Damon S. Hartley

Biomass Blending and Densification: Impacts on Feedstock Supply and Biochemical Conversion Performance

The success of lignocellulosic biofuels and biochemical industries depends on an economic and reliable supply of high‐quality biomass. However, research and development efforts have been historically focused on the utilization of agriculturally derived cellulosic feed‐ stocks, without considerations of their low energy density, high variations in compositions and potential supply risks in terms of availability and affordability. This chapter dem‐ onstrated a strategy of feedstock blending and densification to address the supply chain challenges. Blending takes advantage of low‐cost feedstock to avoid the prohibitive costs incurred through reliance on a single feedstock resource, while densification produces feedstocks with increased bulk density and desirable feed handling properties, as well as reduced transportation cost. We also review recent research on the blending and densifi‐ cation dealing with various types of feedstocks with a focus on the impacts of these pre‐ processing steps on biochemical conversion, that is, various thermochemical pretreatment chemistries and enzymatic hydrolysis, into fermentable sugars for biofuel production.

Supply Chain Sustainability Analysis of Fast Pyrolysis and Hydrotreating Bio-Oil to Produce Hydrocarbon Fuels

The Department of Energy’s (DOE) Bioenergy Technology Office (BETO) aims at developing and deploying technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts and biopower through public and private partnerships (DOE, 2015). BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of technologies to produce biofuels. These assessments evaluate feedstock production, logistics of transporting the feedstock, and conversion of the feedstock to biofuel. There are two general types of TEAs. A design case is a TEA that outlines a target case for a particular biofuel pathway. It enables identification of data gaps and research and development needs, and provides goals and targets against which technology progress is assessed. On the other hand, a state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual experimental results relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available.

An Integrated Landscape Management Approach to Sustainable Bioenergy Production

Integrated landscape management has emerged in recent years as a methodology to integrate the environmental impacts of various agricultural practices along with yield and profitability in a variety of cropping systems. In this study, the Landscape Environmental Assessment Framework (LEAF), a decision support toolset for use in integrated landscape management and developed at Idaho National Laboratory, was used to evaluate the profitability of grain-producing subfields, to determine the efficacy of sustainably harvesting residual biomass after grain harvest, and to determine the efficacy of integrating bioenergy crops into grain-producing landscapes to enhance farmer profitability. Three bioenergy crops, sorghum, switchgrass, and miscanthus, were integrated into non-profitable subfields in four US counties. The manuscript describes in detail the material and methods used to define crop rotations, land management units and practices, subfield units and productivity, grain profitability, sustainability criteria, energy crop integration, and feedstock cost estimation. With the integration of bioenergy crops, the overall annual biomass production rates in the four counties could be increased by factors ranging from 0.8 to 21, depending on the energy crop and county, over the annual residue biomass production rates. By modeling the harvesting of residual biomass and energy crops using geo-referenced, precision harvesting equipment and optimal harvesting paths on individual subfields, the average logistics costs including harvesting of both residual biomass and energy crops were observed to fall well below US DOE’s 2017 goals for biomass feedstock price of US

Simultaneous application of predictive model and least cost formulation can substantially benefit biorefineries outside Corn Belt in United States: A case study in Florida

84/ton or US

Biomass market dynamics supporting the large-scale deployment of high-octane fuel production in the United States

92.6/dry Mg. Miscanthus, grown in counties in Ohio and Kansas, provided the maximum potential, among the three energy crops considered, for increment in biomass production and also posed maximum threat to the grain production. Considerable variability was observed in the harvesting and total costs because of the size, shape, and productivity of individual subfields. It was shown that variability in the harvesting costs could be used to down-select non-profitable farms with low harvesting costs and high residue and bioenergy crop yields and to reduce the negative impacts of bioenergy crop integration into croplands on grain production. The results of the assessment suggest that (1) the potential to produce biomass is considerably enhanced when non-profitable grain-producing subfields are replaced by bioenergy crops and (2) the subfield-scale integrated landscape assessment provides a defensible methodology to directly address individual farmer’s profitability, sustainability, and environmental stewardship.

Techno-Economic Assessment of a Chopped Feedstock Logistics Supply Chain for Corn Stover

Previously, a predictive model was developed to identify optimal blends of expensive high-quality and cheaper low-quality feedstocks for a given geographical location that can deliver high sugar yields. In this study, the optimal process conditions were tested for application at commercially-relevant higher biomass loadings. We observed lower sugar yields but 100% conversion to ethanol from a blend that contained only 20% high-quality feedstock. The impact of applying this predictive model simultaneously with least cost formulation model for a biorefinery location outside of the US Corn Belt in Lee County, Florida was investigated. A blend ratio of 0.30 EC, 0.45 SG, and 0.25 CS in Lee County was necessary to produce sugars at high yields and ethanol at a capacity of 50 MMGY. This work demonstrates utility in applying predictive model and LCF to reduce feedstock costs and supply chain risks while optimizing for product yields.

