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ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Biomass derived energy Southwest KS Project Kansas Renewable Energy Conference September 25-26, 2007 Topeka KS.

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Presentation on theme: "ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Biomass derived energy Southwest KS Project Kansas Renewable Energy Conference September 25-26, 2007 Topeka KS."— Presentation transcript:

1 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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

2 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Abengoa Bioenergy

3 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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. Abengoa overview

4 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Ethanol production from vegetal raw materials (cereal and biomass) Abengoa Bioenergy Abengoa Bioenergy Bioproducts Abengoa Bioenergy Business Renewable Biofuel Null CO 2 emissions DGS – Animal feed CO 2 – Industrial applications Ethanol ETBE Direct blending Hydrogen Cereal Biomass

5 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Production Process Technology based in fermentation of sugars Sugar (glucose)+ AirCO 2 + Ethanol C 6 H 12 O 6 + O 2 3 CO C 2 OH 6 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 C 6 and C 5 sugars Level of Complication Feedstock price Each feedstock yields different co-products

6 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Feedstock Preparation Transformation into sugars FermentationDistillation Collection Sugar case Milling and filtering Distillation Fermentation C6 Cereal case Cooking Distillation Fermentation C6 Saccharification Liquefaction Milling Feedstock cleaning Lignocellulosic Biomass case ConditioningMilling Separation L/S Termochemical hydrolysis Distillation 2nd Enzymatic Hydrolysis Fermentation C6 Fermentation C5 Production Processes

7 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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. Feedstocks

8 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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) Feedstocks

9 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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) Technology

10 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 Technology

11 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 Technology

12 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 Technology

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

14 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Abengoa Bioenergy plans to be a leader in commercialization of cellulosic ethanol production Objective Build first commercial scale cellulose facility by 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

15 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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

16 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 DOE integrated biorefinery proposal

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22 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Biomass available in Kansas 38 million tons per year DOE integrated biorefinery proposal, cont

23 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Abengoas 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 DOE integrated biorefinery proposal, cont

24 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Technical process DOE integrated biorefinery proposal, cont 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.

25 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Oil Displacement From 245,000 BD metric tons biomass DOE integrated biorefinery proposal, cont 386,721 barrels of oil displaced

26 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 DOE integrated biorefinery proposal, cont

27 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 DOE integrated biorefinery proposal, cont

28 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 DOE integrated biorefinery proposal, cont

29 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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 DOE integrated biorefinery proposal, cont

30 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Wheat versus corn/milo residue and switchgrass

31 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D 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

32 ABENGOA BIOENERGY ABENGOA BIOENERGY R&D Abengoa Bioenergy Thank you Question?


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