Kenneth J. Valentas

Phosphorus reclamation through hydrothermal carbonization of animal manures.

Projected shortages of global phosphate have prompted investigation of methods that could be employed to capture and recycle phosphate, rather than continue to allow the resource to be essentially irreversibly lost through dilution in surface waters. Hydrothermal carbonization of animal manures from large farms was investigated as a scenario for the reclamation of phosphate for agricultural use and mitigation of the negative environmental impact of phosphate pollution. Hydrothermal reaction conditions were identified for poultry, swine, and cattle manures that resulted in hydrochar yields of 50-60% for all three manures, and >90% of the total phosphorus present in these systems was contained in the hydrochars as precipitated phosphate salts. Phosphate recovery was achieved in yields of 80-90% by subsequent acid treatment of the hydrochars, addition of base to acid extracts to achieve a pH of 9, and filtration of principally calcium phosphate. Phosphate recovery was achieved in yields of 81-87% based on starting manures by subsequent acid treatment of the hydrochars, addition of base to acid extracts to achieve a pH of 9, and filtration of principally calcium phosphate. Swine and cattle manures produced hydrochars with combustion energy contents comparable to those of high-end sub-bituminous coals.

Maximizing the liquid fuel yield in a biorefining process

Biorefining strives to recover the maximum value from each fraction, at minimum energy cost. In order to seek an unbiased and thorough assessment of the alleged opportunity offered by biomass fuels, the direct conversion of various lignocellulosic biomass was studied: aspen pulp wood (Populus tremuloides), aspen wood pretreated with dilute acid, aspen lignin, aspen logging residues, corn stalk, corn spathe, corn cob, corn stover, corn stover pellet, corn stover pretreated with dilute acid, and lignin extracted from corn stover. Besides the heating rate, the yield of liquid products was found to be dependent on the final liquefaction temperature and the length of liquefaction time. The major compounds of the liquid products from various origins were identified by GC–MS. The lignin was found to be a good candidate for the liquefaction process, and biomass fractionation was necessary to maximize the yield of the liquid bio‐fuel. The results suggest a biorefinery process accompanying pretreatment, fermentation to ethanol, liquefaction to bio‐crude oil, and other thermo‐conversion technologies, such as gasification. Other biorefinery options, including supercritical water gasification and the effectual utilization of the bio‐crude oil, are also addressed.

Industrial symbiosis: Corn ethanol fermentation, hydrothermal carbonization, and anaerobic digestion

The production of dry‐grind corn ethanol results in the generation of intermediate products, thin and whole stillage, which require energy‐intensive downstream processing for conversion into commercial animal feed products. Hydrothermal carbonization of thin and whole stillage coupled with anaerobic digestion was investigated as alternative processing methods that could benefit the industry. By substantially eliminating evaporation of water, reductions in downstream energy consumption from 65% to 73% were achieved while generating hydrochar, fatty acids, treated process water, and biogas co‐products providing new opportunities for the industry. Processing whole stillage in this manner produced the four co‐products, eliminated centrifugation and evaporation, and substantially reduced drying. With thin stillage, all four co‐products were again produced, as well as a high quality animal feed. Anaerobic digestion of the aqueous product stream from the hydrothermal carbonization of thin stillage reduced chemical oxygen demand (COD) by more than 90% and converted 83% of the initial COD to methane. Internal use of this biogas could entirely fuel the HTC process and reduce overall natural gas usage. Biotechnol. Bioeng. 2013;110: 2624–2632.