Workshop and Report on Implications of Bio-refineries for Energy and Trade in the APEC Region (EWG 05/2008A) APEC 21st Century Renewable Energy Development Initiative (Collaborative IX) November 2009 APEC Project No. EWG 05/2008A Produced by Nexant, Inc. and Industrial Technology Research Institute (ITRI) Nexant team led by Larry Song, General Manager Nexant China 44 South Broadway White Plains, NY 10601, USA ITRI team led by Seng-Rung Wu, Senior Researcher Energy and Environment Research Lab. Bldg. 64, 195, Sec. 4, Chung Hsing Rd., Chutung Hsinchu 31040, Chinese Taipei Produced for Asia-Pacific Economic Cooperation Secretariat 35 Heng Mui Keng Terrace, Singapore 119616 Tel：(65) 68919 600 Fax: (65) 68919 690 Email： [email protected] Website: www.apec.org ○c 2009 APEC Secretariat ISBN：978-981-08-4588-9 [APEC# 209-RE-01.7] This report has been prepared for APEC Secretariat. The views and opinions expressed herein do not necessarily reflect those of APEC, of Nexant or of ITRI. Except where specifically stated otherwise in the report, the information contained herein was prepared on the basis of information that is publicly available and has not been independently verified or otherwise examined to determine its accuracy, completeness or financial feasibility. Neither Nexant, ITRI nor any person acting on behalf of either assumes any liabilities with respect to the use of or for damages resulting from the use of any information contained in this report. Nexant or ITRI does not represent or warrant that any assumed conditions will come to pass. This report speaks only as of the date herein and Nexant and ITRI have no responsibility to update this report. This report is integral and must be read in its entirety. This notice must accompany every copy of this report. Table of Contents Section Page 1 Executive Summary........................................................................................................ 1-1 1.1 INTRODUCTION ................................................................................................ 1-1 1.1.1 Bio-refinery Technology Challenges........................................................ 1-3 1.2 TECHNOLOGY................................................................................................... 1-4 1.3 WATER USAGE FOR ETHANOL PRODUCTION .......................................... 1-8 1.4 FEEDSTOCKS..................................................................................................... 1-9 1.5 CO-PRODUCTS................................................................................................... 1-10 1.6 BIO-REFINERY WORKSHOP........................................................................... 1-10 1.7 RECOMMENDATIONS...................................................................................... 1-11 2 Introduction..................................................................................................................... 2-1 2.1 INTRODUCTION ................................................................................................ 2-1 2.2 BIO-REFINERY ISSUES AND DRIVERS ........................................................ 2-3 2.2.1 Liquid Biofuels Issues .............................................................................. 2-3 2.2.2 Bio-refinery Technology.......................................................................... 2-5 2.2.3 Feedstock Challenges Have Emerged ...................................................... 2-7 3 Bio-refinery Technologies .............................................................................................. 3-1 3.1 OVERVIEW......................................................................................................... 3-1 3.2 FERMENTATION ............................................................................................... 3-3 3.2.1 Starchy Feedstocks – Overview................................................................ 3-3 3.2.2 Corn to Ethanol......................................................................................... 3-3 3.2.3 Sugarcane to Ethanol................................................................................ 3-21 3.2.4 Other Starch/Sugar Feeds to Ethanol........................................................ 3-25 3.2.5 Lignocellulosic Biomass to Ethanol ......................................................... 3-25 3.2.6 Biomethane............................................................................................... 3-45 3.2.7 Biobutanol by Fermentation ..................................................................... 3-78 3.2.8 Syngas to Ethanol ..................................................................................... 3-86 3.2.9 Hydrocarbons by Fermentation ................................................................ 3-88 3.2.10 Water Usage for Ethanol Production........................................................ 3-95 3.3 THERMOCHEMCAL.......................................................................................... 3-98 Bio-refineries for Energy and Trade in the APEC Region i Table of Contents 3.3.1 Pyrolysis for Bio-Oil................................................................................. 3-98 3.3.2 Torrefaction for Feed Preparation ............................................................3-102 3.3.3 Gasification...............................................................................................3-103 3.3.4 Derivatives................................................................................................3-136 3.3.5 Hydrocracking FOGs................................................................................3-149 3.3.6 FCC Cracking...........................................................................................3-154 3.3.7 FAME – Homogeneous Catalyst..............................................................3-156 3.3.8 FAME – Heterogeneous Catalyst .............................................................3-160 3.3.9 FFA Pretreatment......................................................................................3-162 3.3.10 Bio Co-Solvent Process ............................................................................3-165 3.3.11 Supercritical Processing............................................................................3-166 3.3.12 FAEE (Fatty Acid Ethyl Esters) ...............................................................3-167 3.3.13 ENSEL™ – Benefuel (new catalyst for tranesterification reaction) ..................................................................................................................3-168 3.3.14 Hydrothermal Upgrading (HTU)..............................................................3-169 3.4 OTHER.................................................................................................................3-171 3.4.1 APR – Virent ............................................................................................3-171 3.4.2 MixAlco – Terrabon.................................................................................3-173 3.4.3 Zeachem – Ethanol via Acetic Acid .........................................................3-176 3.4.4 Vertigro System........................................................................................3-178 3.5 FACILITY INTEGRATION................................................................................3-179 3.5.1 Overview...................................................................................................3-179 3.5.2 Overall Value Premise..............................................................................3-179 3.6 TECHNOLOGY SUMMARY .............................................................................3-180 4 Feedstocks........................................................................................................................ 4-1 4.1 INTRODUCTION ................................................................................................ 4-1 4.2 SUGAR................................................................................................................. 4-1 4.3 GRAINS ............................................................................................................... 4-7 4.3.1 Corn (Maize)............................................................................................. 4-7 4.3.2 Milo (Grain Sorghum) .............................................................................. 4-8 4.3.3 Sweet Sorghum......................................................................................... 4-8 4.3.4 Wheat........................................................................................................ 4-10 Bio-refineries for Energy and Trade in the APEC Region ii Table of Contents 4.4 OTHER CROPS................................................................................................... 4-11 4.4.1 Cassava ..................................................................................................... 4-11 4.4.2 Sweet Potato............................................................................................. 4-13 4.5 BIOMASS............................................................................................................. 4-13 4.5.1 Switchgrass and Other Grasses (i.e. Energy Cane) .................................. 4-13 4.5.2 Willow and Other Trees............................................................................ 4-19 4.5.3 Agricultural Residues..............................................................................