Process Engineering and Analysis 1998-99 Project Summaries


	Process Engineering and Analysis
	Process Engineering and Analysis Work Package (a) Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator:Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Contract Number: N/A Contract Period: 10/97–09/98 Contract Funding: FY 1998: $851,000 Objective:Provide the Biofuels Program (of NREL and the U.S. Department of Energy [DOE]) with the best possible technical evaluations and cost estimates of current and emerging technologies for the conversion of lignocellulosic biomass to ethanol. Specific objectives were as follows. Improve the process model using subcontracts in the specific nonresearch areas of wastewater treatment, burner and boiler design, and overall engin-eering design. Support research activities by evaluating the potential of various research alternatives. Validate and document the design and cost basis of all unit operations. Publish the production cost of ethanol from cellulosic biomass jointly with U.S. Department of Agriculture (USDA). Update the ethanol life cycle from 1993 to reflect new process technologies and feedstock opportunities. Approach/Background: Using software tools, NREL process engineers have developed rigorous mass and energy balances for the biomass-to-ethanol process in its various forms, including dilute acid pretreatment–enzymatic hydrolysis, total hydrolysis, and two-stage dilute -acid–enzymatic hydrolysis. In addition, capital and operating costs have been determined from vendor contact, costing software, and industrial collaboration with corn-ethanol producers. The end result is a set of modeling tools that can be used to evaluate the economic potential of processes and process alternatives. These tools are adaptable, allowing evaluations of differing processes at differing levels of detail, yet they provide a clear picture of areas for improvement. Status/Accomplishments: The process design was updated through three subcontracts described in separate project summaries. The result was the enhanced ability in the ASPEN+ model to readily develop costs of major process areas for the wide range of biomass processing schemes and biomass feedstocks that might be considered in the future. This improved model will be used to publish the cost of ethanol production (with USDA), to update the Multiyear Technical Plan as necessary, and for the 1999 stage gate planning. In 1997 we began to incorporate the way experiments are conducted and the results reported into the way the model is designed. This work was continued, most notably by the modeling and economic evaluation of the lignin utilization project, which had not been previously modeled. A database to facilitate the documentation of design and cost bases has been developed. This includes actual design docu-ments, spreadsheets of calculations, vendor quotes, subcontractor reports and any other supporting information. Additionally, to further the creditability of the model the design and cost basis of each piece of equipment was verified and documented. In addition, applicable parts of the model were validated against an operating corn-to-ethanol plant in York, NE. Plant oper-ating and cost data were used to further refine the ASPEN+ process model. To further increase the credibility of the cost predictions and demonstrate a single Federal government voice, work with USDA to publish a joint paper on the cost of producing ethanol from cellulosic biomass was mapped out and a schedule put in place. A joint project with several California state agencies looked at the life cycle of ethyl tertiary butyl ether, using ethanol derived from various cellulosic biomass feedstocks, and compared that with methyl tertiary butyl ether produced from methanol that was derived from natural gas. The life cycle inventory for biodiesel and petroleum diesel was also reviewed. Publications and Presentations: None Summary Date: February 2000

