11ibbc - 23.2 - pylkkanen · benefits-expected outcomes • environmental sustainability: • the...
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Alpena Biorefinery Update
Vesa Pylkkanen
API Mission
• Produce inexpensive low cost fermentable cellulosic sugars from a variety of feedstocks
AND
• Leverage the power of co-production of cellulosic sugars with other value added products
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Agricultural Residues
Forest Resources
Energy Crops/
Grasses
Biochemical/chemical
Gasification
Pyrolysis
C5 and C6 Sugars
Syngas
Bio-oil
Fermentation
CatalysisEthanol
Biodiesel
Farnecene
Biojet
Biogasoline
Fatty acids Fatty esters
Succinic acid
Squalane
Acrylic acid
Iso butanol, N-butanol
Terpenoids
• Aqueous phase reforming
• Hydro-treating• Alcohol synthesis• Fischer-Tropsch
Sugars are an intermediate feedstockThe production of low-cost, high-purity sugars is a critical
step in producing many bio-fuels, bio-chemicals
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Cellulosic Sugars
Project Summary• The Alpena Biorefinery will convert a biomass steam hydrolyzate to
~894,240 USG/y of cellulosic ethanol and 695,500 USG/y of potassium acetate deicer
• The hydrolyzate is an existing byproduct stream from the adjacent hardboard plant. Presently it is being sent to the WWTP
• This project is a pilot/commercial demonstration of the production of fermentable sugars / cellulosic ethanol and biochemicals from biomass extracted hemicelluloses
• Other feedstocks and biofuel/bio-products will be trialed
• After the demonstration period the biorefinery will remain a viable commercial, on-going operation.
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Alpena Biorefinery•Construction has started•Commissioning 11 / 2011
•7200 T/y of hemicellulose sugars•760,000 gal/yr EtOH•860,000 gal/y Kacetate
•Grants $22 MM
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Project Timeline
• 2007 Conceptual Development
• 1/2008 Initial Agreements
• 8/2008 Feasibility Study – Grant Applications
• 2009 Basic Engineering
• 2010 Detail Engineering
• 2011 Construction
• 11/2011 Commissioning and Start-up
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Project Participants• Partners
• Decorative Panels International• Michigan Technological University• Purdue-Ho Yeast licensed by GTA
• Project Sponsors• State of Michigan – MEDC - $4MM grant• DOE – IBR Grant - $18MM
• Project Management• Engineering: API• Construction: DeVere• Start-up & Commissioning: API• Operations: APER (subsidiary of API)
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apiMAX™ Biorefinery Simulation Model
Design model with inputs from laboratory, pilot, and equipment design and supplier data
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CADSIM Dynamic model
Used to size tanks, operational controls and for operator training
Process Modeling
Equipment Models
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Success Factors & Challenges
• Successful process integration• Continuous dilute acid hydrolysis with sugar yield > 95%.• Continuous co-fermentation of C5 and C6 sugars with ethanol yield >
80% of theoretical• Effective removal of inhibitors - sugar platform for other biofuels /
biochemicals• Plant uptime > 95%• Reverse Osmosis membrane maintenance cost • Cellulosic ethanol production at ~$1/USG• Co-production of sugars/ethanol with other products and process
integration• Lignin removal - proprietary technique• Lime mixing – Gypsum removal – dewatering – proprietary technique• Other acetate co-products
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Benefits-Expected Outcomes
• Environmental sustainability: • The Alpena Biorefinery will make Cellulosic Ethanol and Potassium
Acetate deicer from an industrial waste currently converted to CO2 and sludge via costly waste treatment
• Commercial projects will co-produce ethanol with biomass electricity, at near theoretical highest feedstock yield with low energy and water usage and high investor return
• Rapid replication• Ethanol production cost commercially at <$1.0/USG 1
• Profitable at <10 million GPY• Low entry barrier• Specific CAPEX competitive in commercial replication• Co-production leading to feedstock yield of 135 USG/BDT
1($40/BDT Biomass)
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Green Power+™ Process
Sugar to final product
Steam ExtractionBiomass
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Cellulosic ethanol, butanol, polymers, drop in fuels
Pressing
Washing
Lignin Removal
Evaporation
Hydrolysis
Extraction Module
Sugar Conversion
To Host Facility
HydrolyzateBiomass Boiler
Sugars Value Added Product
Conversion
Acetic Acid Derivatives
Green Power Plus™ Pre-extraction of hemicelluloses prior to biomass combustion
Information developed from patent‐applied for technology and configuration
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Power
BoilerTG Electricity
CND
Biomass1 BDT = $35 1 MWh (1) = $85
Power Boiler TG Electricity
CND
Biomass
Ethanol Module
Extraction Module
Ethanol
1.16 BDT = $40.60
1 MWh = $85
25.5 USG (2)
= $75 - 85
Conventional biomass power generation
Before/After Comparison
Green Power Plus™ Generates 10% Additional Carbon Credits
GP+ Advantages
• Inexpensive source of sugars• Effective theoretical yield to end products• Energy integration with host biomass power plant• Proprietary configuration:
• maximizes sugar yield, • minimizes inhibitor formation• easy lignin removal and return to boiler
• Financially viable at 6 – 10 million GPY ethanol• Minimal technology risk• Low specific and total CAPEX
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GP+ IRR at $60/BDT
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0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
First Plant First Plant with Acetate
Nth Plant with Acetate
Unleveraged
IRR %
Biomass at $60
/BDT
SWD 5 MM USG/y
Mixed 8 MM USG/y
HWD 11 MMUSG/y
Biomass Power
Market Potential
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Ethanol potentialU.S. Biomass electricity 2008 6.7 GW 1.36% EIA 2008 1,120 million GPYU.S. Biomass electricity 2020 18 GW 3.60% EIA 2020 2,964 million GPY
Increase 11 GW 1,844 million GPY
Global biomass electricity 47 GW 1.30% IEA 2007 7,909 million GPYGlobal biomass electricity 2050 145 GW 4% IEA 2050 24,336 million GPY
Increase 98 GW 16,426 million GPY
90.96% 1.36%
0.36%
6.04%
0.02%
1.27%
9.04%
Non‐renewable
Biomass
Geothermal
Hydroelectric Conventional
Solar/PV
Wind
Commercialization Route
•2006 – 2009 Lab Tests
•2007 – 2009 Pilot Tests Alpena Michigan
•2012 Demonstration Plant Expansion / Equity Raise
•2011 Commercial Demonstration ~ 1MM USG/y
•2011 - 2012 Develop Commercial Plants
•2013 - 2014 First Commercial Plant Operations
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