Forest Biorefining and Implications for Future Wood Energy Scenarios

Presentation 2.4: Forest biorefining and implications for future wood energy scenarios

Jack N. Saddler Position: Professor & Dean Organization/Company: University of British Columbia, Faculty of Forestry

Abstract The diversification of the forest products industry to include bioenergy may be characterized by evolution of a number of co products. The biorefinery concept, which considers energy, fuels, and chemical or material production within a single facility or cluster of facilities, may be the route forward for the forest industry that provides optimal revenues and environmental benefits. Forest- based biorefining platforms may use traditional or innovative platforms. A review of biorefineries in other sectors is followed by an examination of potential co products. A number of existing pilot or demonstration facilities exist around the world today, and many of these are described. The growth of biorefining in developed regions creates a technology transfer opportunity that could be facilitated through an FAO-led network similar to IEA Implementing Agreements or Tasks.

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Forest biorefining and implications for future wood energy scenarios

W.E. Mabee, J.N. Saddler Forest Products Biotechnology, Department of Wood Science Faculty of Forestry, University of British Columbia 4043-2424 Main Mall, Vancouver, BC, Canada V6T 1Z4 [email protected]

International Seminar on Energy and the Forest Products Industry Rome, Italy: October 30 2006

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Outline

1. Defining biorefining in the global context 2. Forest-based biorefining platforms 3. Potential coproducts from the forest-based biorefinery 4. Examples of pilot and demonstration sites 5. Summary & Recommendations

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151 Definitions

Lignocellulose-based biorefinery: Combination of bioenergy, 2nd-gen biofuel, bioproducts

1st-generation biofuels Commercial, based on food or foodstuff waste

2nd-generation biofuels Non-commercial, based on non-food (including forest biomass) Can be used in conventional infrastructure

3rd-generation biofuels Non-commercial, non-conventional

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Agricultural biorefinery

WET MILLINGCORN DRY MILLING

Cleaning Cleaning Steeping Corn oil Germ Milling Milling

Fibre Washing

Gluten Gluten Sep. Starch Starch Syrup, Sweetner Hydrolysis Hydrolysis Fermentation Fermentation CO2 CO2 Yeast Recycle Yeast Distillation Distillation Ethanol recovery Centrifuge Distillers Wet Grains (DWG) Distillers Dried Syrup Grains (DDG) Forest Products Biotechnology at UBC

152 Bioethanol Production

(000,000 litres/a) 40,000

35,000

30,000

25,000

20,000 World Bioethanol Production

15,000

10,000 Brazil 5,000 USA & Canada Asia 0 EU 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004

Forest Products Biotechnology at UBC Sources: (1) FO Licht. 2005. (2) Fulton, L. 2004. International Energy Agency, Paris.

Outline

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153 Biorefining Platforms Fast separation Structured BIOMASS & reconstitution separation

Traditional Biological Thermochemical Platforms Platforms Platforms

BIOENERGY BIOPRODUCTS BIOFUELS

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Pulp and paper ‘refinery’ CHEMI-MECHANICAL SULPHITE PULPING WOOD (BCTMP) PULPING

KRAFT PULPING

Sulphite Liquor Black Liquor Recovery Impregnation Recovery Impregnation Impregnation Cycle Pulping Cycle Pulping Refining Washing Washing Washing Spent Sulphite Pulp Energy Pulp Pulp Liquor 40-55% Yield 48-60% Yield 70-85% Yield

Lignosulphonates

Silvichemicals Bleaching Energy Drying Papermaking

Paper

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154 Price of Purchased Power

EUR/MWh 80

50 European average weighted on P&Pb capacity

0 USA Chile China Japan Brazil Russia Canada Indonesia

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Paper production growth vs. power

Relative to 1990 figures 1.6

1.4

1.2

0.8

0.6 Market pulp, paper, board production

0.4 Primary energy consumption

Electricity consumption 0.2

0 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

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155 Outline

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Brazil - Sugar

SUGAR

Pretreatment

Fractionation

Hexoses

Fermentation

Recovery

Forest Products Biotechnology at UBC Sources: (1) FAOStat 2006; www.fao.org (2) Bolling, C. and Suarez, N.R. (2001). USDA/ERS – SSS-232.

156 Brazil - Sugar

SUGAR Sugarcane production by product (million metric tonnes) 500 Pretreatment

400 Fractionation

300

Ethanol 200

Hexoses 100 Sugar Fermentation 0 Recovery 1975 1985 1995 2005

Forest Products Biotechnology at UBC Sources: (1) FAOStat 2006; www.fao.org (2) Bolling, C. and Suarez, N.R. (2001). USDA/ERS – SSS-232.

