Industrial sugar beets to biofuel: Field to fuel production system and cost estimates

Specialized varieties of sugar beets (Beta vulgaris L.) may be an eligible feedstock for advanced biofuel designation under the USA Energy Independence and Security Act of 2007. These non-food industrial beets could double ethanol production per hectare compared to alternative feedstocks. A mixed-integer mathematical programming model was constructed to determine the breakeven price of ethanol produced from industrial beets, and to determine the optimal size and biorefinery location. The model, based on limited field data, evaluates Southern Plains beet production in a 3-year crop rotation, and beet harvest, transportation, and processing. The optimal strategy depends critically on several assumptions including a just-in-time harvest and delivery system that remains to be tested in field trials. Based on a wet beet to ethanol conversion rate of 110 dm³ Mg⁻¹ and capital cost of 128 M$ for a 152 dam³ y⁻¹ biorefinery, the estimated breakeven ethanol price was 507 $ m⁻³. The average breakeven production cost of corn (Zea mays L.) grain ethanol ranged from 430 to 552 $ m⁻³ based on average net corn feedstock cost of 254 and 396 $ m⁻³ in 2014 and 2013, respectively. The estimated net beet ethanol delivered cost of 207 $ m⁻³ was lower than the average net corn feedstock cost of 254–396$ m⁻³ in 2013 and 2014. If for a mature industry, the cost to process beets was equal to the cost to process corn, the beet breakeven ethanol price would be $387 m^-3 (587 $ m⁻³ gasoline equivalent).     

Trading greenhouse gas emission benefits from biofuel use in US transportation: Challenges and opportunities

Replacing petroleum fuels with biofuels such as ethanol and biodiesel has been shown to reduce greenhouse gas (GHG) emissions. These GHG benefits can potentially be traded in the fledgling carbon markets, and methodologies for quantifying and trading are still being developed. We review the main challenges in developing such carbon trading frameworks and outline a proposed framework for the US, the main features of which include, lifecycle assessment of GHG benefits, a combination of project-specific and standard performance measures, and assigning GHG property rights to biofuel producers. At carbon prices of 10 $ t⁻¹, estimated monetary benefits from such trading can be 4.5 M$ hm⁻³ and 17 M$ hm⁻³ of corn ethanol and cellulosic ethanol respectively.     

Bioethanol production potential from Brazilian biodiesel co-products

One major problem facing the commercial production of cellulosic ethanol is the challenge of economically harvesting and transporting sufficient amounts of biomass as a feedstock at biorefinery plant scales. Oil extraction for biodiesel production, however, yields large quantities of biomass co-products rich in cellulose, sugar and starch, which in many cases may be sufficient to produce enough ethanol to meet the alcohol demands of the transesterification process. Soybean, castor bean, Jatropha curcas, palm kernel, sunflower and cottonseed were studied to determine ethanol production potential from cellulose found in the oil extraction co-products and also their capacity to meet transesterification alcohol demands. All crops studied were capable of producing enough ethanol for biodiesel production and, in the case of cottonseed, 470% of the transesterification demand could be met with cellulosic ethanol production from oil extraction co-products. Based on Brazilian yields of the crops studied, palm biomass has the highest potential ethanol yield of 108 m³ km⁻² followed by J. curcas with 40 m³ km⁻². A total of 3.5 hm³ could be produced from Brazilian soybean oil extraction co-products.     

