The Rapid Evolution of Ethanol as a Universal Gasoline ...Ethanol Molecular Sieve 10 Distillation...
Transcript of The Rapid Evolution of Ethanol as a Universal Gasoline ...Ethanol Molecular Sieve 10 Distillation...
The Rapid Evolution of Ethanol as a Universal Gasoline
Blending Component
Gene Peters Consulting
The National Corn-to-Ethanol Research Center
Center of Excellence for Ethanol Research
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Yeast7
Hopper
Hammer Mill Slurry Tank Jet
Cooker
CO2
Enzyme4
Enzyme4
DenaturedEthanol
MolecularSieve
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DistillationSystem
CentrifugeEvaporator
(Syrup)Drum Dryer
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Liquefaction
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Dried DistillersGrain with Solubles
The Corn to Ethanol ProcessNational Corn-to-Ethanol Research Center, SIUE
>2%Gasoline
Added
(200 Proof )
(190 Proof )
(WholeStillage)
Start Here
Ammonia
Steam
(Recycled Water)
Urea
(Cooling)
( Wet Cake)
(ThinStillage)
Water
(Heating)
Enzyme 6
TM
© 2007 All Rights Reserved
Beer Well
Fermentation
8
Sulfuric Acid
• Flexible and capable of operating with a variety of production processes and feedstocks.
• Performs near-term industrial research.
PILOT PLANT: Dry Grind and Wet MillPILOT PLANT: Dry Grind and Wet Mill
• Training center for personnel in the ethanol and biofuels industry.
• USDA theoretical production data.
Workforce Development Program Workforce Development Program
- NCERC is training the biofuels workforce of tomorrow -
• Current Ethanol domestic production 10.2 billion gallons/ year
• Projected 13 billion gallons/ year by 2009
• 171 plants operating in 25 states• 33 plants still under construction• 5 plant expansions
The U.S. has 150 crude oil Refineries operating in 33 states with a combined capacity of 17.7MMB/D….…or 271 billion gal/yr.
Both the corn refining and the petroleum refining industries……
•Use a raw material possessing stored energy from the sun
Both industries……•Use catalysts and process chemicals to promote necessary reactions to produce transportation fuel from that raw material.
•For crude refining, inorganic catalysts, such as cobalt, molybdenum, platinum and acids.
•For corn refining, organic catalysts such as enzymes and yeast.
Both industries……•Deal with byproducts that pose handling or environmental issues but are key to overall economic performance of the facility.
•DDGS for a corn refinery
•Petroleum coke and sulfur for a crude oil refinery
•And carbon dioxide for both
Both industries……
•Make key motor gasoline components for blending finished grades of motor gasoline (“mogas”).
Petroleum Refinery
CornRefinery
Gasoline Components
Ethanol
DistributionTerminals
Service Stations
Motor Gasoline Octane
Ethanol 112
Isooctane 100
“Regular” 87
n-heptane 0
Octane is the measure of the auto-ignition resistance of gasoline in an internal combustion engine.
.
87 octane gasoline performs the same as a blend of 87% isooctane and 13% n-heptane.
1,058950
690 683 679 633
483
270
785
922
0
200
400
600
800
1,000
1,200
Energy Density of FuelsThousand Btu per ft3
< 70% Gasoline Equivalence
United States Gasoline Production
•U.S. gasoline demand is 9.1MMB/D or 140 billion gal/yr
•As of late 2008, Ethanol is 0.7 MMB/D or 10 billion gals/yr
•75% of total U.S. gasoline currently is E-10
•With 75% of the U.S. gasoline pool currently as E-10, 0.7MMB/D of gasoline otherwise refined from crude oil has already been replaced with ethanol from corn.
•Blending 100% of U.S. gasoline to E-10 would replace an additional 0.2MMB/D of crude oil-derived gasoline.
•But by the end of 2009, it is projected that ethanol production will reach 13.5 BGY, or 0.9MMB/D, which is 10% of the total US gasoline demand.
•Thus by 2010, ethanol will hit the “blending wall”.
Energy Independence and Security Act of 2007
•2008 9 BGY from corn
•2015 15 BGY from corn
•2022 36 BGY total renewable fuels• 15 BGY minimum from corn, but not a max.• Up to 21 BGY from “advanced” sources (Biomass, cellulosic), and can be “others”, such as biodiesel.
Policies that will impact ethanol future….
• Energy Independence and Security Act of 2007• Auto industry---Flex Fuel vehicle production and
ethanol concentrations > 10% for existing fleet• Retail Issues---E-10, E-20, E-XX, E-85• Distribution Issues---evolution to pipeline• Blender credit
U.S. Motor Vehicle Fuel Use, 2008
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50
100
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Motor Gasoline (all uses) incl ethanol Distillate Fuel (transport use only)
Ethanol Share ~4.2%(gasoline equivalent)
Source: CRS projections based on U.S. DOE, Energy Information Service, Annual Energy Outlook 2008
Biodiesel share ~0.9%
Billion Gallons
Typical Yield from One Bushel of Corn
-1 bushel of corn (56 lbs.) + 17 lbs. DDGS
+ 17 lbs. CO2
+ 2.8 gallons ethanol
=
Ethanol Yield (gal/bu)
2.4 2.522.72
3.1
1.51.71.92.12.32.52.72.93.13.3
1984 1994 2004 2014
•Current conversion rate (2006) is 2.81 gallons/bushel
•New hydrolysis & fermentation processes will allow producers to get more ethanol out of a bushel
NCERC Crop Research Prioritization StrategyUS Biomass Sources
ABUNDANT & AVAILABLE
ECONOMICAL
U.S. Biomass SourcesU.S. Biomass Sources
Corn Starch
Switch Grass
Paper
Sugar Cane
CottonwoodsStover
Wood Chips
Corn Fiber
Ethanol from Corn = Gasoline from Light Sweet Onshore Louisiana Crude Oil
Ethanol from Dry Fractionated Corn = Gasoline from Athabasca Tar Sands
Ethanol from Cellulose = Gasoline from Colorado Oil Shale
So why is corn the ethanol feedstock of choice at this time?
