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World: Oil and Gas - Biofuels Manufacturing
 - Overview


^ Introduction

The population of the world continues to grow, as does the average standard of living, increasing demand for food, water and energy and placing increasing pressure on the environment. The population of the world doubled from 3.2 billion in 1962 to 6.4 billion in 2005 and is forecast to grow to 9.2 billion in 2050.

Supplies of oil, gas, coal and uranium are forecast to peak as reserves are depleted. At the same time, fear of climate change is putting pressure on the energy sector to move away from carbon burning to nuclear, solar and other environmentally friendly energy sources.

Biofuels are most usually made from sugar cane, maize, soya, rapeseed oil, palm oil or other plant material and then blended with gasoline and diesel for use in motor vehicles, engines and generators. The main drivers behind the development of the biofuels industry are high crude oil prices, energy security and concern about the environment. The major drawbacks to biofuels are cost, energy consumed in the manufacture of biofuels, the impact on food prices and questions about the environmental benefits.

High crude prices are causing balance of payments problems for importing countries. A local biofuels industry cuts down on imports of crude oil and refined products, increases employment and stimulates the local economy. For instance, from 1976 to 2004, Brazil's ethanol production substituted for oil imports worth $US 60.7 billion or as much as $US 121.3 billion including the avoided interest that would have been paid on foreign debt (based on debt previously incurred importing oil).

The World Bank reported that biofuel industries require about 100 times more workers per unit of energy produced than the fossil fuel industry. The ethanol industry is credited with providing more than 200,000 jobs in the USA and half a million direct jobs in Brazil.

For the USA, the key issue was security of fuel supply as the world relied increasingly on countries that were politically unstable or potentially hostile for crude oil and gas supplies. The USA is aiming for 10% ethanol in gasoline. Ethanol is also increasingly being used in reformulated gasoline as MBTE is phased out. The prospect of peak oil does not seem to have been a contributor to the decision.

In the European Union, a combination of energy security and environmental concerns has driven the move towards biofuels. The EU has legislated targets for minimum amounts of biofuels blended with gasoline and diesel. That said, some of the countries supplying vegetable oils for biodiesel have similar political make-up to the crude suppliers and are even OPEC members.

Initially biofuels were seen as being environmentally positive. The plants grown for biofuels absorb more carbon dioxide from the atmosphere than are released when the biomass was combusted as a fuel. This should be much better for the environment than burning oil or coal. Studies have shown that in some, but not all, circumstances when the full cost and energy consumption of the total cycle of building the production facilities, making the fertiliser, ploughing and planting, irrigation, harvesting, conversion and distribution is taken into account, then there is a net loss.

Add to this the slash and burn activities taking place in Indonesia and other countries as tropical forest is replaced by oil palms and the environmental benefits become extremely questionable. A UK government / World Bank study shows Indonesia and Brazil as the third and fourth largest emitters of greenhouse gases after the USA and China as a result of burning of the tropical forests, in many cases to make way for biofuel agriculture.

Finally rising food prices around the world are causing governments to have second thoughts about using arable land for growing biomass rather than food and the incentives provided to farmers. And a litre of biofuel requires roughly 1,000 litres of water to produce at a time when the world is facing a water supply shortage.

On the assumption that biofuels were beneficial, most OECD countries have mandated that biofuels are blended with petroleum products for use in motor vehicles and have introduced systems of subsidies, tariffs and levies as needed to ensure this takes place. Motor manufacturers are redesigning engines so they can both use blended fuels and also reduce overall emissions. As governments have second thoughts about the benefits of biofuels, changes in policy are proving difficult and potentially expensive.

Much of the future of biofuels relies on the development of cellulosic technology. In June 2007, the Seawater Foundation announced plans to use sea water to grow algae for biofuels.

To add fuel to the biofuel fire, in June 2007 OPEC ministers warned that if biofuels growth continues, they would not invest in new crude oil production capacity.

^ Biofuel Products

The main biofuels are ethanol, currently made from corn (maize), sugar cane, sorghum and jatropha, and biodiesel, made from soya, palm oil and rapeseed oil. These are then blended with gasoline and diesel respectively for use in motor vehicles, engines and generators.

