Total and Sustainable Utilization of Biomass Resources: A Perspective.

Feedstock cost is a major variable cost component in conversion to biofuels and chemicals. Consistent feedstock quality is critically important to achieve high product yield and maximum onstream time. Traditionally, raw biomass materials are delivered directly to the biorefineries where they are preprocessed to feedstock prior to being converted to products. Since many types of biomass materials-including agricultural residues, energy crops, and logging residues-are harvested according to growth cycles and optimal harvesting time, just-in-time steady supply of raw biomass to the biorefineries is not possible. Instead, biomass materials are stored, then delivered to the biorefineries as needed. Experience to date indicates that this approach has caused many issues related to logistics, biomass losses due to microbial degradation and fire, and inconsistent feedstock quality due to variability in the properties of as-delivered biomass. These factors have led to high feedstock cost, low throughput, and low product yield for the biorefineries. Idaho National Laboratory has developed a new strategy to address the problems encountered in the traditional approach in biomass feedstock supply, storage, and preprocessing mentioned above. The key components of this strategy are (1) preservation and preconditioning of biomass during storage, (2) utilization of all the biomass, including minor components that are normally considered wastes or contaminants, and (3) maximization of the value of each component. This new approach can be accomplished using feedstock preprocessing depots located near the biomass-production sources.

Compatibility of High-Moisture Storage for Biochemical Conversion of Corn Stover: Storage Performance at Laboratory and Field Scales.

Wet anaerobic storage of corn stover can provide a year-round supply of feedstock to biorefineries meanwhile serving an active management approach to reduce the risks associated with fire loss and microbial degradation. Wet logistics systems employ particle size reduction early in the supply chain through field-chopping which removes the dependency on drying corn stover prior to baling, expands the harvest window, and diminishes the biorefinery size reduction requirements. Over two harvest years, in-field forage chopping was capable of reducing over 60% of the corn stover to a particle size of 6 mm or less. Aerobic and anaerobic storage methods were evaluated for wet corn stover in 100 L laboratory reactors. Of the methods evaluated, traditional ensiling resulted in <6% total solid dry matter loss (DML), about five times less than the aerobic storage process and slightly less than half that of the anaerobic modified-Ritter pile method. To further demonstrate the effectiveness of the anaerobic storage, a field demonstration was completed with 272 dry tonnes of corn stover; DML averaged <5% after 6 months. Assessment of sugar release as a result of dilute acid or dilute alkaline pretreatment and subsequent enzymatic hydrolysis suggested that when anaerobic conditions were maintained in storage, sugar release was either similar to or greater than as-harvested material depending on the pretreatment chemistry used. This study demonstrates that wet logistics systems offer practical benefits for commercial corn stover supply, including particle size reduction during harvest, stability in storage, and compatibility with biochemical conversion of carbohydrates for biofuel production. Evaluation of the operational efficiencies and costs is suggested to quantify the potential benefits of a fully-wet biomass supply system to a commercial biorefinery.

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.

Conversion of distiller's grain into fuel alcohol and a higher-value animal feed by dilute-acid pretreatment.

Over the past three decades ethanol production in the United States has increased more than 10-fold, to approx 2.9 billion gal/yr (mid-2003), with ethanol production expected to reach 5 billion gal/yr by 2005. The simultaneous coproduction of 7 million t/yr of distiller's grain (DG) may potentially drive down the price of DG as a cattle feed supplement. The sale of residual DG for animal feed is an important part of corn dry-grind ethanol production economics; therefore, dry-grind ethanol producers are seeking ways to improve the quality of DG to increase market penetration and help stabilize prices. One possible improvement is to increase the protein content of DG by converting the residual starch and fiber into ethanol. We have developed methods for steam explosion, SO2, and dilute-sulfuric acid pretreatment of DG for evaluation as a feedstock for ethanol production. The highest soluble sugar yields (approximately 77% of available carbohydrate) were obtained by pretreatment of DG at 140 degrees C for 20 min with 3.27 wt% H2SO4. Fermentation protocols for pretreated DG were developed at the bench scale and scaled to a working volume of 809 L for production of hydrolyzed distiller's grain (HDG) for feeding trials. The pretreated DG was fermented with Saccharomyces cerevisiae D5A, with ethanol yields of 73% of theoretical from available glucans. The HDG was air-dried and used for turkey-feeding trials. The inclusion of HDG into turkey poult (as a model non-ruminant animal) diets at 5 and 10% levels, replacing corn and soybean meal, showed weight gains in the birds similar to controls, whereas 15 and 20% inclusion levels showed slight decreases (-6%) in weight gain. At the conclusion of the trial, no negative effects on internal organs or morphology, and no mortality among the poults, was found. The high protein levels (58-61%) available in HDG show promising economics for incorporation of this process into corn dry-grind ethanol plants.

Microbial pretreatment of biomass: potential for reducing severity of thermochemical biomass pretreatment.

