Andy Aden

Process and technoeconomic analysis of leading pretreatment technologies for lignocellulosic ethanol production using switchgrass

Six biomass pretreatment processes to convert switchgrass to fermentable sugars and ultimately to cellulosic ethanol are compared on a consistent basis in this technoeconomic analysis. The six pretreatment processes are ammonia fiber expansion (AFEX), dilute acid (DA), lime, liquid hot water (LHW), soaking in aqueous ammonia (SAA), and sulfur dioxide-impregnated steam explosion (SO(2)). Each pretreatment process is modeled in the framework of an existing biochemical design model so that systematic variations of process-related changes are consistently captured. The pretreatment area process design and simulation are based on the research data generated within the Biomass Refining Consortium for Applied Fundamentals and Innovation (CAFI) 3 project. Overall ethanol production, total capital investment, and minimum ethanol selling price (MESP) are reported along with selected sensitivity analysis. The results show limited differentiation between the projected economic performances of the pretreatment options, except for processes that exhibit significantly lower monomer sugar and resulting ethanol yields.

Industrial scale-up of pH-controlled liquid hot water pretreatment of corn fiber for fuel ethanol production

The pretreatment of cellulose in corn fiber by liquid hot water at 160°C and a pH above 4.0 dissolved 50% of the fiber in 20 min. The pretreatment also enabled the subsequent complete enzymatic hydrolysis of the remaining polysaccharides to monosaccharides. The carbohydrates dissolved by the pretreatment were 80% soluble oligosaccharides and 20% monosaccharides with º1% of the carbohydrates lost to degradation products. Only a minimal amount of protein was dissolved, thus enriching the protein content of the un dissolved material. Replication of laboratory results in an industrial trial at 43 gallons per minute (163 L/min) of fiber slurry with a residence time of 20 min illustrates the utility and practicality of this approach for pretreating corn fiber. The added costs owing to pretreatment, fiber, and hydrolysis are equivalent to less than

The economics of current and future biofuels.

0.84/gal of ethanol produced from the fiber. Minimizing monosaccharide formation during pretreatment minimized the formation of degradation products; hence, the resulting sugars were readily fermentable to ethanol by the recombinant hexose and by pentose-fermenting Saccharomyces cerevisiae 424A (LNH-ST) and ethanologenic Escherichia coli at yields >90% of theoretical based on the starting fiber. this cooperative effort and first successful trial opens the door for examining the robustness of the pretreatment system under extended run conditions as well as pretreatment of other cellulose-containing materials using water at controlled pH.

Life cycle environmental impacts of selected U.S. ethanol production and use pathways in 2022.

This work presents detailed comparative analysis on the production economics of both current and future biofuels, including ethanol, biodiesel, and butanol. Our objectives include demonstrating the impact of key parameters on the overall process economics (e.g., plant capacity, raw material pricing, and yield) and comparing how next-generation technologies and fuels will differ from today’s technologies. The commercialized processes and corresponding economics presented here include corn-based ethanol, sugarcane-based ethanol, and soy-based biodiesel. While actual full-scale economic data are available for these processes, they have also been modeled using detailed process simulation. For future biofuel technologies, detailed techno-economic data exist for cellulosic ethanol from both biochemical and thermochemical conversion. In addition, similar techno-economic models have been created for n-butanol production based on publicly available literature data. Key technical and economic challenges facing all of these biofuels are discussed.

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

Projected life cycle greenhouse gas (GHG) emissions and net energy value (NEV) of high-ethanol blend fuel (E85) used to propel a passenger car in the United States are evaluated using attributional life cycle assessment. Input data represent national-average conditions projected to 2022 for ethanol produced from corn grain, corn stover, wheat straw, switchgrass, and forest residues. Three conversion technologies are assessed: advanced dry mill (corn grain), biochemical (switchgrass, corn stover, wheat straw), and thermochemical (forest residues). A reference case is compared against results from Monte Carlo uncertainty analysis. For this case, one kilometer traveled on E85 from the feedstock-to-ethanol pathways evaluated has 43%-57% lower GHG emissions than a car operated on conventional U.S. gasoline (base year 2005). Differences in NEV cluster by conversion technology rather than by feedstock. The reference case estimates of GHG and NEV skew to the tails of the estimated frequency distributions. Though not as optimistic as the reference case, the projected median GHG and NEV for all feedstock-to-E85 pathways evaluated offer significant improvement over conventional U.S. gasoline. Sensitivity analysis suggests that inputs to the feedstock production phase are the most influential parameters for GHG and NEV. Results from this study can be used to help focus research and development efforts.

