Large-scale ethanol fermentation through pipeline delivery of biomass

Issues of traffic congestion and community acceptance limit the size of biomass-processing plants based on truck delivery to about 2 million (M) dry t/yr or less. In this study, the cost of ethanol from an ethanol fermentation plant processing 2 M dry t/yr of corn stover supplied by truck is compared with that of larger plants in the range of 4–38 M dry t/yr supplied by a combination of trucks plus pipelines. For corn stover, a biomass source with a low yield per gross hectare, the cost of ethanol from larger plants is always higher. For wood chips from the boreal forest, a biomass source with a relatively high yield per gross hectare, a plant processing 14–38 M dry t/yr produces ethanol at a 13% reduction in cost compared with a plant producing 2 M dry t/yr supplied by truck. Processing of value-added products, such as chemicals from lignin, would be enabled by larger-scale plants.     

Development of a multicriteria assessment model for ranking biomass feedstock collection and transportation systems

This study details multicriteria assessment methodology that integrates economic, social, environmental, and technical factors in order to rank alternatives for biomass collection and transportation systems. Ranking of biomass collection systems is based on cost of delivered biomass, quality of biomass supplied, emissions during collection, energy input to the chain operations, and maturity of supply system technologies. The assessment methodology is used to evaluate alternatives for collecting 1.8×10⁶ dry t/yr based on assumptions made on performance of various assemblies of biomass collection systems is based on cost of delivered biomass, quality of biomass supplied, emissions during collection, energy input to the chain operations, and maturity of supply system technologies. The assessment methodology is used to evaluate alternatives for collecting 1.8×10⁶ dry t/yr based on assumptions made on performance of various assemblies of biomass collection systems. A proposed collection option using loafer/stacker was shown to be the best option followed by ensiling and baling. Ranking of biomass transport systems is based on cost of biomass transport, emissions during transport, traffic congestion, and maturity of different technologies. At a capacity of 4×10⁶ dry t/yr, rail transport was shown to be the best option, followed by truck transport and pipeline transport, respectively. These rankings depend highly on assumed maturity of technologies and scale of utilization. These may change if technologies such as loafing or ensiling (wet storage) methods are proved to be infeasible for large-scale collection systems.     

The relative cost of biomass energy transport

Logistics cost, the cost of moving feedstock or products, is a key component of the overall cost of recovering energy from biomass. In this study, we calculate for small- and large-project sizes, the relative cost of transportation by truck, rail, ship, and pipeline for three biomass feedstocks, by truck and pipeline for ethanol, and by transmission line for electrical power. Distance fixed costs (loading and unloading) and distance variable costs (transport, including power losses during transmission), are calculated for each biomass type and mode of transportation. Costs are normalized to a common basis of a giga Joules of biomass. The relative cost of moving products vs feedstock is an approximate measure of the incentive for location of biomass processing at the source of biomass, rather than at the point of ultimate consumption of produced energy. In general, the cost of transporting biomass is more than the cost of transporting its energy products. The gap in cost for transporting biomass vs power is significantly higher than the incremental cost of building and operating a power plant remote from a transmission grid. The cost of power transmission and ethanol transport by pipeline is highly dependent on scale of project. Transport of ethanol by truck has a lower cost than by pipeline up to capacities of 1800 t/d. The high cost of transshipment to a ship precludes shipping from being an economical mode of transport for distances less than 800 km (woodchips) and 1500 km (baled agricultural residues).     

