Amber Hoover

Effect of pelleting process variables on physical properties and sugar yields of ammonia fiber expansion pretreated corn stover

Pelletization process variables, including grind size (4, 6mm), die speed (40, 50, 60 Hz), and preheating (none, 70°C), were evaluated to understand their effect on pellet quality attributes and sugar yields of ammonia fiber expansion (AFEX) pretreated biomass. The bulk density of the pelletized AFEX corn stover was three to six times greater compared to untreated and AFEX-treated corn stover. Also, the durability of the pelletized AFEX corn stover was>97.5% for all pelletization conditions studied except for preheated pellets. Die speed had no effect on enzymatic hydrolysis sugar yields of pellets. Pellets produced with preheating or a larger grind size (6mm) had similar or lower sugar yields. Pellets generated with 4mm AFEX-treated corn stover, a 60Hz die speed, and no preheating resulted in pellets with similar or greater density, durability, and sugar yields compared to other pelletization conditions.

Effect of pelleting on the recalcitrance and bioconversion of dilute-acid pretreated corn stover under low- and high-solids conditions

Background: Knowledge regarding the performance of densified biomass in biochemical processes is limited. The effects of densification on biochemical conversion are explored here. Results: Pelleted corn stover samples were generated from bales that were milled to 6.35 mm. Low-solids acid pretreatment and simultaneous saccharification and fermentation were performed for pelleted and ground stover (6.35 and 2 mm) formats. Monomeric xylose yields were significantly higher for pellets (∼60%) than for ground formats (∼38%). Pellets achieved approximately 84% of theoretical ethanol yield; ground stover formats had similar profiles, reaching approximately 68% theoretical ethanol yield. Pelleted and 6.35-mm ground stover were evaluated using a ZipperClave® reactor under high-solids, process-relevant conditions for multiple pretreatment severities (Ro); feedstock reactivity increased slightly following combined pretreatment and enzymatic hydrolysis for three of five severities tested. Conclusion: Pelleting did not render corn stover more recalcitrant to dilute-acid pretreatment under low- or high-solids conditions, and even enhanced ethanol yields.

Drought effects on composition and yield for corn stover, mixed grasses, and Miscanthus as bioenergy feedstocks

Drought conditions in 2012 were some of the most severe in recent history. The purpose of this study is to examine the impact of drought on quality, quantity, and theoretical ethanol yield (TEY) of three bioenergy feedstocks, corn stover, mixed grasses from Conservation Reserve Program lands, and Miscanthus × giganteus. To assess drought effects on these feedstocks, samples from 2010 (minimal to no drought) and 2012 (severe drought) were compared from multiple locations in the US. In all feedstocks, drought significantly increased extractives and reduced structural sugars and lignin; subsequently, TEYs were reduced 10–15%. Biomass yields were significantly reduced for M. × giganteus and mixed grasses. When reduction in quality and quantity were combined, TEYs decreased 26–59%. Drought negatively affected biomass quality and quantity that resulted in significant TEY reductions. Such fluctuations in biomass quality and yield may have significant consequences for developing lignocellulosic biorefineries.

Method to produce durable pellets at lower energy consumption using high moisture corn stover and a corn starch binder in a flat die pellet mill

A major challenge in the production of pellets is the high cost associated with drying biomass from 30 to 10% (w.b.) moisture content. At Idaho National Laboratory, a high-moisture pelleting process was developed to reduce the drying cost. In this process the biomass pellets are produced at higher feedstock moisture contents than conventional methods, and the high moisture pellets produced are further dried in energy efficient dryers. This process helps to reduce the feedstock moisture content by about 5-10% during pelleting, which is mainly due to frictional heat developed in the die. The objective of this research was to explore how binder addition influences the pellet quality and energy consumption of the high-moisture pelleting process in a flat die pellet mill. In the present study, raw corn stover was pelleted at moistures of 33, 36, and 39% (w.b.) by addition of 0, 2, and 4% pure corn starch. The partially dried pellets produced were further dried in a laboratory oven at 70 °C for 3-4 hr to lower the pellet moisture to less than 9% (w.b.). The high moisture and dried pellets were evaluated for their physical properties, such as bulk density and durability. The results indicated that increasing the binder percentage to 4% improved pellet durability and reduced the specific energy consumption by 20-40% compared to pellets with no binder. At higher binder addition (4%), the reduction in feedstock moisture during pelleting was <4%, whereas the reduction was about 7-8% without the binder. With 4% binder and 33% (w.b.) feedstock moisture content, the bulk density and durability values observed of the dried pellets were >510 kg/m3 and >98%, respectively, and the percent fine particles generated was reduced to <3%.

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.

Impact of Drought on Chemical Composition and Sugar Yields From Dilute-Acid Pretreatment and Enzymatic Hydrolysis of Miscanthus, a Tall Fescue Mixture, and Switchgrass

Environmental factors like drought impact the quality of biomass entering a bioconversion process. Drought often reduces the sugar content in lignocellulosic biomass, which could have economic impacts, particularly when compounded with losses in dry biomass yield; however, the effects on conversion efficiency are not completely understood. This study investigated how drought may impact biomass composition and sugar yields from dilute-acid pretreatment and enzymatic hydrolysis of Miscanthus, a tall fescue mixture, and switchgrass from Nebraska, Missouri, and Oklahoma, respectively, grown as part of Regional Feedstock Partnership field trials. Samples were grown and harvested in 2010 during non-drought conditions and in 2012 during extreme drought conditions. Non-structural glucose and proline were significantly greater in 2012 compared with 2010 for Miscanthus, which suggests drought stress occurred. Structural glucan and xylan were significantly decreased in 2012 for Miscanthus; however, reactivity and sugar yields from dilute-acid pretreatment and enzymatic hydrolysis were significantly greater in 2012 compared with 2010, suggesting that although structural sugars may decrease during drought conditions, sugar yields and reactivity may increase. For the tall fescue mixture, proline was greater, and structural sugars were lower in 2012, indicating drought stress, but minimal differences were observed in the conversion experiments. Few differences were observed for switchgrass composition and reactivity between years. The observed patterns are likely because of site-specific climatic conditions combined with the tolerance each species may have to drought. As drought occurrence and severity have increased, it is necessary to understand drought impacts to mitigate risks to future bioenergy industry growth.