	Process Engineering and Analysis Work Package (b) Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Contract Number: N/A Contract Period: 10/98–09/99 Contract Funding: FY 1999: $1,080,602 Objective: Our objective is to provide the Biofuels Program (of NREL and the U.S. Department of Energy [DOE]) with the best possible technical evaluations and cost estimates of current and emerging technologies for the conversion of lignocellulosic biomass to ethanol. Specific objectives were as follows. Improve the base process design and economic model where appropriate, specifically for the addition of lignin gasification and gas turbine power generation and better defined liquid–solids separation performance and costs. Expand the model to include syngas fermentation, and immobilized-enzyme and transgenetic cellulase. Incorporate actual plant experience into the process design and modeling. Support DOE analyses and update the Multiyear Technical Plan, in addition to providing program analytical support and documentation to program leaders. Approach/Background: Using software tools, NREL process engineers have developed rigorous mass and energy balances for the biomass-to-ethanol process in its various forms, including dilute-acid pretreatment and enzymatic hydrolysis, total hydrolysis, and two- stage dilute-acid–enzymatic hydrolysis. In addition, capital and operating costs have been determined from vendor contact, costing software, and industrial collaboration with corn-ethanol producers. The end result is a set of modeling tools that can be used to evaluate the economic potential of processes and process alternatives. These tools are adaptable, allowing evaluations of differing processes at differing levels of detail, yet they provide a clear picture of areas that can be improved. Status/Accomplishments: We began to investigate gasification and combined cycle power generation by reviewing the work of NREL’s Biomass Power group to determine the optimum power generation design for biomass refining. To address the solids–liquid separation costs, a subcontract was placed to review the design of this process. The cost of syngas fermentation was modeled and found to be about the same as that of sugar fermentation, on the basis of limited information. Fluidizing-bed bioreactors and transgenic cellulase in plants were also investigated and reported on. Several feasibility studies were completed to support the Partnership Development Team’s efforts in deployment of the bioethanol process. Most notable was the South Dakota project, which required site-specific data to be incorporated. To ensure that the process designs developed are consistent with accepted industry practice, we continued to collaborate with several corn-ethanol plants through the Bridge to Corn Ethanol subcontracts and the U.S. Department of Agriculture, which uses information from corn-ethanol producers in its modeling efforts. A revised Multiyear Technical Plan and Strategic Roadmap for Bioethanol were produced as well as several reports on CO₂ emissions, transportation fuels from biomass, and bioethanol’s role in global climate change. Publications and Presentations: None Summary Date: February 2000

	Cellulase Reactor Designs Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: Vogelbusch, U.S.A.. 10810 Old Katy Rd., Suite #107, Houston, TX 77043 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: G. Brodl, 713.461.7374, vbusa@email.msn.com Contract Number: ZXE9-18080-01 (modified) Contract Period: 07/99–02/00 Contract Funding: FY 1999: $15,000 Objective: To improve the process design and accuracy of the cost estimate for cellulase production and develop information that can be included in NREL’s techno-economic model for use in future design sensitivity studies. Alternative bioreactor designs will also be investigated. Approach/Background: A literature study of cellulase production as well as similar systems was initiated to determine the oxygen transfer rate for use in designing the cellulase production area of a biomass-to-ethanol facility. Several designs of this plant area will be developed for the required oxygen transfer rate and costs of each design will be estimated. The designs will include bioreactors, agitators, compressors, and other required equipment. Finally, input on experimental work to help specify and finalize the designs will be provided. That input will include experimental specifications and data collection requirements. Status/Accomplishments: Vogelbusch, after reviewing the literature, determined that the required oxygen transfer rate should be achievable in full-scale facilities. It has proposed two options for the system design that may be more economical than traditional sparged vessels. The options are bubble column vessels and porous spargers. Information on design and economics of these options will be included in the final report. Publications and Presentations: None Summary Date: January 2000

	Alternative Fuels Industry Meeting Participation, Facilitation, Project Reviews, and Reviews of Solicitation Responses Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: J.E. Sinor Consultants Inc., 6964 N. 79^th Street, Suite 1, Niwot, CO 80544 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator:J.E. Sinor, 303.652.2632, JESinor@BoulderNews.infi.net Contract Number: EXL-7-17478-01 Contract Period: 08/97–08/99 Contract Funding: FY 1999: $20,000 Objective: J.E. Sinor Consultants was contacted through an existing consulting agreement (managed by the Center for Transportation Technology) to provide a refinery market perspective for the Lignin Utilization Project. Mr. Sinor was asked to provide expert knowledge about the fuels market, emissions regulations, and potential market share for new fuel additives. No money was added to the existing consulting agreement in FY 1998. Approach/Background: The Biofuels Programs of the U.S. Department of Energy have funded research to investigate the lignin residue produced from the biomass to ethanol process and its potential uses. Work has focused on converting the long chain polymer into aromatic compounds that will improve the octane value and oxygenate level of gasoline, diesel, reform-ulated gasoline, and jet fuel. Status/Accomplishments: Through research on desirable qualities for fuel additives, Mr. Sinor discovered that the target product would not provide a sellable product because of its low octane value. He provided data to help project leaders determine the correct target products. Mr. Sinor also provided a clear picture of current regulations affecting the fuels market, which enabled researchers to take emissions concerns into account when they evaluated sample products. Mr. Sinor provided information on calculation and laboratory methods for determining octane number. Publications and Presentations: Sinor, J. Market assessment for lignin byproducts. June 1998. Presentation to the National Renewable Energy Laboratory, Golden, CO. Sinor, J. Octane number and its determination for lignin byproducts. July 1999. Presentation to the National Renewable Energy Laboratory, Golden, CO. Summary Date: February 2000

