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All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Cooperative valorization of lignin and residual sugar to polyhydroxyalkanoate (PHA) for enhanced yield and carbon utilization in biorefineries

Lignin valorization is essential for a sustainable and economically viable biorefinery. Despite the recent efforts, it is still unclear how the reactivity of native lignin can be improved by pretreatment in a biorefinery and how different components in biorefinery residue especially residual sugar contribute to bioconversion in biorefineries. In the present study, co-utilization of lignin and limited glucose was first evaluated and proved to facilitate lignin conversion and polyhydroxyalkanoate (PHA) production. A new integrated biorefinery was then designed to cooperatively valorize lignin and residual sugar for improving the PHA yield and utilization efficiency of biorefinery residue. By the design of integrated biorefinery, the glucose and xylose yield were 91% and 73%, respectively, which increased by 18% and 12% compared with that only using sodium hydroxide pretreatment. Approximately 85% of the lignin was dissolved into a liquid stream with the integrated biorefinery, corresponding to an increase of 69% compared with that only using sodium hydroxide pretreatment. More than 70% of the residual sugar was released from the biorefinery residue, producing the soluble lignin stream that contains both lignin and residual sugar for synergistic bioconversion. Bioconversion of the soluble lignin stream with Pseudomonas putida KT2440 produced 1.5 g l -1 PHA, representing the record titer of PHA from biorefinery residue. The lignin characterization results from nuclear magnetic resonance and gel-permeation chromatography showed that the integrated process significantly reduced the lignin molecular weight, broke down more β-O-4 and β-5 linkages, and enriched the H-lignin content. Alongside the increased residual sugar concentration, the bioconversion performance of soluble lignin to PHA was significantly improved. Altogether, the integrated biorefinery increased the fermentable sugar yield and improved the PHA production from biorefinery waste by cooperative valorization of lignin and residual sugar, which shows potential advantages for biorefinery sustainability.

09 BIOMASS FUELS↗
DOE OSTI2026

Biochemical Conversion of Herbaceous Biomass to Renewable Diesel: Biorefinery Marginal Air Quality Impacts and Comparison to Feedstock Production

This study assesses the air quality impacts of an advanced biorefinery that produces renewable diesel blendstock (RDB) from lignocellulosic biomass via aerobic respiration (Davis et al. 2022) by estimating fine particulate matter (PM2.5) impacts from biorefinery emissions. It continues a prior analysis that used a geospatial assessment to identify source regions for biomass feedstocks and studied the impact of feedstock production emissions on air quality (Thind et al. 2022). Thind et al. (2022) identified RDB biorefineries that can use corn stover feedstocks of 2,000; 5,200; and 9,100 dry metric tons per day (DMT/day), based in Iowa, and suggested 7 unique counties can serve as hosts for a biorefinery that draws biomass feedstock from neighboring counties. Given 13 unique county-biorefinery size combinations and two waste lignin end uses at the biorefinery (lignin as a fuel for electricity generation and lignin for pellet production), the air-quality-related sustainability aspects of each of these 26 scenarios are assessed by estimating the annual average impacts of biorefinery emissions on the dispersion and formation of secondary PM2.5 in the atmosphere using a novel reduced-complexity air quality model called the Intervention Model for Air Pollution (InMAP). The 26 biorefinery design combinations help capture how a biorefinery's emissions of air pollutants and their resulting impact on local and regional air quality are influenced by the magnitude of production scale, lignin utilization strategy, and location of a proposed biorefinery. Methods developed in Thind et al. (2022) are applied to estimate the constraints on primary PM2.5 and secondary PM2.5 precursor emissions based on compliance with U.S. Environmental Protection Agency's (EPA's) annual primary National Ambient Air Quality Standard (NAAQS) of PM2.5 (i.e.12.0 micrograms per cubic meter (microgram/m3)) at downwind receptors of a biorefinery. Incremental PM2.5 concentrations caused by the emission of biorefining corn stover into RDB are assessed and compared to those of corn stover production. To illuminate which upstream supply chain stage of renewable diesel production contributes most to air quality impacts, marginal PM2.5 concentrations are compared between both stages at multiple downwind air quality monitor locations. In addition, through a hotspot analysis, we identify the primary contributing factors of emissions within the feedstock production and biorefinery stage operations. In doing so, we provide insights for improving the air pollutant emission-related sustainability of advanced lignocellulosic biofuel production.

