Biorefinery Optimization Workshop Summary Report Chicago, Illinois October 2016 Summary report from the October 5‒6, 2016, Biorefinery Optimization Workshop in Chicago, Illinois Workshop and summary report sponsored by the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy Bioenergy Technologies Office Preface The U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) invests in a diverse portfolio of energy technologies to create and sustain American leadership in the transition to a global clean energy economy. This report summarizes the results of a public workshop sponsored by EERE’s Bioenergy Technologies Office in Chicago, Illinois, from October 5‒6, 2016. The views and opinions of the workshop attendees, as summarized in this document, do not necessarily reflect those of the U.S. government or any agency thereof, nor do their employees make any warranty, expressed or implied, or assume any liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represent that its use would not infringe upon privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the U.S. government or any agency thereof. Preface i BIOREFINERY OPTIMIZATION WORKSHOP SUMMARY REPORT Table of Contents Preface ............................................................................................................................................................ i Executive Summary .......................................................................................................................................1 Feedstock and Solid Materials Handling .............................................................................................................................................1 Process Scale-Up, Intensification, and Cost Reduction ................................................................................................................1 Co-Product and Waste Stream Monetization ...................................................................................................................................1 Introduction ................................................................................................................................................. 3 Summary of Plenary Presentations ........................................................................................................... 5 Industry Perspectives ...............................................................................................................................................................................5 Feedstock and Materials Handling ......................................................................................................................................................5 Biomass Material Handling Considerations ................................................................................................................................6 Processing and Handling Herbaceous Biomass ..........................................................................................................................7 Industrial Feed Handling of Lignocellulosic Feedstocks .........................................................................................................9 Process Scale-Up, Intensification, and Cost Reduction .............................................................................................................10 Cellulosic Ethanol Collaborative Improvement Opportunities ............................................................................................10 Scale-Up and Optimization .............................................................................................................................................................. 11 Effective Deployment of Bioenergy Technologies .................................................................................................................. 12 Sugar is the New Crude ...................................................................................................................................................................... 12 Co-Product and Waste Stream Monetization ............................................................................................................................... 13 Policy Drivers for Low-Carbon Fuel Value ................................................................................................................................... 13 Co-Product Opportunities: Lesson Learned ...............................................................................................................................14 Monetizing Biorefinery Residue and Waste Streams .............................................................................................................16 Biomass Waste Stream to Carbon and Composite Product Case Studies ....................................................................16 Summary of Breakout Sessions .................................................................................................................18 Breakout Session One: Feedstock and Materials Handling ....................................................................................................18 Feedstock Characterization and Particle Size Management ...............................................................................................18 Challenges in Biorefinery Operation and Biomass Feedstock Handling ........................................................................20 Future Directions ..................................................................................................................................................................................26 Lessons Learned ...................................................................................................................................................................................29 Breakout Session Two: Process Scale-Up, Intensification, and Cost Reduction .............................................................. 31 Major Challenges Facing Integrated Biorefineries .................................................................................................................. 32 Resources Needed to Address Integrated Biorefineries Challenges ............................................................................... 35 Methods for Reducing Capital and Operational Expenditures ..........................................................................................38 Breakout Session Three: Co-Product and Waste Stream Monetization .............................................................................45 Output Stream Utilization .................................................................................................................................................................45 ii Table of Contents Stream Value ..........................................................................................................................................................................................46 Monetization Challenges .................................................................................................................................................................... 51 Waste Stream Value ............................................................................................................................................................................. 51 Future Directions .................................................................................................................................................................................. 52 Day One Summary ................................................................................................................................................................................. 52 Plenary Session ..................................................................................................................................................................................... 52 Breakout Session One ........................................................................................................................................................................ 52 Breakout Session Two ....................................................................................................................................................................... 53 Breakout Session Three .....................................................................................................................................................................54 Day Two Summary .................................................................................................................................................................................54 Opportunities for Stakeholder Collaboration ............................................................................................................................54 Input for DOE .........................................................................................................................................................................................56