Bryan Bals

Evaluation of ammonia fibre expansion (AFEX) pretreatment for enzymatic hydrolysis of switchgrass harvested in different seasons and locations.

BackgroundWhen producing biofuels from dedicated feedstock, agronomic factors such as harvest time and location can impact the downstream production. Thus, this paper studies the effectiveness of ammonia fibre expansion (AFEX) pretreatment on two harvest times (July and October) and ecotypes/locations (Cave-in-Rock (CIR) harvested in Michigan and Alamo harvested in Alabama) for switchgrass (Panicum virgatum).ResultsBoth harvest date and ecotype/location determine the pretreatment conditions that produce maximum sugar yields. There was a high degree of correlation between glucose and xylose released regardless of the harvest, pretreatment conditions, or enzyme formulation. Enzyme formulation that produced maximum sugar yields was the same across all harvests except for the CIR October harvest. The least mature sample, the July harvest of CIR switchgrass, released the most sugars (520 g/kg biomass) during enzymatic hydrolysis while requiring the least severe pretreatment conditions. In contrast, the most mature harvest released the least amount of sugars (410 g/kg biomass). All hydrolysates were highly fermentable, although xylose utilisation in the July CIR hydrolysate was poor.ConclusionsEach harvest type and location responded differently to AFEX pretreatment, although all harvests successfully produced fermentable sugars. Thus, it is necessary to consider an integrated approach between agricultural production and biochemical processing in order to insure optimal productivity.

Optimization of Ammonia Fiber Expansion (AFEX) Pretreatment and Enzymatic Hydrolysis of Miscanthus x giganteus to Fermentable Sugars

Miscanthus x giganteus is a tall perennial grass whose suitability as an energy crop is presently being appraised. There is very little information on the effect of pretreatment and enzymatic saccharification of Miscanthus to produce fermentable sugars. This paper reports sugar yields during enzymatic hydrolysis from ammonia fiber expansion (AFEX) pretreated Miscanthus. Pretreatment conditions including temperature, moisture, ammonia loading, residence time, and enzyme loadings are varied to maximize hydrolysis yields. In addition, further treatments such as soaking the biomass prior to AFEX as well as washing the pretreated material were also attempted to improve sugar yields. The optimal AFEX conditions determined were 160 °C, 2:1 (w/w) ammonia to biomass loading, 233% moisture (dry weight basis), and 5 min reaction time for water‐soaked Miscanthus. Approximately 96% glucan and 81% xylan conversions were achieved after 168 h enzymatic hydrolysis at 1% glucan loading using 15 FPU/(g of glucan) of cellulase and 64 p‐NPGU/(g of glucan) of β‐glucosidase along with xylanase and tween‐80 supplementation. A mass balance for the AFEX pretreatment and enzymatic hydrolysis process is presented.

Lignocellulosic biomass pretreatment using AFEX.

Although cellulose is the most abundant organic molecule, its susceptibility to hydrolysis is restricted due to the rigid lignin and hemicellulose protection surrounding the cellulose micro fibrils. Therefore, an effective pretreatment is necessary to liberate the cellulose from the lignin-hemicellulose seal and also reduce cellulosic crystallinity. Some of the available pretreatment techniques include acid hydrolysis, steam explosion, ammonia fiber expansion (AFEX), alkaline wet oxidation, and hot water pretreatment. Besides reducing lignocellulosic recalcitrance, an ideal pretreatment must also minimize formation of degradation products that inhibit subsequent hydrolysis and fermentation. AFEX is an important pretreatment technology that utilizes both physical (high temperature and pressure) and chemical (ammonia) processes to achieve effective pretreatment. Besides increasing the surface accessibility for hydrolysis, AFEX promotes cellulose decrystallization and partial hemicellulose depolymerization and reduces the lignin recalcitrance in the treated biomass. Theoretical glucose yield upon optimal enzymatic hydrolysis on AFEX-treated corn stover is approximately 98%. Furthermore, AFEX offers several unique advantages over other pretreatments, which include near complete recovery of the pretreatment chemical (ammonia), nutrient addition for microbial growth through the remaining ammonia on pretreated biomass, and not requiring a washing step during the process which facilitates high solid loading hydrolysis. This chapter provides a detailed practical procedure to perform AFEX, design the reactor, determine the mass balances, and conduct the process safely.

Evaluating the impact of ammonia fiber expansion (AFEX) pretreatment conditions on the cost of ethanol production

Ammonia fiber expansion (AFEX) pretreatment is an ammonia-based process for improving the susceptibility of lignocellulosic biomass to enzymatic attack. Four parameters--ammonia loading, water loading, reaction temperature, and residence time--can be varied in order to optimize AFEX pretreatment. The effect of these parameters on process economics of ethanol production was studied using a leading biorefinery model. Ammonia loading and residence time had the greatest impact on the economics of ethanol production, primarily due to processing costs for the chilled water condenser and the capital cost of the AFEX reactor. Water loading and reaction temperature had only modest impact on process economics. In addition, the impact of pretreatment conditions on makeup ammonia requirements was explored experimentally, which ranged from 15 to 25 g ammonia/kg biomass. Overall, pretreatment conditions can change the costs of ethanol production by up to 35 cents per gallon ethanol in an 850 ton/day refinery. By linking the results obtained from this Aspen model to experimental results for ethanol production and makeup ammonia recovery, this study can be used to create an economic optimum for AFEX pretreatment in contrast with simply maximizing fermentable sugar production.

