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A Primer on theA Primer on the

Technology of BiofuelTechnology of Biofuel

ProductionProduction

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

BiodieselBiodiesel

BioethanolBioethanol

Fuel PelletsFuel Pellets

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Biodiesel Production as anBiodiesel Production as an

Alternative Energy Source from theAlternative Energy Source from the

FarmFarm

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"Biodiesel Basics"

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

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Biodiesel BasicsBiodiesel Basics

What is biodieselWhat is biodiesel How is it usedHow is it used

What is it made fromWhat is it made from

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Biodiesel BasicsBiodiesel Basics Biodiesel = Fuel (similar to diesel)Biodiesel = Fuel (similar to diesel) Can be used in any diesel engineCan be used in any diesel engine

1818--wheeler, combine, pickup truck, rice wellwheeler, combine, pickup truck, rice wellpump, locomotive, home heating system, boat, etcpump, locomotive, home heating system, boat, etc

Normally used as a "blend" with petroNormally used as a "blend" with petro

--dieseldiesel

B2, B5, B20, etcB2, B5, B20, etc.B = % biodiesel to petro.B = % biodiesel to petro--dieseldiesel

Made from vegetable oil or fatMade from vegetable oil or fatnot petroleumnot petroleum

soybean, cotton, sunflower, canola, poultry fat,soybean, cotton, sunflower, canola, poultry fat,pork fat, beef fat, used cooking oil, etcpork fat, beef fat, used cooking oil, etc..("all come from the farm")("all come from the farm")

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What are the advantages of biodieselWhat are the advantages of biodiesel Why would you use biodiesel vs petroWhy would you use biodiesel vs petro--dieseldiesel

What are the disadvantages of biodieselWhat are the disadvantages of biodiesel Why might you not use biodiesel vs petroWhy might you not use biodiesel vs petro--

dieseldiesel

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Advantages of BiodieselAdvantages of Biodiesel Reduces dependence on foreign oilReduces dependence on foreign oil Supports U.S. economySupports U.S. economy

Supports Agri economySupports Agri economy Cleaner Burning FuelCleaner Burning FuelBetter for the EnvironmentBetter for the Environment

Reduced particulates, hydrocarbons, sulfur dioxide,Reduced particulates, hydrocarbons, sulfur dioxide,carbon monoxide, etccarbon monoxide, etc

NonNon--toxic (1/10toxic (1/10thth toxicity of table salt) andtoxicity of table salt) andbiodegradablebiodegradable

Provides lubricity to enginesProvides lubricity to engines

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Potential Disadvantages of BiodieselPotential Disadvantages of Biodiesel Currently costs more (slightly) thanCurrently costs more (slightly) than petropetro--

dieseldiesel

Acts as a solventActs as a solventmay need to change yourmay need to change yourfilter after early usefilter after early use

Potential to "gel" in extended periods ofPotential to "gel" in extended periods of

extreme cold temperaturesextreme cold temperatures Engine warranty issuesEngine warranty issues

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Biodiesel Production Facilities (105) in U.S.

From NBB Web Site

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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 gal2005 = 75M gal2006 = 150M gal

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FutureFuel's Biodiesel ProjectFutureFuel's Biodiesel Project

Feasibility study began in May 2005Feasibility study began in May 2005 Commercial production of B100 began in late October 2005Commercial production of B100 began in late October 2005 FeedstockFeedstock

Soy oil (primarySoy oil (primary current production)current production)

Rendered oil (secondaryRendered oil (secondarycurrent production)current production)

Used Cooking Oil (on hold)Used Cooking Oil (on hold)

MarketMarket Arkansas (primary)Arkansas (primary)

Beyond Arkansas (as opportunities arise)Beyond Arkansas (as opportunities arise)

Internal (using B20 in our own fleet)Internal (using B20 in our own fleet)

Production capabilityProduction capability (all with existing equipment)(all with existing equipment) Initially: ~ 3M gallons/year rateInitially: ~ 3M gallons/year rate

Presently: ~ 24M gallons/year ratePresently: ~ 24M gallons/year rate

Rail & Truck shipment capabilitiesRail & Truck shipment capabilities BQBQ--9000 Accredited Producer (49000 Accredited Producer (4thth in U.S.)in U.S.)