Typical pretreatment requires high-energy (steam and electricity) and corrosion-resistant, high-pressure reactors. A review of the literature suggests that fungal pretreatment could potentially lower the severity requirements of acid, temperature and time. These reductions in severity are also expected to result in less biomass degradation and consequently lower inhibitor concentrations compared to conventional thermochemical pretreatment. Furthermore, potential advantages of fungal pretreatment of agricultural residues, such as corn stover, are suggested by its effectiveness in improving the cellulose digestibility of many types of forage fiber and agricultural wastes. Our preliminary tests show a three- to five-fold improvement in enzymatic cellulose digestibility of corn stover after pretreatment with Cyathus stercoreus; and a ten- to 100-fold reduction in shear force needed to obtain the same shear rate of 3.2 to 7 rev/s, respectively, after pretreatment with Phanerochaete chrysosporium.

Effects of temperature and moisture on dilute-acid steam explosion pretreatment of corn stover and cellulase enzyme digestibility.

Corn stover is emerging as a viable feedstock for producing bioethanol from renewable resources. Dilute-acid pretreatment of corn stover can solubilize a significant portion of the hemicellulosic component and enhance the enzymatic digestibility of the remaining cellulose for fermentation into ethanol. In this study, dilute H2SO4 pretreatment of corn stover was performed in a steam explosion reactor at 160 degrees C, 180 degrees C, and 190 degrees C, approx 1 wt % H2SO4, and 70-s to 840-s residence times. The combined severity (Log10 [Ro] - pH), an expression relating pH, temperature, and residence time of pretreatment, ranged from 1.8 to 2.4. Soluble xylose yields varied from 63 to 77% of theoretical from pretreatments of corn stover at 160 and 180 degrees C. However, yields >90% of theoretical were found with dilute-acid pretreatments at 190 degrees C. A narrower range of higher combined severities was required for pretreatment to obtain high soluble xylose yields when the moisture content of the acidimpregnated feedstock was increased from 55 to 63 wt%. Simultaneous saccharification and fermentation (SSF) of washed solids from corn stover pretreated at 190 degrees C, using an enzyme loading of 15 filter paper units (FPU)/ g of cellulose, gave ethanol yields in excess of 85%. Similar SSF ethanol yields were found using washed solid residues from 160 and 180 degrees C pretreatments at similar combined severities but required a higher enzyme loading of approx 25 FPU/g of cellulose.

Effects of pressing lignocellulosic biomass on sugar yield in two-stage dilute-acid hydrolysis process.

Dilute sulfuric acid catalyzed hydrolysis of biomass such as wood chips often involves pressing the wood particles in a dewatering step (e.g., after acid impregnation) or in compression screw feeders commonly used in continuous hydrolysis reactors. This study addresses the effects of pressing biomass feedstocks using a hydraulic press on soluble sugar yield obtained from two-stage dilute-acid hydrolysis of softwood. The pressed acid-impregnated feedstock gave significantly lower soluble sugar yields than the never-pressed (i.e., partially air-dried or filtered) feedstock. Pressing acid-impregnated feedstocks before pretreatment resulted in a soluble hemicellulosic sugar yield of 76.9% from first-stage hydrolysis and a soluble glucose yield of 33.7% from second-stage hydrolysis. The dilute-acid hydrolysis of partially air-dried feedstocks having total solids and acid concentrations similar to those of pressed feedstocks gave yields of 87.0% hemicellulosic sugar and 46.9% glucose in the first and second stages, respectively. Microscopic examination of wood structures showed that pressing acid-impregnated wood chips from 34 to 54% total solids (TS) did not cause the wood structure to collapse. However, pressing first-stage pretreated wood chips (i.e., feedstock for second-stage hydrolysis) from approximately 30 to 43% TS caused the porous wood matrix to almost completely collapse. It is hypothesized that pressing alters the wood structure and distribution of acid within the cell cavities, leading to uneven heat and mass transfer during pretreatment using direct steam injection. Consequently, lower hydrolysis yield of soluble sugars results. Dewatering of corn stover by pressing did not impact negatively on the sugar yield from single-stage dilute-acid pretreatment.

Effects of operating parameters on countercurrent extraction of hemicellulosic sugars from pretreated softwood.

In a previous study using a continuous countercurrent screw extractor for two-stage dilute-acid hydrolysis, which was focused on the effects of liquid-to-insoluble solids (L/IS) ratio, we demonstrated that by using low volumes of wash water soluble sugars can be recovered from first-stage pretreated softwood at high yields and also at high sugar concentrations. In this study, we investigated the effects of important operating parameters other than the L/IS ratio, such as the feed rates of water and pretreated biomass and the extractor inclined angle, on the performance of the extractor using first-stage pretreated softwood. As biomass and water feed rates increased at the same L/IS ratio, the recovery yield of soluble sugars decreased, probably owing to a reduced solids residence time in the extractor, which is related to the solid/liquid contact time. The sugar recovery yield was higher at a higher extractor inclined angle. This may be attributed to the effects of increased back mixing and a longer residence time for solids at a higher extractor angle. Countercurrent extraction was also carried out with other pretreated biomass having smaller particle sizes and poor drainage rates. The countercurrent screw extractor was found to be unsuitable for these fine materials due to the slow liquid drainage rate and filter-clogging problems. In a test for stability of soluble sugars in first-stage softwood hydrolysate, irrespective of the storage temperature and storage form, the sugar concentration slowly decreased with storage time. However, storage in slurry form showed higher sugar stability compared with that in liquor form at the same conditions.