Provide credible, first-hand information on renewable, biomass-based fuels and chemicals.

Create research, testing, demonstration and training opportunities on cost-effective biomass

conversion systems.

Focus on biomass-based fuels and chemicals as value-added agricultural products.

Bridge the gap between laboratory research and real-world applications by working

at the pilot plant scale.

Create opportunities for rural economic development.

A U n i q u e A p p r o a c h T O R E N E W A B L E E N E R G Y

Bridging the Gaps

Bridging the gaps between laboratory research and real world applications is a hallmark of the Iowa

Energy Center.

In this tradition, the Center created the Biomass Energy CONversion facility (BECON), located in

Nevada, Iowa. BECON is a focal point for developing value-added products from Iowa's abundant

biomass resources. It provides credible, first-hand information on biomass technologies to create

fuels and chemicals, as well as demonstrations of pilot-scale biomass conversion systems.

Biomass - What It Is and It's Many Uses

Biomass typically refers to organic material such as crops, crop wastes, trees, wood waste and

animal waste. Some examples of biomass include wood chips, corn, corn stalks, soybeans,

switchgrass, straw, animal waste and food-processing by-products.

Processing biomass through a variety of conversion systems can yield hundreds of valuable fuels and

chemicals. A common example is ethanol, a biomass fuel that can replace gasoline. Biomass-based

chemicals can replace petroleum-based chemicals to produce plastics and many other products.

Producing fuels and chemicals from biomass is not a new concept. Cellulose, ethanol, methanol,

vegetable oils and a host of other biomass-based chemicals have been in use since the 1800's to

make products like paint, glue, adhesives, synthetic cloth and solvents. It was not until the 1930's

and 40's that petrochemicals began to dominate the market and displace chemicals and products

derived from biomass.

Renewed hterest in Biomass

Three main factors are responsible for the renewed interest in biomass - economics, environmental

concerns and national security.

First, economics are the strongest driver in renewing interest in biomass fuels and chemicals. New

advances in biotechnology and bioprocesses, such as those demonstrated at BECON, can

dramatically reduce the costs of producing biochemicals. The following table shows a cost

A U n i q u e A p p r o a c h T O R E N E W A B L E E N E R G Y

comparison of common products produced with petrochemicals versus biochemicals and the current

percentage of the product produced from biomass. As the table shows, many biochemicals can already

compete economically with petrochemicals. When environmental benefits are factored in, biochemicals

may have even lower production, handling, use and risk management costs than their petroleum-based

counterDarts.

Second, biomass fuels generally have less impact on the environment than fossil fuels, such as coal and

oil. Finally, our nation imports over half of the oil it uses to produce gasoline.

MILLION T O N S

Furfural 0.3 0.75 0 78 97 0 Adhesives 5.0 1.65 1 40 40.0 Fatly Acids 2.5 0 46 0.33 40 0 Surfactants 3.5 0 45 0 45 35 0 Acetic Acid 2 3 0.33 0 35 17 5 Plasticizers 0 8 1 50 2 50 150 Carbon black 1 5 0 50 0 45 120 Detergents 12 6 110 1 7 5 11 0 Pigments 15 5 2 00 5 80 6 0 Dyes 4 5 12.00 21 .oo 6 0 Wall Paints 7 8 0 50 120 3 5 Inks 3 5 2 00 2 50 3 5 Special Paints 24 0 80 1 7 5 2 0 Plastics 30 0 0 50 2 00 1 8

Cost of PIanVCrop-Based Raw Matenal Source Insbtute for Local Self Reliance Minneapolis, MN

Biomass and Iowa’s Future

It makes sense that Iowa, with its significant agricultural industries, lead the way in developing and

expanding the market for value-added, biomass-based fuels and chemicals.

Rather than simply selling raw materials, Iowa businesses can produce higher value, marketable

products. The following figure shows the flow of raw materials during the production of fuels and

chemicals. It illustrates that biomass feedstocks can be substituted for petroleum feedstocks in the

production of most fuels and chemicals used today. All of the final products can be made from crops

B i o c h e m i c a l s - VAL U E - A D D E D A G R I C U L T U R A L P R O D U C T S

and crop by-products The additional

facilities needed to process and produce

biofuels and biochemicals create jobs and

significantly increase the financial benefit

of growing agricultural crops

BECON’S Role in Iowa’s Future

The heart of BECON is made up of full-scale systems that process agricultural-related biomass into

fuels and chemicals Additional equipment at the site also demonstrates how biomass fuels can be

used to generate electricity, heat and valuable by-products.

