Wes Bolsen – CMO & VP The Coskata Process – The Best of ... · Source: RFA; U.S. Congress. U.S....
Transcript of Wes Bolsen – CMO & VP The Coskata Process – The Best of ... · Source: RFA; U.S. Congress. U.S....
The Next Generation of Ethanol
Wes Bolsen – CMO & VPThe Coskata Process – The Best of Both Worlds
Biofuels Journal WorkshopOctober 30th, 2008
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2002 2007 2012 2017 2022
Other advanced
Cellulosic
Conventional (corn)
Source: RFA; U.S. Congress
U.S. biofuel consumptionBillion gallons
Ethanol has grown into a large marketEthanol represents 6% of gasoline pool and > $20 billion market in 2008Volume growth of 25% per year since 2003Industry has added over 60 plants and 4.5 billion gallons of capacity in the last 5 years
Government support will stimulate continued growthEnergy Act of 2007 requires 36 billion gallons:
• Corn capped at 15 billion • At least 21 billion from “advanced
biofuels, of which 16 billion must be from cellulosic biofuels
Credits, tariff and R&D grants further support domestic industry growth
Biofuels are a large and growing industry in the U.S.
RFS mandate
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2nd generation ethanol expands the industry beyond corn
Cellulosic ethanol can take industry to the next level
Projected biomass sources
100%= 1.3 billion dry tons
Corn (6%)
Crop residues (31%)
Forest resources(27%)
Energy crops(28%)
Other(8%)
Second generation technology unlocks the potential of new feedstock sources
Using cellulosic materials could displace significant amounts of gasoline (Billion ton report estimates over 1/3rd)
Use of locally grown resources enhances energy security
Source: “Biomass as Feedstock for a Bioenergy and Bioproducts Industry: Technical Feasibility of a Billion Ton Annual Supply,” 2005, DOE and USDA
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Biomass
19% Reduction 28%
Reduction
52% Reduction
86% Reduction
78% Reduction
Gasoline
Natural Gas
BiomassCurrent Average
Cellulosic Ethanol
Corn Ethanol
Petroleum
Sugarcane EthanolBiomass
Cellulosic ethanol reduces GHGs even further
Up to 96%Reduction*
Biomass
* As independently estimated by Michael Wang and Argonne National Labs in a GREET study; Based on forest residuals
Source: Wang et al, Environ. Research Letters, May 2007; Wang et al, Life-Cycle Energy Use and GHG Implications of Brazilian Sugarcane Ethanol Simulated with GREET Model, Dec. 2007. As presented by DOE August 2008
DOE analysis targets GHG reduction from ethanol
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Production costsOperating costs, USD/gallon*
<1.00
1.33~1.00~1.50
~1.60
~2.60
Gasoline at $100/bbl**
Source: DOE; NREL; Coskata estimates
Cellulosic ethanol economics can be very competitive
Brazilian ethanol(Cane @ $120/ton)
DOE cellulosic ethanol 2012 target
Early commercial target
Corn ethanol (Corn @ $4/bu)
* Costs at plant gate, not including capital recovery. Gasoline cost assumes $7/bbl (16 c/gal) refining uplift. Corn ethanol assumes 2.9 gal/bu yield. Brazilian ethanol assumes 170 gal/ton yield; DOE target as reported in presentation of August 20, 2008.
