2005 OBP Bi-Annual Peer Review Thermochemical Processing Effort Dr. Don J. Stevens, PNNL Thermochemical Platform November 14, 2005

Overview Budget (K) NREL PNNL Bioengineering Resources Antares Eastman Chemical Weyerhaeuser University of Utah Partners Work Objective: Promote efficient conversion of lignin-rich biomass to useful intermediates including syngas Relevant Pathways: Agricultural Residues, Energy Crops, Forest Products, Pulp and Paper

Technical Barrier Areas Addressing technical barriers: Handling varying biorefinery residues, lignin-rich feedstocks, and “off-specification” biomass Efficiently converting biomass with low tar production Achieving desired syngas composition Handling/recovering inorganic material

Strategy and Pathways – Intermediate to Long Term

Impact of Thermochemical Platform R&D on A and B Milestones in the Agricultural Residues and Perennial Crops Pathways Complete systems level demonstration and validation of all key technologies to utilize Agricultural residues feedstocks and perennial crops in existing or new facilities Demonstrate and validate lignin gasification to produce syngas for $0.xx/MM Btu by 20xx Demonstrate and validate biomass gasification to produce syngas for $4.89/MM Btu by 2020 Demonstrate and validate combined heat and power from lignin intermediates/residues Demonstrate and validate products (i.e. ethanol from mixed alcohols) from lignin or biomass derived syngas for $0.60/gal by 2025

Impact of Thermochemical Platform R&D on A and B Milestones in the Pulp and Paper and Forest Products Pathway Complete systems level demonstration and validation of technologies to improve pulp and paper mill facilities and/or produce additional products (fuels, chemicals and /or power) from wood feedstock in pulp and paper and forest product mills environment Demonstrate and validate gas cleanup and process chemical recovery and recycle from spent pulping liquor syngas Demonstrate and validate production of DME/mixed alcohols/FT liquids or other products from syngas in a pulp or forest products mill at a price competitive with current commercial practice Demonstrate and validate cost- effective biomass gasification of wood residues and other process residues and synthesis gas cleanup in a pulp and paper or forest products mill environment Demonstrate and validate reliable and economic gasification of spent pulping liquor and recycle liquor causticization in a pulp mill Demonstrate and validate syngas utilization in a pulp or forest products mill for CHP and direct fuel gas including clean cold gas Demonstrate and validate bio-oil production to a stable intermediate Achieve cost-effective conversion of bio-oil intermediate into product(s) in a forest products mill

3.0 Thermochemical Platform R&D 3.1 Feed Processing and Handling 3.2 TC Processing 3.3 Cleanup and Conditioning 3.5 TC Platform Analysis Feed Improvement Biomass Gasification Pyrolysis Black Liquor Gasification Innovative Gasification Cleanup and Conditioning Core R&D Cleanup and Conditioning Partnerships TC Platform Analysis BLG for Fuels/ Chemical in at Kraft Mills Thermochemical Platform

3.2. TC Processing Biomass Gasification Gasification of Corn Stover and Biorefinery Residues Wet Gasification of Biorefinery Residues Black Liquor Gasification Adv. High Temp BLG Tech Innovative Gasification TC Conversion of Corn Stover Catalytic Hydrothermal Conversion Innovative Membranes/Gasification Technologies

Thermochemical Processing Thermal gasification using oxygen-blown or indirectly heated gasifiers for medium-energy syngas Hydrothermal gasification for medium-energy syngas Current focus is on producing syngas, suitable with conditioning, for liquid fuels production Current Program Includes:

TC Processing Technical Areas Project AreasDescription Biomass Gasification (NREL, PNNL) Core R&D to better understand gasification processes and guide process improvements, with particular emphasis on agricultural biorefinery residues Black Liquor Gasification (Weyerhaeuser) Process R&D to assist with integrated gasification of black liquor to syngas in a forest biorefinery Innovative Gasification (Antares/Eastman, Bioengineering Resources, PNNL/NREL) R&D on innovative, higher risk thermal conversion approaches that will, if successful, provide advantages for biorefineries.

TC Processing: Biomass Gasification Task Biomass Gasification of Biorefinery Residues Objective: Obtain basic data on thermochemical gasification of selected feedstocks to facilitate production of liquid fuels Technical Approach: Conduct benchmark studies using NREL and PNNL gasification systems Focus specifically on corn stover and biorefinery residues Collect detailed data on solids conversion, tar and char yields, gas compositions, N and S release, and other parameters Needs: Basic data on gasification of corn stover and biorefinery residues is not available. Reliable data is needed to ensure compatibility with industry goals for liquid fuels Milestones Relevance: Data assists meeting programmatic milestones on TC conversion to syngas Projects and Participants: NREL – Basic studies of gasifying corn stover and biorefinery residues PNNL – Parametric studies of wet gasification of biorefinery residues NREL TCPDU Gasifier System

TC Processing: Biomass Gasification Task Biomass Gasification of Biorefinery Residues (Continued) Accomplishments & Plans: NREL Basic Gasification Studies Work conducted in NREL TCPDU gasification system 20+ corn stover gasification conditions studied to provide data for crucial for development of technical validation model Work proceeding as scheduled, milestones met FY06 work to focus on fermentation based lignin-rich biorefinery residues PNNL Parametric Wet Gasification Study Work conducted in PNNL wet gasification reactor system Hydrothermal catalytic process at 350°C, 200 atm Produces methane-rich gas Data collection on gasification of biorefinery residues underway as scheduled All work complete in early FY06, project will end as planned PNNL Wet Gasification System

