Biofuels Basics: Harvesting, Handling and Storage

Biofuels Basics: Harvesting, Handling

and StorageWhat’s Up?

Biofuels Basics: Harvesting, Handling

and StorageWhat’s Up?

Carol Jones, Ph.D.Stored Product EngineerBiosystems and Ag Engineering

SPREC – Okla. State University

Top World Oil Producing & Consuming Countries, 2006

Producers

12

11

10

9

8

7

6

5

4

3

2

1

Rank

3.02.6Nigeria

3.02.7Kuwait

3.02.8Venezuela

3.02.8Un. Arab Em.

3.63.0Norway

3.73.1Canada

4.43.8China

4.53.8Mexico

4.94.2Iran

9.98.3U.S.

11.29.7Russia

13.110.7Saudi Arabia

PercentMM bpd

Country

DOE EIA, 08/08

Consumers

12

11

10

9

8

7

6

5

4

3

2

1

Rank

2.42.0Saudi Arabia

2.42.0France

2.52.1Mexico

2.62.2South Korea

2.62.2Brazil

2.72.3Canada

3.12.6India

3.12.5Germany

3.42.8Russia

6.45.2Japan

8.27.2China

24.620.7U.S.

PercentMM bpd

Country

USA Oil Imports USA Oil Imports –– The RiskThe Risk

•• 35 % from 35 % from politically volatilepolitically volatile(and potentially (and potentially volatile) areasvolatile) areas

2008 YTD 2008 YTD Oil Imports Oil Imports

(million barrels/day)(million barrels/day)CountryCountry

1.291.29MexicoMexico

1.531.53Saudi ArabiaSaudi Arabia

9.379.37……..TotalTotal

0.660.66IraqIraq

1.041.04NigeriaNigeria

1.151.15VenezuelaVenezuela

1.831.83CanadaCanada

Some US Energy Statistics• In 2006…

– consumed 139.9 billion gallons of gasoline– produced 3.9 billion gallons of ethanol

– consumed 43.2 billion gallons of diesel– produced 91 million gallons of biodiesel

– imported 65 percent of all petroleumSPREC – OSU

Ethanol as a FuelEthanol as a Fuel

Clean-burning, renewable fuel for vehicles

E10 (10% EtOH) is approved for most vehicles sold in the U.S.

Currently blended into about 46% of gasoline

SPREC – OSU

6.2 Billion gallons EtOH currently produced6.2 Billion gallons EtOH currently produced-- Over 134 plantsOver 134 plants-- 77 new plants under construction77 new plants under construction

Most ethanol made from cornMost ethanol made from corn-- Yield 2.7 gallons per bushelYield 2.7 gallons per bushel-- Uses ~20% of corn cropUses ~20% of corn crop

Currently No Commercial Cellulosic Plants in USACurrently No Commercial Cellulosic Plants in USASix proposed for Federal FundingSix proposed for Federal Funding

U.S. Ethanol ProductionU.S. Ethanol Production

SPREC – OSU

Current Ethanol Production Facilities Current Ethanol Production Facilities 134 operational, 77 under construction134 operational, 77 under construction

Ethanol Plant OwnershipEthanol Plant Ownership

•• Current PlantsCurrent Plants–– 47 percent of plants are farmer owned47 percent of plants are farmer owned

•• Plants under ConstructionPlants under Construction–– 12 percent of plants are farmer owned12 percent of plants are farmer owned


Potential ImpactPotential Impact50 MGY Ethanol Plant50 MGY Ethanol Plant

Employment requirements:Employment requirements:190190 Harvest Workers (9Harvest Workers (9--month)month)5050 Truck Drivers (12Truck Drivers (12--month)month)3030 Plant PersonnelPlant Personnel

270270 TotalTotal

Economic impact = $40 million per Economic impact = $40 million per yearyear

Some Biofuels StatisticsSome Biofuels Statistics•• 1 bushel of corn = 2.7 gallons of ethanol1 bushel of corn = 2.7 gallons of ethanol•• Corn Ethanol: 1.25 Corn Ethanol: 1.25 -- 1.33 to 1 energy ratio1.33 to 1 energy ratio

