A System Approach to Sustainability and the Ethanol Challenge

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A System Approach to Sustainability and the
Ethanol Challenge

• Said S.E.H. Elnashaie
• Quentin Berg University Chair Professor of
  Engineering
• Pennsylvania State University at Harrisburg, USA
• Presentation at The Rachel Carson Forum on Future
  of the Environment, DEP, Harrisburg,
  Pennsylvania, July 20, 2006

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• A PRELUDE

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• The U.S. Department of Energy (DOE) has set a
• goal of (June 2006, Roadmap for Developing
  Cleaner Fuels.- Research Aiming at making
  Cellulosic Ethanol a Practical Alternative to
  gasoline. Based on 2005 Workshop)
• displacing 30 of 2004 gasoline demand with
  biofuels, primarily ethanol, by 2030.
• This will require a rapid expansion of the U.S.
  fuel ethanol from about 4 billion gallons/year of
  corn grain ethanol to about 60 billion
  gallons/year per year from a variety of plant and
  waste materials ( biomass, switchgrass, corn
  stover , etc)

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Main Topics

• The multidisciplinary nature of sustainable
  development. The system and the subsystems.
• Sustainable economy, biomass efficient
  utilization and bioethanol
• The matrix of biofuels and the critical position
  of bioethanol.
• Critical evaluation of the different routes to
  bioethanol from biomass
• Bioethanol from Corn . Positive or negative net
  energy?
• Some USA Bioethanol facts
• International Bioethanol production
• 3.The success story of the Brazilian bioethanol.
• 4.The success story of the chaotic fermenter
  for bioethanol.
• 5.Ethanol/bioethanol in Pennsylvania. The coal
  gasification/syngas
• 6.The biorefinery as one of the main tools for
  sustainability.
• 7.Importance of intensive multidisciplinary
  research. Sequential de-bottlenecking and the
  optimal next steps.
• 8.Ethical/moral, socio-economical and political
  factors.

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1- The Multidisciplinary Nature of Sustainable
Development.The system and the subsystems.

• System approach is the best to organize knowledge
  and exchange it.
• It depends on defining every system through its
  boundary, main processes within this boundary,
  exchange with the environment through this
  boundary and its subsystems/ elements
• Depends upon thermodynamics and information
  theory.
• Applicable to all kinds of systems which makes it
  most suitable for multidisciplinary
  investigations.

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Sustainable Development. Multidisciplinary by Its
Very Nature

• Main Components of Sustainable Development
• 1- Political e.g. Legislations
• and strategic decisions..
• 2-Economical e.g. Investment
• in novel new technologies
• 3-Social e.g. Consumption
• Trends, acceptance of novel
• clean technologies and products...
• 4-Technological e.g. Novel
• efficient clean technologies, clean fuels,
• efficient utilization of renewable
• feedstocks, new environmentally
• friendly products, In-process
• Modification for MPMP, efficient
• waste treatment.
• ________________________________
• Ethical and Moral Factors ( Don Browns Book
  American Heat, 2003)

Sustainable Development
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Renewable Energy
Change of Consumption Trends
Novel Technologies With Renewable Feedstocks
Rationalize
The Producing Consuming Society
Non-Renewable Energy (NRE)
Waste
Novel Cleaner Technologies With Classical
Feedstocks
Ecology Credit
Waste Treatment
Minimum NRE USE
Society , Renewable, Non-renewable Energies,
Waste, Technologies and Consumption
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Sustainable Engineering Subset of Sustainable
Development As Engineers we Focus on Technology
within the Frame Work of Other Components

• DOE Extensive Hydrogen Research
• Support to Hydrogen Economy by President

Technology
Socioeconomics
Politics
Sustainable Engineering Other
Engineering/Science Disciplines
Sustainable Development
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Classical Components of SD/SE and the Critical
LinksRenewable Raw Materials and Sensible
Consumption
AIChE and Sustainable Engineering 1-Novel
chem.engng. applications to satisfy needs of
sustainable society. 2-Joining sustainability
discussions. 3-Be a bridge between chem. Engng.
community/industry/government, etc.
4-Providing education and outreach on role of
chemical engineering in creating a sustainable
future.
UK Chem. Engrs. Inst. Components of Sustainable
Development (triple bottom line)
1-Environmental Component 2-Economical
Component ( Generation of Wealth) 3-Social
Component
The American Society of Civil Engineers
(ASCE) 1-sustainable planning, design,
construction and operations. 2-Sustainable
Materials 3-Sustainable Communities ,
transportation and Smart Growth 4-Sustainability
Practices in Industry. 5-Changing the Way We Do
Business Globally 6-Integration of
Sustainability into Engineering Education
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2- Sustainable economy and the role of biomass
efficient utilization
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Not Hydrogen Economy ButRenewable Economy

