forest products an industry for the future
TRANSCRIPT
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Forest Products Forest Products An Industry for the FutureAn Industry for the Future
Sustainability & Forest Biorefinery II ConferenceSyracuse, NYOctober 20th, 2008
John G. Cowie Ph.D.Director
Technology Management and Deployment Agenda 2020 Technology Alliance
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DiscussionDiscussion
Agenda 2020 overview
Current programs in Agenda 2020
US government support for breakthrough research and development
Opportunities for the industry
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Agenda 2020 OverviewAgenda 2020 Overview
Started in 1994 as a partnership with the US Department of Energy
Since 2005, a membership alliance with expanded mission to better serve industry needs
Organized as industry-led partnership with government and academia to address shared industry and national goals
A special project of the American Forest & Paper Association (AF&PA)
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Agenda 2020 MissionAgenda 2020 Mission
Agenda 2020 works to lead the industry’s technology strategy by –
Identifying and prioritizing important technology needs targeted at breakthrough developments
Technology roadmaps, task groups, workshops
Facilitating the funding and execution of collaborative, pre-competitive RD&D programs to address the needs
Contacts with federal agencies and CongressEstablishment of consortia
Investigating new and emerging technologies as opportunities for members and industry
Contacts with small companies, research institutes, national labs
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Agenda 2020Agenda 2020Forest Products Industry RoadmapsForest Products Industry Roadmaps
Available online at www.agenda2020.org
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Agenda 2020 MembershipAgenda 2020 MembershipFull Alliance Members
Open to any company – not restricted to forest products or to membership in AF&PA
Participation in CTO Executive Committee
Platform Members
Smaller companies with specific interests
Associate Members
Suppliers, service providers
No direct forest-based manufacturing operations
Affiliates
Non-profit organizations
Universities, research institutions, government agencies
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Agenda 2020Agenda 2020Staged Development ProcessStaged Development Process
ConceptGeneration
RiskAssessment
Proof ofConcept
Proof ofProcess
TransferDemonstrationApproach
DeploymentDecisions
StageI
StageI
ConceptGeneration
Stage2
Stage2
Risk Assessment &
Proof of Concept
Stage3
Stage3
CompellingBusiness Case
Stage4
Stage4
Proof ofProcess
Stage5
Stage5
Large ScaleDemonstration &
Technology Transfer
Gate1
Gate1
Gate2
Gate2
Gate3
Gate3
Gate4
Gate4
Gate5
Gate5
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Agenda 2020 Focus for the Future
Sustainable Forest ProductivityExtracting Value Prior to PulpingNew Value from Residuals and
Spent Liquors
Advancing the Forest “Biorefinery”
Breakthrough Mfg. Technologies
Major Manufacturing Cost/Capital ReductionSignificant Enhancementin Product Properties
with Existing AssetsSubstantial Improvement in Energy Efficiency for Existing Processes
Advancing the Wood Products Revolution
Improved Building SystemsReduced System Costs
Next Generation Fiber Recoveryand Utilization
Recycled Fiber Indistinguishable from Virgin Fiber
Technologically Advanced WorkforceFrom Workforce to Knowledge Workers in 7 years
Positively Impacting the EnvironmentExpand the Carbon Cycle BenefitsEnhanced Site, Activity and Product Environmental Footprint
NanotechnologyBiomaterials manipulation
and manufacturing at atomic level
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Agenda 2020Agenda 2020Current Activities Discussed TodayCurrent Activities Discussed Today
Breakthrough Manufacturing Technologies
Integrated Biorefineries
Nanotechnology in Forest Products
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Agenda 2020Agenda 2020Breakthrough Manufacturing TechnologiesBreakthrough Manufacturing Technologies
Roadmap – potential for $17 billion impact
Pulping, recovery, and papermaking
Basis for DOE RFPs
Platform goal – Utilize new technology to:
Reduce raw materials and fiber up to 33%
Reduce energy use up to 50%
Enhance fiber functional properties
Taking fresh look at priorities
Changes since 2005
Bandwidth study in 2006
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Bandwidth StudyBandwidth StudyOpportunities for Pulp & Paper Energy ReductionOpportunities for Pulp & Paper Energy Reduction
Base Case to Best Available Technology (BAT)26% potential energy reductionPursued by companies and suppliers
BAT to Practical Minimum17% potential energy reductionProvince of Agenda 2020
2006 study by Jacobs and IPST
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Agenda 2020Agenda 2020Forest BiorefineryForest Biorefinery
Primary focus - facilities integrated with pulp millsBenefits in wood handling, integration with mill steam and powersystems, mill infrastructure, human resources
Agenda 2020 interestsHemicellulose extraction and conversionBlack liquor gasificationWoody biomass to biofuels and chemicalsAssociated technologies that add value to pulp and paper mills
Influenced by federal legislationEISA 2007 – Mandates 16 bgpy cellulosic biofuels by 2022Farm Bill 2008 – Tax credit for cellulosic biofuels from renewable feedstocks that satisfy criteria
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Agenda 2020 Managed R&D Project Agenda 2020 Managed R&D Project --Value Prior to Pulping (VPP)Value Prior to Pulping (VPP)
Collaborative program – currently Stage 3Multiple companies and universitiesPartial funding from US DOECurrent phase complete in late 2009
ConceptGeneration
RiskAssessment
Proof ofConcept
Proof ofProcess
TransferDemonstrationApproach
