Mark Ruth

Lignocellulosic Biomass to Ethanol Process Design and Economics Utilizing Co-Current Dilute Acid Prehydrolysis and Enzymatic Hydrolysis Current and Futuristic Scenarios

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 enzymatic based process. The process design includes the core technologies being researched by the U.S. Department of Energy (DOE): prehydrolysis, simultaneous saccharification and co-fermentation, 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. The process design and costing for the lignin burner and boiler turbogenerator has been reviewed by Reaction Engineering Inc. and the wastewater treatment by Merrick and Company. An overview of both reviews is included here. The purpose of this update was to ensure that the process design and equipment costs were reasonable and consistent with good engineering practice for plants of this type using available technical data. 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.

Process Design and Costing of Bioethanol Technology: A Tool for Determining the Status and Direction of Research and Development

Bioethanol is a fuel‐grade ethanol made from trees, grasses, and waste materials. It represents a sustainable substitute for gasoline in todays passenger cars. Modeling and design of processes for making bioethanol are critical tools used in the U.S. Department of Energys bioethanol research and development program. We use such analysis to guide new directions for research and to help us understand the level at which and the time when bioethanol will achieve commercial success. This paper provides an update on our latest estimates for current and projected costs of bioethanol. These estimates are the result of very sophisticated modeling and costing efforts undertaken in the program over the past few years. Bioethanol could cost anywhere from

A bioethanol process development unit: initial operating experiences and results with a corn fiber feedstock.

1.16 to

Modeling the enzymatic hydrolysis of dilute-acid pretreated Douglas Fir

1.44 per gallon, depending on the technology and the availability of low cost feedstocks for conversion to ethanol. While this cost range opens the door to fuel blending opportunities, in which ethanol can be used, for example, to improve the octane rating of gasoline, it is not currently competitive with gasoline as a bulk fuel. Research strategies and goals described in this paper have been translated into cost savings for ethanol. Our analysis of these goals shows that the cost of ethanol could drop by 40 cents per gallon over the next ten years by taking advantage of exciting new tools in biotechnology that will improve yield and performance in the conversion process.

NREL/DOE ethanol pilot-plant: Current status and capabilities

Interest in bioethanol production from lignocellulosic feedstocks for use as an alternative fuel is increasing, but near-term commercialization will require a low cost feedstock. One such feedstock, corn fiber, was tested in the US Department of Energy (DOE)/National Renewable Energy Laboratory (NREL) bioethanol pilot plant for the purpose of testing integrated equipment operation and generating performance data. During initial runs in 1995, the plant was operated for two runs lasting 10 and 15 days each and utilized unit operations for feedstock handling, pretreatment by dilute sulfuric-acid hydrolysis, yeast inoculum production, and simultaneous saccharification and fermentation using a commercially available cellulase enzyme. Although significant operational problems were encountered, as would be expected with the startup of any new plant, operating experience was gained and preliminary data were generated on corn fiber pretreatment and subsequent fermentation of the pretreated material. Bacterial contamination was a significant problem during these fermentations.

Hydrogen Pathways. Cost, Well-to-Wheels Energy Use, and Emissions for the Current Technology Status of Seven Hydrogen Production, Delivery, and Distribution Scenarios

Glucose yield from the enzymatic hydrolysis of cellulose was investigated as a function of cellulase enzyme loading (7–36 filter paper units [FPU]/g cellulose) and solids concentration (7–18% total solids) for up to 72 h on dilute sulfuric-acid pretreated Douglas Fir. The saccharification was performed on whole hydrolysate with no separation or washing of the solids. Enzyme loading had a significant effect on glucose yield; solids concentration had a much smaller effect even at higher glucose concentrations. The data were used to generate an empirical model for glucose yield, and to fit parameters of a cellulose hydrolysis kinetic model. Both models could be used for economic evaluation of a separate hydrolysis and fermentation process.

Transactive Home Energy Management Systems: The Impact of Their Proliferation on the Electric Grid

The National Renewable Energy Laboratory (NREL) has built and operated a pilot-plant to convert lignocellulosic feedstocks to ethanol for the U.S. Department of Energy (DOE). The process development unit (PDU) has a designed throughput of 1 ton (dry basis)/day of biomass and is equipped to handle a variety of feedstocks. Major processing systems include feedstock milling, pretreatment, simultaneous saccharification and fermentation (SSF), and ethanol distillation. Several experimental runs have been successfully completed since the startup of the plant in March 1995. The plant capabilities are continually being improved to meet the needs of our industrial partners and to facilitate NRELs process development work. This paper reports on various aspects of commissioning and operations, the present capabilities, and plans for use of the facility.

Enzyme Production, Growth, and Adaptation of T. reesei Strains QM9414, L-27, RL-P37, and Rut C-30 to Conditioned Yellow Poplar Sawdust Hydrolysate

Report of levelized cost in 2005 U.S. dollars, energy use, and GHG emission benefits of seven hydrogen production, delivery, and distribution pathways.

Enzyme production, growth, and adaptation of T. reesei strains QM9414, L-27, RL-P37, and Rut C-30 to conditioned yellow poplar sawdust hydrolysate : Scientific note

Approximately 100 million singlefamily homes in the United States account for 36% of the electricity load, and often they determine the peak system load, especially on hot summer days when residential air-conditioning use is high. Traditional building power profiles are changing. Currently, there is an increased use of energy-efficient building materials and designs, which decreases building loads. In addition, there is an increased adoption of rooftop solar photovoltaic (PV), which leads to bidirectional power flow and significant power ramps as PV output decreases in the late afternoon. Building power profiles are likely to change even more as residential energy storage products proliferate. Therefore, a better understanding of residential electricity demand is key to addressing the envisioned transition of the electric power system from its traditional structure to one that is transactive.

Potential Reductions in Emissions and Petroleum Use in Transportation: Perspectives from the Transportation Energy Futures Project

National Renewable Energy Laboratory (NREL) has developed a conditioning process that decreases acetic acid levels in pretreated yellow poplar hydrolysate. Trichoderma reesei is sensitive to acetic acid and this conditioning method has enabled applied cellulase production with hardwoods. T. reesei strains QM9414, L-27, RL-P37, and Rut C-30 were screened for growth on conditioned hydrolysate liquor. Tolerance to hydrolysate was found to be strain-dependent. Strain QM9414 was adapted to grow in 80% (v/v) conditioned hydrolysate (40 g/L of soluble sugars and 1.6 g/L acetic acid from pretreated poplar). However, enzyme production was highest at 20% (v/v) hydrolysateusing strain L-27. Cellulasetiters of 2–3 International Filter Paper Units (IFPU)/mL were achieved using pretreated yellow poplar liquors and solids as the sole carbon sources.