	Steam and Electricity Generation Options for the Biomass-to-Ethanol Process Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: Reaction Engineering International, 77 W. 200 South, Suite 210, Salt Lake City, Utah 84101 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: Stan Harding, 801.364.6925, harding@reaction-eng.com Contract Number: ACO-8-18019-01 Contract Period: 03/98–03/99 Contract Funding: FY 1998: $44,594 Objective: Reaction Engineering International (REI) was contracted to provide a better design and capital costing of the burner–boiler–turbogenerator area in the biomass to ethanol process. REI also evaluated emissions and control systems for them. Approach/Background: The National Renewable Energy Laboratory (NREL) has undertaken a complete review and update of the process design and economic model for the biomass-to-ethanol process based on cocurrent dilute-acid prehydrolysis, along with simultaneous saccharification (enzymatic) and cofermentation. The process design includes the core technologies being researched by the U.S. Department of Energy: prehydrolysis, simul-taneous saccharification and cofermentation, and cellulase enzyme production. In addition, all ancillary areas—feed handling, product recovery and purification, wastewater treatment, lignin burner and boiler-turbogenerator, and utilities—are included. NREL engaged REI to assist in evaluating designs and costing equipment for the steam and electricity generation area. Status/Accomplishments: Using the NREL report of October 8, 1997, titled "Co-current Dilute Acid Prehydrolysis/Enzymatic Hydrolysis Report," as a starting point, REI began working interactively with NREL, providing system reviews and comments, as well as developing specific PFDs for the combustion burner–boiler and turbogenerator system. The basic plant was designed on a feed flow rate of 2000 metric tons per day of dry wood. REI also reviewed NREL’s process spreadsheet for equipment, cost factoring for different capacities, and operating costs. REI contacted vendors of combustion equipment to determine realistic operating conditions, cost, and expected emissions levels. REI also looked at the total hydrolysis and softwood processes to determine their steam and power needs. Publications and Presentations: Harding, S. and C. Lee. March 1999. Energy analysis of biomass to ethanol processes, final report. NREL subcontract ACO-8-18019-01, National Renewable Energy Laboratory, Golden, CO. Summary Date: January 2000

	Wastewater Treatment Options for the Biomass-to-Ethanol Process Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: Merrick & Company, 2450 S. Peoria St., Aurora, CO 80014 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: F. Ferraro, 303.751.0741, Fran.Ferraro@merrick.com Contract Number: AXE-8-18020-01 Contract Period: 04/98-10/98 Contract Funding: FY 1998: $36,000 Objective: Design an efficient wastewater treatment (WWT) system for an enzyme-based process for converting lignocellulosic biomass to fuel ethanol and develop cost estimates for the same. Use actual wastewater characterization to determine compositions expected in the WWT system. Approach/Background: A sound wastewater treatment (WWT) strategy is to concentrate contaminants into a relatively small stream, leaving the major stream sufficiently clean for reuse or discharge. By selecting waste streams that can be recycled separately upstream of the treatment, the WWT system becomes much smaller and overall plant efficiency is greatly increased. These issues were considered in the selection of the best alternative for WWT. Some of the major WWT alternatives available are anaerobic biological treatment, aerobic biological treatment, evaporation (and incineration), stream discharge, land application, and discharge to a publicly owned treatment works. Status/Accomplishments: A WWT system was designed for an enzyme-based process for converting lignocellulosic biomass to fuel ethanol. The bioethanol process was based on NREL’s technology and included the following basic unit operations: biomass pretreatment, hydrolyzate conditioning, fermentation, cellulase production, product recovery, and energy recovery. Anaerobic digestion followed by aerobic treatment was selected as the best WWT strategy, and centrifugation and evaporation of the stillage was employed to minimize wastewater and optimize water recycling. An independent laboratory characterized actual wastewater treatment samples. For a 2000 dry tons/day biomass-to-ethanol plant, the capital cost estimate for a WWT system is about $10.4 million. The impact of capital costs and the associated operating expenses of the WWT system correspond to $0.89/gal of ethanol. The WWT strategy and cost estimates developed can be generally applicable to similar bioethanol plants. Publications and Presentations: Kadam, Kiran L., Robert J. Wooley, Francis M. Ferraro, Richard E. Voiles, Joseph J. Ruocco, Frederick T. Varani, and Victoria L. Putsche. 1999. Wastewater treatment for a biomass-to-ethanol process: System design and cost estimates. Proceedings, Fourth Biomass Conference of the Americas: Biomass—A Growth Opportunity in Green Energy and Value-Added Products. Edited by R.P. Overend and E. Chornet. Pergamon/Elsevier Science, Oxford, U.K. Kadam, K. et al. 1999. Wastewater treatment for a biomass-to-ethanol process: System design and cost estimates. Proceedings of the Fourth Biomass Conference of the Americas: Biomass—A Growth Opportunity in Green Energy and Value-Added Products, Vol. 1. Edited by R.P. Overend and E. Chornet, Pergamon/Elsevier Science, Oxford, U.K., p. 699-705. Merrick & Company. 1998. Wastewater treatment options for the biomass-to-ethanol process, final report. NREL subcontract AXE-8-18020-01. National Renewable Energy Laboratory, Golden, CO. Summary Date: January 2000