DeploymentDecisions
StageI
StageI
ConceptGeneration
Stage2
Stage2
Risk Assessment &
Proof of Concept
Stage3
Stage3
CompellingBusiness Case
Stage4
Stage4
Proof ofProcess
Stage5
Stage5
Large ScaleDemonstration &
Technology Transfer
Gate1
Gate1
Gate2
Gate2
Gate3
Gate3
Gate4
Gate4
Gate5
Gate5
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Value Prior to Pulping (VPP) ProjectValue Prior to Pulping (VPP) ProjectPurposePurpose
Utilizing available enzymes and microorganisms, develop sufficient scientific fact, modeling tools, realistic process design concepts and engineering economic information to credibly determine if there is a compelling business case for proceeding to commercial scale demonstration and, if successful, for broad deployment within the industry
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Value Prior to Pulping (VPP) ProjectValue Prior to Pulping (VPP) Project
Project is focused on:Production of fuel ethanol and acetic acid from wood chips of industrially important species in a Forest BiorefinerySubsequent processing (pulping) of extracted wood chips
including recalcitrant celluloseinto paper and paperboard products
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Integrated Forest Products Biorefinery Integrated Forest Products Biorefinery (IFBP)(IFBP)
Forest Building Products Mill Pulp Mill Recovery/
Power PlantPaper, Board,
Other Mills
Paper, Boxes/Cartons, Tissue/Diapers,
Specialties
Chips
Energy
Black Liquor
Energy
Boards, Paneling,
Etc.
Ethanol,Polymers,
Etc.
Gasifier
Fuels/ Chemicals
Ethanol,DME,Others
Biomass
Optimized Plantations
Hemi Extraction and Conversion
Fuels/ Chemicals
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Value Prior to Pulping (VPP) Project Value Prior to Pulping (VPP) Project ObjectivesObjectives
The seven critical objectives for commercial success: 1. Determine conditions for extracting hemicellulosic sugars, prior to the pulp digester, while maintaining value of the pulp and paper products and producing an acceptable extract for fermentation 2. Produce sufficient quantities of the extract to enable hydrolysis and fermentation evaluations 3. Hydrolyze extract from three tree species (maple, pine and spruce) to a monosaccharide rich extract4. Upgrade/concentrate the sugar solution 5. Evaluate four known microorganisms (Pichia stipitis, Zymomonas mobilis, Escherichia coli and Saccharomyces cerevisiae) 6. Conduct more detailed studies, improve conditions and protocols of the combined hydrolysis and fermentation steps to obtain high-yield production of ethanol and provide data input to the economic model 7. Using the best results employ an integrated model of the extraction, fermentation and pulp mill processes to determine economic viability
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Technical FeasibilityPre-extraction & pulpingExtract processing or conditioningFermentation and ethanol production
Commercial FeasibilityInnovative process designEffective plant integrationCapital & operating costs of the best case process design & integration
Value Prior to Pulping (VPP) Project Value Prior to Pulping (VPP) Project Key ElementsKey Elements
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Value Prior to Pulping (VPP) ProjectValue Prior to Pulping (VPP) ProjectFocus of WorkFocus of Work
The focus of the federally funded work is on the process with the most technical and economic uncertainty
Production and utilization of pentose/hexose sugar solutions and the identification of fermentation systems that are tolerant to low pH and inhibitors
The industrial partners will support Extraction, production and evaluation of the pulp and paper products Integration of the extraction and fermentation technology into existing facilities.
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Value Prior to Pulping (VPP) Project Value Prior to Pulping (VPP) Project Participating Research InstitutionsParticipating Research Institutions
Forest Products LaboratoryTMP extraction & pulpingSouthern Pine extraction & pulpingExtract processingFermentation & ethanol productionModeling & business case development
North Carolina State UniversitySouthern Pine extraction & pulpingExtract processing
SUNY-ESFMaple extraction & pulpingExtract processing
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Value Prior to Pulping (VPP) Project Value Prior to Pulping (VPP) Project Participating Research Institutions (continued)Participating Research Institutions (continued)
IPST at Georgia Institute of TechnologyModeling & business case development
National Renewable Energy LaboratoryFermentation & ethanol production
Neoterics InternationalModeling & business case development
University of MaineMixed hardwoods extraction & pulpingExtract processing
PurdueFermentation and ethanol production
VereniumFermentation and ethanol production
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Value Prior to Pulping (VPP) Project Value Prior to Pulping (VPP) Project Participating Pulp & Paper CompaniesParticipating Pulp & Paper Companies
Pulp & Paper CompaniesInternational Paper CompanyLongview FibreMeadWestvaco (MWV)New PagePotlatchSAPPIWeyerhaeuser
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Agenda 2020Agenda 2020Black Liquor GasificationBlack Liquor Gasification
Princeton study (2006) showed significant economic benefits in typical modern kraft mill
Basis of two recent articles in Paper 360 and presentation at 2008 TAPPI IBBE Conference
Tracking commercial-scale plants
Assessing merits of smaller scale gasification in mill
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Agenda 2020Agenda 2020Woody Biomass to Biofuels & ChemicalsWoody Biomass to Biofuels & Chemicals
Many conversion pathways, many projects, many playersBiochemical, thermochemical, otherLarge companies are involved – DuPont, BP, Shell, Marathon, General Motors, Honda, . . . .
