Minerals Processing Research Institute Louisiana State University White Paper on Integrating Biomass Feedstocks into Chemical Production Complexes using New and Existing Processes by Ralph W. Pike, Director Debalina Sengupta Graduate Research Assistant Minerals Processing Research Institute 1139 Energy Coast and Environment Building Louisiana State University Baton Rouge, LA 70803 and Thomas A. Hertwig Mosaic Corporation Uncle Sam, LA 70792 November 3, 2008 Minerals Processing Research Institute Louisiana State University Baton Rouge, LA 70803 (225) 578-3428 (225) 578-1476 fax www.mpri.lsu.edu Table of Contents Abstract........................................................................................................................................... 3 Introduction..................................................................................................................................... 4 A Research Vision .......................................................................................................................... 5 New Frontiers.................................................................................................................................. 5 The Chemical and Petroleum Refining Industry in the Lower Mississippi River Corridor ........... 6 Development of New Industries based on Renewable Resources that Initially Require Nonrenewable Resources Supplements .......................................................................................... 9 New Processes for the Chemical Complex - Chemicals from Biomass based Feedstocks .......... 14 Biomass Fermation ....................................................................................................................... 17 The Calvin-Benson Cycle......................................................................................................... 18 The C4 cycle ............................................................................................................................. 19 The CAM cycle......................................................................................................................... 19 Biomass Classification and Composition ..................................................................................... 20 Starch ........................................................................................................................................ 20 Lignocellulosic Biomass ........................................................................................................... 20 Cellulose ................................................................................................................................... 21 Hemicellulose ........................................................................................................................... 21 Lignin........................................................................................................................................ 24 Lipids, Fats and Oils ................................................................................................................. 24 Feedstock Availability .................................................................................................................. 25 Biomass availability in United States ....................................................................................... 25 Biomass availability in Louisiana ............................................................................................. 29 New Feedstock Options – Algae................................................................................................... 31 Biomass Conversion Routes ......................................................................................................... 36 Biomass Pretreatment ................................................................................................................... 36 Hot Wash Pretreatment ............................................................................................................. 37 Acid Hydrolysis ........................................................................................................................ 37 Enzymatic Hydrolysis ............................................................................................................... 38 Ammonia Fiber Explosion........................................................................................................ 38 Fermentation ................................................................................................................................. 38 Anaerobic Digestion ..................................................................................................................... 39 Transesterification......................................................................................................................... 43 Gasification/Pyrolysis................................................................................................................... 51 Biomass Conversion Products – by Carbon Number ................................................................... 54 1 Single-Carbon Compounds ........................................................................................................... 54 Methane..................................................................................................................................... 54 Methanol ................................................................................................................................... 55 Two-Carbon Compounds .............................................................................................................. 55 Ethanol ...................................................................................................................................... 55 Economies of Scale ............................................................................................................... 64 Plant Size and Collection Distance....................................................................................... 64 Corn Stover Cost................................................................................................................... 66 Total Cost of Ethanol as a Function of Plant Size ................................................................ 67 Ethanol from Glycerol .......................................................................................................... 67 Ethanol from Synthesis Gas Fermentation ........................................................................... 68 Acetic Acid ............................................................................................................................... 70 Ethylene .................................................................................................................................... 71 Three-Carbon Compounds ............................................................................................................ 73 Glycerol..................................................................................................................................... 73 Lactic acid................................................................................................................................. 74 Propylene Glycol ...................................................................................................................... 74 1,3-Propanediol......................................................................................................................... 75 Four-Carbon Compounds.............................................................................................................. 76 Butanol...................................................................................................................................... 76 Succinic Acid............................................................................................................................ 77 Aspartic acid ............................................................................................................................. 78 Five-Carbon Compounds .............................................................................................................. 78 Levulinic Acid .......................................................................................................................... 78 Xylitol/Arabinitol ...................................................................................................................... 80 Itaconic Acid............................................................................................................................. 81 Six-Carbon Compounds ................................................................................................................ 82 Sorbitol...................................................................................................................................... 82 2,5-Furandicarboxylic Acid ...................................................................................................... 82 Cellulose Acetate ...................................................................................................................... 83 Vegetable Oil Based Chemicals .................................................................................................... 84 Incorporating Processes for Chemicals from Biomass in Chemical Production Complexes ....... 85 Chemical Complex Analysis System ...........................................................................................