Ethanol from Sugar Cane = Gasoline from Uinta Basin Crude
Biomass or Cellulosic Ethanol
•Cellulose 30-50 % plant matter, produces C6 sugars (glucose)
•Hemicellulose 20-30 % plant matter, produces C5 sugars (xylose)
•Lignin 15-30 % plant matter, does not convert to ethanol
•Pretreatment of cellulose is difficult and expensive
•Requires high quantities of complex enzymes
Food and Fuel Forum
Agricultural Business Council of Kansas City
October 23, 2008Congressional Research Service•Growth in ethanol industry will reduce corn available for animal feed
•Non-farm costs are 80 percent of retail food prices
•Energy efficiency of ethanol from corn much higher than gasoline from crude oil
•Whispered concerns about cellulosics economic viability
National Corn Growers Association•Non-farm costs are 80 percent of retail food prices
•Available technology will supply adequate corn to meet all needs with low environmental impact
American Bakers Association•Increases in corn acreage will begin to limit acreage to wheat
•Foreign concerns of genetics is limiting research for wheat yield increases
Ethanol Uses an Increasing Share of U.S. Corn Production
0%
25%
50%
75%
100%
1960 1970 1980 1990 2000 2010
Perc
ent o
f Tot
al U
se
Source: USDA and Renewable Fuels Association; www.ethanolrfa.org.
FeedEthanol
Processed Food
Exports
80%35%
35%
2008
0%
25%
50%
75%
100%
Farm Gate Elevator Wholesale Processor Retail
Farm Share of Market Price Declines as Commodity Moves to Retail Outlet
Source: Retail Shares, USDA; all other categories are hypothetical representations by CRS.
Raw CommodityShare
100%
Labor
Other
Retailing
19.5%
TransportEnergy
Value is Added from Farm to Retail
Corn to Ethanol -- Energy CycleNatural Gas Solar Energy
Fertilizer Production
Corn Farming
FertilizersNG / LPG ElectricityDiesel Fuel
Corn TransportationDiesel Fuel
Ethanol Production
Ethanol TransportationDiesel Fuel
CoalNG / LPG Electricity
Ethanol at Refueling Stations
0.74 million Btu of Fossil Fuel Energy
Produces
1.0 million Btu of Ethanol
Efficiency Rate of 1.35
Animal Feed
Fossil Energy Balance –Ethanol, Gasoline, Bio-Diesel, and
Diesel10.3
8
2 2 1.67 1.35 1 0.85 0.8
0
1
2
3
4
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6
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8
9
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Cellulosic eth.
Eth. (sugar c
ane)
Eth. (wheat)
Eth. (sugar b
eets)
Biodeisl
Eth. (corn)
Eth. (sorghum)
Diesel (crude oil)
Gas. (crude oil)
Source: Worldwatch Institute, “Biofuels for Transportation, Global Potential and Implications for Sustainable Agriculture and Energy in the 21st Century”, Table 10-1, page 127, June 2006.
1.6 - 1.7 ?
Corn Yield (bu/acre)
177160.4
138.6106.7
020406080
100120140160180200
1984 1994 2004 2014
Bushels of Corn per Pound of Fertilizer, 1966-02
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0.100
0.200
0.300
0.400
0.500
0.600
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1969 1974 1979 1984 1989 1994 1999
Bus
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Fertilizer Efficiency
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Bushels
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Bushels of Corn per Pound of Pesticides, 1991-02
Pest Control Efficiency
30 lbSeed corn
< 1 galPesticides
3 galFuel
50 lbPotash
50 lbPhosphorus
200 lbNitrogen
11,200 pounds of corn (200 bushels)
560 gallons of ethanol
and
3600 pounds of distillers grains
Inputs per acre…
87% of U.S. corn acreage is non-irrigated
Higher Corn Prices Expand the Zone of Profitable Corn Production
Corn & Soybean
BeltHard Winter Wheat Belt
Spring Wheat Belt
Cotton Belt
Food and Fuel Forum
Agricultural Business Council of Kansas City
October 23, 2008
Consensus:
The United States needs an energy policy.
Finally, just a calibration……..
America burns 140 billion gallons/year of gasoline.
That’s 380 million gallons/day…..
….or a quarter million gallons each second.
For several months, gasoline was more than $2.00/gallon higher than costs would justify.
For the $1 billion excess we were paying out each dayover that period…
…know that someone can build one of these babies:
And building them, they are!!
Thank you!!Gene Peters Consulting