1. An Economy where the basic building blocks to
   produce energy as well as industrial and
   consumer goods ,utilize renewable resources.
2. Achieves Sustainable Development (SD)

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Biomass and Bioenergy
We are Looking to a Day When a Ton of Biomass
Will Be Traded Like a Barrel of Imported Oil is
Today
WHERE ARE WE TODAY 2006?
Dan W. Reicher Assistant Secretary of Energy 2000
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The matrix of biofuels and the critical position
of bioethanol

• Bio the process and/or the feedstock
• 
  Membrane
  Separation, PSA
• FT
  
  
• 
  
  
• 
  
  
  Bio, thermal, catalytic
• 
  
  
• FT
  
  Gasification/fast Pyrolysis-
• 
  
  Reforming
• 
  Fermentation
  Hydrolysis
• 
  
• 
  Dry/Wet Milling
• 
  

Biohydrogen
Syngas
Biodiesel
Sugars
Bioethanol
Biomass
Starch Corn
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Biohydrogen and Biodiesel.Optimal Biofuel and
Production Route are Location Sensitive.

• Advanced Catalytic
  Membrane Gasification (one Step)
• Gasification(2
  steps)
• Fast Pyrolysis (3 steps)
• Steam Reforming
  Separation
• 
  
  
  
  
• 
  in-situ / ex-situ
• 
  FT
• 
  
  
  

Biomass
Syngas
Biomass and/or Carbohydrates
Bio-Diesel
Bio-oil
Biohydrgen
Vegetable Oil Waste Oil
Alcohol
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Direct Biohydrogen

• Catalytic Gasification
  with Hydrogen Membranes(1)
• 
  
• 
  Biological Treatment (2) X
• Elnashaie and co-workers
• Bruce Logan (Penn State), and co-workers
• X Most Desired Field of Research Among
  Students at UBC 2005/2006

Biomass
Biohydrogen
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Critical evaluation of the different routes to
bioethanol from biomass

• 
  Acid Hydrolysis
• 
  
• 
  Enzymatic
• 
  Hydrolysis
• 
  
• 
  
• 
  SSF
  Fermentation
• 
  
  Mutated Microorganisms
• SSFSimultaneous Saccrification/Ferment
  ation

Biomass Lignocellulosic Waste
Sugars
Cellulose and Hemi-Cellulose
Lignin to Variety of Chemicals or fuel Also
possible to sugars for fermentation
Bioethanol
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Bioethanol from Corn . Positive or negative net
energy?

• Net Energy Ratio (NER) of a Fuel
• (Energy of Fuel-Energy Consumed to
• Produce the Fuel)(/-) Energy consumed to
• produce the fuel/ (Energy Consumed to
• Produce the Fuel) Y (/-)X/X
• (/-) it is when Y is positive and when Y
• is negative.

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Examples

• (1) One researcher gave Total energy use for
  producing ethanolA 78,081.00 Btu/gal,
  considered energy of ethanol (B) 83,961.00
  Btu/gal, thus Y 5,880.0. and the above sign is
  and NER (5,880.0 78,081)/78,081 1.1
• Meaning if we consume 100.0 kJ to produce an
  amount of ethanol this ethanol will contain 110
  kJ of Energy
• ( 2) Another researcher gave Total energy use
  for producing ethanolA 131,017Btu/gal,
  considered energy of ethanol (B) 76,000 Btu/gal,
  thus Y -55,017.00 and the above sign is - and
  NER (-55,017.00 131,017)/131,017 -1.42
• Meaning if we consume 100.0 kJ to produce an
  amount of ethanol this ethanol will contain 58kJ
  of Energy ( But May be of Higher Quality)

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Estimates and Disputes about NER

• DOE gives NER for ethanol 1.34 and expect itto
  increase up to 2.0-2.5
• Professor Pimentel (Cornell Univ.) NER -1.44(
  2001), - 1.29 (2003)
• Professors Pimental and Patzek (Cornell/UC-Berkely
  ) NER -1.29 ( 2005)
• Differences
• 1- Energies included
• 2-Levels of technologies
• 3-Energy estimation techniques
• 4-Including/not including solar energy as
  consumed
• 5- Including/not including energy in capital cost
  and estimation techniques.
• 6- Including/not including energy credits for
  by-products.