BECON is open to researchers from all of Iowa’s universities, colleges and community colleges,

private non-profit organizations and their research partners from the private sector. An important

objective of BECON is to provide a place where researchers can collaborate and exchange ideas and

information.

Business people and the public also come to the facility to learn about biomass technologies and

how they can be put to use. Demonstrations, field days and training sessions are held periodically at

the BECON site

The BECON Site

BECON is located in Nevada, Iowa on six acres in an industrial park The facility is approximately five

miles east of the intersection of Interstate 35 and US. 30. A map showing the location is shown below.

Several processes and systems used to produce fuels and chemicals from biomass are being studied at

BECON. These include thermal gasification, pyrolysis, anaerobic digestion, fermentation and bio-diesel

production units. BECON staff and researchers are working to perfect and promote the use of these

conversion systems through research and pilot-scale demonstrations.

Thermal Gastification

Gasification involves transforming solid biomass into a gas through partial combustion. Various types of

biomass are fed into a feedstock-processing unit that prepares the fuel by chipping, grinding or shredding

it and then conveying it into a gasifier. At controlled temperatures and pressures the gasifier heats the

feedstock to produce a low-Btu gas. This gas can then be burned in a boiler, internal-combustion engine,

fuel cell or an advanced gas turbine.

At BECON researchers are working on

improving process efficiency, mitigating

problems associated with turbine and

engine deposits caused by burning low-

Generator

+ To Ash Disposal

Btu gas and converting and refining the

gas into biochemicals.

Thermal Gastification

Pyrolysis

Pyrolysis is similar to thermal gasification except that instead of producing a low-Btu gas, the process

produces biocrude, a liquid similar to crude oil. By subjecting the biomass to varying temperatures and

pressures, oils with different

characteristics can be produced.

Research to determine the

combustion characteristics of

various types of biocrude made

~

from different biomass resources Pyrolysis

M a k i n g F U E L S A N D C H E M I C A L S

is being conducted at BECON. Also, researchers are working to better understand the interactions between

pyrolysis conditions and the resulting characteristics of the oils produced, validating combustion tests,

removing ash and refining the oils produced to make biochemicals.

Anaerobic Digestion

Anaerobic digestion is the

controlled decomposition

of biomass in an oxygen-

free environment. As with

the other conversion

systems, the biomass is

first prepared before being

fed into an anaerobic

digestion tank. Several types of bacteria break down or digest the biomass. First it is broken down into

organic acids, sugars and alcohols, then it is converted into acetate and hydrogen and finally into methane

and carbon dioxide.

Anaerobic Digestion

There are many variables associated with the performance of the anaerobic digestion process. Research

at BECON is attempting to optimize anaerobic digestion systems in light of these numerous variables,

reduce the cost of the systems, develop simple and reliable operation practices and create markets for

by-products.

Anaerobic Digestion

F U E L S A N D C H E M I C A L S

~

Fermentation ~

Fermentation uses microorganisms to convert organic material from one chemical form into another. For ~~

example, a material such as corn or switchgrass is first prepared in a feedstock processing unit and then

sent to a pretreatment unit where it is converted into simple sugars. The sugars are then sent to the

fermentation tank where they are converted to ethanol or some other biochemical. Through distillation the

product can be further purified by removing water and solids.

The Iowa Energy Center is supporting research that will improve the efficiency of microorganisms used in

the conversion processes. At BECON researchers are trying to improve the biochemical purification and

separation processes, investigating the production of new biochemicals and finding ways to reduce the

costs of conversion systems.

Corn-Based Fermentation

~

~

M a k i n g FUELS A N D C H E M I C A L S

Sugar Crop Fermentation

Biodiesel

Biodiesel is a cleaner burning, alternative diesel fuel that is non-toxic, biodegradable and virtually sulfur

free. It is produced from reactions that take place when vegetable oils and animal fats are mixed with

alcohol. One of the most exciting benefits of biodiesel is that it can be used as a direct substitute for diesel

fuel in an existing diesel engine without any significant engine modifications. Biodiesel fuel can be

manufactured from a wide variety of fats and oils from both plants and animals. Soybeans are currently

the most common feedstock used in producing biodiesel.

Biodiesel

BECON will be equipped with several systems that allow researchers to investigate ways to

make heat and electricity. The visiting public can see how crops, crop wastes and other

biomass waste products can be used to power internal combustion engines and generators,

steam turbine generators, microturbines and fuel cells.

