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Liquid Transportation Fuels from Coal and Biomass: Technological Status, Costs, and Environmental Impacts (2009)
National Academy of Sciences (NAS)
 National Academy of Engineering (NAE)
 National Research Council (NRC)

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Below are the first 10 and last 10 pages of uncorrected machine-read text (when available) of this chapter, followed by the top 30 algorithmically extracted key phrases from the chapter as a whole.
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Prepublication Copy—Subject to Further Editorial Correction Figures 277

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Prepublication Copy—Subject to Further Editorial Correction 200 162 160 Number of sites 129 120 82 80 40 17 0 800 to 2200 2200 to 4000 4000 to 7000 > 7000 Biomass availability (dry tons per day) within 40 miles FIGURE S-1 Number of sites in the United States with a potential to supply indicated daily amounts of biomass within a 40-mile radius. BIOCHEMICAL CONVERSION INDIRECT THERMOCHEMICAL CONVERSION FEEDSTOCK BIOMASS Coal, Biomass, or Coal and Biomass Plant sugar/starch Lignocellulose PRETREATMENT Liquefaction Pretreatment Processing, drying SACCHARIFICATION CO2 Glucoamylase Cellulolytic Enzymes GASIFICATION Syngas FERMENTATION FISCHER – TROPSCH (FT) METHANOL SYNTHESIS CO2 DISTILLATION UPGRADING METHANOL TO GASOLINE ETHANOL BIOBUTANOL MTG Example of second generation cellulosic biofuel GASOLINE GASOLINE DIESEL FIGURE S-2 Steps involved in biochemical conversion of biomass and indirect thermochemical conversion of coal, biomass, and coal plus biomass to liquid transportation fuels. 279

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Prepublication Copy—Subject to Further Editorial Correction FIGURE S-3 Supply function for biomass feedstocks in 2020. 280

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Prepublication Copy—Subject to Further Editorial Correction Per Barrel Cost Gasoline Equivalent Product Cost (With No Carbon Price) $180 Carbon Storage Cost Additional Transportation Cost $160 Non-Feedstock Oper Cst Capital Cost Feedstock Cost Total Cost $140 $120 $100 $80 $60 $40 $20 $0 -$20 -$40 FIGURE S-4 Costs of alternative liquid fuels produced from coal, biomass, or coal and biomass with zero carbon price. 281

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Prepublication Copy—Subject to Further Editorial Correction Net CO2 (Tonnes per Gasoline Equivalent BBL) 1.20 1.00 1.06 0.88 0.80 0.60 0.49 0.47 0.40 0.44 0.42 0.42 0.37 0.20 0.00 (0.13) (0.13) (0.21) (0.25) (0.20) (0.40) (0.60) (0.76) (0.80) FIGURE S-5 Estimated carbon dioxide (CO2) emissions over the life cycle of alternative fuels, from the mining and harvesting of resources to the conversion process to the consumption of fuels. 282

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Prepublication Copy—Subject to Further Editorial Correction Per Barrel Cost Gasoline Equivalent Product Prices CO2 cost (ignoring indirect CO2 consequences) Carbon Storage Cost $180 Additional Transportation Cost Non-Feedstock Oper Cst Capital Cost $160 $114 Feedstock Cost Total Cost (without carbon price) $132 $134 $140 $126 $104 $121 $121 $105 $116 $120 $104 $95 $94 $95 $100 $88 $80 $60 $40 $20 $0 -$20 -$40 FIGURE S-6 Cost of alternative liquid fuels produced from coal, biomass, or coal and biomass with a CO2 equivalent price of $50/tonne. 283

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Prepublication Copy—Subject to Further Editorial Correction FIGURE S-7 Estimated supply of cellulosic ethanol plus corn-grain ethanol at different price points in 2020. The red solid and dotted lines show the supply of crude oil at $60/bbl and $100/bbl for comparison. 284

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Prepublication Copy—Subject to Further Editorial Correction FIGURE S-8 Estimated supply of gasoline and diesel produced by thermochemical conversion via Ficher-Tropsch with or without carbon capture and storage at different price points in 2020. 285