09 BIOMASS FUELS↗
DOE OSTI2016

A distributed cellulosic biorefinery system in the US Midwest based on corn stover

Corn stover supply chains in a distributed biorefinery system are explored here. The distributed cellulosic biorefinery uses pre-processed and densified cellulosic feedstock from a geographically separated facility (a depot) as raw material. A network of small-scale depot facilities supplies pre-processed feedstock to a distributed biorefinery. Depot facilities are assumed to be located at existing grain elevators, while distributed biorefineries are located adjacent to coal-fired power plants in areas with high gasoline consumption (urban areas) in the Midwest. The county level corn stover projections in 2022 by the US Billion-Ton Update report (2011) are used to estimate ethanol selling price and greenhouse gas (GHG) emissions of the ethanol fuel. The supply chain for each distributed biorefinery is determined by minimizing the ethanol selling price. Approximately ten distributed biorefineries based on corn stover could be established in the Midwest. Over 700 individual depot facilities participate in supplying the distributed biorefinery systems which collectively can produce greater than 12 hm3 of ethanol (3.3 billion gallons) per year. Ethanol selling price in the distributed system ranges from US$\$ $0.66 to US$\$ $1.03 per liter. Some distributed biorefineries are economically competitive with a centralized biorefinery. However, not every region can support a distributed biorefinery system due to inadequate corn stover availability. Cradle-to-gate GHG emissions of ethanol in the distributed systems are 22.1–46.6 g CO 2 per MJ. The external energy consumption in the depot facilities is the major GHG source. Optimizing process energy use in the depot facility is required to reduce both operation costs and GHG emissions.

09 BIOMASS FUELS↗
DOE OSTI2015

Pilot-Scale Biorefinery: Sustainable Transport Fuels from Biomass via Integrated Pyrolysis and Catalytic Hydroconversion - Wastewater Cleanup by Catalytic Hydrothermal Gasification

DOE-EE Bioenergy Technologies Office has set forth several goals to increase the use of bioenergy and bioproducts derived from renewable resources. One of these goals is to facilitate the implementation of the biorefinery. The biorefinery will include the production of liquid fuels, power and, in some cases, products. The integrated biorefinery should stand-alone from an economic perspective with fuels and power driving the economy of scale while the economics/profitability of the facility will be dependent on existing market conditions. UOP LLC proposed to demonstrate a fast pyrolysis based integrated biorefinery. Pacific Northwest National Laboratory (PNNL) has expertise in an important technology area of interest to UOP for use in their pyrolysis-based biorefinery. This CRADA project provides the supporting technology development and demonstration to allow incorporation of this technology into the biorefinery. PNNL developed catalytic hydrothermal gasification (CHG) for use with aqueous streams within the pyrolysis biorefinery. These aqueous streams included the aqueous phase separated from the fast pyrolysis bio-oil and the aqueous byproduct streams formed in the hydroprocessing of the bio-oil to finished products. The purpose of this project was to demonstrate a technically and economically viable technology for converting renewable biomass feedstocks to sustainable and fungible transportation fuels. To demonstrate the technology, UOP constructed and operated a pilot-scale biorefinery that processed one dry ton per day of biomass using fast pyrolysis. Specific objectives of the project were to: The anticipated outcomes of the project were a validated process technology, a range of validated feedstocks, product property and Life Cycle data, and technical and operating data upon which to base the design of a full-scale biorefinery. The anticipated long-term outcomes from successful commercialization of the technology were: (1) the replacement of a significant fraction of petroleum based fuels with advanced biofuels, leading to increased energy security and decreased carbon footprint; and (2) establishment of a new biofuel industry segment, leading to the creation of U.S. engineering, manufacturing, construction, operations and agricultural jobs. PNNL development of CHG progressed at two levels. Initial tests were made in the laboratory in both mini-scale and bench-scale continuous flow reactor systems. Following positive results, the next level of evaluation was in the scaled-up engineering development system, which was operated at PNNL.