Aspen Plus simulation of biomass integrated gasification combined cycle systems at corn ethanol plants

Biomass integrated gasification combined cycle (BIGCC) systems and natural gas combined cycle (NGCC) systems are employed to provide heat and electricity to a 0.19 hm³ y⁻¹ (50 million gallon per year) corn ethanol plant using different fuels (syrup and corn stover, corn stover alone, and natural gas). Aspen Plus simulations of BIGCC/NGCC systems are performed to study effects of different fuels, gas turbine compression pressure, dryers (steam tube or superheated steam) for biomass fuels and ethanol co-products, and steam tube dryer exhaust treatment methods. The goal is to maximize electricity generation while meeting process heat needs of the plant. At fuel input rates of 110 MW, BIGCC systems with steam tube dryers provide 20–25 MW of power to the grid with system thermal efficiencies (net power generated plus process heat rate divided by fuel input rate) of 69–74%. NGCC systems with steam tube dryers provide 26–30 MW of power to the grid with system thermal efficiencies of 74–78%. BIGCC systems with superheated steam dryers provide 20–22 MW of power to the grid with system thermal efficiencies of 53–56%. The life-cycle greenhouse gas (GHG) emission reduction for conventional corn ethanol compared to gasoline is 39% for process heat with natural gas (grid electricity), 117% for BIGCC with syrup and corn stover fuel, 124% for BIGCC with corn stover fuel, and 93% for NGCC with natural gas fuel. These GHG emission estimates do not include indirect land use change effects.     

The economic potential of wood pellet production from alternative,low-value wood sources in the southeast of the U.S.

The global demand for wood pellets used for energy purposes is growing. Therefore, increased amounts of wood pellets are produced from primary forestry products, such as pulp wood. The present analysis demonstrates that substantial amounts of alternative, low-value wood resources are available that could be processed into wood pellets. For three resources, test batches have been produced and tested to qualify for industrial pellet standards. These include: primary forestry residues from premerchantable thinning operations, secondary forestry residues from pole mills and post-consumer wood wastes from discarded wooden transport pallets. The total wood potential of these resources in the southeast of the U.S. (Florida, Georgia, North Carolina, South Carolina), was estimated to be 1.9 Tg y⁻¹ (dry) available at roadside (excluding transport cost) for 22 $ Mg⁻¹ (dry) increasing to over 5.1 Tg y⁻¹ at 33 $ Mg⁻¹ (dry). In theory, 4.1 Tg y⁻¹ pellets could be produced from the estimated potential. However, due to the geographically dispersed supply of these resources, the cost of feedstock supply at a pellet plant increases rapidly at larger plants. It is therefore not expected that the total potential can be processed into wood pellets at costs competitive with those of conventional wood pellets. The optimal size of a pellet plant was estimated at between 55 Gg y⁻¹ and 315 Gg y⁻¹ pellets depending on the location and feedstock supply assumptions. At these locations and plant sizes, pellets could be produced at competitive costs of between 82 $ Mg⁻¹ and 100 $ Mg⁻¹ pellets.     

Exploring the potential of Eucalyptus for energy production in the Southern United States: Financial analysis of delivered biomass. Part I

Eucalyptus plantations in the Southern United States offer a viable feedstock for renewable bioenergy. Delivered cost of eucalypt biomass to a bioenergy facility was simulated in order to understand how key variables affect biomass delivered cost. Three production rates (16.8, 22.4 and 28.0 Mg ha⁻¹ y⁻¹, dry weight basis) in two investment scenarios were compared in terms of financial analysis, to evaluate the effect of productivity and land investment on the financial indicators of the project. Delivered cost of biomass was simulated to range from $55.1 to $66.1 per delivered Mg (with freight distance of 48.3 km from plantation to biorefinery) depending on site productivity (without considering land investment) at 6% IRR. When land investment was included in the analysis, delivered biomass cost increased to range from $65.0 to $79.4 per delivered Mg depending on site productivity at 6% IRR. Conversion into cellulosic ethanol might be promising with biomass delivered cost lower than $66 Mg⁻¹. These delivered costs and investment analysis show that Eucalyptus plantations are a potential biomass source for bioenergy production for Southern U.S.     