	Process Engineering Support—Review Current Process Designs and Costs, and Supply Hard-to-Get Vendor Equipment Estimates Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: Delta-T Corporation, 460 McLaws Circle, Williamsburg, VA 23185 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: H. M. Majdeski, 757.220.2955 and A. Galvez, 757.220.2955 Contract Number: KCO-8-18004-01 Contract Period: 01/98–04/99 Contract Funding: FY 1998: $146,000 Objective: Delta-T was commissioned to assist NREL in performing technical and economical assessments of its previous plant designs for countercurrent and co-current conversion of wood chips to ethanol. Specifically, Delta-T was asked to develop a more realistic distillation and molecular sieve dehydration approach and cost for NREL. In addition, NREL had requested that Delta-T develop an evaporator design to incorporate into the basic process. Once completed, this information was used to ensure that the process design and equipment costs used by NREL were reasonable and consistent with good engineering practice for plants of this type. Approach/Background: NREL has completely reviewed and updated the biomass-to-ethanol process based on cocurrent dilute-acid prehydrolysis along with simultaneous saccharification (enzymatic) and cofermentation. The process design includes the core technologies being researched by the U.S. Department of Energy (DOE): prehydrolysis, simultaneous saccharification and cofermentation, and cellulase enzyme production. In addition, all ancillary areas—feed handling, product recovery and purification, wastewater treatment, lignin burner and boiler-turbogenerator, and utilities—are included. NREL engaged Delta-T Corporation to assist in the process design evaluation, equipment costing, and overall plant integration. Status/Accomplishments: Using the NREL report of October 8, 1997, titled "Co-current Dilute Acid Prehydrolysis/Enzymatic Hydrolysis Report," as a starting point, Delta-T began working interactively with NREL, providing overall PFD reviews and comments, as well as developing specific PFD’s for distillation and evaporation. The basic plant design was designed on a feed flow rate of 2000 metric tons per day of dry wood. A portion of Delta-T’s effort was also focused on reviewing NREL’s process spreadsheet for equipment, cost factoring for different capacities, and total plant investment. Delta-T provided input and recommended changes to specific components and plant costs consistent with its industrial experience. This work has resulted in an economic model that can be used to predict the cost of producing ethanol from cellulosic biomass using this technology, if a plant were to be built in the next few years. The model was also extended using technology improvements that are expected to be developed based on the current DOE research plan. Future process designs and cost estimates are given for the years 2005, 2010, and 2015. The process design and economic model will also be useful for predicting the cost benefits of proposed research. Proposed research results can be translated into modifications of the process design and the economic impact assessed. This will allow DOE, NREL, and other researchers to set priorities on future research based on its potential to reduce the cost of producing ethanol. Publications and Presentations: Wooley, R., M. Ruth, J. Sheehan, and K. Ibsen. July 1999. Lignocellulosic biomass to ethanol process design and economics utilizing co-current dilute acid prehydrolysis and enzymatic hydrolysis: Current and future scenarios. NREL/TP-580-26157. National Renewable Energy Laboratory, Golden, CO. Wooley, R., M. Ruth, D. Glassner, and J. Sheehan. 1999. Technology: A tool for determining the status and direction of research and development. Biotechnology Progress, 15:794–803. Summary Date: January 2000