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Energy Ratio ER

• Energy Ratio (ER) of a Fuel (Energy of Fuel)/
  (Energy Consumed to Produce the Fuel)
• For example 1 it will be the same 1.1 For
  example 2 it will be 0.58
• __________________________________________________
  _________
• USDA, ERNER and Other Sources
• Examples from USDA( supporting Ethanol from
  corn)
• Fuel ER NER
  Fuel ER NER
• Gasoline 0.8 -1.2
  NG 0.9 -1.1
• Diesel 0.8 -1.2
  LPG 0.95 -1.05
• Electricity 0.4 -1.6
  Coal 0.95 - 1.05
• Ethanol 1.6 1.6
• Other Sources
• 
  ER NER
  
• Ethanol from Corn
  1.25-1.35 1.25- 1.35
• Ethanol from Cellulosic Waste
  1.8 1.8

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Argonne National Laboratory Estimates for
Reductions in Greenhouse Gas Emissions

• Reduction in Greenhouse Gas Emission/Vehicle
  Mile Traveled
• E10
  E85
• Corn-based Ethanol 2
  24-26
• Cellulosic Ethanol 8-10
  68-91

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Improvements and Intensive Multidisciplinary
Research

• Bioethanol Production today compared with 1980s
• 1- Requires 50 less energy .
• 2- Ethanol yields increased by more than 22 (
  from 2.2 gallons/bushel to 2.7 gallons/ bushel) .
• 3- Capital cost decreased from 2/gallon/year to
  1.5/gallon/year
• More Intensive Improvements Using
  Multidisciplinary
• Research is Needed and is Possible

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Ethanol Simple Facts

• Ethanol meets the Kyoto requirements
• Ethanol has octane rating of 111
• Henry Ford 100 years ago praised alcohols as the
  fuels of the future.

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Some USA Bioethanol Facts

• Most Bioethanol in USA is produced from corn
  which
• may be not the best raw material.
• Dominating process now is dry mill ( 70)
• Production in 1980, 200 million gallons/year, in
  2000, 2
• billion gallons /year, 1000 increase in 20
  years.
• Example Chippewa Valley Ethanol Company (CVEC)
• increased production from 15 million gallon/year
  in
• 1996 to 20 million gallon/year, 33 increase in 4
  years.
• Largest plant is New Energy plant in Indiana 85
  million gallons/year
• 12 additional ethanol plants on 2002

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Important Statistics

• A study in Minnesota shows
• every 1 state support to ethanol production
  gives back to state 12-13
• Statistics for typical 15 million gallons/year
  plant
• 28 full time jobs, payroll of 1.0 million
  per year, 300,000/year local and state taxes,
  22 million gross revenues per year, 80 of the
  dollars are spent within a 75 miles radius, total
  economic impact of 30.0 millions/year.

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California. Sacramento Valley

• Solving the problem of black cloud due to rice
  straw burning
• Bioethanol from rice straw by SSF (Simultaneous
  Saccharification and Fermentation ). Consists of
  enzymatic conversion of the cellulose and
  hemicelluloses to sugar using enzyme followed by
  fermentation of sugar to ethanol in the same
  reactor.
• Using genetically engineered E.coli bacterium
  developed by the University of Florida
• turning 300,000 tons of dry rice straw into 23
  million gallons of ethanol annually.
• Arkenol established a commercial facility in
  Sacramento, California, to convert rice straw to
  ethanol, using the concentrated acid hydrolysis
  process, followed by fermentation
• Other Projects
• BC International developed two such projects the
  Collins Pine Ethanol Project, a 23 million gallon
  per year plant using forest thinning and wood
  wastes as feedstock
• Gridley Ethanol Project, a 20 million gallon per
  year ethanol plant using rice straw as its
  primary feedstock.