** No adjustment for energy content made given no mileage loss assumed at an E10 blend level
Gasoline at $60/bbl**
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• Fuels• Power• Bio-products
Biochemical Conversion• Enzymatic
hydrolysis• Fermentation
Thermochemical Conversion• Gasification • Catalysis
Biomass
• Energy crops• Residue harvesting
2nd generation biofuels involve several technologies
DOE is targeting 2 major pathways for cellulosic biofuels
Coskata’s Hybrid Gasification + Fermentation (thermo/bio) technology combines the best of both routes
Source: DOE Biomass program presentation to Governor’s Ethanol Coalition, Aug. 20, 2008
Products
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Source: Press clippings
Gen 2 technologies are advancing to commercialization
* Includes announcements for all cellulosic biofuels facilities except algae biodiesel. May not be exhaustive
Over 40 demonstration or pilot scale cellulosic biofuel plants worldwide as of August 2008
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Cellulosic ethanol will represent large markets
A 16 billion gallon mandated cellulosic ethanol industry in the U.S. =
Feedstock (at $0.50/gal) $8 billion
Sales (at $2.50/gal) $40 billion
Capex (at $4.00/gal) $64 billion
Global pesticide industry
Markets of comparable size
10 large world class oil
refineries*
Brazilian sugarindustry**
Source: US Bureau of Economic Analysis; Phillips McDougall; FAPRI
* ~500,000 barrel/day in scale** Assumes 32 million metric tons @ $263/ton as per FAPRI 2007/08
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Coskata’s 3 step process is flexible and efficient
FlexibleWide variety of feedstocksScalable around syngas output
EfficientYields over 100 gal/dry ton biomassProduces only fuel grade ethanol
AffordableProduction costs under $1/gallon
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Step 1: Gasification has many advantages
Fully utilizes feedstock -chemical bonds from all components are ‘cracked’ to breakdown feedstock into synthesis gas (“syngas”, CO, H2 and CO2)
Provides feedstock flexibility –can use any carbonaceous feedstock
Multiple technologies proven at scale
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Step 2: Biofermentation uses proprietary microorganisms and bioreactor designs
Microorganisms utilize the chemical energy of the syngas to selectively produce ethanol
Proprietary microorganisms consume both CO and H2, allowing efficient conversion across the range of H2:CO ratios 6 CO + 3 H20 C2H5OH + 4 CO26 H2 + 2 CO2 C2H5OH + 3 H20
Proprietary bioreactor designs encourage maximum productivity
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Microorganisms and bioreactors are highly efficient
Exclusive license to many strains of anaerobic bacteriaAble to convert both CO and H2Selectively produce ethanolRequire typical impurities found in biomass derived syngasAble to operate at low or moderate pressures and low temperaturesVarious strains can selectively produce ethanol and/or other organics (butanol, butyric acid, propanol)
Microorganisms
Patents pending for several proprietary designsEncourage maximum mass transfer and productivityHighly scalable
Bioreactors
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Step 3: Options exist for separation
Ethanol is separated out of solution and converted to fuel-grade ethanol (99%+ concentration)
Recoverable heat is sufficient to complete traditional distillationMembrane separation has advantages• For co-location applications,
membrane separation offers energy integration benefits
• Coskata has proprietary co- developed membrane separation technology
• Provides significant energy savings (up to 50% vs. traditional distillation)
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Coskata process is ready for commercialization
Microorganism productivity has
surpassed best case economic threshold
Commercial productivity EtOH productivity, g/L/hr
Best case economics (<$1/gallon)
Base case economics ($1/gallon)
Minimum economic threshold (corn)
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Coskata has the leading technology pathway
Gasification +
Enzymatic Chemical
Feedstock Flexibility No Yes Yes
Ethanol Specificity Yes No Yes
Yield*(gal/dry ton) ~55-85 76-89** >100
Capital Cost (US$ Mil. for 100MMGY)* $450-$700 $400-$700 ~$400
Operating Cost (US$/gal)* $2.00-$5.00 $1.25-$2.50 <$1.00
* Best estimates from publicly available data** Chemical catalysis yield estimate from 2012 NREL targets (76 for ethanol, 89 for all alcohols)
Source: Press; DOE; Company reports
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Coskata has a two pronged commercialization strategy
License technology to development partners including• Feedstock suppliers• Chemical manufacturers• Petroleum companies• Ethanol distributors/blenders• Project developers
Enables rapid scale up of technologyEstablishes Coskata as the industry enabler
License
Own
Build, own and operate facilitiesEncourages continual process improvementsAllows Coskata to capture full economic benefits of its technology
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Coskata is proceeding to commercial scale
Lighthouse (Q1 2009)Commercial DemonstrationMadison, Pennsylvania
• Minimum engineering scale (linear scale-up to commercial commercial production)
• Front-end biomass gasifier• Will test multiple commercial-
commercial-scale bioreactor and and separations designs
Flagship (2011)Commercial ProductionLocation TBD
• 50-60 MM Gallons / yr• Multiple gasifiers that process
process ~1500 dry tons/day of of biomass
• ~ $1.00/gallon production cost cost
• $4-5/ gallon of capacity CAPEX CAPEX (plant 1 economics)
Horizon (Q1 2008)Integrated ProcessingWarrenville, IL
Integrated processing system system with methane thermal thermal reformer, multiple multiple bioreactor designs, designs, and distillation
Currently Operating Under Construction In Development
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StaffStaff
Coskata has assembled a capable team to execute
William Roe, CEO
Nearly 50 employees, over half with PhDsTechnical staff from leading science based companies, e.g. Dow, Abbott, Nalco, Eli Lilly
Senior executivesSenior executives
29 years at Nalco culminating as President & COO
30+ years experience; formerly CFO of Westmoreland CoalFormerly CFO of ICM
27 years with UOP
28 years with Dow
30+ years experience at Exxon, Michigan Biotech Institute and Corn Products
David Blair, CFO
Wes Bolsen, CMO
Jeff Burgard, VP-Eng.
Dick Tobey, VP-R&D
Rathin Datta, CSO