	Process Design and Cost Estimation of Critical Equipment in the Biomass-to-Ethanol Process Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: Harris Group, Inc., 1000 Denny Way, Suite 800, Seattle, WA 98109-5338 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: R. Lynn Montague, 206.494.9544, lynn.montague@harrisgrp.com Contract Number: ACO-9-29067-01 Contract Period: 06/99–03/00 Contract Funding: FY 1999: $85,000; $91,420 Objective: Improve the design and accuracy of the cost estimate in three specific areas of the process for converting lignocellulosic biomass to ethanol. These areas are dilute-acid high-temperature hydrolysis reactors, liquid–solids separations, including requirements for solids washing or very high solids (or both), and baled feedstock. Approach/Background: The three process areas identified above are high capital items and their costs have been uncertain in previous design studies. Part of the problem has been poor contacts with the equipment manufacturers and little incentive for vendors to cooperate. The Harris Group will use its knowledge and contacts in the related pulp and paper industry to identify potential vendors for the equipment to be used in these three areas of the lignocellulosic biomass-to-ethanol process. Having identified the vendors, Harris will work with them to determine what experimental data (equipment testing or corrosion testing) will be necessary to enable the vendors to design and quote a piece of equipment for the service. Harris will work closely with the vendors to ensure that they understand the process and the potential of this process to support future sales of their equipment (develop an incentive for the vendors to cooperate). Harris is in a position to hire the vendors to complete the designs and cost estimates if necessary. Status/Accomplishments: Vendors for all of the critical equipment have been identified. Sufficient quantities of representative material have been produced at NREL and Tennessee Valley Authority, Muscle Shoals, AL. Vendor testing for liquid–solids separations has begun. Corrosion testing using this same material has been completed. Publications and Presentations: None Summary Date: February 2000

	Compositional Analysis of Biomass Samples Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: Hauser Laboratories, 5555 Airport Boulevard, Boulder, Colorado 80301-2339 Principal Investigator: Anne Cargill, 720.406.4625, cargill@hauser.com Contract Number: JAC-4-14108-01 Contract Period: 03/94–08/99 Contract Funding: FY 1998: $150,000 FY 1999: $150,100 Objective: This contract supports the use of an outside analytical testing laboratory to provide accurate analysis of biomass samples of interest to the Ethanol Project at NREL. Approach/Background: Requests for analytical services in support of project research efforts increased to the point that it has been necessary to send routine samples to an outside laboratory for analysis. During this reporting period, NREL used Hauser Chemical Research Inc. Depending on the type of sample submitted, the analyses requested for liquid samples may include total solids, total dissolved solids, cellobiose, monomeric sugars, total sugars, organic acids, glycerol, xylitol, ethanol, hydroxyl-methyl-furfural, and furfural. Analyses typically requested for solid samples may include total solids, extractives, acid-insoluble lignin, acid-soluble lignin, cellulose (as glucose), hemicellulosic sugars, starch, O-acetyl groups, and ash. All analytical work is performed following NREL Laboratory Analytical Procedures. Status/Accomplishments: During this reporting period Hauser has provided NREL researchers with high-quality analytical data. Strict quality assurance–quality control has been maintained throughout this subcontract by following the practices prescribed in the NREL Quality Assurance Plan. The analytical results reported by this external laboratory have been, and will be, used by various research groups within the Project to meet specific technical objectives defined in their respective annual operating plans. Publications and Presentations: None Summary Date: March 2000