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American Coalition for Ethanol, ACE. Ethanol.
org    

• ACE Vision of Ethanol's Production
• 1- drives economic development
• 2- adds value to agriculture
• 3- moves our nation toward energy independence
• This year the U.S. ethanol industry will grow to
  provide more than 5 billion gallons of clean
  burning, renewable fuel to our country's supply.

http//www.ethanol.org/EthanolHandbook2006.pdf.pdf
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Some Very Recent USA Bioethanol News.

• July 2006
• Before the crisis in Lebanon

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Ethanol prices hit record. Friday, July 07, 2006

• Ethanol prices on July 5 extended a three-month
  rally to record levels as increased demand for
  the gasoline additive outpaced production,
  Bloomberg News reported July 6.
• Competition for ethanol between refiners and fuel
  companies soared after the additive was phased in
  as the primary blending component in
  cleaner-burning gasoline, and the use of a rival
  additive, methyl tertiary butyl ether, known at
  MTBE, was reduced.
• U.S. ethanol averaged a record 3.9757 a gallon
  on July 5, up 4.1 percent from June 30, according
  to data compiled by Bloomberg. That average,
  based on ethanol traded in Des Moines and 29
  other Midwest locations, was more than double
  1.5929 a year ago.This was before the crisis
  in Lebanon

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Kroger to offer E85 in Columbus, Cincinnati,
Dayton Monday, July 10, 2006

• Kroger announced July 6 that it will offer
  corn-based ethanol E85 fuels at gas stations,
  first in Columbus, then in Cincinnati and
  Dayton.
• The program is announced in partnership with
  General Motors Corp., one of the manufacturers of
  cars outfitted to burn E85 and the state of Ohio
• Critics of using ethanol gasoline point to its
  high price, that a gallon of gasoline is 10 to 15
  percent more efficient than ethanol and that the
  corn used to make it could be used to feed hungry
  people around the world.
• Support of using E85 gasoline in recent months
  has increased, however supporters warn that it
  is not the "magic" solution to eliminating U.S.
  dependency on foreign oil. Using biodiesel,
  propane gas and natural gas should also be
  figured into the mix.
• Ohio State Sen. Eric Kearney, D-North Avondale,
  proposed legislation more than a week ago that
  would create incentives for the processing of
  ethanol within Ohio. Kearney said he believes his
  bill, which will be introduced when the
  legislature reconvenes in November, will have
  wide support. "What Kroger and GM are doing
  marries well with what I am doing," Kearney said.
  "I am just glad and really happy that they are
  embracing this.
• General Motors Corp., Ford Motor Co., and
  DaimlerChrysler AG's Chrysler Group have produced
  5 million flex-fuel vehicles capable of running
  on E85. The automakers plan to build 1 million
  flex-fuel cars this year. Their commitment would
  lead to the production of 2 million flex-fuel
  vehicles annually by 2010.

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International Bioethanol Facts

• EU plans to increase of biofuels from 2 now to
  6 by 2010. Bioethanol is a major component of
  this biofuel
• 60 new bioethanol plants in EU by 2010, each
  producing 100,000 tons/year(30 million
  gallons/year)
• Germany has the capacity of 240 million
  gallons/year
• Brazil produces 4.8 billion gallons/year.
  Expected to rise on 2010 to 6.6 billion gallons
  /year
• USA in 2004 producing 3.2 billion gallons/years

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3.The success story of bioethanol in Brazil( 180
millions)

• Brazil is the world's largest producer of ethanol
  and is independent of exported oil.
• It produces 4.8 billion gallons/year, or 38
  percent of the worldwide total.
• Brazil uses sugar cane as the raw material,
  raising fears among environmentalists regarding
  forests and biodiversity
• It is expected to produce 6.6 billion gallons/
  year on 2010( 30 will be for export, 2.2
  billion gallons/year).
• This will require expanding the current area of
  sugar cane cultivation from the present 5
  millions to 7.5 millions hectares.
• In 2004 it exported about 0.6 billion gallons
  three times the amount in 2003.
• Brazil's ethanol has the lowest production cost
  internationally.
• In 1980, ethanol productivity was 925
  gallons/hectare, on 2004 it became 1850
  gallons/hectare
• Brazil still Seeks Clean Energy - in the
  Garbage, ethanol from cellulosic waste and
  methane from landfills.
• Carbon credits are an important incentive for
  city governments in Brazil to fulfill their
  constitutional obligation to properly dispose
  of garbage, and develop clean energy.

