132. Biomass derived energy Southwest KS Project
Sector Eléctrico
Biomass derived energy Southwest KS Project
Kansas Renewable Energy Conference
September 25-26, 2007
Topeka KS
Thomas W. Robb, Ph.D.
Abengoa Bioenergy R&D

133. Sector Eléctrico
Abengoa Bioenergy

134. Abengoa overview Sector Eléctrico
Abengoa is a technological company that applies innovative solutions for sustainable development in infrastructures, environment and energy sectors. It is present in over 70 countries where it operates through its five Business Units: Solar, Bioenergy, Environmental Services, Information Technology, and Industrial Engineering and Construction.

135. CO2 – Industrial applications
Sector Eléctrico
Abengoa Bioenergy Business
Abengoa
Bioenergy
Ethanol production from vegetal raw materials (cereal and biomass)
Renewable Biofuel
Null CO2 emissions
DGS – Animal feed
Cereal
CO2 – Industrial applications
ETBE
Ethanol
Direct blending
Biomass
Hydrogen
Bioproducts

136. Technology based in fermentation of sugars
Sector Eléctrico
Production Process
Technology based in fermentation of sugars
Sugar (glucose)+ Air CO2 + Ethanol
C6H12O6 + O2 3 CO2 + 3 C2OH6
Yeast
Used feedstock is transformed into sugars, the process would change depending on the chemical composition:
Sugar beet or sugar cane: direct fermentation
Cereal: starch, previous saccharification (enzymes)
Lignocellulosic biomass: cellulose and hemicellulose. Hydrolysis to break long chains and produce C6 and C5 sugars
Level of
Complication
Feedstock price
Each feedstock yields different co-products

137. Production Processes Feedstock Preparation Transformation into sugars
Sector Eléctrico
Production Processes
Feedstock Preparation
Transformation into sugars
Fermentation
Distillation
Collection
Sugar case
Milling and filtering C6
Cereal case
Cooking
Saccharification
Liquefaction
Milling
Feedstock cleaning
Lignocellulosic Biomass case
Conditioning
Separation L/S
Termochemical hydrolysis
2nd Enzymatic Hydrolysis C5

138. Feedstocks Abengoa Bioenergy Goals
Sector Eléctrico
Feedstocks
Abengoa Bioenergy Goals
Promote development of seeds with improved characteristics to establish win-win contracts with farmers, link certified seeds to the contracts.
Abengoa Bioenergy is establishing strategic alliances with seeds
companies to develop/improve specifics crops
Promote better agronomic practices under long term contracts to
increase farm income
Promote energy crops for ethanol production
Abengoa Bioenergy is working closely with research centers to promote the development of crops for ethanol production.
Abengoa Bioenergy is helping governments define policies and R&D programs to promote energy crops.

139. Sector Eléctrico
Feedstocks
Objective
Taylor made energy crops for the different conversion pathways and for particular regions ensuring sustainability and environmental quality. Main crops characteristics:
Domestic crops, high starch and biomass yields per hectare,
stress tolerances (abiotic, disease…)
Minimum inputs maintaining sustainability
Composition to maximize the ethanol
Ensure sustainability and environmental quality
(from…analysis of microbial communities underlying soils…
to formulation of management guidelines for biomass
removal)

140. Technology Cereal technology – current situation
Sector Eléctrico
Technology
Cereal technology – current situation
All Abengoa Bioenergy plants are currently running on cereals
Yields varying depending on cereal used
DDGs produced containing 30% protein and 10% humidity
Cereal technology – Future situation
Objective
Increase competitiveness of the production facilities. Abengoa Fuel and Feed (AFF) process to be patented by Abengoa Bioenergy
Steps
Decrease amount of residual starch (minimum facility modifications)
Increasing protein content (>40%)
Increase digestability
Increase the quality of the co-product (DDGs)