Rail vs truck transport of biomass

This study analyzes the economics of transshipping biomass from truck to train in a North American setting. Transshipment will only be economic when the cost per unit distance of a second transportation mode is less than the original mode. There is an optimum number of transshipment terminals which is related to biomass yield. Transshipment incurs incremental fixed costs, and hence there is a minimum shipping distance for rail transport above which lower costs/km offset the incremental fixed costs. For transport by dedicated unit train with an optimum number of terminals, the minimum economic rail shipping distance for straw is 170 km, and for boreal forest harvest residue wood chips is 145 km. The minimum economic shipping distance for straw exceeds the biomass draw distance for economically sized centrally located power plants, and hence the prospects for rail transport are limited to cases in which traffic congestion from truck transport would otherwise preclude project development. Ideally, wood chip transport costs would be lowered by rail transshipment for an economically sized centrally located power plant, but in a specific case in Alberta, Canada, the layout of existing rail lines precludes a centrally located plant supplied by rail, whereas a more versatile road system enables it by truck. Hence for wood chips as well as straw the economic incentive for rail transport to centrally located processing plants is limited. Rail transshipment may still be preferred in cases in which road congestion precludes truck delivery, for example as result of community objections.     

Availability of crop residues as sustainable feedstock for bioethanol production in North Carolina

The amount of corn stover and wheat straw that can be sustainably collected in North Carolina was estimated to be 0.64 and 0.16 million dry t/yr, respectively. More than 80% of these crop residues are located in the coastal area. The bioethanol potential from corn stover and wheat straw was estimated to be about 238 million L (63 million gal/yr) in North Carolina. The future location of ethanol plant in North Carolina was estimated based on feedstock demand and collection radius. It is possible to have four ethanol plants with feedstock demand of 400, 450, 500, and 640 dry t/d. The collection radii for these four ethanol plants are 46, 60, 42, and 67 km (28, 37, 26, and 42 miles), respectively. The best location for a bioethanol plant includes four counties (Beaufort, Hyde, Tyrrell, and Washington) with feedstock demand of 500 t/d and collection radius about 26 mile.     

Assessment of Xylanase Activity in Dry Storage as a Potential Method of Reducing Feedstock Cost

Enzymatic preprocessing of lignocellulosic biomass in dry storage systems has the potential to improve feedstock characteristics and lower ethanol production costs. To assess the potential for endoxylanase activity at low water contents, endoxylanase activity was tested using a refined wheat arabinoxylan substrate and three commercial endoxylanases over the water activity range 0.21–1.0, corresponding to water contents of 5% to >60% (dry basis). Homogeneously mixed dry samples were prepared at a fixed enzyme to substrate ratio and incubated in chambers at a variety of fixed water activities. Replicates were sacrificed periodically, and endoxylanase activity was quantified as an increase in reducing sugar relative to desiccant-stored controls. Endoxylanase activity was observed at water activities over 0.91 in all enzyme preparations in less than 4 days and at a water activity of 0.59 in less than 1 week in two preparations. Endoxylanase activity after storage was confirmed for selected desiccant-stored controls by incubation at 100% relative humidity. Water content to water activity relationships were determined for three lignocellulosic substrates, and results indicate that two endoxylanase preparations retained limited activity as low as 7% to 13% water content (dry basis), which is well within the range of water contents representative of dry biomass storage. Future work will examine the effects of endoxylanase activity toward substrates such as corn stover, wheat straw, and switchgrass in low water content environments.     

Methodology for estimating removable quantities of agricultural residues for bioenergy and bioproduct use

A methodology was developed to estimate quantities of crop residues that can be removed while maintaining rain or wind erosion at less than or equal to the tolerable soil-loss level. Six corn and wheat rotations in the 10 largest corn-producing states were analyzed. Residue removal rates for each rotation were evaluated for conventional, mulch/reduced, and no-till field operations. The analyses indicated that potential removable maximum quantities range from nearly 5.5 million dry metric t/yr for a continuous corn rotation using conventional till in Kansas to more than 97 million dry metric t/yr for a corn-wheat rotation using no-till in Illinois.     

