2005 OBP Bi-Annual Peer Review Thermochemical Processing Effort

1. 2005 OBP Bi-Annual Peer Review Thermochemical Processing Effort Dr. Don J. Stevens, PNNL Thermochemical Platform November 14, 2005

2. Overview Work Objective: Promote efficient conversion of lignin-rich biomass to useful intermediates including syngas Relevant Pathways: Agricultural Residues, Energy Crops, Forest Products, Pulp and Paper Partners NREL PNNL Bioengineering Resources Antares Eastman Chemical Weyerhaeuser University of Utah Budget (K)

3. Technical Barrier Areas • Addressing technical barriers: • Handling varying biorefinery residues, lignin-rich feedstocks, and “off-specification” biomass • Efficiently converting biomass with low tar production • Achieving desired syngas composition • Handling/recovering inorganic material

4. Strategy and Pathways – Intermediate to Long Term

5. Impact of Thermochemical Platform R&Don A and B Milestones in the Agricultural Residues and Perennial Crops Pathways

6. Impact of Thermochemical Platform R&Don A and B Milestones in the Pulp and Paper and Forest Products Pathway

7. Thermochemical Platform 3.0 Thermochemical Platform R&D 3.1 Feed Processing and Handling 3.2 TC Processing 3.3 Cleanup and Conditioning 3.5 TC Platform Analysis 3.3.1. Cleanup and Conditioning Core R&D 3.1.1.2. Feed Improvement 3.2.1. Biomass Gasification 3.5.1. TC Platform Analysis 3.2.2. Pyrolysis 3.3.2. Cleanup and Conditioning Partnerships 3.5.2. BLG for Fuels/ Chemical in at Kraft Mills 3.2.3 Black Liquor Gasification 3.2.4 Innovative Gasification

8. Thermochemical Platform 3.2. TC Processing 3.2.1. Biomass Gasification 3.2.3. Black Liquor Gasification 3.2.4. Innovative Gasification 3.2.1.2. Gasification of Corn Stover and Biorefinery Residues 3.2.3.1.3. Adv. High Temp BLG Tech. 3.2.4.2. TC Conversion of Corn Stover 3.2.1.3. Wet Gasification of Biorefinery Residues 3.2.4.3. Catalytic Hydrothermal Conversion 3.2.4.4. Innovative Membranes/Gasification Technologies

9. Thermochemical Processing Current Program Includes: • Thermal gasification using oxygen-blown or indirectly heated gasifiers for medium-energy syngas • Hydrothermal gasification for medium-energy syngas • Current focus is on producing syngas, suitable with conditioning, for liquid fuels production

10. TC Processing Technical Areas

11. TC Processing: Biomass Gasification Task 3.2.1. Biomass Gasification of Biorefinery Residues Objective: Obtain basic data on thermochemical gasification of selected feedstocks to facilitate production of liquid fuels Technical Approach: • Conduct benchmark studies using NREL and PNNL gasification systems • Focus specifically on corn stover and biorefinery residues • Collect detailed data on solids conversion, tar and char yields, gas compositions, N and S release, and other parameters Needs: Basic data on gasification of corn stover and biorefinery residues is not available. Reliable data is needed to ensure compatibility with industry goals for liquid fuels Milestones Relevance: Data assists meeting programmatic milestones on TC conversion to syngas Projects and Participants: • NREL – Basic studies of gasifying corn stover and biorefinery residues • PNNL – Parametric studies of wet gasification of biorefinery residues NREL TCPDU Gasifier System

12. TC Processing: Biomass Gasification Task 3.2.1. Biomass Gasification of Biorefinery Residues (Continued) Accomplishments & Plans: • NREL Basic Gasification Studies • Work conducted in NREL TCPDU gasification system • 20+ corn stover gasification conditions studied to provide data for crucial for development of technical validation model • Work proceeding as scheduled, milestones met • FY06 work to focus on fermentation based lignin-rich biorefinery residues • PNNL Parametric Wet Gasification Study • Work conducted in PNNL wet gasification reactor system • Hydrothermal catalytic process at 350°C, 200 atm • Produces methane-rich gas • Data collection on gasification of biorefinery residues underway as scheduled • All work complete in early FY06, project will end as planned PNNL Wet Gasification System

13. TC Processing: Black Liquor Gasification Task 3.2.2. Gasification for fuels/chemicals in a pulp mill Objective: Conduct process R&D to assist with integrated gasification of black liquor to syngas in a paper mill Technical Approach: • Conduct research on q high temperature gasification concept • Focus on black liquor feedstock • Recognize BL gasification must be integrated with heat and chemical recovery • Collect process data to assist industry Needs: Black Liquor is a difficult feedstock to handle with high sulfur content. Process must also provide integration of heat use and chemical recovery. Milestones: Prior analysis shows BL Gasification has the potential to be more cost effective than current combustion systems. Project technical milestones support the syngas cost goal. Projects and Participants: • Weyerhaueser – High temperature BL gasification