141. Technology Enzymatic hydrolysis technology – current situation
Sector Eléctrico
Technology
Enzymatic hydrolysis technology – current situation
Abengoa Bioenergy has develop a proprietary fractionation technology for biomass processing.
Pilot scale plant in York, (Nebraska, US) to validate our biomass fractionation process and integrate downstream systems
Demonstration plant in Babilafuente (Salamanca, Spain) to validate biomass to ethanol enzymatic technology at a commercial scale.
Enzymatic technology – Future situation
Objective
Competitive production of ethanol from biomass.
Steps
Complete the process engineering development demonstrations phases.
Build first of a kind commercial facility after the
demonstration of the technology in Salamanca and
Nebraska
Valorization of all biomass fractions

142. Technology Steps (continue)
Sector Eléctrico
Technology
Steps (continue)
Research in the biological deconstruction of the biomass to produce tailor made enzyme mixes for each specific case:
Determine fundamental physical and chemical factors in the recalcitrante of lignocellulosic biomass to processing
Understand cellulase and cellulosome
Develop new enzymatic systems to soften termochemical pretreatment conditions
Advance in the sugar fermentation to ethanol through the engineering of microbial systems to achieve:
high yield with complete sugar utilisation, minimal by- product formation, and minimal loss of carbon into cell mass.
high final ethanol concentration
tolerance to inhibitors present in hydrolysates
higher overall volumetric productivity, especially under high solids conditions

143. Sector Eléctrico
Technology
Biomass gasification and synthesis (BtL) technology –current situation
Available catalysts are not productive enough to make the
process economically feasible.
Low conversion per pass
Mixed alcohols product with low ethanol selectivity
Several existing technologists licensing gasification processes
for syngas production for further chemical synthesis.
Catalysts development programs in European research centers,
combined with process design and analysis.
Recently granted by the US-DOE a program (3 MM$) for
synthesis catalysts development

144. YTD Production Capacity
Sector Eléctrico
YTD Production Capacity
Production Facilities in EU
Production Facilities in U.S.
EU (Mgal)
Production
Construction *
US (Mgal)
Production
Construction •
Cartagena (40 Mgal) •
La Coruña (50 Mgal) •
York, NE (55 Mgal) •
Portales, NM (30 Mgal) •
Salamanca (52 Mgal) •
AB France (65 Mgal) •
Colwich, KS (25 Mgal) •
Ravenna, NE (88 Mgal)
Abengoa Bioenergy is the only international producer of ethanol

145. Build first commercial scale cellulose facility by 2011
Sector Eléctrico
Abengoa Bioenergy plans to be a leader in commercialization of cellulosic ethanol production
Objective
Build first commercial scale cellulose facility by 2011
15 million gpy from biomass, 85 million gpy from starch (hybrid facility)
Cornerstones
Two biomass facilities now underconstruction
York, NE pilot plant (operational 2006) will demonstrate biomass fractionation and fermentation technology
Salamanca, Spain facility (2 mgpy - operational 2007) will demonstrate enzymatic hydrolysis technology

146. DOE integrated biorefinery solicitation
Sector Eléctrico
DOE integrated biorefinery solicitation
Overview
DOE will award of up to 40% of the cost of a biorefinery facility ($76.8 million)
Award criteria:
Facility must be able to utilize 700 bone dry metric tons of biomass per day
Facility must be replicable and proposal to include appropriate deployment plan of the proposed technology
After construction costs are paid, the facility must be profitable without subsidies
Additional merit points given for:
Significant showing of state support
Energy generation from multiple sources feedstocks
Barrels of oil displaced

147. Risk mitigation for biomass availability and site selection
Sector Eléctrico
DOE integrated biorefinery proposal
Risk mitigation for biomass availability and site selection
Risk factors
Inclimate weather during biomass harvest period
Due to this risk factor, Eastern US corn-belt was not considered as a viable location for plant location until one-pass harvest technology is available (potential for one in seven years for biomass harvest to be limited)
Biomass crop residue abundance
As the DOE is focused on cereal crop residues, areas such as California and South East US (wood residue) were not considered as viable locations for proposal
Multiple sources of biomass
Multiple biomass sources demonstrate plant replicability over a wider geographic area
Multiple biomass sources with harvest periods during different times of the year reduce risk of biomass harvest being compromised by bad weather
Multiple biomass sources and harvest times spread harvest machinery investment and will reduce feedstock costs