09 BIOMASS FUELS↗
DOE OSTI2015

Jobs and Economic Development Impact (JEDI) User Reference Guide: Fast Pyrolysis Biorefinery Model

This guide -- the JEDI Fast Pyrolysis Biorefinery Model User Reference Guide -- was developed to assist users in operating and understanding the JEDI Fast Pyrolysis Biorefinery Model. The guide provides information on the model's underlying methodology, as well as the parameters and data sources used to develop the cost data utilized in the model. This guide also provides basic instruction on model add-in features and a discussion of how the results should be interpreted. Based on project-specific inputs from the user, the JEDI Fast Pyrolysis Biorefinery Model estimates local (e.g., county- or state-level) job creation, earnings, and output from total economic activity for a given fast pyrolysis biorefinery. These estimates include the direct, indirect and induced economic impacts to the local economy associated with the construction and operation phases of biorefinery projects.Local revenue and supply chain impacts as well as induced impacts are estimated using economic multipliers derived from the IMPLAN software program. By determining the local economic impacts and job creation for a proposed biorefinery, the JEDI Fast Pyrolysis Biorefinery Model can be used to field questions about the added value biorefineries might bring to a local community.

09 BIOMASS FUELS↗
DOE OSTI2017

Optimizing Biorefinery Design and Operations via Linear Programming Models

The ability to assess and optimize economics of biomass resource utilization for the production of fuels, chemicals and power is essential for the ultimate success of a bioenergy industry. The team of authors, consisting of members from the National Renewable Energy Laboratory (NREL) and the Idaho National Laboratory (INL), has developed simple biorefinery linear programming (LP) models to enable the optimization of theoretical or existing biorefineries. The goal of this analysis is to demonstrate how such models can benefit the developing biorefining industry. It focuses on a theoretical multi-pathway, thermochemical biorefinery configuration and demonstrates how the biorefinery can use LP models for operations planning and optimization in comparable ways to the petroleum refining industry. Using LP modeling tools developed under U.S. Department of Energy's Bioenergy Technologies Office (DOE-BETO) funded efforts, the authors investigate optimization challenges for the theoretical biorefineries such as (1) optimal feedstock slate based on available biomass and prices, (2) breakeven price analysis for available feedstocks, (3) impact analysis for changes in feedstock costs and product prices, (4) optimal biorefinery operations during unit shutdowns / turnarounds, and (5) incentives for increased processing capacity. These biorefinery examples are comparable to crude oil purchasing and operational optimization studies that petroleum refiners perform routinely using LPs and other optimization models. It is important to note that the analyses presented in this article are strictly theoretical and they are not based on current energy market prices. The pricing structure assigned for this demonstrative analysis is consistent with $4 per gallon gasoline, which clearly assumes an economic environment that would favor the construction and operation of biorefineries. The analysis approach and examples provide valuable insights into the usefulness of analysis tools for maximizing the potential benefits of biomass utilization for production of fuels, chemicals and power.

09 BIOMASS FUELS↗
DOE OSTI2021

Nth-plant supply: corn stover supplies and costs in a fleet of biorefineries

Feedstock cost and cost variability is expected to increase with the number of biorefineries. To quantify this effect, this spatial-economic analysis simulates feedstock cost and cost variability of an industry based on corn stover as a function of the number of biorefineries. Results are reported for nine scenarios (a base case and sensitivity analysis of four variables – harvest efficiency, sustainability constraints, opportunity cost, and corn grain yield) under deterministic and stochastic simulations, assuming biorefineries using 658 000 Mg (725 000 tons) year- 1 of corn stover in 2019. The resulting supply curves are highly elastic (i.e. little change in cost) for the first 50 of the 121 biorefineries, with price increases in subsequent biorefineries depending on scenario. In the base-case deterministic scenario, weighted-average stover costs are $66 Mg -1 ($60 ton- 1 ), $69 Mg -1 ($62 ton -1 ), and $156 Mg -1 ($142 ton -1 ), at the first, 60th, and 121st biorefineries, respectively. The stochastic simulations, subject to observed 30-year corn yield variability, follow a similar pattern, with price distributions that vary by scenario. The base-case stochastic simulations illustrate minimal cost variability for the first 60 biorefineries, but rapid increases in cost variability in the second half of potential biorefineries, with similar patterns observed in the other scenarios. Of the four variables explored, price was most sensitive to harvest efficiency, followed by sustainability constraints, corn yield, and opportunity cost. Results suggest that, under conventional logistics, about half of the US corn stover resource is reliably available with minimum cost increase and variability. Interactive visualization is available at https://doi.org/10.11578/1828779.