Design and Evaluation of an Optimal Controller for Simultaneous Saccharification and Fermentation Process

Ethanol from corn is produced using dry grind corn process in which simultaneous saccharification and fermentation (SSF) is one of the most critical unit operations. In this work an optimal controller based on a previously validated SSF model was developed by formulating the SSF process as a Bolza problem and using gradient descent methods. Validation experiments were performed to evaluate the performance of optimal controller under different process disturbances that are likely to occur in practice. Use of optimal control algorithm for the SSF process resulted in lower peak glucose concentration, similar ethanol yields (13.38±0.36% v/v and 13.50±0.15% v/v for optimally controlled and baseline experiments, respectively). Optimal controller improved final ethanol concentrations as compared to process without optimal controller under conditions of temperature (13.35±1.28 and 12.52±1.19% v/v for optimal and no optimal control, respectively) and pH disturbances (12.65±0.74 and 11.86±0.49% v/v for optimal and no optimal control, respectively). Cost savings due to lower enzyme usage and reduced cooling requirement were estimated to be up to $1 million for a 151 million L/yr (40 million gal/yr) dry grind plant.     

Effect of microwave pretreatment of coal for improvement of rheological characteristics of coal-water slurries

Indian high-ash coal contains alpha-silica components of the mineral matter. When coal is transported in the form of a slurry, alpha-silica adds to the settling properties of coal and enhances erosion of pipelines. As such any technique that will contribute to changing the characteristics of mineral matter by selective demineralization is bound to supplement the knowledge of coal slurries in the science of rheology. One such method is the use of a novel microwave technology, which changes the alpha-silica to less harmful beta-silica. Thus microwave-treated coal slurry facilitates enhanced flow characteristics and abates the erosion problem in pipeline transport as well as in coal-slurry injection furnaces. This paper reports on the rheological study of closely sized coal particles of medium-volatile, low-ash, low-moisture cleans and high-ash rejects with and without microwave treatment. Viscosity of suspensions of microwave-treated coal was found to be less than that of untreated coal, in the case of both cleans and rejects. Microwave pretreatment thus reduces the viscosity and the pumping cost and opens a new outlook for pipeline transport. An attempt has been made to quantify the improvement of rheological characteristics due to microwave pretreatment.     

A Simplified Method for the Measurement of Insoluble Solids in Pretreated Biomass Slurries

The biochemical conversion of cellulosic biomass to liquid transportation fuels includes the breakdown of biomass into its soluble, fermentable components. Pretreatment, the initial step in the conversion process, results in heterogeneous slurry comprised of both soluble and insoluble biomass components. For the purpose of tracking the progress of the conversion process, it is important to be able to accurately measure the fraction of insoluble biomass solids in the slurry. The current standard method involves separating the solids from the free liquor and then repeatedly washing the solids to remove the soluble fraction, a laborious and tedious process susceptible to operator variations. In this paper, we propose an alternative method for calculating the fraction of insoluble solids which does not require a washing step. The proposed method involves measuring the dry matter content of the whole slurry as well as the dry matter content in the isolated liquor fraction. We compared the two methods using three different pretreated biomass slurry samples and two oven-drying techniques for determining dry matter content, an important measurement for both methods. We also evaluated a large set of fraction insoluble solids data collected from previously analyzed pretreated samples. The proposed new method provided statistically equivalent results to the standard washing method when an infrared balance was used for determining dry matter content in the controlled measurement experiment. Similarly, in the large historical data set, there was no statistical difference shown between the wash and no-wash methods. The new method is offered as an alternative method for determining the fraction of insoluble solids.     

Development of an ultra-high-pressure liquid chromatography–tandem mass spectrometry multi-residue sulfonamide method and its application to water,manure slurry,and soils from swine rearing facilities