•• 1 ton of switchgrass = 60 to 80 gallons of ethanol1 ton of switchgrass = 60 to 80 gallons of ethanol•• Cellulosic Ethanol: 5 Cellulosic Ethanol: 5 –– 10 to 1 energy ratio 10 to 1 energy ratio

(depending on feedstock)(depending on feedstock)

•• 7.5 lbs of soybean oil = 1 gallon B1007.5 lbs of soybean oil = 1 gallon B100•• B100 has a 3.2 to 1 energy ratioB100 has a 3.2 to 1 energy ratio


What crop makes which fuel???What crop makes which fuel???•• EthanolEthanol

–– Corn starchCorn starch–– Cereal grains starchCereal grains starch–– Cellulosic materials (forestry products, Cellulosic materials (forestry products,

grasses, crop residues)grasses, crop residues)•• BiodieselBiodiesel

–– Oilseeds like soybean, rapeseed, canola, Oilseeds like soybean, rapeseed, canola, sunflowersunflower

–– Waste oilWaste oil SPREC – Okla. State University

BiodieselBiodiesel


Biodiesel OutlookBiodiesel Outlook

•• much better energy balance than ethanolmuch better energy balance than ethanol•• smaller, more dispersed conversion plantssmaller, more dispersed conversion plants•• higher feedstock costs as percent of inputhigher feedstock costs as percent of input•• less fuel specifications certainty and less fuel specifications certainty and

research than ethanolresearch than ethanol•• 1 to 3 years behind ethanol in consumer 1 to 3 years behind ethanol in consumer

acceptanceacceptance


Biodiesel StatisticsBiodiesel Statistics•• plants can be relatively smallplants can be relatively small•• cost about $1/gallon of capacitycost about $1/gallon of capacity•• full economies of scale at around 10 m full economies of scale at around 10 m

gallonsgallons•• currently about 395 m gallons of currently about 395 m gallons of

capacitycapacity•• 700 m gallons of new capacity under 700 m gallons of new capacity under

constructionconstruction SPREC – Okla. State University

Soybean Acres NeededSoybean Acres Needed•• If the majority of expansion uses If the majority of expansion uses

soybean oil:soybean oil:–– By 2011 we will need 4.5 million By 2011 we will need 4.5 million

additionaladditional acres of soybeans at trendacres of soybeans at trend--line line yieldsyields

–– SBO has competition from corn oil, white SBO has competition from corn oil, white or yellow grease, rapeseed, canolaor yellow grease, rapeseed, canola


EthanolEthanol


Sugar Conversion

Ethanol Process

Sugars

ThermochemicalConversion

Syn-Gas

Ethanol (Fuel), Chemicals, Waste Products

GrassesStover and Straw

Sugar Cane Sweet Sorghum

Wood Products

GrainGrain--based Ethanolbased Ethanol


Current Grain to Ethanol Current Grain to Ethanol Conversion TechnologyConversion Technology

Adopted from Adopted from C. Riley, NRELC. Riley, NREL

Ethanol

Grain

Corn Acres NeededCorn Acres Needed•• In order to maintain existing markets:In order to maintain existing markets:

–– by 2011, we will need 14 million by 2011, we will need 14 million additional additional corn acres at trendcorn acres at trend--line yieldsline yields

–– Expected ethanol production of 10 to 11 Expected ethanol production of 10 to 11 billion gallonsbillion gallons

–– Use of more than 10% of corn crop will Use of more than 10% of corn crop will impact food and feed pricesimpact food and feed prices

–– Currently using 20% of crop for ethanolCurrently using 20% of crop for ethanolSPREC – Okla. State University

Potential Crop Acreage ShiftPotential Crop Acreage Shift•• Corn BeltCorn Belt

–– soybeans and winter wheat to cornsoybeans and winter wheat to corn–– CRP will come back into productionCRP will come back into production

•• Great PlainsGreat Plains–– increase in corn and sorghumincrease in corn and sorghum–– decrease in small grainsdecrease in small grains–– increase in minor oilseedsincrease in minor oilseeds–– little change in soybeanslittle change in soybeans–– CRP will be reducedCRP will be reduced SPREC – Okla. State University

Conversion of Available FeedstocksConversion of Available Feedstocks

DOE DOE ““Billion TonBillion Ton”” study:study:Enough biomass to displace over 30% of Enough biomass to displace over 30% of current U.S. petroleum consumption, with current U.S. petroleum consumption, with no impacts to food, feed, or export no impacts to food, feed, or export demand.demand.