Many countries around the world have biofuel production projects underway including:

Sugar cane Brazil, India, Pakistan
Corn / maize USA, China
Wheat Germany, France, Spain, UK
Soya USA, Brazil, Argentina
Canola / rapeseed EU, Russia, Ukraine
Sunflower EU, Russia, Ukraine
Palm Indonesia, Malaysia, Thailand
Callow USA, Brazil, Australia
Jatropha Being tried in India, Burma, South Africa, Mozambique, East Africa, parts of Asia
Waste oil China, USA
Pongamia Being tried in India
Others China, Africa, Thailand

Biofuels are less efficient than power generation at converting biomass to useable energy and reducing carbon dioxide production. They have limited compatibility with conventional vehicle engine systems, limiting the concentration in liquid fuels to 15%. They also have a lower energy content than other hydrocarbon fuels.

Crude oil comes out of the ground ready for refining. Before one can make biofuels, ground has to be cleared, fields ploughed, fertilizer and herbicide manufactured and spread, water pumped into the irrigation system and the crop harvested and moved to the factory. All these steps take energy, the more so when the land undulates or the climate is moderate, which is why Brazil with its flat plains and wet, semi-tropical climate is better for growing sugar cane for ethanol than most other places in the world.

The cost of producing biofuels includes the feedstock, fertilizers, and energy consumed in harvesting, transport and manufacture. Biofuels are becoming increasingly economically viable as petroleum prices rise and technological advances decrease biofuel production costs and energy consumption. Ethanol from corn in the United States and from sugar cane in Brazil is probably cost-competitive with petroleum products even if subsidies are removed and petroleum prices fall considerably.

There is some disagreement about whether the amount of energy required to produce biofuels, particularly ethanol from corn, is more than the energy content of the resulting biofuel. One result of the debate has been the promotion of the use of biofuels waste as an energy source in the manufacture process rather than coal.

Because they cost more to produce both per litre, and per unit of energy, than hydrocarbon fuels, usage has to be subsidised. According to the Global Subsidies Initiative, the biofuels industry will receive more than US$ 92 billion in subsidies between 2006 and 2012.

Distribution and delivery of biofuels are difficult because of hydration and miscibility, particularly of ethanol.

^ Supply and Demand

Total world biofuel production in 2004 was 130 million barrels, 95% of which was ethanol. The 2005 world market for biofuels was US$ 15.7 billion, up 15% from 2004. World production of biofuels in 2007 was 54 billion litres, 20% higher than 2006. Other sources claim world biofuel production increased 60% from 2004 to 2005, reaching 31 million tonnes. In 2004, ethanol made up 44% of the total fuel consumption in all non-diesel motor vehicles in Brazil while it was being blended with 30 percent of total gasoline sold in US.

The US Department of Energy aims to increase the use of renewables in the US transportation sector to the equivalent of 135 billion litres of ethanol by 2017. The U.S. Energy Independence and Security Act of 2007 expanded the U.S. Renewable Fuels Standard, calling for the use of 136 billion litres of biofuels in 2022, with 60 billion litres mandated for cellulosic ethanol. The US already provides a tax credit of 51 cents per gallon of biofuel to fuel blenders and retailers, while at the same time imposing an import duty of 54 cents a gallon on imported biofuels.

The EU has a target of biofuels comprising 5.75% of transport fuels by 2010 and 10% by 2020, equivalent to 14% of current EU cereal production. From March 2008, all UK fuel suppliers are required to ensure 2.5% of fuel is derived from biomass, increasing to 5% in 2010 and 33% in 2050. Japan aims to produce 6 billion litres per year by 2030 and China 13 billion litres of ethanol and 2.3 billion litres of biodiesel by 2020. As the adverse effect of biofuels becomes better known, these targets could well be revised downwards.

Demand for biofuels is forecast to expand almost 20% per year through 2011 to 92 million metric tons, despite recent concerns about the impact of biofuels on the environment and world food supplies. The global market for ethanol is expected to increase 100%, with the biodiesel market achieving even more rapid growth. Other biofuels will also achieve double digit gains, though from a much smaller base.