Converting Eucalyptus biomass into ethanol: Financial and sensitivity analysis in a co-current dilute acid process. Part II

The technical and financial performance of high yield Eucalyptus biomass in a co-current dilute acid pretreatment followed by enzymatic hydrolysis process was simulated using WinGEMS^® and Excel^®. Average ethanol yield per dry Mg of Eucalyptus biomass was approximately 347.6 L of ethanol (with average carbohydrate content in the biomass around 66.1%) at a cost of $0.49 L⁻¹ of ethanol, cash cost of ∼ $0.46 L⁻¹ and CAPEX of $1.03 L⁻¹ of ethanol. The main cost drivers are: biomass, enzyme, tax, fuel (gasoline), depreciation and labor. Profitability of the process is very sensitive to biomass cost, carbohydrate content (%) in biomass and enzyme cost. Biomass delivered cost was simulated and financially evaluated in Part I; here in Part II the conversion of this raw material into cellulosic ethanol using the dilute acid process is evaluated.     

The current bioenergy production potential of semi-arid and arid regions in sub-Saharan Africa

This article assesses the current technical and economic potential of three bioenergy production systems (cassava ethanol, jatropha oil and fuelwood) in semi-arid and arid regions of eight sub-Saharan African countries. The results indicate that the availability of land for energy production ranges from 2% (1.3 Mha) of the total semi-arid and arid area in South Africa to 21% (12 Mha) in Botswana. Land availability for bioenergy production is restricted mainly by agricultural land use, but also by steep slopes and biodiversity protection. The current total technical potential for the semi-arid and arid regions of the eight countries is calculated to be approximately 300 PJ y⁻¹ for cassava ethanol production, 600 PJ y⁻¹ for jatropha biodiesel or 4000 PJ y⁻¹ for fuelwood. The analysis of economic potentials shows that in many semi-arid regions, cassava ethanol, jatropha oil and fuelwood can compete economically with the reference energy sources. However, fuelwood, jatropha oil, and cassava ethanol production costs in most arid regions of sub-Saharan Africa are often above average national market prices of gasoline, diesel, and fuelwood. Nevertheless, for example, in arid Kenya 270 PJ could be produced annually with fuelwood at production costs of less than 3 US$ GJ⁻¹. Despite high production costs, it is important to investigate and invest in sustainable bioenergy production in semi-arid and arid regions of sub-Saharan Africa because of its potential to drive rural economic and social development.     

Ethanol plant investment using net present value and real options analyses

A real options analysis of entry–exit decisions for dry-grind corn ethanol plants is conducted to incorporate the impact of rising volatility in market prices. For a large plant, the estimated gross margins (ethanol price less corn price), in current dollars, that induce entry and exit were 0.35 US$ dm⁻³ and 0.03 US$ dm⁻³, respectively; nearly 207% (63%) above (below) their respective net present value estimates. Under baseline conditions, a large operating plant would become mothballed at 0.05 US$ dm⁻³ and reactivate if margins rebounded to 0.17 US$ dm⁻³. Growth in the variability of ethanol margins will lead to delays in new plant investments, as well as exits of currently operating facilities. To the extent that alternative renewable fuel technologies become viable, the model can be easily adapted to estimate and compare the results across alternative bioenergy investments.     

Nutrient and alkalinity removal by corn grain, stover and cob harvest in Upper Midwest USA

In the USA, most corn stover currently remains in fields as crop residue that provides soil erosion control and maintains soil organic carbon levels. This stover is a potential biofuel feedstock for direct combustion, pyrolysis, and ethanol fermentation. At a research site in south central Wisconsin, the northern edge of the US Corn Belt, corn grain harvest averaged 9.8 Mg ha⁻¹ DM over a 6-year period, 1997 to 2002. Removal of all stover could recover an additional 7.2 Mg ha⁻¹ y⁻¹ DM and, in the process, remove an additional 47, 6, 81 and 197 kg ha⁻¹ y⁻¹ of N, P, K and calcium carbonate equivalent, respectively. The fertilizer replacement cost for stover removal is 32 $ Mg⁻¹ DM, which is 95% of the fertilizer value of the grain. However, most of the N, P, K and alkalinity of the stover is found in the leaves, stalk, and husks, not in the cob. At our study site, complete stover removal would export 235 $ ha⁻¹ y⁻¹ of fertilizer and limestone, mainly as K, while cob export would be worth 20 $ ha⁻¹ y⁻¹ in nutrient equivalents. Based on this research, removal of cobs only is equivalent to 16.6% of total stover removal but with a greatly reduced fertilizer replacement cost of 17 $ Mg⁻¹ DM and the same energy density.     