09 BIOMASS FUELS↗
DOE OSTI2023

Supply chain system for a centralized biorefinery system based on switchgrass grown on marginal land in Michigan

The feedstock supply chain of a biorefinery is critical in determining the economic and environmental performance of biofuels. This study investigated various feedstock supply chains for a centralized biorefinery based on different objective functions and how the biorefinery responds to supply chain volatility. For the analysis, a hypothetical centralized biorefinery was supplied by switchgrass grown on marginal lands in Michigan. From an economic standpoint, the minimum biofuel selling price is an important metric of the objective function, and the greenhouse gas mitigation potential is a similarly important metric for global warming impact. A trade-off therefore exists between the economic and environmental performance of biofuels under this system configuration. However, when a carbon tax credit is applied to soil organic carbon sequestration in switchgrass production, the metric of the objective function may not be the key factor in establishing a supply chain as long as it is associated with biorefinery capacity as well as economic or environmental values. Year-to-year fluctuations in cellulosic biomass yield (supply chain volatility) might also prevent the biorefinery from operating at full capacity. Cellulosic biomass pellets can serve as an auxiliary feedstock for the centralized cellulosic biorefinery system to minimize the impacts of supply chain volatility.

09 BIOMASS FUELS↗
DOE OSTI2016

Optimal contracting structure between cellulosic biorefineries and farmers to reduce the impact of biomass supply variation: game theoretic analysis

There is considerable year–to–year variability in the supply of cellulosic biomass used in the production of cellulosic biofuels, yet strategies to mitigate these variations in biofuel development are not well understood. Biorefineries and farmers venturing into the cellulosic biofuel industry will require biomass supply and contracting strategies that can minimize the impact of these large variations. Some studies have proposed biomass pre–treatment and storage to address biomass supply variations. Other studies have used transportation modeling approaches to manage supply variations and select the optimal location of a cellulosic biorefinery. However, storage, pre–treatment, and similar engineering approaches lead to higher costs and have other limitations such as additional infrastructural requirements. There is a gap in understanding how contracting strategies between biorefineries and the biomass suppliers (farmers) can reduce the risks with biomass supply variations. In this study, the contracting structure between biorefineries and biomass suppliers is studied under different market structures for the US Corn Belt. A theoretical framework is then developed to use contracting strategies for mitigating the impact of biomass supply variations. First, the trade–offs between intricately linked components of biomass cost, such as biomass transport, biomass price (incentive) to suppliers, variation in biomass supply, biorefinery size, and alternative feedstock availability are examined. Next, an optimal contracting structure is developed between biorefineries and biomass suppliers using game theoretic analysis. Here, the results show that both the impact of biomass supply variations and the overall biomass cost can be significantly reduced through the use of the optimal contracting strategy between biorefineries and suppliers.

cellulosic biofuel↗
DOE OSTI2020

Assessment of the feedstock supply for siting single- and multiple-feedstock biorefineries in the USA and identification of prevalent feedstocks

An integrated multi-feedstock bioenergy (i.e., biofuel, biopower, or bioproduct) supply system has potential to reduce biomass supply system uncertainties and costs. This study identifies optimal configurations of multi-feedstock biomass-to-biorefinery supply chains and pertinent feedstock combinations based on spatial distribution of feedstock and lowest delivered cost to the biorefinery. We used the Supply Characterization Model (SCM) to allocate feedstock supplies to candidate biorefinery facilities. Model runs were performed for herbaceous energy crops, agriculture residue, and woody biomass available in 2017, 2022, 2025, and 2030 as estimated by the Policy Analysis System (POLYSYS) and Forest Sustainable and Economic Analysis Model (ForSEAM) models. Three feedstock supply scenarios were compared: (a) an herbaceous scenario: switchgrass, miscanthus, biosorghum, and corn stover; (b) a woody scenario: coppice wood, noncoppice wood, whole trees, and forestry residues, and (c) a mixed scenario: a combination of all feedstocks in herbaceous and woody scenarios. By 2030 the analyses predicted that 323, 168, and 473 biorefineries were sited in the herbaceous, woody, and mixed scenario, respectively, in the conterminous USA. Feedstock mixes supplied to the biorefineries were mostly dominated by a single feedstock. The most prominent feedstock mixes identified were: (1) switchgrass and miscanthus; (2) coppice and noncoppice wood; and (3) coppice wood, noncoppice wood, switchgrass and miscanthus. Biorefineries using multi-feedstock would be beneficial for growth of bioeconomy, however flexible and cost-effective conversion platforms should be developed to efficiently utilize multiple feedstocks. This analysis identifies biorefinery locations and feedstock supply mixes while minimizing delivered feedstock costs based on spatial and temporal feedstock availability.