An analytical method was developed using ultra-high-pressure liquid chromatography–triple quadrupole-tandem mass spectrometry (UHPLC–TQ-MS/MS) to simultaneously analyze 14 sulfonamides (SA) in 6 min. Despite the rapidity of the assay the system was properly re-equilibrated in this time. No carryover was observed even after high analyte concentrations. The instrumental detection limit based on signal-to-noise ratio (S/N) > 3, was below 1 pg/μL (5 pg on column) for all SAs except sulfachloropyridazine. Surface water, ground water, soil, and slurry manure contained in storage ponds in and around swine [Sus scrofa domesticus] rearing facilities were analyzed. Sample cleanup for ground water and surface water included using solid phase extraction (SPE) using Oasis^® hydrophilic–lipophilic balance (HLB) cartridges. The soil and slurry manure required tandem strong anion exchange (SAX) and HLB solid phase extraction cartridges for sample cleanup. With few exceptions, the recoveries ranged from 60 to 100% for all matrices. The minimum detectable levels were below 2.0 ng/L for water, 30 ng/L for slurry manure, and 45 ng/kg for soil except for sulfachloropyridazine. The coefficient of variation (CV) was within 20% for most of the compounds analyzed. Using this method, sulfamethazine concentrations of 2250–5060 ng/L, sulfamethoxazole concentrations of 108–1.47 × 10⁶ ng/L, and sulfathiazole concentrations of 785–1700 ng/L were found in the slurry manure. Sulfadimethoxine (2.0–32 ng/L), sulfamethazine (2.0–5.1 ng/L), and sulfamethoxazole (20.5–43.0 ng/L) were found in surface water and ground water. In top soil (0–15 cm), sulfamethazine ranged 34.5–663 ng/kg dry weight in those locations that received slurry manure as a nutrient; no SAs were found in the soil depths between 46 and 61 cm. The speed makes the method practical for medium to high throughput applications. The sensitivity and positive analyte identification make the method suitable for the demanding requirements for real world applications.     

Ammonia Fiber Expansion (AFEX) Pretreatment,Enzymatic Hydrolysis,and Fermentation on Empty Palm Fruit Bunch Fiber (EPFBF) for Cellulosic Ethanol Production

Empty palm fruit bunch fiber (EPFBF), a readily available cellulosic biomass from palm processing facilities, is investigated as a potential carbohydrate source for cellulosic ethanol production. This feedstock was pretreated using ammonia fiber expansion (AFEX) and enzymatically hydrolyzed. The best tested AFEX conditions were at 135 °C, 45 min retention time, water to dry biomass loading of 1:1 (weight ratio), and ammonia to dry biomass loading of 1:1 (weight ratio). The particle size of the pretreated biomass was reduced post-AFEX. The optimized enzyme formulation consists of Accellerase (84 μL/g biomass), Multifect Xylanase (31 μL/g biomass), and Multifect Pectinase (24 μL/g biomass). This mixture achieved close to 90% of the total maximum yield within 72 h of enzymatic hydrolysis. Fermentation on the water extract of this biomass affirms that nutrients solely from the pretreated EPFBF can support yeast growth for complete glucose fermentation. These results suggest that AFEX-treated EPFBF can be used for cellulosic biofuels production because biomass recalcitrance has been overcome without reducing the fermentability of the pretreated materials.     

Oxidative lime pretreatment of high-lignin biomass

Lime (Ca[OH]₂) and oxygen (O₂) were used to enhance the enzymatic digestibility of two kinds of high-lignin biomass: poplar wood and newspaper. The recommended pretreatment conditions for poplar wood are 150°C, 6 h, 0.1 g of Ca(OH)₂/g of dry biomass, 9 mL of water/g of dry biomass, 14.0 bar absolute oxygen, and a particle size of −10 mesh. Under these conditions, the 3-d reducing sugar yield of poplar wood using a cellulase loading of 5 filter paper units (FPU)/g of raw dry biomass increased from 62 to 565 mg of eq. glucose/g of raw dry biomass, and the 3-d total sugar (glucose + xylose) conversion increased from 6 to 77% of raw total sugars. At high cellulase loadings (e.g., 75 FPU/g of raw dry biomass), the 3-d total sugar conversion reached 97%. In a trial run with newspaper, using conditions of 140°C, 3 h, 0.3 g of Ca(OH)₂/g of dry biomass, 16 mL of water/g of dry biomass, and 7.1 bar absolute oxygen, the 3-d reducing sugar yield using a cellulase loading of 5 FPU/g of raw dry biomass increased from 240 to 565 mg of eq. glucose/g of raw dry biomass. A material balance study on poplar wood shows that oxidative lime pretreatment solubilized 38% of total biomass, including 78% of lignin and 49% of xylan; no glucan was removed. Ash increased because calcium was incorporated into biomass during the pretreatment. After oxidative lime pretreatment, about 21% of added lime could be recovered by CO₂ carbonation.     