14. TC Processing: Black Liquor Gasification Task 3.2.2. Gasification for fuels/chemicals in a pulp mill (continued) Accomplishments & Plans: Weyerhaeuser – Advanced High Temperature Gasification • Project began in 2005 • Utilizing CHEMREC New Bern gasifier as a test-bed facility • Conducting long-term continuous trials under real process conditions • Combining fundamental chemistry and modeling to address issues • FY06 work will continue tests and modeling • Project has clear milestones and go/no-go decision points New Bern Gasifier

15. TC Processing: Innovative Gasification Task 3.2.3. Innovative Gasification Objective: Conduct research on innovative thermal conversion approaches that will, if successful, provide advantages for biorefineries Technical Approaches: • Industry-led R&D on the hydrothermal gasification of wet biomass (Antares/Eastman Chemical/PNNL) • Industry-led R&D to determine the feasibility of gasification systems followed by fermentation of syngas (Bioengineering Rseources) • Assess the feasibility of ceramic membranes inside or close-coupled to biomass gasifiers for producing improved syngas for producing liquid transportation fuels (NREL/PNNL) Needs: The innovative nature of these projects entail higher technical and economic risks, but they offer potential for significant improvement if successful. In most cases, Industry is providing cost-sharing. Milestones: Projects have clear technical milestones, and industry projects are reviewed regularly against go/no-go decisions. Projects and Participants: • Antares/Eastman Chemical/PNNL – Catalytic hydrothermal gasification of biosludge • Bioengineering Resources – Thermochemical conversion of corn stover • NREL/PNNL – Evaluation of membrane systems for biomass gasification

16. TC Processing: Innovative Gasification Task 3.2.3. Innovative Gasification (continued) Accomplishments & Plans: Competitive, industry cost-shared projects • Antares/Eastman Chemical/PNNL – Catalytic Hydrothermal Gasification • Low temperature catalytic wet gasification of biosludge, 350 °C, 200 atm • FY05: Feedstock characterization and conversion studies in bench-scale units • FY06: Go/no-go decision on conducting larger scale gasification tests at the Eastman Chemical site. Critical success factor: catalyst lifetimes • Bioengineering Resources – Thermochemical Conversion of Corn Stover • Pilot scale gasification/fermentation process to convert corn stover to ethanol • Utilizes oxygen-enriched gasification in a Consutech gasifier • Syngas converted to ethanol by anaerobic fermentation • Gasifier constructed and operated in 2005 • FY06 will include studies to convert syngas to ethanol. Critical success factor: 50 g/l-day must be achieved

17. TC Processing: Innovative Gasification Task 3.2.3. Innovative Gasification (continued) Accomplishments & Plans: • NREL/PNNL – Evaluation of Membrane Systems for Biomass Gasification • Evaluation of high-temperature membranes located in or closely coupled to a biomass gasifier • Focus on systems producing liquid transportation fuels • Includes technical and economic feasibility • “One-time” study to be completed in FY06 From: Julbe, et al, Catalysis Today, 2005

18. Stage Placement & Portfolio Alignment Review DOE Office of the Biomass Program FY05 Thermochemical Portfolio Alignment Review June 7-8, 2005 “Stage placement” of all new and existing projects (16) in the Thermochemical Platform. Evaluations based on: Program Relevance, Approach, Progress, Success Factors, and Future Plans • 7 core R&D projects (NREL, PNNL) primarily focused on developing biomass gasification and gas clean-up technology that can applied many different biomass feedstocks. • 9 subcontracted industrial/cost-shared R&D projects selected by competitive solicitations or directed by Congress to develop/commercialize gas cleanup technology, black liquor gasification, and other thermochemical processes. Reviewers • Professor Robert Brown, Iowa State University • Professor Esteban Chornet, Université de Sherbrooke • Viorel Duma, Abengoa Bioenergy R&D, Inc. • John Scahill, DOE Golden Field Office • David Turpin, MeadWestvaco Research

19. Stage Placement & Portfolio Alignment Review General Comments on Thermochemical Program • Thermochemical Program has clear goals which support the overall program • Technical barriers are clearly identified • R&D is good fit with the program and there is good balance • Funding may be inadequate to meet program goals Specific Reviewer Comments on TC Processing: • Reviewers offered many detailed technical suggestions: Response: DOE provided technical feedback to PI’s • High level BL Gasification milestones may not be met at current budget levels Response: Current funding availability is limited • Several projects have high risk – enforce stage gate Response: DOE agrees, reviews will be held as scheduled • Pyrolysis should be supported in the TC Processing Area Response: Given current budget levels and priorities, DOE is currently unable to fund pyrolysis to bio-oil R&D

20. Summary and Future Work TC Processing: Work In FY06 Biomass Gasification: • Core R&D on gasification of stover and biorefinery residues will continue at the NREL TCPDU gasifier • Other projects will end as scheduled Pyrolysis: • Future projects on biocrude as a refinery feedstock will depend on industry interest and OBP funding availability Black Liquor Gasification: • R&D work will continue in the larger-scale facility with industry cost-sharing • Progress will be tracked and reviewed Innovative Gasification: • Two industry-led projects will continue • Go/no-go decision in FY06 for Antares/Eastman project • Ongoing reviews for Bioengineering Resources syngas fermentation