Every time I drive into nearby Madison, Wisconsin, I pass a gas station that sells e85 ethanol fuel along with gasoline, which these days, contains up to 10 percent ethanol. Like everyone else, the first thing I notice is the surging cost of gas--upwards of $3.55 a gallon now in Madison. Meanwhile, this same store is selling e85 for $2.79 per gallon. This has me wishing I had a flex-fuel vehicle capable of running on the much cheaper e85.
But is e85 really that great of a deal for the individual motorist, or for the common good? And if e85 is good for us, is it a viable, long-term solution, or will some other fuel source do a better job? I got some insights into such questions at the opening sessions of "Wisconsin Biofuels Destiny: Food, Fiber and Forest Products for the 21st Century," a conference put on the Wisconsin Technology Council at UW-Stevens Point in mid-April.
The short take of what I learned is that Wisconsin's corn-based ethanol industry is booming, and that today's mainstream biofuel--e85--is becoming more attractive for consumers with the right vehicles and fuel access given skyrocketing gas prices. The more complex take I got from the conference is that biofuels made from wood pulp, grasses, and other cellulosic plant material could be the longer term answer to our fuel needs, and could help revive Wisconsin's faltering paper mill industry in the process.
Let's start with the outlook on e85. Joshua Morby, executive director of The Wisconsin Bio Industry Alliance, presented some numbers on the rapid growth of the ethanol industry in Wisconsin. The first corn ethanol refinery in Wisconsin opened in 2002, and today, there already are seven refineries making corn-based ethanol in the state, and two that make biodiesel. These ethanol plants, once fully operational, could produce 500 million gallons of ethanol annually, says Morby. Nationally, 30 biorefineries opened just last year, he says, increasing annual production by 32 percent.
But for consumers at the pump--e85--a blend that contains 85 percent ethanol and 15 percent gas-- can be hard to find. In 2006, Morby says, there were fewer than 30 locations in Wisconsin selling e85. That number doubled in 2007, and today, stands at more than 100 locations. But, he concedes, "it's still hard to find these places."
Another plus for ethanol, says Morby, is the often overlooked employment boon. The typical ethanol plant, he says, employs about 40 people. And of course, the corn is grown largely by U.S.farmers, with local or regional cooperatives owning many of the refineries.
Now the negatives for e85. One big concern is that it gets significantly fewer miles per gallon than gas. Morby says a 40 cents a gallon price differential makes up for the lower mileage. He also acknowledges that corn-based ethanol is taking heat for everything from driving up food prices to bolstering the market for genetically modified corn. Then there is the debate over whether ethanol actually has a net energy balance. According to a U.S. Dept. of Energy publication about ethanol myths & facts, each gallon of corn ethanol produced delivers one third or more energy than is used to produce it, but there are researchers who say it has a negative energy balance.
These e85 questions merit another post, but for now, it's safe to say that corn-based ethanol is seen by many as a flawed biofuel. Even proponents of corn-based ethanol say that other technologies, including cellulosic biofuel, should be pursued to solve our fuel needs. "Ethanol and biodiesel are part of the solution to energy independence, not necessarily the entire solution," as Morby told conference goers.
Biofuel made from grasses, corn stover, and wood pulp--known as cellulosic materials--could be a big part of the eventual solution. At the conference, I chatted briefly with Timothy Donohue, principal investigator with the Great Lakes Bioenergy Research Center, one of three major centers established by the U.S. Dept. of Energy to accelerate the science needed for bioenergy breakthroughs. I asked Professor Donohue how far out we are from seeing cellulosic ethanol come to market, and he said that generally, the first cellulosic ethanol is being made from grasses and corn stover, with wood pulp as a source further down the line.
Wood pulp and other biomass from the lumber and paper industries could shape up as one of the best sources of biofuels. At the opening day of the conference, two UW-Stevens Point professors--Don Guay and Eric Singaas--gave an overview of their research on creating an integrated forest biorefinery that can work with multiple feed stocks, and create multiple products.
This biorefinery could use miscanthus grass, corn stover, or wood pulp and other woody biomass as raw materials, including under-pulped material from mills, slash and waste from lumber operations, and even laminated paper that is hard to recycle. But the goal isn't simply to turn all this matter into ethanol. Instead, their process would separate three key components in the material (cellulose, hemicellulose, and lignin), create what they call a "sugar platform" from the separated materials, and convert the sugars and lignin into products.
Two key outputs would be methyl butenol, which has a higher energy content than ethanol and could be used to produce a next generation biofuel, and isoprene, which could be used to manufacture rubber, replacing a carcinogenic chemical known as butadiene. "We don't want to make ethanol," Guay told conference goers. "Ethanol is a fine first generation fuel. We want to make something more energy dense, and more equivalent to today's gasoline or diesel fuel."
What's more, the researchers envision that a forest biorefinery could be retrofitted to existing or closed paper mills, potentially reviving the sagging paper industry in Wisconsin.
So here we have a biofuel with higher energy content than corn ethanol, that doesn't drive up the price of food, and that can be made with biomass that isn't even used to make paper. What's not to love? Mainly, it will take time. Guay says the bench testing for such a forest biorefinery will take a year and half to two years to complete, and then pilot testing could take another two to three years, putting commercial readiness roughly five years out on the horizon.
Another huge question such research raises is whether the booming corn ethanol industry is simply a temporary market. Again, that question merits another posting. For now, ethanol and biodiesel producers are thinking of ways to future-proof their facilities against market changes, such as biodiesel refineries that are built to use multiple feed stocks instead of just one, like soybeans.
My overall take is that our biofuels destiny isn't settled around one technology. Morby seems on the mark in saying that corn-based ethanol needs to be part of the answer. We will see if corn ethanol turns out to be more of a transitionary technology.