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4. The success story of the chaotic fermenter
for bioethanol

• Said S.E.H.Elnashaie and Parag Garhyan, Chaotic
  Fermentation of Ethanol, US Full Patent
  10/978,293 filled on 10/29/2004.Published 4th
  August 2005
• See a summary of the many mathematical and
  experimental papers in
• Said Elnashaie and Parag Garhyan, Bioethanol
  Production-Sloving the Efficiency
• Bottleneck The Chemical Engineer(tce), 755, May
  Issue, pp.30-32, 2004
• Invention is product of PhD work of my student
  Dr.Parag Garhyan( Now researcher with Lilly in
  Indianapolis). He won the award of the best PhD
  in Auburn University, 2004.
• Patent bought on March 2006 by investors
• Investors formed a company, INFINOL, on this
  patent
• Basic idea is
• Operate fermenter dynamically( periodic/chaotic)
  at high feed sugar concentration.
• Use pervaporation membranes to prevent inhibitory
  effect of ethanol and stabilize the fermenter.
• Much More improvements are still possible.

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5-Ethanol/bioethanol in Pennsylvania

• Example of Pennsylvania Pioneering Biofuel
  Initiative
• Worley Obetz, Inc., Highspire, PA
• On the fall of 2004 became the first energy
  company in Pennsylvania to provide BioHeating Oil
  to all its heating oil customers. Now expanded
  and currently provide E85 and Biodiesel blended
  fuels.
• AmeriGreen E85 Used in thousands of cars. It is
  85 percent ethanol and just 15 percent gasoline
• AmeriGreen BioDiesel used in many diesel engine
  with no modifications.
• AmeriGreen BioHeating Oil for any heating
  system using heating oil. All available in many
  places throughout PA ( Lancaster, York, Dauphin,
  Berks,etc)
• A filling station in Middletown near the fire
  station

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• On Oct. 28, 2005, the Governor opened the East
  Coasts first, state-of-the-art biofuels
  injection facility in Middletown, PA.
• It replaces 3.2 million gallons of foreign oil
  with domestically produced biodiesel.
• It will also keep about 6 million worth of
  energy dollars in the commonwealth by reducing
  the states need to purchase imported fuels. 
• Biofuel is the future and PA is taking good steps
  forward.

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Ethanol from Coal

• Pennsylvania is very rich in coal
• 
  FT
• Gasification
• 
  
• 
  FT
• Bio-route
• e.g. Anaerobic
  Bacterium
• 
  Clostridium ljungdahlii

Synthetic Ethanol
Coal
Syngas
Synthetic Diesel
Bioethanol
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Pennsylvania and Diesel from Coal

• In Sept. 2005, Pennsylvania governor Edward
  Rendell announced a venture with Waste Management
  and Processors Inc. using technology licensed
  from Shell and Sasol to build an FT plant that
  will convert so-called waste coal (leftovers from
  the mining process) into low-sulfur diesel fuel
  at a site outside of Mahanoy City, northwest of
  Philadelphia.
• The state of Pennsylvania has committed to buy a
  significant percentage of the plant's output and,
  together with the U.S. Dept. of Energy, has
  offered over 140 million in tax incentives.

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6-The biorefinery as one of the main tools for
sustainability.

• Fuel is a major part of economy, but it is not
  all the economy.
• A biorefinery integrates biomass conversion
  processes to produce fuels, power, and chemicals
  from biomass.
• The biorefinery concept is analogous to today's
  petroleum refineries/petrochemical complexes,
  which produce multiple fuels and other products
  from petroleum.
• Industrial biorefineries are the most promising
  route to the creation of a new domestic
  sustainable bio-based industry.

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Example of the Simple PureVision
BiorefineryBiorefineries refines biomass (wood,
agricultural and paper wastes, energy crops,
etc.) into sugars, bio-plastics, ethanol,
acetic acid and other chemicals. This is
carbon-neutral, eliminating fossil fuel inputs
while providing green products.VERY LIMITED,
e.g. IT DOES NOT UTILIZE SYNGAS AND FT
                                                  
                                         click
here for printable copy
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World's First "Biorefinery"

• Golden Valley, MN, August 25, 2003
• Biorefining, Inc. started its first commercial
  application of their patented "Biorefining
  Process." The project incorporating this process
  is a 22 million joint-ventured production
  facility with Ace Ethanol, LLC.
• The new "biorefinery" generates value-added
  co-products from the further fractionation of the
  corn fiber in distiller's grain.