09 BIOMASS FUELS↗
DOE OSTI2020

BioSTEAM-LCA: An Integrated Modeling Framework for Agile Life Cycle Assessment of Biorefineries under Uncertainty

Biorefineries will play a critical role in sustainable bioeconomies, but projections of their environmental impacts vary widely. A core challenge with life cycle assessments (LCAs) of biorefineries is that they are often disconnected from biorefinery design, simulation, and techno-economic analysis (TEA). This lack of integration is a barrier to early stage technology and process evaluations, reducing consistency and transparency across sustainability indicators while limiting our understanding of the relative importance of individual factors (e.g., design decisions, greenhouse gas emission accounting procedures), how these factors interact, and trade-offs or synergies with process economics. In this study, we propose a new agile LCA framework, BioSTEAMLCA, which layers onto BioSTEAM (Biorefinery Simulation and Techno-Economic Analysis Modules, which automates biorefinery design, simulation, and TEA) to characterize the environmental impacts of biorefineries across a landscape of designs, technology performance assumptions, and contexts. Inventory databases and impact assessment methods are integrated to enable flexible user defined LCA system models, and the implications of uncertainties throughout the production system are characterized via Monte Carlo simulation. To demonstrate the capabilities of BioSTEAMLCA, we present a case study for sugarcane ethanol production. Overall, BioSTEAM-LCA enables computationally efficient, agile gate-to-gate LCA to evaluate biorefinery processes, the production of candidate biofuels and bioproducts, and trade-offs among productivity, economics, and environmental impacts under uncertainty.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Impacts of uncertain feedstock quality on the economic feasibility of fast pyrolysis biorefineries with blended feedstocks and decentralized preprocessing sites in the Southeastern United States

Abstract This study performs techno‐economic analysis and Monte Carlo simulations (MCS) to explore the effects that variations in biomass feedstock quality have on the economic feasibility of fast pyrolysis biorefineries using decentralized preprocessing sites (i.e., depots that produce pellets). Two biomass resources in the Southeastern United States, that is, pine residues and switchgrass, were examined as feedstocks. A scenario analysis was conducted for an array of different combinations, including different pellet ash control levels, feedstock blending ratios, different biorefinery capacities, and different biorefinery on‐stream capacities, followed by a comparison with the traditional centralized system. MCS results show that, with depot preprocessing, variations in the feedstock moisture and feedstock ash content can be significantly reduced compared with a traditional centralized system. For a biorefinery operating at 100% of its designed capacity, the minimum fuel selling price (MFSP) of the decentralized system is $3.97–$4.39 per gallon gasoline equivalent (GGE) based on the mean value across all scenarios, whereas the mean MFSP for the traditional centralized system was $3.79–$4.12/GGE. To understand the potential benefits of highly flowable pellets in decreasing biorefinery downtime due to feedstock handling and plugging problems, this study also compares the MFSP of the decentralized system at 90% of its designed capacity with a traditional system at 80%. The analysis illustrates that using low ash pellets mixed with switchgrass and pine residues generates a more competitive MFSP. Specifically, for a biorefinery designed for 2,000 oven dry metric ton per day, running a blended pellet made from 75% switchgrass and 25% pine residues with 2% ash level, and operating at 90% of designed capacity could make an MFSP between $4.49 and $4.71/GGE. In contrast, a traditional centralized biorefinery operating at 80% of designed capacity marks an MFSP between $4.72 and $5.28.

09 BIOMASS FUELS↗