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Prepublication Copy—Subject to Further Editorial Correction Global Transportation by sector 70 Average Growth Year 2005-2030 1.4% 0.7% 60 2.5% 50 1.9% MBDOE 40 2.0% 30 20 0.3% 10 0 1980 2005 2030 Year Rail ? Light-Duty ? ? Heavy-Duty FIGURE 1-1 Worldwide demand for energy for transportation, 1980-2030. SOURCE: ExxonMobil (2008). Reprinted with permission. FIGURE 1-2 CO2 emissions from fossil-fuel combustion by different end-use sectors. Source: EPA (2008). 286

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Prepublication Copy—Subject to Further Editorial Correction Soil Organic Matter Change Cultivation Stover harvest Projected with cover crops Soil organic matter intercropping, or other carbon input sources Pre-cultivation steady-state Projected with no-till Management change With No management changes Time FIGURE 2-1 Conceptual diagram of how agriculture has affected soil organic matter and what may occur after various strategies for crop-residue removal. 8 Stover to retain (ton ac- ) 1 Soil organic 6 Water 5.58 Wind 4 3.56 3.52 3.38 2.34 2 1.39 1.22 0.43 0.77 0.29 0.15 0.06 0 No-tillage or Moldboard plow No-tillage or Moldboard plow conservation tillage conservation tillage Continuous corn Corn-soybean FIGURE 2-3 Tillage and crop rotation effects on the amount of corn stover required to protect soil resources against wind or water erosion and to sustain soil carbon (organic matter) levels. Adapted from Wilhelm et al. (2007). 287

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Prepublication Copy—Subject to Further Editorial Correction Million gallons gasoline 200000 150000 Case 1 (H2 per year Success) 100000 Reference 50000 0 2000 2010 2020 2030 2040 2050 Year FIGURE 9-1 Oil consumption with maximum practical penetration of HFCVs compared with reference case. SOURCE: NRC (2008). million gallons gasoline/y 180000 160000 140000 120000 Case 4 (Portfolio) 100000 80000 Ref 60000 40000 20000 0 2000 2010 2020 2030 2040 2050 Year FIGURE 9-2 Oil consumption for combined HFCVs, high-efficiency conventional vehicles, and biofuels compared with reference case. SOURCE: NRC (2008). 312

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Prepublication Copy—Subject to Further Editorial Correction FIGURE A-1 America’s Energy Future Project. 313

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Prepublication Copy—Subject to Further Editorial Correction FIGURE I-1 Schematic of processing steps for converting corn to ethanol. SOURCE: Schwietzke et al. (2008). This material is sourced from IEA Bioenergy:T41(2):2008:01 and is reprinted with permission from IEA Bioenergy. 314

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Prepublication Copy—Subject to Further Editorial Correction FIGURE I-2 Schematic of processing steps for converting corn to ethanol used in SuperPro Designer with example of summary of economic evaluation report. 315

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Prepublication Copy—Subject to Further Editorial Correction Ba ckse t En zyme 8 Eth an ol (C el lul as e, He mic ell ul ase , etc) Ye ast Wa ter 1 L ign oc ell ul osi c 5 Li qu id Bi om ass Stea m Stea m Ce ntrifu ga ti on 2 Pre tr ea tm en t S acch ar ifica tio n F e rmen tatio n 7 Wate r Di sti ll atio n a nd D ryi ng 3 4 Sol ids 6 R esi du al S ol id s FIGURE I-3: Simple schematic of cellulosic-ethanol manufacturing process. Courtesy of M. Ladisch and colleagues (Purdue University). FIGURE I-4 SuperPro Designer network model for cellulosic-ethanol manufacturing process. 316