Will require a variety of biomass types:Will require a variety of biomass types:•• Dedicated energy cropsDedicated energy crops•• Forest landsForest lands•• Residue/wasteResidue/waste SPREC – Okla. State University

Cellulosic EthanolCellulosic Ethanol


Ethanol Conversion TechnologiesEthanol Conversion Technologies

Adopted from Adopted from C. Riley, NRELC. Riley, NREL

Ethanol

Grain

Cellulosic Biomass

EmergingCurrent

Ethanol

GRASSoholGRASSGRASSoholoholUsing gasificationUsing gasification--fermentation fermentation

to convert biomass to fuelto convert biomass to fuel--grade ethanol grade ethanol

Biomass Potential from Crop Residue AloneBiomass Potential from Crop Residue Alone

•• Corn Belt Corn Belt –– 98.9 m tons 98.9 m tons –– (corn stover)(corn stover)•• Great Plains Great Plains –– 35.5 m tons 35.5 m tons –– (corn and (corn and

soybean stover, wheat, barley and oat soybean stover, wheat, barley and oat straw)straw)

•• West Coast West Coast –– 2.4 m tons 2.4 m tons –– (corn stover, (corn stover, wheat, barley and oat straw)wheat, barley and oat straw)

•• Delta Delta –– 4.6 m tons 4.6 m tons –– (rice straw)(rice straw)•• Southeast Southeast –– 3.6 m tons 3.6 m tons –– (sugarcane bi(sugarcane bi--

product)product) SPREC – Okla. State University

Barriers for Cellulosic EthanolBarriers for Cellulosic Ethanol•• Cost of production: $2.26/gal Cost of production: $2.26/gal (ORNL)(ORNL)

•• Large capital investment high riskLarge capital investment high risk•• Producer paradigm shiftProducer paradigm shift•• Lack of supply chain infrastructure, Lack of supply chain infrastructure,

industry standards, industry standards, regsregs..•• Consumer acceptance and awarenessConsumer acceptance and awareness•• High cost of harvest, handling, transport High cost of harvest, handling, transport

and storageand storage•• High feedstock variabilityHigh feedstock variability•• Unproven at commercial scaleUnproven at commercial scale


00 operationaloperational

6 plants proposed or under 6 plants proposed or under construcitonconstruciton

Current Cellulosic Ethanol Current Cellulosic Ethanol Production Facilities in the Production Facilities in the

U.S.U.S.


Biorefinery RequirementsBiorefinery Requirements•• Guaranteed consistent supply of high Guaranteed consistent supply of high

quality, low cost feedstockquality, low cost feedstock……365 365 days/yeardays/year

•• Cost must be LOW!!!!Cost must be LOW!!!!•• Quality must be consistentQuality must be consistent

–– Fermentation process depends on itFermentation process depends on it•• AVAILABILITY is essentialAVAILABILITY is essential


Conventional ProcessesConventional ProcessesCollectionCollection PackagingPackaging DeliveryDelivery

Supply ModelSupply ModelProducerProducer

Collection PointCollection Point

““ImprovedImproved”” Supply ModelSupply ModelProducerProducer

Country ElevatorCountry Elevator

DensificationDensification……ReductionReduction……ValueValue--Added ProcessAdded Process

““ProducerProducer”” Supply ModelSupply ModelProducerProducer DensificationDensification……

Chopped and modulesChopped and modules……Size ReductionSize Reduction……ValueValue--Added ProcessAdded Process

Eastern gamagrass

Indiangrass Bermudagrass

SwitchgrassSwitchgrass Traditional grasses with high production potential

SwitchgrassSwitchgrass

20 20

60 60DistributionDistribution

High biomass yield with High biomass yield with low inputlow input

Two types Two types Upland (5 Upland (5 –– 6 ft tall)6 ft tall)Lowland (10+ tall)Lowland (10+ tall)

Model herbaceous Model herbaceous species for development species for development as a bioenergy as a bioenergy feedstock cropfeedstock cropNative to N. America tall Native to N. America tall grass prairiesgrass prairies