According to Clean Edge, the global biofuels market could grow from US$ 20 billion in 2007 to US$ 80 billion in 2016.

The IEA forecasts MTOE biofuels consumption with no new government measures as follows:

  2010 2015 2030
Europe 14.8 18.0 26.6
USA 14.9 19.8 22.8
Brazil 8.3 10.4 20.3
China 0.7 1.5 7.9
India 0.1 0.2 2.4
Total 41.5 54.4 92.4

With additional government measures, consumption could be up to 60% higher.

The value of biofuel production plants announced or under construction exceeds $US 4 billion in the United States, $US 4 billion in Brazil and $US 2 billion in France. However 2007 investment in biofuels was lower than 2006 due to increasing feedstock prices and socio-environmental concerns.

In 2007, biofuel companies raised $US 1 billion in equity, approximately $2 billion less than in 2006. Shares in the sector lost 19% of their value in 2007. Some one third of the profits of Archer Daniels Midland, leading producer of ethanol from corn in the USA and biodiesel from seeds in Europe, now come from biofuels. In November 2006, the company announced plans to further boost biofuel production from biomass, sugar and palm oil.

^ Ethanol

Ethanol is made from sugar cane (50%), corn / maize (36%), wheat (9%) and other vegetation (5%). Ethanol is likely to continue to be made predominantly from sugar cane in tropical countries and corn in moderate climates. There are around 600 ethanol plants in operation around the world, of which more than 100 are in the USA, where a further 75 are under construction. Ethanol is blended with crude oil derived gasoline. Ethanol is corrosive and soluble in water, making handling difficult.

Global ethanol production more than doubled between 2000 and 2005. In 2005, ethanol comprised about 1.2% of the world's gasoline supply by volume and about 0.8% percent by transport distance traveled (due to its lower energy content).

In 2005, Brazil produced 16.5 billion liters of fuel ethanol, 45.2% percent of the world's total and mostly from sugar cane. Ethanol provides roughly 40% of Brazil's non-diesel fuel. Brazil increased its ethanol production by 21% in 2007 to 19 billion litres.

In 2005, the USA produced 16.2 billion liters of ethanol, 44.5% of the world's total and mostly from corn (maize). Ethanol provides 2 to 3% of US non-diesel fuel. The USA increased output 33% to 24.5 billion litres in 2007. 2007 / 2008 US corn demand for ethanol production was expected to be one billion bushels higher than a year before at 2.15 billion.

The European Union, with a production of about 0.5 million tons per annum, is estimated to account for about 10% of the total world ethanol.

From 1976 to 2004, Brazil's ethanol production substituted for oil imports worth $US 60.7 billion or as much as $US 121.3 billion including the avoided interest that would have been paid on foreign debt (based on debt previously incurred importing oil).

The global ethanol market is expected to exceed 120 billion litres by the end of 2020, with a growth rate of above 6.5% from 2006.

A study in the USA has shown that the process of creating ethanol from maize can consume 27% more energy than is contained in the resulting ethanol.

Next-generation cellulosic technologies will become commercially significant in the longer term.

^ Biodiesel

Methyl ester, the core ingredient of biodiesel, is derived from soya oil (43%), canola / rapeseed oil (34%), sunflower oil (9%), palm oil (7%), callow (4%) and waste oil (4%). There are about 400 biodiesel plants around the world, with the USA accounting for more than 100 of these and with another 80 under construction there. Biodiesel is blended with crude oil derived diesel fuel.

Overall worldwide production of biodiesel was 5.4 million tonnes in 2007, up 80% from 3 million tonnes in 2006. Global production of biodiesel, starting from a much smaller base than ethanol, expanded nearly fourfold between 2000 and 2005 and rose sharply in 2006 but slowed in 2007 as new German taxes cut demand. Growing at the rate of more than 30% from the year 2006, world biodiesel production is likely to 12 billion litres by the end of 2010.