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Prepublication Copy—Subject to Further Editorial Correction FIGURE I-5 Superpro economic analysis report sample Economic Evaluation Report June 24, 2008 For 2008jun22 Poplar- Mid 1. EXECUTIVE SUMMARY (2008 prices) Total Capital Investment 207923000.00 $ Capital Investment Charged to This Project 207923000.00 $ Operating Cost 81119000.00 $/yr Production Rate 119454958.36 kg MP/yr Unit Production Cost 0.68 $/kg MP Total Revenues 116032000.00 $/yr Gross Margin 30.09 % Return On Investment 10.91 % Payback Time 9.16 years IRR (After Taxes) 22.27 % NPV (at 5.0% Interest) 188837000.00 $ MP = Total Flow of Stream EtOH 2. MAJOR EQUIPMENT SPECIFICATION AND FOB COST (2008 prices) Quantity/ Standby/ Name Description Unit Cost ($) Cost ($) Staggered 9/0/0 V-101 Stirred Reactor 669000.00 6021000.00 Vessel Volume = 783714.15 gal 9/0/0 V-102 Stirred Reactor 651000.00 5859000.00 Vessel Volume = 754229.44 gal 9/0/0 V-103 Fermentor 676000.00 6084000.00 Vessel Volume = 796094.41 gal 1/0/0 DDR-101 Drum Dryer 160000.00 160000.00 Drum Area = 59.88 m2 1/0/0 DC-101 Decanter Centrifuge 2748000.00 2748000.00 Throughput = 4400.64 L/min 1/0/0 FSP-101 Flow Splitter 0.00 0.00 Size/Capacity = 207810.03 kg/h 1/0/0 SR-101 Shredder 182000.00 182000.00 Size/Capacity = 102938.72 kg/h 1/0/0 SB-101 Solids Bin 771000.00 771000.00 317

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Prepublication Copy—Subject to Further Editorial Correction Vessel Volume = 12110.44 m3 1/0/0 C-101 Distillation Column 4782000.00 4782000.00 Column Volume = 182.20 m3 1/0/0 V-104 Seed Fermentor 7200000.00 7200000.00 Vessel Volume = 13056.19 L 1/0/0 Burner Generic Box 9290000.00 9290000.00 Size/Capacity = 1352538.12 kg/h 2/0/0 HX-102 Heat Exchanger 23000.00 46000.00 Heat Exchange Area = 95.36 m2 2/0/0 HX-103 Heat Exchanger 14000.00 28000.00 Heat Exchange Area = 51.18 m2 1/0/0 MX-101 Mixer 0.00 0.00 Size/Capacity = 182244.79 kg/h 1/0/0 HX-105 Heat Exchanger 90000.00 90000.00 Heat Exchange Area = 5488.56 m2 1/0/0 MX-102 Mixer 0.00 0.00 Size/Capacity = 205863.81 kg/h 1/0/0 MX-103 Mixer 0.00 0.00 Size/Capacity = 127857.22 kg/h 1/0/0 Steam Turbine Generic Box 13530000.00 13530000.00 Size/Capacity = 1350432.04 kg/h Unlisted Equipment 0.00 TOTAL 56791000.00 3. FIXED CAPITAL ESTIMATE SUMMARY (2008 prices in $) 3A. Total Plant Direct Cost (TPDC) (physical cost) 1. Equipment Purchase Cost 56791000.00 2. Installation 8480000.00 3. Process Piping 17037000.00 4. Instrumentation 11358000.00 5. Insulation 1704000.00 6. Electrical 8519000.00 7. Buildings 11358000.00 8. Yard Improvement 1136000.00 9. Auxiliary Facilities 0.00 TPDC 116383000.00 3B. Total Plant Indirect Cost (TPIC) 10. Engineering 11638000.00 11. Construction 29096000.00 TPIC 40734000.00 3C. Total Plant Cost (TPC = TPDC+TPIC) TPC 157117000.00 3D. Contractor's Fee & Contingency (CFC) 12. Contractor's Fee 7856000.00 318

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Prepublication Copy—Subject to Further Editorial Correction 13. Contingency 23552000.00 CFC = 12+13 31407000.00 3E. Direct Fixed Capital Cost (DFC = TPC+CFC) DFC 188524000.00 4. LABOR COST - PROCESS SUMMARY Unit Cost Annual Amount Annual Cost Labor Type % ($/h) (h) ($) Operator 0.00 0.00 0.00 0.00 Biomass Operators 20.00 1744.00 34880.00 0.88 Shift Operator 34.00 69760.00 2371840.00 59.53 Lab Technitians 45.00 5886.00 264870.00 6.65 Maintenance 40.85 23326.00 952867.00 23.92 Plant Supervisor 60.00 5995.00 359700.00 9.03 TOTAL 106711.00 3984157.00 100.00 5. MATERIALS COST - PROCESS SUMMARY Unit Cost Annual Amount Annual Cost Bulk Material % ($/kg) (kg) ($) Cellulase 2.49 4026493.00 10004063.00 23.64 poplar 0.04 897625670.00 31416898.00 74.25 Water 0.00 691548911.00 30428.00 0.07 Yeast 2.30 373412.00 858848.00 2.03 Recovered Steam 0.00 9999000000.00 0.00 0.00 Air 0.00 1552967692.00 0.00 0.00 Sugar Water 0.00 1149931.00 0.00 0.00 Trychomonas 2.30 115.00 264.00 0.00 TOTAL 13146692225.00 42310502.00 100.00 NOTE: Bulk material consumption amount includes material used as: - Raw Material - Cleaning Agent - Heat Tranfer Agent (if utilities are included in the operating cost) 6. VARIOUS CONSUMABLES COST (2008 prices) - PROCESS SUMMARY THE CONSUMABLES COST IS ZERO. 319

