1st Demonstration-scale Cellulosic Ethanol Plant Opens in U.S.

A 1.4 million gallon demonstration-scale plant will use waste biomass to make biofuel.

A biorefinery built to produce 1.4 million gallons of ethanol a year from cellulosic biomass will open tomorrow in Jennings, LA. Built by Verenium, based in Cambridge, MA, the plant will make ethanol from agricultural waste left over from processing sugarcane.

The new Verenium plant is the first demonstration-scale cellulosic ethanol plant in the United States. It will be used to try out variations on the company's technology and is designed to run continuously. Verenium wants to demonstrate that it can create ethanol for $2 a gallon, which it hopes will make the fuel competitive with other types of ethanol and gasoline. Next year, the company plans to begin construction on commercial plants that will each produce about 20 to 30 million gallons of ethanol a year.

Until now, technology for converting nonfood feedstocks into ethanol has been limited to the lab and to small-scale pilot plants that can produce thousands of gallons of ethanol a year. Since these don't operate continuously, they don't give an accurate idea of how much it will ultimately cost to produce cellulosic ethanol in a commercial-scale facility.

Almost all ethanol biofuel in the United States is currently made from corn kernels. But the need for cellulosic feedstocks of ethanol has been underscored recently as food prices worldwide have risen sharply, in part because of the use of corn as a source of biofuels. At the same time, the rising cost of corn and gas have begun to make cellulosic ethanol more commercially attractive, says Wallace Tyner, a professor of agricultural economics at Purdue University. A new Renewable Fuels Standard, part of an energy bill that became law late last year, mandates the use of 100 million gallons of cellulosic biofuels by 2010, and 16 billion by 2022.

So far, however, there are no commercial-scale cellulosic ethanol plants in operation in the United States, although a number of facilities are scheduled to start production in the next few years. The Department of Energy is currently funding more than a dozen companies that will be building demonstration- and commercial-scale plants. One of these, Range Fuels, based in Broomfield, CO, plans to open a commercial-scale plant next year. It will have the capacity to produce 20 million gallons of ethanol and methanol a year.

Verenium will use a combination of acid pretreatments, enzymes, and two types of bacteria to make ethanol from the plant matter--called bagasse--that's left over from processing sugarcane to make sugar. It will also process what's called energy cane, a relative of sugarcane that's lower in sugar and higher in fiber. The high fiber content allows the plants to grow taller, increasing yield from a given plot of land.

Cane bagasse largely consists of bundles of cellulose that are surrounded by hemicellulose. Cellulose is made of long chains of glucose, a six-carbon sugar of the type usually fermented to make ethanol from sources such as corn. Hemicellulose, however, is made of five-carbon sugars, which typically can't be fermented using the same organisms as glucose. One of the things that makes Verenium's process novel, says John Malloy, the company's executive vice president, is its ability to ferment sugars from both cellulose and hemicellulose.

The process begins when the cane is ground up and cooked under high pressure with a mild acid to hydrolyze the hemicellulose and separate it from the cellulose. The five-carbon sugars in hemicellulose are then fermented using genetically modified E. coli. The cellulose is broken down with enzymes and fermented with another type of bacteria called Klebsiella oxytoca. This bacteria does double duty, since it also produces enzymes that break down cellulose, reducing the amount of enzymes from outside sources by 50 percent. The dilute ethanol produced from fermentation of both types of sugar is then distilled to make fuel.

In addition to opening the demonstration plant, Verenium is also starting to grow energy cane and to work with local farmers to ensure a steady stream of material for its planned commercial plants. Short term, the company says that it can rely on leftover bagasse from sugar production, but eventually it will draw on energy cane grown specifically to make ethanol. Provisions in the Farm Bill, which was recently passed by the United States Congress, will help by providing farmers with incentives to plant energy crops, says Carlos Riva, Verenium's CEO. The incentives are important because it takes two to three years for energy cane, a perennial plant, to become established and reach ideal production levels. As a result, farmers will need to start planting the crops next year, before commercial plants are built and there is a market for these crops.

The opening of the demonstration plant, and the current construction of a number of other demonstration- and commercial-scale cellulosic ethanol plants, marks a turning point for the industry, Riva says. The development of improved enzymes and fermentation organisms means that no further scientific breakthroughs are needed to make cellulosic ethanol commercially successful, he says. "There's been a tremendous amount of background work in science and technology development," he says. "We've learned so much about the process that the really important thing now is to start to deploy the technology at a commercial scale."

Source - Technology Review

Photo Credit: Shelly Harrison Photography

Oil from Wood - Startup Kior has developed a process for creating "biocrude" directly from biomass.

Dutch biofuels startup Bioecon and Khosla Ventures have launched a joint venture called Kior, which will commercialize Bioecon's process for converting agricultural waste directly into "biocrude," a mixture of small hydrocarbon molecules that can be processed into fuels such as gasoline or diesel in existing oil refineries. The process, Kior claims, boasts numerous advantages over other methods of producing biofuels: it could prove relatively cheap, relies on a nontoxic catalyst, taps into the present fuel-refining and transportation infrastructure, and produces clean-burning fuels that can be used in existing engines.

Biofuels are widely seen as a key stepping-stone on the path from fossil fuels to renewable energy sources, particularly for transportation. Their use could also reduce emissions of carbon dioxide and other greenhouse gases. But ethanol, the most widely produced biofuel, contains little energy compared with gasoline or diesel. And a great deal of energy goes into its production: growing the grain from which it is fermented, distilling it, and transporting it. Many biofuels boosters have pinned their hopes on finding ways to produce ethanol from cellulose, the tough polymer that makes up much of plant stems and wood. In practice, though, cellulose must be broken down into simple sugars before it can be fermented into ethanol or converted into synthetic gas and turned into fuels. Despite three decades of research, these remain difficult, expensive, and energy-intensive processes that are not yet commercially viable. Additionally, recent research shows that ethanol, which is highly volatile, may actually exacerbate smog problems when it evaporates directly into the air instead of burning in vehicle engines.