Integrated Conversion of Lignocellulosic Biomass to Bio-Based Amphiphiles using a Functionalization-Defunctionalization Approach

Concerns over the sustainability and end-of-life properties of fossil-derived surfactants have driven interest in bio-based alternatives. Lignocellulosic biomass with its polar functional groups is an obvious feedstock for surfactant production but its use is limited by process complexity and low yield. Here, we present a simple two-step approach to prepare bio-based amphiphiles directly from hemicellulose and lignin at high yields (29 % w/w based on the total raw biomass and >80 % w/w of these two fractions). Acetal functionalization of xylan and lignin with fatty aldehydes during fractionation introduced hydrophobic segments and subsequent defunctionalization by hydrogenolysis of the xylose derivatives or acidic hydrolysis of the lignin derivatives produced amphiphiles. The resulting biodegradable xylose acetals and/or ethers, and lignin-based amphiphilic polymers both largely retained their original natural structures, but exhibited competitive or superior surface activity in water/oil systems compared to common bio-based surfactants.     

Continuous separation of oil from water surface by a novel tubular unit based on graphene coated polyurethane sponge

We develop a new strategy for the continuous separation of oil from water surface using a novel tubular unit based on graphene coated polyurethane (P‐GEPU) sponge, and the P‐GEPU sponge was fabricated by a simple dip‐coating method; the as‐prepared sponges could adsorb different kinds of oil and organic liquids while repelling water. Moreover, the tubular unit was assembled by wrapping the P‐GEPU sponge on a porous PU hollow tube and combined with the accessories including pipes and joints. The tubular unit could float on the surface of water, and a continuous oil collection from water surface through vacuum pressure could be fulfilled, showing a high oil‐water separation efficiency (>96%). Finally, oil‐water separation efficiency remains above 93% after 10 cycles, exhibiting excellent reusability. In addition, our findings are easily scaled up, showing a great promise for large‐scale oil spill remediation.     

松木粉气流床气化特性实验研究

在气流床气化实验装置上进行了松木粉气化特性的研究。考察了温度、氧当量比、水蒸气配比对气体产物的成分、气化特性和固体产物的微观形态及成分的影响,结果表明,随着温度的升高,CO与H₂浓度显著升高,CO₂与CH₄浓度明显下降,碳转化率、产气率、产气热值有所提高;氧当量比从0.2上升至0.5时,CO与H₂浓度降低超过10%,CO₂浓度则上升100%以上,碳转化率提高至92.9%,产气率有所上升,而产气热值则降低超过20%;水蒸气配比从0增大至0.58时,H₂/CO体积比由0.63提高为1.40,碳转化率、产气率和产气热值均呈现先增大后减小趋势。由SEM照片可以看出,固体残渣主要由类球状或块状结构与纤维团聚结构两部分组成。温度升高使残渣颗粒由呈现不规则形状逐渐向球形转化,氧当量比的增大使残渣中类球状颗粒表面孔洞与裂缝明显增多直至破碎。     

Evaluation of Methanogenic Activity of Biogas Plant Slurry for Monitoring Codigestion of Ossein Factory Wastes and Cyanobacterial Biomass

Overall measurement of methanogenic activity of sludge and or slurry is thought as a key for understanding the basic physiology of anaerobic consortia involved in anaerobic digestion process of an alternative biomass. In this study, the methanogenic activity of biogas plant slurry was used to evaluate the anaerobic digestion of ossein factory wastes such as sinews and primary clarified bone waste (PCBW) and cyanobacterial biomass in standard assay conditions. A maximum methanogenic activity was reported here when ossein factory wastes mixed with cyanobacterial biomass in specific proportions in which sinews and PCBW alone also favored to a significant methane yield. Cyanobacterial biomass alone did not give a desirable methanogenic activity. Approximately 48% of total solids were destroyed from these wastes after 30 days. This study gives information on the use of these wastes with suitable proportions for taking an effort in a large-scale anaerobic digestion in an effective way of ossein factory.     