Softwood forest thinnings as a biomass source for ethanol production: a feasibility study for California.

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 distillers 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 (∼77% of available carbohydrate) were obtained by pretreatment of DG at 140°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 distillers 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.

Continuous Countercurrent Extraction of Hemicellulose from Pretreated Wood Residues

A plan has been put forth to strategically thin northern California forests to reduce fire danger and improve forest health. The resulting biomass residue, instead of being open burned, can be converted into ethanol that can be used as a fuel oxygenate or an octane enhancer. Economic potential for a biomass‐to‐ethanol facility using this softwood biomass was evaluated for two cases: stand‐alone and co‐located. The co‐located case refers to a specific site with an existing biomass power facility near Martell, California. A two‐stage dilute acid hydrolysis process is used for the production of ethanol from softwoods, and the residual lignin is used to generate steam and electricity. For a plant processing 800 dry tonnes per day of feedstock, the co‐located case is an economically attractive concept. Total estimated capital investment is approximately

Improved ethanol yield and reduced minimum ethanol selling price (MESP) by modifying low severity dilute acid pretreatment with deacetylation and mechanical refining: 2) Techno-economic analysis

70 million for the co‐located plant, and the resulting internal rate of return (IRR) is about 24% using 25% equity financing. A sensitivity analysis showed that ethanol selling price and fixed capital investment have a substantial effect on the IRR. It can be concluded that such a biomass‐to‐ethanol plant seems to be an appealing proposition for California, if ethanol replaces methyl tert‐butyl ether, which is slated for a phaseout.

Effect of corn stover compositional variability on minimum ethanol selling price (MESP).

Two-stage dilute acid pretreatment followed by enzymatic cellulose hydrolysisis an effectivemethod for obtaining high sugar yields from wood residuessuchassoftwood forest thinnings. In the first-stage hydrolysis step, most of the hemicellulose is solubilized using relatively mild conditions. The soluble hemicellu losic sugars are recovered from the hydrolysateslurry by washing with water. The washed solids are then subjected tomoresevere hydrolysis conditions to hydrolyze approx 50% of the cellulose to glucose. The remaining cellulose can further be hydrolyzed with cellulase enzyme. Our process simulation indicates that the amount of water used in the hemicellulose recovery step has a significan tim pact on the cost of ethanol production. It is important to keep water usage as low as possible while mainta ining relatively high recovery of solublesugars. To achieve this objective, a prototype pilot-scale continuous countercurrent screw extractor was evaluated for the recovery of hemicellulose from pretreated forest thinnings. Using the 274-cm (9-ft) long extractor, solubles recoveries of 98, 91, and 77% were obtained with liquid-to-insoluble solids (L/1S) ratios of 5.6, 3.4, and 2.1, respectively. An empirical equation was developed to predict the performance of the screwextractor. This equation predicts that soluble sugar recovery above 95% can be obtained with an L/IS ratio as low as 3.0.

Life Cycle Assessment of the Energy Independence and Security Act of 2007: Ethanol - Global Warming Potential and Environmental Emissions

BackgroundOur companion paper discussed the yield benefits achieved by integrating deacetylation, mechanical refining, and washing with low acid and low temperature pretreatment. To evaluate the impact of the modified process on the economic feasibility, a techno-economic analysis (TEA) was performed based on the experimental data presented in the companion paper.ResultsThe cost benefits of dilute acid pretreatment technology combined with the process alternatives of deacetylation, mechanical refining, and pretreated solids washing were evaluated using cost benefit analysis within a conceptual modeling framework. Control cases were pretreated at much lower acid loadings and temperatures than used those in the NREL 2011 design case, resulting in much lower annual ethanol production. Therefore, the minimum ethanol selling prices (MESP) of the control cases were