European biodiesel production in 2006 was 3.96 million tonnes of fuel, a 50% increase jump from 2.63 million tonnes in 2005. For 2007, European biodiesel production was 4.7 million tonnes, up 19% on 2006. The EU accounted for nearly 90% of all biodiesel production worldwide in 2005. Biodiesel, produced mainly from rapeseed or sunflower seed, comprises 80% of Europe's total biofuel production.

Germany alone produced 1.9 billion litres, or more than half the world total. Germany increased biodiesel production capacity by 60% in 2007. Several large producers have since announced production cuts, and overall output is now falling well short of available capacity.

The Americas, mostly the USA, produced 980,000 tonnes of biodiesel in 2006. FAPRI estimates that US biodiesel production could rise to 1.8 million tonnes in 2007/08 from 1.3 million in 2006/07.

Malaysia plans to capture 10% of the global biodiesel market by 2010 through expansion of its palm oil plantations. Indonesia aims to expand its palm oil plantations to 1.5 million hectares by 2008 and increase palm oil production from 17 million tonnes in 2007 to 27 million tonnes in 2015, largely by replacing tropical jungle with biofuels plantations. In September 2007, Indonesia imposed a 10% surcharge on crude palm oil exports and plans to further increase export taxes on palm oil.

Biodiesel production will continue to centre on soy oil in the Americas, rapeseed oil in Europe and palm in the Asia/Pacific. Jatropha, a low cost, high yield non edible plant that can be grown in marginal areas, is being pioneered as a feedstock in Africa and Asia Pacific.

Palm oil prices increased by 60% in 2006 and by another 20% in 2007. In March 2008, palm oil prices reached record levels.

In November 2006, Archer Daniels Midland, leading producer of ethanol from corn in the USA and biodiesel from seeds in Europe, announced plans to boost biofuel production from biomass, sugar and palm oil.

Next-generation algal biodiesel technologies will become commercially significant in the longer term.

^ Emissions

Transportation, including emissions from the production of transport fuels, is responsible for about one-quarter of energy-related greenhouse gas emissions, and that share is rising. Energy crops have the potential to reduce greenhouse gas emissions by more than 100% (relative to petroleum fuels) because such crops can also sequester carbon in the soil as they grow.

Estimated reductions for biofuel feedstock include: fibers (switchgrass, poplar) 70-110%; wastes (waste oil, harvest residues, sewage) 65-100%; sugars (sugar cane, sugar beet) 40-90%; vegetable oils (rapeseed, sunflower seed, soybeans) 45-75%; and starches (corn, wheat) 15-40%.

The greenhouse gas balance of biofuels varies depending on such factors as feedstock choice, associated land use changes, feedstock production system, and the type of processing energy used. The greatest greenhouse gas benefits will be achieved with cellulosic inputs, such as dedicated energy crops and waste residues.

Recent studies conclude that clearing grass and forestlands to produce ethanol and other biofuels could potentially double the output of greenhouse gas emissions instead of reducing them.

The Netherlands has biodiesel refineries which use imported palm oil; however environmentalists there now worry that the Indonesian tropical forests being mown down to plant oil palms absorbed much more carbon dioxide from the atmosphere than are saved by palm-oil derived ethanol.

^ Food Supplies and Prices

In the last few years, the prices of food and of biofuel crops have risen significantly as a result of a number of factors. The world population continues to grow, living standards are rising in the developing world, the cost of fuel and fertilisers has risen in tandem with oil prices and many food growing areas have been stricken by drought or flood. The conversion of land from growing food crops to biofuel feedstock production is just another factor. Government policies on food and fuel, as well as taxes, tariffs and subsidies, all play a role, as does investor speculation. No one factor is solely responsible for the food price rises, though blame is frequently attributed to biofuels. At the same time new crop strains, including genetic modifications, improve yields and reduce requirements for fertilisers and pesticides.

As a result of high oil and gas prices, the price of urea, used in fertilisers, tripled between 2003 and 2008. Fertiliser prices rose more than 50% during 2007 to their highest in a decade. The chairman and CEO of Nestle reported that 70% of water was already being used by agriculture and that 1,000 litres of water are needed to produce one litre of biofuels.