Thermal analysis and gas chromatography coupled mass spectrometry analyses of hydroxypropyl-β-cyclodextrin inclusion complex containing Lippia gracilis essential oil

Inclusion complexation with cyclodextrins is an effective way to improve stability and turn liquid materials into re-dispersible and easy-to-handle powders. In the present work, the complexation of L. gracilis essential oil, already recognized as a potent larvicide material, with hydroxylpropyl-β-cyclodextrin was performed using slurry and paste procedures and the complexes obtained were evaluated. The gas chromatography coupled to mass spectrometry (GC/MS) analysis showed a total volatile content of 99.24% in the L. gracilis oil. The characterization of the complex involved the analysis of the original essential oil, the surface, and the total extracted oils. The major components in L. gracilis essential oil were identified as carvacrol (23.52%), p-cymene (15.82%), γ-terpinene (14.17%), and thymol (7.27%). GC/MS results showed significant differences between the original oil, the slurry, and paste complexation. Thermal characterization indicates the occurrence of complexation, mainly in paste complexes, which presents a TG–DTA peak at 230–275 °C, probably related to oil loss.     

Crop Yield and Essential Oil Composition of Two Thymus vulgaris Chemotypes along Three Years of Organic Cultivation in a Hilly Area of Central Italy

Thymus vulgaris L. is one of the most commonly used medicinal and aromatic plants (MAPs), owing to a range of therapeutic properties of its essential oil. Plant growth, biomass yield, essential oil content and composition are influenced by chemotype, environmental conditions, cultivation techniques and vegetative development. Since in MAPs cultivation special attention is paid on high quality of raw material, the adoption of sustainable agriculture methods is of pivotal importance. Therefore, we evaluated the agronomic and qualitative performances of two Thymus vulgaris L. chemotypes, organically cultivated under the Mediterranean climate of hilly lands of central Italy for three consecutive years (2017–2019). Along the trial, total above-ground dry biomass significantly increased from the 1st to 3rd year after planting and large variations in the main biological, biometric and productive traits were observed between the two chemotypes. The ‘thymol’ chemotype EO obviously showed thymol as the major constituent (51.26–49.87%) followed by γ-terpinene and p-cymene. The ‘linalool’ chemotype EO showed high percentages of oxygenated monoterpenes (about 90%) with linalool (75%), linalyl acetate (8.15%) and b-caryophyllene (3.2%) as main constituents. This study highlighted that T. vulgaris can be successfully organically grown in the hilly lands of Tuscany, with interesting biomass and essential oil yields, even though the plants were in the initial years of crop establishment (start in 2017). The introduction of this species into organic cultivation systems could contribute to obtain high-quality raw material, as well as to enhance crop rotation diversification, which is of pivotal importance in the management of organic farms.     

Conversion of the Estonian fossil and renewable feedstocks in the medium of supercritical water

Two different Estonian oil shales, peat, and willow biomass were submitted to supercritical water conversion at unified operating conditions. The yield and chemical composition of conversion products were investigated by chromatographic, FTIR-spectroscopic and ultimate analysis techniques. The results reveal significant difference in products yield and composition those depending on the feedstock origin and its chemical composition. Common and specific features in conversion of fossil and renewable matter were described. The maximum and the minimum oil yield per organic matter, 62.7 and 18.6%, respectively, were obtained in conversion of oil shales. Willow biomass conversion resulted in the highest yield of gas and water (50%). The solubility of oils despite original feedstock increases with solvents used in the raw: dimethyl ketone < water < benzene. The investigation on group composition of the benzene-soluble compounds demonstrated that various oxygen compounds dominate over hydrocarbons in all cases. The majority of hydrocarbons was represented by polycyclic aromatic ones. Aliphatic hydrocarbons, making 6–11% of the benzene-soluble oil were represented by n-alkanes up to C₃₃. Conversion gases, especially those of peat and willow were characterized by high carbon dioxide content. Supercritical water conversion can be used as an alternative method for the liquefaction and gasification of different feedstocks.