Three process designs for producing ethanol and electricity from switchgrass are evaluated: a basecase technology scenario involving dilute acid pre-treatment and simultaneous saccharifi cation and fermentation, and two mature technology scenarios incorporating ammonia fi ber expansion pre-treatment and consolidated bioprocessing -one with conventional Rankine power coproduction, and one coproducing power via a gas turbine combined cycle. Material and energy balances -resulting from detailed Aspen Plus models -are reported and used to estimate processing costs and perform discounted cash fl ow analysis to assess plant profi tability. The mature technology -designs signifi cantly improve both process effi ciency and cost relative to base-case cellulosic ethanol technology, with the resulting fossil fuel displacement being decidedly positive and production costs competitive with gasoline, even at relatively low prices.

Seven process designs for producing ethanol and several coproducts from switchgrass are evaluated:four involving combinations of ethanol, thermochemical fuels (including Fischer-Tropsch liquids, hydrogen, and methane) and/or power, and three coproducing animal feed protein. Material and energy balances -resulting from detailed Aspen Plus models -are reported and used to estimate processing costs and perform discounted cash fl ow analysis to assess plant profi tability. In these mature technology designs, fossil fuel displacement is decidedly positive and production costs competitive with gasoline.

EXECUTIVE SUMMARYThis project sought to address six objectives, outlined below. The objectives were met through the completion of ten tasks. 1) Solidify the theoretical understanding of the binary CO2/H2O system at reaction temperatures and pressures. The thermodynamics of pH prediction have been improved to include a more rigorous treatment of non-ideal gas phases. However it was found that experimental attempts to confirm theoretical pH predictions were still off by a factor of about 1.8 pH units. Arrhenius experiments were carried out and the activation energy for carbonic acid appears to be substantially similar to sulfuric acid. Titration experiments have not yet confirmed or quantified the buffering or acid suppression effects of carbonic acid on biomass.2) Modify the carbonic acid pretreatment severity function to include the effect of endogenous acid formation and carbonate buffering, if necessary. It was found that the existing severity functions serve adequately to account for endogenous acid production and carbonate effects.3) Quantify the production of soluble carbohydrates at different reaction conditions and severity. Results show that carbonic acid has little effect on increasing soluble carbohydrate concentrations for pretreated aspen wood, compared to pretreatment with water alone. This appears to be connected to the release of endogenous acids by the substrate. A less acidic substrate such as corn stover would derive benefit from the use of carbonic acid. 4) Quantify the production of microbial inhibitors at selected reaction conditions and severity. It was found that the release of inhibitors was correlated to reaction severity and that carbonic acid did not appear to increase or decrease inhibition compared to pretreatment with water alone. 5) Assess the reactivity to enzymatic hydrolysis of material pretreated at selected reaction conditions and severity. Enzymatic hydrolysis rates increased with severity, but no advantage was detected for the use of carbonic acid compared to water alone. 6) Determine optimal conditions for carbonic acid pretreatment of aspen wood. Optimal severities appeared to be in the mid range tested. ASPEN-Plus modeling and economic analysis of the process indicate that the process could be cost competitive with sulfuric acid if the concentration of solids in the pretreatment is maintained very high (~50%). Lower solids concentrations result in larger reactors that become expensive to construct for high pressure applications.i TABLE OF CONTENTS Project Summary 1Task 1 ii PROJECT SUMMARY Task 1a: Xylan and Xylose were hydrolysed in 1% H 2 SO 4 at 121 C for varying reaction times. Samples were analyzed with high performance anion exchange (HPAE) and an ultra-violet spectrophotometer. Peak areas for xylan oligomers were integrated by completing a mass balance on samples of varying degrees of hydrolysis. This yielded an appropriate calibration for peaks representing oligomer concentrations, and confirmed theoretical expectations that the area of oligomer peaks was propor...

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