Demand for animal fodder is growing. Indians now each eat 40% more meat than in 1990 and in China, which now eats one third of the world's meat production, twice as much. In Brazil, the amount of meat eaten per person has risen by a third in 15 years. By 2025 India's consumption of food and other products is expected to quadruple to US$ 1,500 billion, creating the world's 5th largest consumer economy after the USA, Japan, China and the UK.

The UN Food and Agriculture Organisation and the US Department of Agriculture estimated that the 2006 harvest wouldn't be enough to feed the world's population for the sixth time in seven years. Food production dropped from 2.6 billion tons in 1994 to under 2 billion tons in 2006, while food stocks dropped from enough to feed the world for 116 days in 1999 to 57 days in 2006.

In December 2007, the US Agriculture Department warned that stocks of corn, wheat and soya beans could drop sharply. In February 2008, US inventories of wheat dropped to their lowest level in 60 years. In October 2007 the Ukraine, with 41% of the world export market in sunflower oil, considered banning exports to keep local prices down. In early 2008, Asian rapeseed crops were hit by bad weather while Indonesia announced plans to increase export taxes on palm oil. In March 2008, prices of palm oil, soyabean and soyaoil reached record levels.

By February 2007, prices of malting barley, used in making beer, had risen by 85% since May 2006. 2006 USA barley production was the lowest since 1936. The US Department of agriculture estimated global barley production in 2007 would be the same as 2006, 10% down on 2005. The main reason given was the increased use of farm land for biofuel crops.

A July 2007 FAO / OECD report showed corn prices rose 60%, wheat prices 53% and soyabean prices 40% in the previous twelve months and predicted food price increases of between 20% and 50% over the next ten years, due to reduced subsidies, greater demand for protein, higher production costs and the demand for biofuels. According to the UN FAO the price of dairy products rose 80% and grain 42% during 2007. In February 2008, US prices for spring wheat reached record levels. On February 25th 2008, the world price of wheat rose 22% as Kazakhstan announced plans to curb exports.

In July 2007, the UN World Food Program reported that unit food costs had risen by 50% in five years, with maize costs alone up 120% over the previous year. In April 2008, the UN FAO forecast that the cost of African cereal imports in 2008 would rise 49% to US$ 15.2 billion. In April 2008, the UN FAO reported that poor countries will spend US$ 38.7 billion on cereal imports in 2008, up 57% from 2007 and more than 100% from 2006.

In the USA net returns from corn in 2007 were expected to reach US$ 334 per acre versus US$ 125 in 2006 as farmers played off the food and biofuels markets against each other. In February 2008, the US Department of Agriculture forecast ethanol's share of US corn would increase from 25% in 2007 to 31% in 2008. The March 2008 USDA report Prospective Plantings shows US farmers reducing land planted to corn by 8.1% and increasing land planted to soya beans from 63.6 million acres to 74.8 million acres.

Demand for rice has exceeded supply in six of past eight years and rice stocks are at their lowest level since 1976. Although the 2007 global rice crop of 420 million tonnes is a record, consumption is 423 million tonnes. On one day in March 2008, the price of rice in Asia rose 30% after Egypt, following the examples of Vietnam and India, banned the export of rice and the Philippines planned a large purchase on the open market. By April 2008, the price had doubled since January 2008 and stocks had dropped to 50% of 2000 levels. Rice prices, up 75% in a year, are at a 20 year high and stocks at a 25 year low.

In Mexico there were riots in 2007 when the cost of maize for tacos tripled. During January 2008, Pakistan experienced unrest after Egypt banned rice exports and Indonesia saw protests against record soyabean prices resulting from poor harvests in Brazil and Australia and US farmers moving to biofuels production. In April 2008, Indonesia banned the export of rice.

ISAAA estimated that the area of land planted with GM crops increased 70 times between 1997 and 2007 and will double again by 2015 from the existing 114 million hectares. The USA and Argentina are the largest users of GM crops out of the 23 countries that allow GM crops. Cropnosis estimates that the value of GM crops, mostly soybean, cotton, canola and corn will be worth US$ 6.9 billion in 2008.

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Information Source: MBendi - Modified: 08.May.2008
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