United States - Starch

SUGAR STARCH

Pretreatment

Fractionation

Enzymatic Hydrolysis

Hexoses

Fermentation

Recovery

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157 United States - Starch

SUGAR STARCH

Corn production by product (million metric tonnes) Pretreatment 300

Residual Fractionation 200 Ethanol

Trade Enzymatic Hydrolysis 100 Food, Bioproducts Hexoses

Fermentation Animal Feed 0 Recovery 1980 1990 2000

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Oil refinery Traditional oil refining:

Oil Demand by Sector (million barrels per day) 25 ~68-70% transportation sector Electricity 20 Res'l/Comm'l (i.e. gasoline, diesel)

15 ~21% industrial processing Industrial ~5% ind. plastics, chemicals 10 (over 2,000 refinery products)

5 Transportation ~4% residential/ commercial

0 heating 1950 1960 1970 1980 1990 2000 <3% electricity generation

Forest Products Biotechnology at UBC Source: (1) EIA. 2005. Annual Energy Review. US oil demand by end-use sector. http://www.eia.doe.gov/pub/oil_gas/petroleum/analysis_publications/oil_market_basics/Dem_image_US_cons_sector.htm

158 Biological platform

LIGNOCELLULOSE

Pretreatment

Fractionation Lignin Cellulose

Enzymatic Extractives Hydrolysis Hemicellulose

Hexoses Pentoses

Fermentation

Recovery

BIOFUELS BIOENERGY

Forest Products Biotechnology at UBC BIOPRODUCTS

Thermochemical biorefinery

BIOMASS

Fast pyrolysis Fast pyrolysis to Bio-oil

Boiler Turbine Upgrade Gasify Reform Fractionation

Synthesis

Methanol, Fischer- Heat Electricity Bio-oil Tropsch, etc. Hydrogen Chemicals

BIOENERGY BIOFUELS BIOPRODUCTS

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159 Bioproducts Company

Bulk polymers: BIOLOGICAL NatureWorks, DuPont, Polylactide (PLA), 3-hydroxypropionic acid, 1,3- Cargill propanediol, etc. Nutraceuticals: Codexis, etc. xylitol, arabitol, etc. Platform chemicals: DuPont, etc. Glycerol, furfural, levulinic acid, succinic acid, etc. THERMOCHEMICAL Biofuels: Iogen, Abengoa, etc. ethanol, bio-hydrogen, etc. Biofuels: Choren, etc. bio-oil, methanol, ethanol, Fischer-Tropsch, BTL, etc. Bioenergy: Williams Lake electricity, steam, combined heat & power (cogen), Bioenergy Facility, etc. district heating, wood pellets, etc.

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Outline

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160 Iogen Corporation

Bioconversion commercial development facility in Ottawa

$29 million in collaboration with Royal Dutch Shell (2003) $30 million investment by Goldman Sachs (2006)

40 ton/day of straw, grasses and corn stalks

Preparation for $300-400 million full-scale facilities

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Lignol Innovations

Organosolv pulping originally developed by G. E. and Repap ($200 million)

Products include (1) unique, pure lignin with developed markets, (2) furfural, and (3) cellulose-to-ethanol

Benefits of focus: – 3 key products can minimize risk – Resources devoted to primary goals – Further co-products will strengthen business later

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161 SunOpta Bioprocess Group

Focus on steam-explosion pretreatment, including a continuous digestor

Owns/operates 3 biomass conversion facilities producing dietary fibre

Partnered with Abengoa Bioenergy in developing 2 pilot biomass-to-ethanol facilities (Spain, USA)

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Tembec Chemical Group

Part of Tembec’s sulphite pulp mill on the Ottawa River

Mix of hardwood and softwood feedstocks for pulping

Produces lignosulfonates, resins, and ethanol from spent sulphite liquor

Produces about 17 million litres EtOH annually, sold primarily in the food sector

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162 Etek Etanolteknik AB (Sweden)

Bioconversion pilot facility in Örnsköldsvik

$15 million investment by four primary shareholders

500 l per 24 hours (equivalent to 2 tonnes input material)

Research and development centre

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Abengoa (Spain, USA)

Castilla y Leon (start 2004) – 200 million litres/a EtOH; – 2.5% lignocellulosic-based – Co-products: Dried Distillers

Grains, CO2 for food

York, Nebraska 2 – Starch pilot plant (2004) – Biomass pilot plant (2005) (corn stover) – $36.1 million ($US) project with DOE

Partnership with SunOpta

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163 NREL (USA)

National Renewable Energy Laboratory, DOE

Bioconversion pilot facility in Golden, CO

1 tonne per day capacity

National centre for R&D activities

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Outline

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164 Conclusions

The biorefinery concept can maximize returns and improve the economic performance of bioenergy technologies

Greatest historical increases in energy demand are for transportation fuels

Most advances have been made in ‘developed’ regions; we need a network to transfer technologies to ‘developing’ partners

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IEA Bioenergy Task 39 European Commission Kyriakos Maniatis Norway TBC Sweden Guido Zacchi, Bärbel Hahn-Hägerdal Finland Tuula Makinen Denmark Birgitte K. Ahring, Lisbeth Olsson Germany Axel Munack Austria Manfred Wörgetter The Netherlands John Neeft, René Wismeijer United Kingdom Tony Sidwell Ireland Bernard Rice Canada Bill Cruickshank United States Larry Russo, Mike Ladisch Japan Shiro Saka (TBC) Australia Forest Products Biotechnology at UBC Steve Schuck (TBC)

165 Acknowledgements

IEA Bioenergy Task 39 Natural Resources Canada BIOCAP Canada Foundation

Don O’Connor, Bill Cruickshank Forest Products Biotechnology Colleagues and collaborators

Questions?

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166