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7.Importance of intensive multidisciplinary
research. Sequential de-bottlenecking and the
optimal next steps.

• The biggest improvements will be through
  intensive multidisciplinary research to
  efficiently achieve
• 1-Change of raw material to cellulosic waste,
• 2-Efficient fermentation of difficult sugars
  using mutated microorganisms.
• 3-Unconventional operation (dynamic, chaotic).
• 4-Membrane fermenters.
• 5-Immobilization of microorganisms
• 5-Immobilized packed bed fermenters, etc
• 6-Efficient Ethanol production through Syngas
  followed by FT.

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Competing Raw Materials and Processes. All Need
Intensive Multidisciplinary Research. Compare
Optimums

• Dry/Wet Milling Hydrolysis
  Steam
  Reforming Bioreactor
  landfills
• 
  
• 
  SSF
• 
  
  Gasification
• Fermentation
  FT
  Multidisciplinary Research, e.g.
• 
  
  Fermentation Research Microorganisms
  
• 
  
  Bioreactor Configurations Immobilization
• 
  
  Membranes Mode of Operation, etc
• 
  Steam
  Reforming Gasification Research
  

1-PyrolysisSteam Reforming
(better) Or 2-Gasification
NG
Corn
Biomass
Syngas
Biomass
Sugars
Coal
Ethanol
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8. Ethical/moral, socio-economical and political
factors.

• Ethical/moral
• Is sustainability profitable or is it a
  moral/ethical obligation?
• Does moral/ethical obligations change with the
  change of the philosophy we believe in?
• How much is moral/ethical obligations related to
  religion, i.e. can we have good moral/ethical
  obligations without religion. How does this apply
  to sustainability?

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Socio-economical

• Is there a contradiction between sustainability
  and profitability? and if there is, is it
  solvable within a profitability based society? Is
  Innovation an answer?
• Is sustainability more critically dependent on
  the production or consumption domains? Can they
  be separated?
• Can we achieve sustainability with the present
  mode of consumption in the US?
• How will be the situation if the US mode and size
  of consumption prevailed in the entire planet?
  will biofuels and bioproducts be able to sustain
  this mode of consumption internationally?
• Are biofuels/bioproducts enough to achieve
  sustainability?
• How much does the future of bioethanol and other
  biofuels depend upon the decisions of large oil
  companies? Is this a socio-economical or
  political question?
• Will sustainable economy leads to a different
  socio-economical systems?
• Will sustainable development affect international
  relations, decreasing international tensions and
  wars?
• Is sustainable development compatible or
  contradictory to global development?
• How much it will localize great parts of
  production/consumption and affect international
  trade?
• Are the present definitions of sustainable
  development sufficient/suitable?

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Political

• What level of public awareness is needed to adopt
  sustainable polices and what are the best
  techniques to achieve that? Is this political or
  socio-economical question?
• Does world politics and large corporate
  businesses affect adaptation of biofuels?
• Does biofuels adaptation affect world policies,
  specially in places like the ME?
• How much the future of bioethanol and other
  biofuels depends upon the political and military
  situation in the ME?
• What degree of national and international
  equality is needed to succeed in developing
  sustainable economy?
• Is the US refusal of the Kyoto agreement
  scientific, economical, political, ethical?
• Is the recent interest in bioethanol, biodiesel,
  biohydrogen scientific, economical, political,
  ethical,.?
• For politicians what is the correlation between
  adopting sustainable policies and
  popularity/winning elections?
• How much does bioethanol adaptation depend upon
  the political decision of subsidizing it?

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General

• Is nuclear energy an option?
• Is the main bottleneck scientific/technological,
  economical or political? Or all of them
  non-linearly interacting?
• Is there a contradiction between sustainable
  development and the second law of thermodynamics?
• Will sustainable development decrease the
  possibilities of bifurcation, chaos and self
  organizational criticality?
• Will it lead the world toward a stable stationary
  non-equilibrium state? Or an equilibrium state?

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Thank You I will Be Happy to Answer Any
Questions and Discuss Any Topics