Old World BluestemsOld World Bluestems

FlaccidgrassFlaccidgrass

“Exotic” grasses with high production potential

MiscanthusMiscanthus

Approx. 3 T/acre

Barrel of Barrel of Liquid FuelLiquid Fuel

1 barrel = 42 gallons

Processed SwitchgrassProcessed Switchgrass

Yield : Total Acres Yield : Total Acres 2 t/acre : 333,000 acre2 t/acre : 333,000 acre3 t/acre : 222,000 acre3 t/acre : 222,000 acre4 t/acre : 167,000 acre4 t/acre : 167,000 acre5 t/acre : 133,000 acre 5 t/acre : 133,000 acre

50 MGY Ethanol Plant50 MGY Ethanol Plant……Requires approximately 667,000 tons of Requires approximately 667,000 tons of

biomass per year (At 75 gal/ton)biomass per year (At 75 gal/ton)


More Options:More Options:Direct Fermentation of SugarsDirect Fermentation of Sugars(Sugarcane or Sweet Sorghum)(Sugarcane or Sweet Sorghum)


Ethanol Conversion TechnologiesEthanol Conversion Technologies

Ethanol

Grain SugarSugar


Sweet SorghumSweet Sorghum

•• High energy crop for ethanol High energy crop for ethanol production (15production (15--20% directly 20% directly fermentable sugar) fermentable sugar)

•• Can be grown in temperate climatesCan be grown in temperate climates

•• Low fertility requirements Low fertility requirements

•• Low water requirement: 1/2 corn and Low water requirement: 1/2 corn and 1/3 sugarcane1/3 sugarcane SPREC – Okla. State University

Sorganol Sorganol ®®

InIn--field harvesting, pressing, field harvesting, pressing, and fermenting sweet and fermenting sweet

sorghum juicesorghum juice


Traditional Sugar Processing

Sugarcane

Central FacilityOn-Farm

Press

Juice

Bagasse

Fermentation Distillation &Dehydration

Heat Energy

Potential In-Field Processing of Sweet Sorghum

Sorghum Press

Juice

Bagasse

Fermentation Distillation Dehydration

Central FacilityOn-Farm

Field Residue

Silage

Heat Energy

Three Different Planting DatesThree Different Planting Dates

300+ gal/acre300+ gal/acre

•• Develop biobased Develop biobased productsproducts

•• Stimulate economic Stimulate economic activityactivity

OKLAHOMABIOENERGY CENTER

Oklahoma Bioenergy Center Act

• Created the Oklahoma Bioenergy Center• $40 million over 4 years• Founding member institutions:

• Oklahoma State University• University of Oklahoma• The Samuel Roberts Noble Foundation


Purpose of Center

The conduct of research and the delivery of practical outcomes to:

• Enable the competitive and sustainableproduction of liquid biofuels in Oklahoma, and

• Contribute to the national research effortto enable the United States to achieve prescribed levels of petroleum independence.


Research Programs

• Primary research program• Outcomes: Sustainable, economic production of

cellulosic ethanol (or other high-value outputs)• Approach: Comprehensive, whole-system research

that integrates solutions from each stage of the biofuels production/value chain.

• Secondary research program• Outcomes: Critical elements in production of

biodiesel and ethanol from non-cellulosic sources


Biofuels Value Chain

Oklahoma State UniversityUniversity of OklahomaThe Samuel Roberts Noble Foundation

Oklahoma Bioenergy Center

This might be YOU!

A New Day is InevitableA New Day is Inevitable

•• Producers MUST play a roleProducers MUST play a role•• There will be challengesThere will be challenges•• Is it time yet?Is it time yet?•• BE INVOLVED AND BE INVOLVED AND ……•• BE PREPAREDBE PREPARED


What can you do NOW?What can you do NOW?•• Keep updated on: Keep updated on:

–– Latest legislationLatest legislation–– Latest developments in productionLatest developments in production–– Latest developments of refinery locationsLatest developments of refinery locations

•• Be thinking about dual purpose Be thinking about dual purpose cropscrops……feed and feedstockfeed and feedstock

•• Be thinking about sustainability in your Be thinking about sustainability in your operationoperation


Questions???Comments???Questions???Comments???

Carol Jones, Ph.D.Stored Product EngineerBiosystems and Ag Engineering


Biofuels Basics: Harvesting, Handling and Storage

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