148. Sector Eléctrico

149. Sector Eléctrico

150. Sector Eléctrico

151. Sector Eléctrico

152. Sector Eléctrico

153. Biomass available in Kansas 38 million tons per year
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Biomass available in Kansas 38 million tons per year

154. Abengoa’s hybrid plant concept
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Abengoa’s hybrid plant concept
35 million bushels grain facility
88 million gallons ethanol
290,000 tons feed co-product
245,000 BD metric tons biomass (315,000 short tons-as is)
400 BD metric tons/day
15 million gallons ethanol
300 BD metric tons/day
Syngas production
1,597,200 MMBTU (syngas+flue gas)
100% steam needs of biomass processing
~30% steam needs of grain to ethanol processing
Syngas can be utilized for production of chemical intermediates
Opportunity to leverage infrastructure and many plant operations

155. Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Technical process
Enzymatic Hydrolysis (EH) will convert biomass to ethanol, lignin and biomass animal feed.
- The EH technology is being developed in house and will be tested and improved at the facilities in York, NE (pilot plant) and Salamanca (demo plant).
- Coproduct development (lignin and biomass animal feed) is being performed and will contribute to the overall profitability of the facility.
Gasification will convert biomass to syngas, which will be combusted for steam generation.

156. Oil Displacement From 245,000 BD metric tons biomass
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Oil Displacement From 245,000 BD metric tons biomass
386,721 barrels of oil displaced

157. Strong showing of state support
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Strong showing of state support
State government
Attractive incentive package
Strong governmental support
Producer organization support
Kansas Farm Bureau
Kansas Wheat Growers association
Kansas Milo Growers association
Kansas Corn Growers association
Kansas BioAuthority
Kansas Association of Ethanol Processors

158. Biomass logistics – P&L cornerstone
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Biomass logistics – P&L cornerstone
Biomass inputs
50 mile radius of plant site
65% wheat straw, 20% milo residue, 15% corn stalks
Opportunistically use other residues such as gin trash, wood chips, etc.
Areas evaluated = ~5% of total available
80 to 85% of input needs
Producer harvests and stores material field side
Abengoa collects material as needed
15 to 20% of input needs
Producer delivered material to plant site

159. Contracted at least one year in advance
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Biomass economics
80 to 85% of material
Contracted at least one year in advance
Crop residue is valued at $10/short ton in the field
Added to the $10/ton
Custom rates for harvesting
Custom rates for transporting/stacking at field side
Storage fee dependant on amount of time between harvest and Abengoa collection – to include competitive insurance rate and weather protection
$10 plus rates above = price paid for biomass at field side
15 to 20% of material
Spot market pricing

160. Biomass economics What $10/ton means to biomass producers
Sector Eléctrico
DOE integrated biorefinery proposal, con’t
Biomass economics What $10/ton means to biomass producers
Of the $10/ton, between $3 to $4 needs to be returned to the soil for nutrient loss
Producer net will be $6 to $7 per ton
1 ton/acre net = $6 to $7 per acre
2.4 ton/acre net = $14.4 to $16.8 per acre
5 ton/acre net = $30 to $42 per acre
Many Kansas producers live on $25 per acre profit

161. Wheat versus corn/milo residue and switchgrass
Sector Eléctrico
Wheat versus corn/milo residue and switchgrass

162. Cost effective enzymes Pentose to ethanol organism (s)
Sector Eléctrico
Needs to make cellulosic ethanol cost effective/ competitive with grain ethanol
Process
Cost effective enzymes
Pentose to ethanol organism (s)
Fractionation process
Plant design and operational learning curve
Feedstock
High density balers
One-pass harvesting systems
Storage infrastructure and systems to maintain quality
Improved genetics of feedstock varieties
Energy efficient harvesting systems
Transportation infra- structure and biomass friendly regulations

163. Abengoa Bioenergy Thank you Question? www.abengoabioenergy.com
Sector Eléctrico
Abengoa Bioenergy
Thank you
Question?