The way to make cellulosic biofuels viable, says Bioecon's founder, Paul O'Connor, is to use catalysts to convert biomass into a hydrocarbon biocrude that can be processed into gasoline and diesel in existing petroleum refineries. After decades developing catalysts for the petroleum industry, O'Connor started Bioecon in early 2006 to develop methods for converting biomass directly into biofuels. His first success is a catalytic process that can convert cellulosic biomass into short-chain hydrocarbons about six to thirteen carbon atoms long. Khosla Ventures agreed to provide an undisclosed amount of series A funding to spinoff Kior in order to commercialize the process. Vinod Khosla, founder of the venture fund, believes that converting biomass into liquid transportation fuels is key to decreasing greenhouse-gas emissions and compensating for dwindling petroleum reserves. Khosla is funding a number of biofuels startups with competing technologies and says that Kior's approach is unique. "They have some very clever proprietary catalytic approaches that are pretty compelling," he says. "They can produce relatively cheap crude oil--that's attractive."

The most effective method of converting biomass into fuel is to subject it to high temperatures and high pressure to produce synthetic gas, or syngas. In the presence of a catalyst, the syngas reacts to produce fuels such as ethanol or methanol (used as an additive in biodiesel). But this is a costly process, and catalysts able to withstand the high temperature of the syngas are expensive and frequently toxic.

Attempts to produce fuel by directly exposing agricultural cellulose to a catalyst have had little success because most of the cellulose is trapped inside plant stems and stalks. O'Connor says that while the Bioecon researchers are developing new catalysts, their "biomass cracking" process is the real breakthrough. Using proprietary methods, they have been able to insert a catalyst inside the structure of the biomass, improving the contact between the materials and increasing the efficiency of the process. While O'Connor won't go into details, he says that the most basic version of the technique might involve impregnating the biomass with a solution containing the catalyst; the catalyst would then be recrystallized. "What we're doing now is improving the method to make it easier and cheaper," O'Connor says.

Such a method would eliminate the need for the superhigh temperatures and toxic catalysts used in other thermochemical methods for cellulosic-biofuel production. While O'Connor says that he is still improving Kior's catalyst, his first versions are different kinds of modified clays, which are both cheap and environmentally friendly. The product is high quality as well, containing less acid, oxygen, and water. These characteristics make it suitable for burning as heating oil or for use in petroleum refineries, which can use existing processes and equipment to convert it into the longer hydrocarbon chains of gasoline and diesel fuel.

Bioecon has produced lab-scale quantities of its biocrude, a few grams at a time, from materials such as wood shavings, sugarcane waste, and various grasses. While the input material affects the yield somewhat, O'Connor says that the output is "all very similar, so we do not have a real preference." This means that the process can work around the world, with whatever biomass is locally available, almost year-round.

Kior is already in talks with at least two oil companies to establish partnerships to further develop the technology. It is starting a pilot plant with one company that should produce around 20 kilograms of biocrude a day within six to twelve months, says Kior CEO Rob van der Meij. If all goes well, the process could scale up to production of hundreds of kilos per day by 2009, and refined versions of Kior's biocrude might be blended into gasoline or diesel by 2010. In addition to being renewable, these fuels would have lower sulfur and nitrogen content, which should decrease smog in cities such as Los Angeles and Houston.

Because of its ability to slide into the existing petroleum refining and delivery infrastructure, the technology has a huge cost advantage, says O'Connor. It could also be adopted much more rapidly, according to Khosla. "If you can do a solution that's compatible with the oil companies and their current refineries, it becomes much easier for them to get comfortable with it," he says. "Getting them into the game would be a big addition."

Steve Deutch, a senior research scientist at the National Renewable Energy Laboratory, says that the little information Kior has released about its process is plausible enough, but that until the details are available, the company's claims are "not really possible to evaluate." The main challenge for Kior, or anyone working on cellulosic fuels, Deutch says, is to develop a process simple enough to bring close to the sources of biomass--farms. "Collecting biomass and getting enough of it in one place to make a difference is a problem in the biomass world," Deutch says. "Trucking costs can become exorbitant. You want to preprocess it at the farm and then ship a high-density, high-energy intermediate to processing plants."

DOE Announces up to $33.8 Million for Cellulosic Biofuels Development

On August 27, DOE announced a Funding Opportunity Announcement (FOA), providing as much as $33.8 million to support research into enzymes to convert cellulosic biomass into biofuels

DOE announced on August 27th a Funding Opportunity Announcement (FOA) offering up to $33.8 million to support the development of enzymes for converting cellulosic biomass into biofuels. Cellulosic biomass includes a variety of non-food plant materials, such as agricultural wastes, sawdust, paper pulp, and switchgrass. Enzymes can be used in biorefineries to more efficiently break down cellulosic biomass into simple sugars, which can then be fermented into biofuels such as ethanol. Enzymes developed under the FOA must prove durable and effective in the conditions at which biorefineries would operate.

Funding will total nearly $68 million, with 50% of the cost shared by industry. Letters of intent are due on September 10, 2007, and completed applications are due on October 30, 2007. Projects are expected to begin in fiscal year 2008 and continue through fiscal year 2011. See the DOE press release and the complete FOA.