Reducing life cycle greenhouse gas emissions of corn ethanol by integrating biomass to produce heat and power at ethanol plants

A life-cycle assessment (LCA) of corn ethanol was conducted to determine the reduction in the life-cycle greenhouse gas (GHG) emissions for corn ethanol compared to gasoline by integrating biomass fuels to replace fossil fuels (natural gas and grid electricity) in a U.S. Midwest dry-grind corn ethanol plant producing 0.19 hm³ y⁻¹ of denatured ethanol. The biomass fuels studied are corn stover and ethanol co-products [dried distillers grains with solubles (DDGS), and syrup (solubles portion of DDGS)]. The biomass conversion technologies/systems considered are process heat (PH) only systems, combined heat and power (CHP) systems, and biomass integrated gasification combined cycle (BIGCC) systems. The life-cycle GHG emission reduction for corn ethanol compared to gasoline is 38.9% for PH with natural gas, 57.7% for PH with corn stover, 79.1% for CHP with corn stover, 78.2% for IGCC with natural gas, 119.0% for BIGCC with corn stover, and 111.4% for BIGCC with syrup and stover. These GHG emission estimates do not include indirect land use change effects. GHG emission reductions for CHP, IGCC, and BIGCC include power sent to the grid which replaces electricity from coal. BIGCC results in greater reductions in GHG emissions than IGCC with natural gas because biomass is substituted for fossil fuels. In addition, underground sequestration of CO₂ gas from the ethanol plant’s fermentation tank could further reduce the life-cycle GHG emission for corn ethanol by 32% compared to gasoline.     

Enhanced performance of LSCF cathode through surface modification

Mixed ionic-electronic conductors in the family of La_xSr_1−xCo_yFe_1−yO_3−δ (LSCF) have been widely studied as cathode materials for solid oxide fuel cells (SOFCs). However, the long-term stability and the limited surface catalytic activity are still a concern. Here we report a new catalyst La_0.4875Ca_0.0125Ce_0.5O_2−δ (LCC), which can significantly enhance the performance and stability of LSCF cathodes when applied as a thin-film coating on LSCF surface. For example, with 5 μL 0.25 mol L⁻¹ LCC solution infiltrated into LSCF cathode, the cathodic polarization resistance was reduced by ∼60% (to ∼0.076 Ω cm²) at 750 °C, leading to a peak power density of ∼1.25 W/cm², which is ∼18% higher than that for the unmodified LSCF cathode in an anode-supported cell. In addition, stable power output was observed for over 500 h operation at 750 °C under a constant voltage of 0.7 V.     

Vegetable oil production potential from Jatropha curcas, Croton megalocarpus, Aleurites moluccana, Moringa oleifera and Pachira glabra: Assessment of renewable energy resources for bio-energy production in Africa