	Technical and Analytical Assistance for the Biofuels Program Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: R. LeGassie, 301.670.6390 and S. Zukor, 301.670.6390 Contract Number: KXL-9-29017-00 Contract Period: 03/99–09/00 Contract Funding: FY 1999: $215,000 Objective: Our objectives are as follows: to provide impartial technical, economic, environmental and policy support for the production and review of reports and documents for the Biofuels Program, to help integrate Biofuels Program planning with other programs funded by the Department of Energy, and to assist in the assessment of international markets and the development of international collaborations. Approach/Background: The subcontractor assists NREL by providing technical support for the DOE National Biofuels Program. The technical support includes, but is not limited to, reviewing technical documents, producing professional papers and presentations, and planning and designing communication materials such as brochures, pamphlets, and web sites. We also provide technical, economic, environmental, and policy analyses. Status/Accomplishments: The following work was accomplished in FY99. A web-based information-sharing system was developed that improved communications within the Biofuels Program. An article for publication in a national trade journal explained the recent advances and promise of cellulosic ethanol in the United States. A workshop in California explored the attitudes of oil refiners and distributors and state officials toward the wider use of ethanol–gasoline blends in light-duty vehicles in the state. The Bioethanol Data Reference System began to be developed. It will allow an organized and effective way to manage and disseminate program information, especially that used for technical, economic, and policy analysis. An international strategy for cooperation and development of bioethanol in Western Europe, Latin America, and the Caribbean began to be devised. We explored ways to enhance the Biofuels Program through better collaboration with, and utilization of, the Regional Biomass Energy Program. Publications and Presentations: Santos-Leon, G., R. LeGassie, and S. Zukor. 1999 (in preparation). What role for ethanol in tomorrow’s gasoline market? Prepared for the Oil and Gas Journal. Post, R. 1999. Outreach activities relating to commercialization of advanced ethanol production technologies. Ethanol Workshop for Oil Companies and State Officials, Sacramento, CA. June 29–30 [1999]. Summary Date: February 2000

	Combustion Properties of Lignin Residue Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: University of California at Davis, Dept. of Biology & Agricultural Engineering, One Shields Avenue, Davis, CA 95616-5294 and National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: B. Jenkins, 530.752.1422, bmjenkins@ucdavis.edu Contract Number: ACG-8-18021-01 Contract Period: 02/98–10/99 Contract Funding: FY 1999: $28,000 Objective: The objective of this research was to determine combustion properties of lignin-rich residues produced from the fermentation of softwood and hardwood biomass. Approach/Background: Fermentation of lignocellulosic biomass produces a lignin-rich residue, which is proposed as fuel for steam and power generation to support the operations of the bioethanol facility and to export power. Several studies have used ligneous residues as primary fuel sources or cofired lignin with either natural gas or coal. The fermentation of both hardwood (enzymatic process) and softwood (two-stage dilute-acid process) materials yields residues that are believed to be good candidates for thermal conversion. This study endeavored to determine the thermal conversion characteristics of such residues and to confirm their suitability as boiler fuel. Status/Accomplishments: Ligneous residues from bench-scale fermentations were evaluated for their fouling and slagging tendencies, as well as for their standard fuel properties. Samples of residue were tested for volatile ash and ash fusibility to assess the potential for slagging in biomass furnaces and boilers and fireside fouling of heat exchangers. Recently developed whole-fuel testing procedures were also compared against standard American Society for Testing and Materials (ASTM) fusibility procedures. Whole-fuel tests generally show initial ash deformation at lower temperatures than the ASTM pyrometric cone method using calcined ash (ASTM D 1875). Based on laboratory experiments and compositional analysis, the two lignin residues appear to be of low-to-moderate fouling type. Weak sintering was observed in the whole pellet fusibility test at 900° C for the hardwood and 950° C for the softwood residue. The hardwood lignin contains substantially more alkali and has a higher total ash content compared with the softwood material. The alkali index for hardwood lignin indicates a greater propensity for fouling. The hardwood lignin also contains more sulfur even after washing. Both lignins were very fine and would require special handling for use as fuel in most power plants, except possibly in suspension units. Larger-scale combustion tests of such lignins should be conducted to confirm these results. Publications and Presentations: Blunk, S.L., B.M. Jenkins, and K.L. Kadam. 1999. Combustion properties of lignin residue from lignocellulose fermentation. Proceedings, Fourth Biomass Conference of the Americas: Biomass—A Growth Opportunity in Green Energy and Value-Added Products. Edited by R.P. Overend and E. Chornet. Pergamon/ Elsevier Science, Oxford, U.K. Blunk, S.L., B.M. Jenkins, and K.L. Kadam. 1999. Combustion properties of lignin residue from lignocellulose fermentation. Proceedings of the Fourth Biomass Conference of the Americas: Biomass—A Growth Opportunity in Green Energy and Value-Added Products, Vol. 2. Edited by R.P. Overend and E. Chornet, Pergamon/Elsevier Science, Oxford, U.K. p. 1385-1391. Summary Date: January 2000