Internal Combustion Engines and Generators

The same type of engine that drives our cars and trucks can be used to turn a generator and

produce electricity. These engines can be modified to use ethanol, methane, biodiesel and

many other fuels. Additionally, heat can be recovered from the exhaust and engine cooling

systems to heat water for a building or an industrial process.

Fuel Air

Internal Combustion Engine/Generator

Steam Turbine Generator

Steam turbine generators are commonly used in power plants to generate electricity. Instead

of using conventional fossil fuels, a biomass fuel can be burned to heat water in a boiler. The

water turns into steam and that steam is used to make a turbine spin. The power developed

Boiler

Steam Turbine Generator

M a k i n g E L E C T R I C I T Y A N D H E A T

by the spinning turbine drives an electric generator to produce electricity. As with an internal combustion

engine, heat recovered from a turbine can be captured and used for other purposes.

Microturbine Generator

A new development in gas turbine

technology is the microturbine, a very

small and simple version of the large gas

turbines used by utilities. With only one

moving part, microturbines promise

simplicity and reliability for small-scale

power generation. Gas turbines are able to burn a wide range of liquid and gaseous fuels and can be used

to turn a generator to make electricity. Their exhaust can also be recovered to provide heat.

Fuel Cell

Fuel cells use a chemical reaction to produce electricity. First used by the US. space program, fuel cells

are nearly twice as efficient at making electricity as a steam turbine generator Because they have virtually

no harmful emissions (most of the exhaust from a fuel cell is hot water and carbon dioxide) and quiet

operation, fuel cells can eventually be installed inside buildings.

There are several fuel cell models in commercial use that are fueled by natural gas, methanol or ethanol.

Fuel quality is of particular concern for fuel cell manufacturers and operators since small amounts of

contaminants can create significant problems. Research at BECON is exploring how to produce bio-fuels

that are clean enough to be used in fuel cells.

fuel Cell

M a k i n g E L E C T R I C I T Y A N D H E A T

Combined Systems: Putting the Pieces Together at BECON

Combining various processes that produce fuels, chemicals, electricity and heat into larger, integrated

systems can create exciting possibilities and enhanced operating efficiencies. BECON, which houses many

of the basic technologies in one location, provides the perfect setting for exploring these combined

systems and their potential benefits for Iowa agribusinesses.

One scenario for pulling all the technologies together at BECON using a common feedstock like cornstalks

could look like this:

M a k i n g E L E C T R I C I T Y A N D H E A T

The cornstalks are fermented to produce ethanol. The ethanol

produced can be used to power a fuel cell, making electricity,

which can be sold to outside markets, and heat, which can be

used on site. Animal feed is also one of the by-products of

producing ethanol.

Processing the cornstalks in an enclosed, odorless,

environmentally-friendly anaerobic digester could also produce

methane. If the digester is located near the ethanol production

unit, it can also process the residue from the ethanol

production. The methane created can be used to power the fuel

cell, making more electricity and heat. Alternatively, that

methane can be used to make industrial chemicals for market.

The nutrients from the cornstalks and other wastes fed into the

anaerobic digester are not destroyed during the digestion

process. These nutrients can be used, in liquid form, at a greenhouse to grow hydroponic vegetables. The

nutrients in the solids that settle to the bottom of the digester can be removed annually to fertilize fields.

They can also be dried and sold as organic fertilizer.

Finally, the fuel cell provides all of the electricity required to operate these systems. In the winter, the heat

from the fuel cell can heat the greenhouse, buildings and processes. In the summer, the heat can dry the

organic fertilizer.

Ethanol, animal feed, methane, industrial chemicals, organic fertilizer, vegetables, electricity, heat and

year-round economic activity - all produced from cornstalks.

- A b o u t t h e IOWA E N E R G Y C E N T E R

- The Iowa Energy Center is a research, demonstration and educational organization dedicated to increasing

Iowa's energy efficiency and use of renewable energy.

Established under the State of Iowa's Energy Efficiency Act (Sec. 266.39~ Code of Iowa), the Center was

created to conduct and sponsor research on energy efficiency and renewable energy production systems.

The Center is also charged with assisting Iowans in assessing energy-related technologies.

-~

In pursuit of this mission, the Center has funded an array of research and demonstration projects

addressina enerav-related issues and their associated economic and environmental impacts.

to develop practical, cost-effective approaches to energy use that create positive

in Iowa's communities. - . l'*. v

. r l co

' C

ual assessment equal to eighty-fivf thousandths of one percent

(0.085%) of the gross intrastate revenues of all gas and electric utilities in