Principal interest – integrated biorefineries at pulp millsNewPage – Wisconsin Rapids, WIFlambeau River – Park Falls, WI
Tracking non-integrated biorefineriesPotential impact on woody biomass supply55 cellulosic biofuels projects counted by EESI in July 2008 (not all are woody biomass)
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Agenda 2020Agenda 2020Nanotechnology in Forest ProductsNanotechnology in Forest Products
Focus Areas
Benefit from tree-based nanoscience and nanomaterialsNanocellulosePotential for new revenue streamsLearn from nature – biomimicry
Use nanotechnologies in the manufacture of forest productsStronger, lighter productsNew product features – photonics, optics, electronics
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Agenda 2020Agenda 2020Nanotechnology in Forest ProductsNanotechnology in Forest Products
Multiple elements of Agenda 2020 programUS Forest Service R&DFundamental and applied R&D in universities and consortiaResearch in US national laboratories
Seeking significant new federal funding for FY2009 and FY2010
Congressional Nanotechnology Caucus Seminar SeriesForest products – tentative September 22, 2008
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U.S. Government Programs U.S. Government Programs Relevant to Forest Products Industry R&DRelevant to Forest Products Industry R&D
US Forest ServiceForest Products Laboratory
Department of AgricultureCSREES
Department of EnergyIndustrial Technologies ProgramBiomass Program
NISTNational Nanotechnology Initiative
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1994 - Forest Products Vision and formation of Agenda 2020
Active program from mid-1990s to 2003
~175 cost-shared projects
ITP R&D budget declined >80% between 2002-2008
Recent emphasis on near-term technical assistance
R&D focus on “Crosscutting R&D” to maximize impact
2008 – Forest products R&D funding is < $2 million a year
US DOE Industrial Technologies ProgramUS DOE Industrial Technologies Program
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FY ‘07 FY ‘08 FY ‘09
ITP’s Budget In Thousands of DollarsIndustries of the Future (Specific) 16,585 11,245 11,392
Industries of the Future (Crosscutting)
2,888 1,4483,626 2,256
2,139973
4,273303
50,7274,654
5830
19,567Energy-Intensive Process R&D 7,186 14,846
Nanomanufacturing and Other Interagency MFG R&D 4,823 4,861
Energy Efficiency Information Technologies 2,948 0
3,889
1,498
82962,119
2,273986
6,812
39,1789,8822,3663,062
23,868
55,763
Forest and Paper Products Industry 1,738Steel Industry 3,569
1,737192
3,710299
53,1634,717
6411,805
12,751
2,805
14,467
1,02064,408
Aluminum Industry Metal Casting Industry Chemicals IndustrySBIR/STTR
Industrial Materials for the Future
Industrial Distributed Energy
SBIR/STTR
Combustion
Industrial Technical Assistance Sensors & Automation
Fuel and Feedstock Flexibility
Total
DOE Industrial Technologies Program DOE Industrial Technologies Program R&D BudgetR&D Budget
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Agenda 2020 seeking higher funding for industry-specific programs in FY2009 and beyond
Working with other industries
ITP recognizes needs in forest products industryAdvanced water removalHigh-efficiency pulpingInnovative wood drying and curingImproved fiber recycling
Recent RFPsEnergy intensive processes – some proposals from forest products industryNanomanufacturing for energy efficiency
DOE Industrial Technologies ProgramDOE Industrial Technologies Program
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US Department of Energy US Department of Energy Biomass ProgramBiomass Program
Program areasFeedstocksProcessing and conversionIntegrated biorefineriesInfrastructure
$198 million in FY2008
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Goal: In 2022, Provide 36 Billion Gal of Goal: In 2022, Provide 36 Billion Gal of Renewable FuelRenewable Fuel
Energy Independence and Security Act (EISA) Renewable Fuels Standard
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Closing RemarksClosing RemarksOpportunities for our IndustryOpportunities for our Industry
New technology roadmap that defines and addresses current industry priorities
Collaborative R&D programs to address industry priorities
International cooperation and collaboration
More government support for industry’s technology development priorities
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For More Information About Agenda 2020For More Information About Agenda 2020
Contact Information:John G. Cowie
American Forest & Paper AssociationAgenda 2020 Technology Alliance
1111 19th Street NW, Suite 800Washington, DC 20036 USA
[email protected] (USA)