Soon to introduce "Biodiesel Services" businessSoon to introduce "Biodiesel Services" business

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Biodiesel Business ModelSoybean Oil

SoybeanSupply

Feedstock

Soybean Oil

Biodiesel

Production

Biodiesel

Marketing &

Distribution

Soybean

Meal

Glycerin

Animal

Feed

Alternative

Products or

Fuel

Rendered

Fat

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Triglyceride

Methanol

Catalyst

Glycerin/Methanol/Catalyst

Biodiesel

Water/Methanol/Glycerin

Water

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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% maxFlash Point 130.0C min

Copper Strip Corrosion No 3 max

Carbon Residue 0.050 wt% max

Cloud Point C report

*Viscosity at 40C 1.9-6.0 centistokesAtmospheric Equivalent 360C

Temperature (distillation of sample, 90% recovered)

Cetane Number 47 min

(uses specially instrumented diesel engine)

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Issues facing Arkansas BiodieselIssues facing Arkansas BiodieselBusinessBusiness

QualityQualityAvailability & Price of Raw Material OilAvailability & Price of Raw Material Oil

Extension of Market beyond AgriExtension of Market beyond Agri

Competitive State LegislationCompetitive State Legislation

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Bioethanol from CelluloseBioethanol from Cellulose

Feedstock ConsiderationsFeedstock Considerations HardwoodHardwood

Commercial harvesting infrastructure in placeCommercial harvesting infrastructure in place Abundant and available year roundAbundant and available year round Cleanest feedstock (debarked and chipped logs)Cleanest feedstock (debarked and chipped logs)

Crop residuesCrop residues

Rice hullsRice hulls Rice hulls cheap and availableRice hulls cheap and available High silicaHigh silica SeasonalSeasonal

Rice and wheat strawRice and wheat straw Harvested on a limited commercial basis for hayHarvested on a limited commercial basis for hay

Rice straw is high in silicaRice straw is high in silica

SeasonalSeasonal

Energy cropsEnergy crops Not produced in our areaNot produced in our area Future opportunityFuture opportunity Must consider potential competition with oil seed cropsMust consider potential competition with oil seed crops

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Technology ConsiderationsTechnology Considerations Feedstock pretreatmentFeedstock pretreatment Leading pretreatment technologiesLeading pretreatment technologies

Steam explosionSteam explosion -- SunOptaSunOpta

Ammonia explosionAmmonia explosion Michigan State UniversityMichigan State University

Dilute AcidDilute Acid -- NRELNREL

FractionationFractionation

Separating cellulose, hemicellulose, and ligninSeparating cellulose, hemicellulose, and lignin Necessary to separate hemicellulose from cellulose (5Necessary to separate hemicellulose from cellulose (5carbon sugars from 6 carbon sugars)carbon sugars from 6 carbon sugars)

Removal of lignin increases effectiveness of enzymaticRemoval of lignin increases effectiveness of enzymatichydrolysishydrolysis

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Technology ConsiderationsTechnology Considerations Enzymatic hydrolysisEnzymatic hydrolysis Use of enzymes toUse of enzymes to depolymerizedepolymerize cellulose into glucose (6cellulose into glucose (6

carbon sugars)carbon sugars)

Critical yield and capacity determining stepCritical yield and capacity determining step FermentationFermentation

Continuous fermentation superior to batch fermentationContinuous fermentation superior to batch fermentation

Realize value from hemicellulose (5 carbon sugar)Realize value from hemicellulose (5 carbon sugar)Virent aqueous phase reformingVirent aqueous phase reforming Converts hemicellulose (5 carbon sugars) into green diesel,Converts hemicellulose (5 carbon sugars) into green diesel,

green gasoline, and other chemical productsgreen gasoline, and other chemical products

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Progress and Path ForwardProgress and Path Forward Producing ethanol in the lab from steam exploded celluloseProducing ethanol in the lab from steam exploded cellulose Implementing NREL analytical methodsImplementing NREL analytical methods

Contracted with NREL to conduct site assessmentContracted with NREL to conduct site assessment

Utilizing enzymes fromUtilizing enzymes from NovozymesNovozymes andand GenencorGenencor

Secured a sample ofSecured a sample ofNovozymesNovozymes most effectivemost effective cellulasecellulase enzymeenzyme Testing smallTesting small--scale steam exploderscale steam exploder Attempting to duplicate industries best performanceAttempting to duplicate industries best performance

Preparing sample of extracted hemicellulose for testing inPreparing sample of extracted hemicellulose for testing inVirent'sVirent's lablab

Complete large scale batch plant trialComplete large scale batch plant trial Planning 5 to 7 trial batchesPlanning 5 to 7 trial batches Requires significant campaign inRequires significant campaign in SunOpta'sSunOpta's pilot plantpilot plant