	Develop Cost Estimate for a Corn-to-Ethanol Plant Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: F. Ferraro, 303.751.0741, fran.ferraro@merrick.com Contract Number: ZXE-9-18080-04 Contract Period: 02/99–01/00 Contract Funding: FY 1998: $273,000 FY 1999: $154,571 Objective: To develop capital cost and operating cost estimates for a corn stover-to-ethanol plant colocated at the existing High Plains Corporation, York, NE, corn-to-ethanol facility; and to develop a project pro forma and run sensitivity analyses for major cost factors. Approach/Background: A reasonable corn stover feed rate and corn stover delivered cost were developed by High Plains Corporation based on local stover availability and previously published information. Cellulase technology being developed by PureVison Technology, Inc. was used to determine the cost of corn stover hydrolysis including onsite cellulase production. Hydrolysis and fermentation were done separately. Fermentation was done using NREL-developed Zymomonas mobilisin order to ferment both five- and six-carbon sugars. Distillation and dehydration were done to conventional fuel grade ethanol specifications. Lignin rich solids were assumed to be sold at cost as a fuel because on-site power cogenerating facilities were felt to overly complicate the economic analysis. Status/Accomplishments: The pro forma indicated the need to develop various aspects of the process to increase economic rates of return. Although this was disappointing, the principal cost factors were identified which will help direct future efforts in bringing corn stover derived ethanol to the market place. Colocation was not as attractive as originally thought because the low-protein corn stover byproduct solids were kept separate from the high-protein distillers grain in the existing operation. Corn stover is required in very large volumes, requiring the handling of hundreds of large bales daily. Chopping and compression at the farm during harvest could substantially reduce costs. The main areas for economic improvement remain in the biochemistry of corn stover hydrolysis and fermentation. The cost or volume (or both) of required cellulase must be reduced and fermentation must be improved through high temperature or more efficient yeast strains. The project is essentially complete, and a first draft has been issued to NREL. Publications and Presentations: Building a bridge to the corn ethanol industry: Corn stover to ethanol at High Plains Corporation’s York, Nebraska co-located plant site. 2000 (in preparation). Summary Date: February 2000

