methanol/Glycerin
Biodiesel ASTM D 6751

Free Glycerin (GC) 0.020 wt% max


Total Glycerin (GC) 0.240 wt% max (free + mono/di/
triglycerides)
Water & Sediment (centrifuge) 0.050 vol% max
*Sulfur (ICP) 0.05 wt% max (500 ppm)
Phosphorous (ICP) 0.001 wt% max (10 ppm)
*Acid Number (mg KOH/g) 0.80 max
Sulfated Ash 0.020 wt% max
Flash Point 130.0ºC min
Copper Strip Corrosion No 3 max
Carbon Residue 0.050 wt% max
Cloud Point ºC report
*Viscosity at 40ºC 1.9-6.0 centistokes
Atmospheric Equivalent 360ºC
Temperature (distillation of sample, 90% recovered)
Cetane Number 47 min
(uses specially instrumented diesel engine)
Issues facing Arkansas Biodiesel
Business
• Quality
• Availability & Price of Raw Material Oil
• Extension of Market beyond Agri
• Competitive State Legislation
Bioethanol from Cellulose
• Feedstock Considerations
– Hardwood
• Commercial harvesting infrastructure in place
• Abundant and available year round
• Cleanest feedstock (debarked and chipped logs)
– Crop residues
• Rice hulls
– Rice hulls cheap and available
– High silica
– Seasonal
• Rice and wheat straw
– Harvested on a limited commercial basis for hay
– Rice straw is high in silica
– Seasonal
– Energy crops
• Not produced in our area
• Future opportunity
• Must consider potential competition with oil seed crops
Bioethanol from Cellulose
• Technology Considerations
– Feedstock pretreatment
• Leading pretreatment technologies
– Steam explosion - SunOpta
– Ammonia explosion – Michigan State University
– Dilute Acid - NREL
– Fractionation
• Separating cellulose, hemicellulose, and lignin
– Necessary to separate hemicellulose from cellulose (5
carbon sugars from 6 carbon sugars)
– Removal of lignin increases effectiveness of enzymatic
hydrolysis
Bioethanol from Cellulose
• Technology Considerations
– Enzymatic hydrolysis
• Use of enzymes to depolymerize cellulose into glucose (6
carbon sugars)
• Critical yield and capacity determining step
– Fermentation
• Continuous fermentation superior to batch fermentation
– Realize value from hemicellulose (5 carbon sugar)
• Virent aqueous phase reforming
– Converts hemicellulose (5 carbon sugars) into green diesel,
green gasoline, and other chemical products
Bioethanol from Cellulose
• Progress and Path Forward
– Producing ethanol in the lab from steam exploded cellulose
– Implementing NREL analytical methods
– Contracted with NREL to conduct site assessment
– Utilizing enzymes from Novozymes and Genencor
• Secured a sample of Novozymes most effective cellulase enzyme
– Testing small-scale steam exploder
• Attempting to duplicate industries best performance
– Preparing sample of extracted hemicellulose for testing in
Virent's lab
– Complete large scale batch plant trial
• Planning 5 to 7 trial batches
• Requires significant campaign in SunOpta's pilot plant
– Define a project scope and conduct financial evaluation
• NOBS II retrofit, greenfield, or both
Sludge
Dewatering
Cellulosic
ethanol

Kilo lab available to setup enzyme


development and production

EASTMAN
Cellulosic
ethanol

EASTMAN
Cellulosic Ethanol Plant Components
Component Status Comments
Biomass Sizing/Storage X
Biomass Pretreatment ? Vessels for Slurry/Extraction
Biomass Fractionation ? Vessels for Slurry/Extraction
Fermenters X
Distillation √ NOBS II Columns
Ethanol Drying √ NOBS II + S.R. Azeo Columns

"Solids" Separation √ Solid bowl Centrifuges


"Solids" Drying √ Ring Dryers
"Solids" Handling/Storage √ NOBS II Convey Systems/Bins

Enzyme Propagation √ Kilo lab + Batch Plant


Infrastructure:
Land, Buildings √
Utilities √ Coal Cost Advantage
Rail & Bulk Liquid √
Waste Handling √ Incineration, WWT, RTO
Laboratories √ Analytical, Development
Fuel from Wood Waste
Fuel Pellets

• Challenges of Producing Solid Wood Pellet Fuel


– Securing a reliable supply of raw material (sawdust)
– Significant supply of wood pallets
– Significant investment in packaging material
– Large area to store pallets, bags, and other packaging material
– Controlling moisture content of raw material
– Moisture content must be controlled between 10 and 13%
– Average % moisture from local sawmills is 35% moisture
– Meeting quality standards
• Density: minimum 40 pounds/cubic foot
• Dimensions: length (1 ½” maximum) and diameter (1/4”)
• Fines: amount of fines passing through 1/8” screen no more than .5 percent
by weight
• Chlorides: no more than 300 parts per million
• Ash content: important factor in maintenance frequency
Fuel Pellets
• Challenges of Producing Solid Wood Pellet Fuel
– Requires specialized equipment to convert sawdust to pellets
– Permit from the EPA
– 12 to 18 months for Plant construction
– Specialized Operator Training
– Dependable work force

• Advantages of Fuel Pellets


– Clean
– Efficient
– Easy to Store
– Cost Effective
– Low Ash
– Low Maintenance
– High Heat Value
– Easy to Use
– Environmentally Friendly
Current Status

Continuing to examine the existing facilities,


evaluate the options under consideration
for use of these facilities for the
conversion of locally available biomass to
fuels and chemicals, and to collect
information on existing and underutilized
infrastructure.

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