Predictive modeling to de-risk bio-based manufacturing by adapting to variability in lignocellulosic biomass supply

US Department of Energy research aimed at co‐optimizing fuels and engine performance identified several bioblendstocks that can improve fuel economy including an aromatic‐rich hydrocarbon derived from woody biomass. This work supports an analysis of its large‐scale deployment implying a production target of approximately 15 billion liters of bioblendstock for the supply of 57 billion liters of high‐octane fuel by 2050. It simulates potential transition pathways to lignocellulosic feedstock market structures capable of supplying a mature biorefining industry at this scale. In the present absence of biorefineries, transitions are modeled via nonbiofuel feedstock markets, so‐called companion markets. The resource distribution across several demand industries is simulated to determine biomass availability and price dynamics over time. Results indicate that the wood supply base is mainly influenced by traditional markets including housing and pulp and paper. The selected companion market of wood pellet combustion for heat and electricity generation is found to positively stimulate biomass mobilization, especially in the initial absence of biorefineries. Eventually, biorefineries are found to be able to out‐compete the companion market. As such, they directly benefit from the processing (i.e., pelleting) capacity established to produce commodity‐type intermediates for the companion market. We conclude that the amount of bioblendstock produced is directly related to the size of the companion market (and its pelleting capacity). An initially larger companion market generates up to 20 million dry tonnes of additional feedstock, equivalent to 27 commercial‐scale biorefineries, or an additional production of 5 billion liters by 2050. Distinguishing between industry‐specific feedstock preferences based on average biomass quality characteristics, this analysis goes beyond past research efforts that assume automatic fungibility across different feedstocks. Improving engine performance is a key driver for the promotion of low‐carbon fuels derived from bioblendstocks. This analysis portrays feedstock market transition pathways for their large‐scale deployment.

Application of air classification and formulation to manage feedstock cost, quality and availability for bioenergy

Storing corn stover in wet, anaerobic conditions is an active management approach to reduce the risk of significant aerobic degradation and catastrophic loss due to fire. An estimated 50% of the corn stover available in the U.S. is too wet at the time of harvest to be stored safely in baled formats and is compatible with wet, anaerobic storage through ensiling. A logistics system based on field-chopping and particle size reduction early in the supply chain removes the dependency on field-drying of corn stover prior to baling, allows for an expanded harvest window, results in diminished size reduction requirements at the biorefinery, and is compatible with ensiling as a storage approach. The unit operations were defined for this chopped logistics system, which included field chopping, bulk transportation to a biorefinery site, on-site preprocessing to meet biorefinery size and ash specifications, industrial-scale storage through ensiling, and delivery of corn stover at a rate of 2,000 tonnes per day for approximately 50% of the year. The chopped system was compared to the conventional bale system for 30% moisture (wet basis) corn stover, a likely delivered moisture content for baled corn stover harvested wet. Techno-economic analysis showed that the chopped logistics system is cost competitive, costing only 10% more than the baled logistics system, meanwhile reducing the energy consumption by 48% and greenhouse gas release by 60%. In summary, a chopped logistics system utilizing on-site preprocessing and storage at a biorefinery gate is an economically viable approach to provide a stable source of corn stover for use when dry bales are not available, meanwhile reducing the risk of loss in long-term storage.

Economic and life cycle assessments of biomass utilization for bioenergy products

Commercial-scale bio-refineries are designed to process 2000tons/day of single lignocellulosic biomass. Several geographical areas in the United States generate diverse feedstocks that, when combined, can be substantial for bio-based manufacturing. Blending multiple feedstocks is a strategy being investigated to expand bio-based manufacturing outside Corn Belt. In this study, we developed a model to predict continuous envelopes of biomass blends that are optimal for a given pretreatment condition to achieve a predetermined sugar yield or vice versa. For example, our model predicted more than 60% glucose yield can be achieved by treating an equal part blend of energy cane, corn stover, and switchgrass with alkali pretreatment at 120°C for 14.8h. By using ionic liquid to pretreat an equal part blend of the biomass feedstocks at 160°C for 2.2h, we achieved 87.6% glucose yield. Such a predictive model can potentially overcome dependence on a single feedstock.