	Regional Biomass Energy Program Research Funded by: U.S. Department of Energy Office of Fuels Development through the National Renewable Energy Laboratory Project Manager: Robert Wooley 303.384.6825, Robert_Wooley@nrel.gov Performing Organization: National Renewable Energy Laboratory, 1617 Cole Boulevard, Golden, CO 80401-3393, http://www.nrel.gov Principal Investigator: P. Lusk, Resource Development Associates, 202.546.6283, plusk@pipeline.com Contract Number: ECG-8-17098-01, KXL-9-29061-00 Contract Period: 11/97–12/99, 03/99–09/00 Contract Funding: FY 1997: $119,980 FY 1999: $80,263 Objective: To provide technical and analytic support services to NREL and the U.S. Department of Energy’s Regional Biomass Energy Program (RBEP), and to provide greater continuity and integration to the broader objectives of the National Biofuels Program. Approach/Background: The U.S. Department of Energy’s Regional Biomass Energy Program (RBEP) is a federally supported program located in five regions of the continental United States, the specific goal of which is to increase the production and use of bioenergy resources. The RBEP carries out activities related to technology transfer, industry support, and matching local resources to conversion technologies. With an emphasis on technologies best suited to near-term application, its major focus is the transfer of current, reliable economic and technical information to potential bioenergy users. Status/Accomplishments: The publication "Methane Recovery from Animal Manures: A Current Opportunities Casebook," examines some of the current technologies for recovering methane gas from the anaerobic digestion of animal manures in the United States. The Casebook introduces the types of digestion systems currently used on livestock production facilities, and some of the applications for methane gas manufactured by the digestion process. Following the introduction, pro forma economic evaluations of typical types of digesters found on domestic farms are provided. To provide practical information, a number of case studies of operating and nonoperating anaerobic digestion systems are described. The case study information includes project and maintenance histories and the operator's "lessons learned." The economic evaluations and case studies indicate that the anaerobic digestion of livestock manures is a commercially available technology with significant potential for providing a cost-effective renewable fuel that can readily be used by livestock production operations. Two thousand copies of the bookhave been distributed. The Review Report of the RBEP Technical Projects provides a narrative of some of the technical projects being conducted by the five regional programs. For its technical projects, each RBEP seeks active cooperation and cost sharing from the participating states, private industry, universities, and other federal agencies. The following RBEP activity areas were covered: liquid biofuels (bioethanol and biodiesel), biopower (co-firing and biopower sytems), biogas recovery (farm, industrial and municipal, and landfill gas), stakeholder relationships and infrastructure development, feedstock development, and educational outreach. A brief case study shows how a RBEP state grant project can grow into a regional technical project that finally translates into a national effort. Five hundred copies of the Technical Projects Report have been distributed. An oral presentation on the Technical and State Grant Projects was also presented at the Fourth Biomass Conference of the Americas in Oakland, CA. The 1998 Review Report of the Regional Biomass Energy Program State Grant Projects provided a brief narrative of some of the initiatives being conducted by the 49 states and the District of Columbia. Each RBEP seeks active cooperation and cost-sharing with states, private industry, universities, and other federal agencies for its state-funded initiatives. Beyond the potential economic development benefits, participating states gain the opportunity to strengthen and integrate the work of energy, forestry, air quality, and other relevant offices through the RBEP’s promotion of bioenergy use. The importance of positive, supportive attitudes towards bioenergy use by government officials and other public policy makers is one vital "lesson learned" from the RBEP states in developing this industry. Developing positive attitudes for bioenergy is based on credible information, public education, and sound technology demonstration. Information regarding the economic and environmental advantages of bioenergy use, resource data and capacity assessments, and the potential applications for new products and technologies made from biomass still needs to be widely shared with a variety of audiences. Five hundred copies of the State Grant Projects Report have been distributed. Publications and Presentations: Lusk, P. 1998. Methane Recovery from Livestock Manures: A Current Opportunities Casebook, 3rd edition. SR-25145. NREL subcontract ECG-8-17098-01), National Renewable Energy Laboratory, Golden, CO. Lusk, P. 1999. Review report of the Regional Biomass Energy Program Technical and State Grant projects. Task Order KXL-9-29061-01. Proceedings of the Fourth Biomass Conference of the Americas, Oakland, Calif. Edited by R.P. Overend and E. Chornet. Pergamon/Elsevier Science, Oxford, U.K. p. 1655–1662. Lusk, P. 1999. Review report of the Regional Biomass Energy Program Technical Projects. Task Order KXL-9-29061-01. Lusk, P. 1998. Review report of the Regional Biomass Energy State Grant Projects. Subcontract ECG-8-17098-01. Lusk, P. 1999. Review report of the Regional Biomass Energy Program’s FY 1999 budget. Task Order KXL-9-29061-01. Lusk, P. 1999. Analysis of international anaerobic digestion deployment. Subcontract ECG-8-17098-01. Summary Date: February, 2000

	98-99 Project Summaries - Table of Contents Last updated: Wednesday, 30-Aug-2000 08:03:42 EDT

Process Engineering and Analysis

Process Engineering and Analysis Work Package (a)

Process Engineering and Analysis Work Package (b)

Cellulase Reactor Designs

Alternative Fuels Industry Meeting Participation, Facilitation, Project Reviews, and Reviews of Solicitation Responses

Steam and Electricity Generation Options for the Biomass-to-Ethanol Process

Wastewater Treatment Options for the Biomass-to-Ethanol Process

Process Engineering Support—Review Current Process Designs and Costs, and Supply Hard-to-Get Vendor Equipment Estimates

Process Design and Cost Estimation of Critical Equipment in the Biomass-to-Ethanol Process

Compositional Analysis of Biomass Samples

Technical and Analytical Assistance for the Biofuels Program

Combustion Properties of Lignin Residue

Develop Cost Estimate for a Corn-to-Ethanol Plant

Regional Biomass Energy Program