An integrated paradigm for cellulosic biorefineries: utilization of lignocellulosic biomass as self-sufficient feedstocks for fuel, food precursors and saccharolytic enzyme production

Simultaneously achieving economic, environmental and social sustainability is a major challenge for the emerging renewable fuel industry. We approach this problem by demonstrating a cellulosic biorefinery paradigm which produces ethanol and food precursors using lignocellulosic biomass as the exclusive source for carbohydrates and minerals. Enzymatic hydrolysate from Ammonia Fiber Expansion (AFEX)-pretreated corn stover at 18% w/w solids loading was found to be nutrient-rich. This hydrolysate was fermented completely within 48 h in two stages to produce ethanol and native yeast cells. An in-house saccharolytic enzyme production using AFEX-pretreated corn stover as carbohydrate source greatly reduces the dependence on commercial enzymes. The inducer mixture is 2.5–7 times more potent than lactose, a common enzyme inducer. Economic analysis indicates that the proposed paradigm is substantially more cost-effective relative to the 2005 NREL model. This improvement is largely attributed to the native yeast cells co-production and the reduction of enzyme cost through the in-house production.

Techno-economic analysis of decentralized biomass processing depots

Decentralized biomass processing facilities, known as biomass depots, may be necessary to achieve feedstock cost, quantity, and quality required to grow the future U.S. bioeconomy. In this paper, we assess three distinct depot configurations for technical difference and economic performance. The depot designs were chosen to compare and contrast a suite of capabilities that a depot could perform ranging from conventional pelleting to sophisticated pretreatment technologies. Our economic analyses indicate that depot processing costs are likely to range from ∼US

Enzymatic digestibility and ethanol fermentability of AFEX-treated starch-rich lignocellulosics such as corn silage and whole corn plant

30 to US

A packed bed Ammonia Fiber Expansion reactor system for pretreatment of agricultural residues at regional depots

63 per dry metric tonne (Mg), depending upon the specific technology implemented and the energy consumption for processing equipment such as grinders and dryers. We conclude that the benefits of integrating depots into the overall biomass feedstock supply chain will outweigh depot processing costs and that incorporation of this technology should be aggressively pursued.

Developing a model for assessing biomass processing technologies within a local biomass processing depot

BackgroundCorn grain is an important renewable source for bioethanol production in the USA. Corn ethanol is currently produced by steam liquefaction of starch-rich grains followed by enzymatic saccharification and fermentation. Corn stover (the non-grain parts of the plant) is a potential feedstock to produce cellulosic ethanol in second-generation biorefineries. At present, corn grain is harvested by removing the grain from the living plant while leaving the stover behind on the field. Alternatively, whole corn plants can be harvested to cohydrolyze both starch and cellulose after a suitable thermochemical pretreatment to produce fermentable monomeric sugars. In this study, we used physiologically immature corn silage (CS) and matured whole corn plants (WCP) as feedstocks to produce ethanol using ammonia fiber expansion (AFEX) pretreatment followed by enzymatic hydrolysis (at low enzyme loadings) and cofermentation (for both glucose and xylose) using a cellulase-amylase-based cocktail and a recombinant Saccharomyces cerevisiae 424A (LNH-ST) strain, respectively. The effect on hydrolysis yields of AFEX pretreatment conditions and a starch/cellulose-degrading enzyme addition sequence for both substrates was also studied.ResultsAFEX-pretreated starch-rich substrates (for example, corn grain, soluble starch) had a 1.5-3-fold higher enzymatic hydrolysis yield compared with the untreated substrates. Sequential addition of cellulases after hydrolysis of starch within WCP resulted in 15-20% higher hydrolysis yield compared with simultaneous addition of hydrolytic enzymes. AFEX-pretreated CS gave 70% glucan conversion after 72 h of hydrolysis for 6% glucan loading (at 8 mg total enzyme loading per gram glucan). Microbial inoculation of CS before ensilation yielded a 10-15% lower glucose hydrolysis yield for the pretreated substrate, due to loss in starch content. Ethanol fermentation of AFEX-treated (at 6% w/w glucan loading) CS hydrolyzate (resulting in 28 g/L ethanol at 93% metabolic yield) and WCP (resulting in 30 g/L ethanol at 89% metabolic yield) is reported in this work.ConclusionsThe current results indicate the feasibility of co-utilization of whole plants (that is, starchy grains plus cellulosic residues) using an ammonia-based (AFEX) pretreatment to increase bioethanol yield and reduce overall production cost.

Economic comparison of multiple techniques for recovering leaf protein in biomass processing

Background: Pretreatment of biomass at regional depots could simplify supply logistics for the emerging biofuels industry. Ammonia Fiber Expansion (AFEX™) could be an appropriate pretreatment method for use at depots, if the process can be simplified. Here we investigate pretreatment of corn stover and wheat straw using a simple packed bed AFEX system that exploits the high porosity of biomass to facilitate ammonia transport. Results & discussion: Steam stripping vertical packed beds allowed recovery of more than 90% residual ammonia as substantially dry vapor. AFEX-treated biomass gave enzyme hydrolysis yields equal to biomass treated in stirred batch reactors, and formed durable pellets. Conclusion: Packed bed AFEX shows significant promise as a biomass pretreatment for use at distributed depots.