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Prepublication Copy—Subject to Further Editorial Correction 7. WASTE TREATMENT/DISPOSAL COST (2008 prices) - PROCESS SUMMARY THE TOTAL WASTE TREATMENT/DISPOSAL COST IS ZERO. 8. UTILITIES COST (2008 prices) - PROCESS SUMMARY Annual Cost Utility Annual Amount Reference Units % ($) Electricity 56,800,000 kWh 0.00 0.00 6 MW Available Energy from Steam 475,974,147 kWh 0.00 0.00 54 MW Usable Steam Energy (80%) 380,779,318 kWh 0.00 0.00 43 MW Remaining Steam Energy 323,979,318 kWh 0.00 0.00 37 MW Sales Price of Electricity 0.05 $/kWh 0.00 0.00 Revenue from Electicity 16,198,966 $ 0.00 0.00 Steam 0.00 kg 0.00 0.00 Steam (High P) 652362127.00 kg 0.00 0.00 Cooling Water 63753240963.00 kg 3187662.00 99.33 Chilled Water 0.00 kg 0.00 0.00 TOTAL 3209010.00 100.00 320

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Prepublication Copy—Subject to Further Editorial Correction 9. ANNUAL OPERATING COST (2008 prices) - PROCESS SUMMARY Cost Item $ % Raw Materials 42311000.00 52.16 Labor-Dependent 3984000.00 4.91 Facility-Dependent 31616000.00 38.97 Consumables 0.00 0.00 Waste Treatment/Disposal 0.00 0.00 Utilities 3209000.00 3.96 Miscellaneous 0.00 0.00 Advertising/Selling 0.00 0.00 Running Royalties 0.00 0.00 Failed Product Disposal 0.00 0.00 TOTAL 81119000.00 100.00 10. PROFITABILITY ANALYSIS (2008 prices) A. Direct Fixed Capital 188524000.00 $ B. Working Capital 4087000.00 $ C. Startup Cost 11311000.00 $ D. Up-Front R&D 0.00 $ E. Up-Front Royalties 4000000.00 $ F. Total Investment (A+B+C+D+E) 207923000.00 $ G. Investment Charged to This Project 207923000.00 $ 321

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Prepublication Copy—Subject to Further Editorial Correction H. Revenue Stream Flowrates Total flow of stream EtOH 119454958.00 kg/yr Total flow in Steam 10153761372.00 kg/yr Total Production of Recovered Steam 9,999,000,000 kg/yr Total Energy Conternt of Recovered Steam 2,844,215,150,040KJ/yr Total Requirements of Steam (High P) 652,362,126 kg/yr Total Energy Conternt of Steam (High P) 1,130,708,220,559 kJ/yr Total Energy Left over for Electricity 1,713,506,929,481 kJ/yr I. Production Unit Cost EtOH 0.68 $/kg J. Selling / Processing Price Total flow of stream EtOH 0.84 $/kg Total flow in Steam 1.60 $/1000 kg K. Revenues EtOH 99833000.00 $/yr Steam 16199000.00 $/yr Total Revenues 116032000.00 $/yr L. Annual Operating Cost AOC 81119000.00 $/yr M. Gross Profit (K-L) 34913000.00 $/yr N. Taxes (35%) 12220000.00 $/yr O. Net Profit (M-N) 22694000.00 $/yr Gross Margin 30.09 % Return On Investment 10.91 % Payback Time 9.16 years 322