Define a project scope and conduct financial evaluationDefine a project scope and conduct financial evaluation NOBS II retrofit,NOBS II retrofit, greenfieldgreenfield, or both, or both

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EASTMANEASTMANEASTMANEASTMAN

Cellulosic

ethanol

Kilo lab available to setup enzyme

development and production

Sludge

Dewatering

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EASTMANEASTMANEASTMANEASTMAN

Cellulosic

ethanol

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Cellulosic Ethanol Plant ComponentsCellulosic Ethanol Plant Components

Coal Cost AdvantageCoal Cost Advantage

Incineration, WWT, RTOIncineration, WWT, RTO

Analytical, DevelopmentAnalytical, Development

Infrastructure:Infrastructure:Land, BuildingsLand, BuildingsUtilitiesUtilitiesRail & Bulk LiquidRail & Bulk LiquidWaste HandlingWaste Handling

LaboratoriesLaboratories

Kilo lab + Batch PlantKilo lab + Batch PlantEnzyme PropagationEnzyme Propagation

NOBS II Convey Systems/BinsNOBS II Convey Systems/Bins"Solids" Handling/Storage"Solids" Handling/Storage

Ring DryersRing Dryers"Solids" Drying"Solids" DryingSolid bowl CentrifugesSolid bowl Centrifuges"Solids" Separation"Solids" Separation

NOBS II + S.R.NOBS II + S.R.AzeoAzeo ColumnsColumnsEthanol DryingEthanol Drying

NOBS II ColumnsNOBS II ColumnsDistillationDistillationXXFermentersFermenters

Vessels for Slurry/ExtractionVessels for Slurry/Extraction??Biomass FractionationBiomass Fractionation

Vessels for Slurry/ExtractionVessels for Slurry/Extraction??Biomass PretreatmentBiomass Pretreatment

XXBiomass Sizing/StorageBiomass Sizing/StorageCommentsCommentsStatusStatusComponentComponent

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Fuel from Wood WasteFuel from Wood Waste

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Challenges of Producing Solid Wood Pellet FuelChallenges of Producing Solid Wood Pellet Fuel

Securing a reliable supply of raw material (sawdust)Securing a reliable supply of raw material (sawdust) Significant supply of wood palletsSignificant supply of wood pallets

Significant investment in packaging materialSignificant investment in packaging material

Large area to store pallets, bags, and other packaging materialLarge area to store pallets, bags, and other packaging material

Controlling moisture content of raw materialControlling moisture content of raw material Moisture content must be controlled between 10 and 13%Moisture content must be controlled between 10 and 13%

Average % moisture from local sawmills is 35% moistureAverage % moisture from local sawmills is 35% moisture

Meeting quality standardsMeeting quality standards Density: minimum 40 pounds/cubic footDensity: minimum 40 pounds/cubic foot

Dimensions: length (1Dimensions: length (1 maximum) and diameter (1/4maximum) and diameter (1/4)) Fines: amount of fines passing through 1/8Fines: amount of fines passing through 1/8screen no more than .5 percentscreen no more than .5 percentby weightby weight

Chlorides: no more than 300 parts per millionChlorides: no more than 300 parts per million Ash content: important factor in maintenance frequencyAsh content: important factor in maintenance frequency

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Challenges of Producing Solid Wood Pellet FuelChallenges of Producing Solid Wood Pellet Fuel Requires specialized equipment to convert sawdust to pelletsRequires specialized equipment to convert sawdust to pellets Permit from the EPAPermit from the EPA

12 to 18 months for Plant construction12 to 18 months for Plant construction

Specialized Operator TrainingSpecialized Operator Training

Dependable work forceDependable work force

Advantages of Fuel PelletsAdvantages of Fuel Pellets CleanClean

EfficientEfficient

Easy to StoreEasy to Store

Cost EffectiveCost Effective

Low AshLow Ash

Low MaintenanceLow Maintenance

High Heat ValueHigh Heat Value

Easy to UseEasy to Use

Environmentally FriendlyEnvironmentally Friendly

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Current StatusCurrent Status

Continuing to examine the existing facilities,Continuing to examine the existing facilities,

evaluate the options under considerationevaluate the options under consideration

for use of these facilities for thefor use of these facilities for theconversion of locally available biomass toconversion of locally available biomass to

fuels and chemicals, and to collectfuels and chemicals, and to collect

information on existing and underutilizedinformation on existing and underutilizedinfrastructure.infrastructure.

Documents

14812_88395biodiesel