TC Processing: Black Liquor Gasification Task Gasification for fuels/chemicals in a pulp mill Objective: Conduct process R&D to assist with integrated gasification of black liquor to syngas in a paper mill Technical Approach: Conduct research on q high temperature gasification concept Focus on black liquor feedstock Recognize BL gasification must be integrated with heat and chemical recovery Collect process data to assist industry Needs: Black Liquor is a difficult feedstock to handle with high sulfur content. Process must also provide integration of heat use and chemical recovery. Milestones: Prior analysis shows BL Gasification has the potential to be more cost effective than current combustion systems. Project technical milestones support the syngas cost goal. Projects and Participants: Weyerhaueser – High temperature BL gasification

TC Processing: Black Liquor Gasification Task Gasification for fuels/chemicals in a pulp mill (continued) Accomplishments & Plans: Weyerhaeuser – Advanced High Temperature Gasification Project began in 2005 Utilizing CHEMREC New Bern gasifier as a test-bed facility Conducting long-term continuous trials under real process conditions Combining fundamental chemistry and modeling to address issues FY06 work will continue tests and modeling Project has clear milestones and go/no-go decision points New Bern Gasifier

TC Processing: Innovative Gasification Task Innovative Gasification Objective: Conduct research on innovative thermal conversion approaches that will, if successful, provide advantages for biorefineries Technical Approaches: Industry-led R&D on the hydrothermal gasification of wet biomass (Antares/Eastman Chemical/PNNL) Industry-led R&D to determine the feasibility of gasification systems followed by fermentation of syngas (Bioengineering Rseources) Assess the feasibility of ceramic membranes inside or close-coupled to biomass gasifiers for producing improved syngas for producing liquid transportation fuels (NREL/PNNL) Needs: The innovative nature of these projects entail higher technical and economic risks, but they offer potential for significant improvement if successful. In most cases, Industry is providing cost- sharing. Milestones: Projects have clear technical milestones, and industry projects are reviewed regularly against go/no-go decisions. Projects and Participants: Antares/Eastman Chemical/PNNL – Catalytic hydrothermal gasification of biosludge Bioengineering Resources – Thermochemical conversion of corn stover NREL/PNNL – Evaluation of membrane systems for biomass gasification

TC Processing: Innovative Gasification Task Innovative Gasification (continued) Accomplishments & Plans: Competitive, industry cost- shared projects Antares/Eastman Chemical/PNNL – Catalytic Hydrothermal Gasification Low temperature catalytic wet gasification of biosludge, 350 °C, 200 atm FY05: Feedstock characterization and conversion studies in bench-scale units FY06: Go/no-go decision on conducting larger scale gasification tests at the Eastman Chemical site. Critical success factor: catalyst lifetimes Bioengineering Resources – Thermochemical Conversion of Corn Stover Pilot scale gasification/fermentation process to convert corn stover to ethanol Utilizes oxygen-enriched gasification in a Consutech gasifier Syngas converted to ethanol by anaerobic fermentation Gasifier constructed and operated in 2005 FY06 will include studies to convert syngas to ethanol. Critical success factor: 50 g/l-day must be achieved

TC Processing: Innovative Gasification Task Innovative Gasification (continued) Accomplishments & Plans: NREL/PNNL – Evaluation of Membrane Systems for Biomass Gasification Evaluation of high-temperature membranes located in or closely coupled to a biomass gasifier Focus on systems producing liquid transportation fuels Includes technical and economic feasibility “One-time” study to be completed in FY06 From: Julbe, et al, Catalysis Today, 2005

Stage Placement & Portfolio Alignment Review DOE Office of the Biomass Program FY05 Thermochemical Portfolio Alignment Review June 7-8, 2005 “Stage placement” of all new and existing projects (16) in the Thermochemical Platform. Evaluations based on: Program Relevance, Approach, Progress, Success Factors, and Future Plans 7 core R&D projects (NREL, PNNL) primarily focused on developing biomass gasification and gas clean-up technology that can applied many different biomass feedstocks. 9 subcontracted industrial/cost-shared R&D projects selected by competitive solicitations or directed by Congress to develop/commercialize gas cleanup technology, black liquor gasification, and other thermochemical processes. Reviewers Professor Robert Brown, Iowa State University Professor Esteban Chornet, Université de Sherbrooke Viorel Duma, Abengoa Bioenergy R&D, Inc. John Scahill, DOE Golden Field Office David Turpin, MeadWestvaco Research

Stage Placement & Portfolio Alignment Review General Comments on Thermochemical Program Thermochemical Program has clear goals which support the overall program Technical barriers are clearly identified R&D is good fit with the program and there is good balance Funding may be inadequate to meet program goals Specific Reviewer Comments on TC Processing: Reviewers offered many detailed technical suggestions: Response: DOE provided technical feedback to PI’s High level BL Gasification milestones may not be met at current budget levels Response: Current funding availability is limited Several projects have high risk – enforce stage gate Response: DOE agrees, reviews will be held as scheduled Pyrolysis should be supported in the TC Processing Area Response: Given current budget levels and priorities, DOE is currently unable to fund pyrolysis to bio-oil R&D

Summary and Future Work TC Processing: Work In FY06 Biomass Gasification: Core R&D on gasification of stover and biorefinery residues will continue at the NREL TCPDU gasifier Other projects will end as scheduled Pyrolysis: Future projects on biocrude as a refinery feedstock will depend on industry interest and OBP funding availability Black Liquor Gasification: R&D work will continue in the larger-scale facility with industry cost- sharing Progress will be tracked and reviewed Innovative Gasification: Two industry-led projects will continue Go/no-go decision in FY06 for Antares/Eastman project Ongoing reviews for Bioengineering Resources syngas fermentation