Research on vegetable oil for biofuels in Africa and Asia has focused mainly on Jatropha curcas while other potential oil bearing plants have received little attention. Vegetable oil production potential for five oil bearing plant species namely: Aleurites moluccana, Croton megalocarpus, Jatropha curcas, Moringa oleifera and Pachira glabra were investigated. Nuts and seeds of the plants were collected from the wild and their potential for vegetable oil production assessed in terms of seed/nut acreage yield, seed/nut oil content, harvesting requirement, and upstream processing before vegetable oil recovery. All five varieties were found to contain acceptable but different oil content ranging from 20 to 33% w/w, and seed/nut acreage yield of 3 t ha⁻¹ y⁻¹ to 12.5 t ha⁻¹ y⁻¹. Upstream processing was needed for A. moluccana to break open nuts to release the kernel, and dehulling for both C. megalocarpus and J. curcas to release the seeds, before extracting the vegetable oil, while the seeds of both M. oleifera and P. glabra did not need upstream processing. The Multi-criteria Decision Analysis ranked C. megalocarpus as the plant with the highest vegetable oil production potential of 1.8 t ha⁻¹ y⁻¹ followed by M. oleifera, J. curcas (1 t ha⁻¹ y⁻¹), A. moluccana, and P. glabra. The analysis underlines the need for more studies on C. megalocarpus and M. oleifera for biofuel production in Africa and other regions.     

Enzymatic hydrolysis and fermentation of crushed whole sugar beets

Pectinase and cellulase enzymes were used for hydrolysis of whole sugar beets and the hydrolyzates were fermented with Escherichia coli KO11 and Saccharomyces cerevisiae via simultaneous saccharification and fermentation (SSF). Ethanol production rate was significantly higher for S. cerevisiae than for E. coli KO11. The combined effect of pectinase and cellulase loadings on ethanol production as well as residual galacturonic acid and arabinose concentrations were modeled for fermentations with S. cerevisiae. Ethanol yields of more than 92% were reached with moderate to high cellulase and pectinase loadings at 0.51 FPU g⁻¹ and 51 U g⁻¹ of dry biomass, respectively. Ethanol yields of 85% were achieved without any enzyme addition. However, addition of cellulase and pectinase enzymes increased effluent arabinose and galacturonic acid concentrations and reduced total suspended solids. This study demonstrated the yield potential of fermentation of crushed, whole sugar beets with or without the addition of cellulase and pectinase enzymes.     

Biohydrogen from molasses with ethanol-type fermentation: Effect of hydraulic retention time

Though ethanol-type fermentation has many advantages for improving hydrogen production rate (HPR) in continuously mode hydrogen producing system, information on this fermentation is very deficient. The effect of hydraulic retention time (HRT) on biohydrogen production and operational stability of ethanol-type fermentation was investigated in a continuous stirred tank reactor (CSTR) using molasses as substrate. Five HRTs were examined, ranging from 4 to 10 h. At HRT 5 h, the highest HPR of 12.27 mmol L⁻¹ h⁻¹ was obtained from ethanol-type fermentation in the pH range of 4.3–4.4. During the whole operation process, ethanol, butyrate and acetate were the predominant metabolites. A total COD concentration of ethanol and acetate accounted for above 73.3% of total soluble microbial products. Linear regression showed that HPR and ethanol production rate were proportionately correlated at all HRTs which could be expressed as y = 0.9821x − 3.5151 (r² = 0.9498). It is meaningful that the proposed recovery of both hydrogen and ethanol from fermentation process can improve energy production rate and economic profit. Results demonstrated that the best energy production rate was 15.50 kJ L⁻¹ h⁻¹, occurred at HRT = 5 h.     

Ba1−xCo0.9−yFeyNb0.1O3−δ (x = 0-0.15, y = 0-0.9) as cathode materials for solid oxide fuel cells

Perovskite oxide Ba_1.0Co_0.7Fe_0.2Nb_0.1O_3−δ has been reported as oxygen transport membrane and cathode material for solid oxide fuel cells (SOFCs). In this study, the effects of A-site cation deficiency and B-site iron doping concentration on the crystal structure, thermal expansion coefficient (TEC), electrical conductivity and electrochemical performance of Ba_1−xCo_0.9−yFe_yNb_0.1O_3−δ (x = 0-0.15, y = 0-0.9) have been systematically evaluated. Ba_1−xCo_0.9−yFe_yNb_0.1O_3−δ (x = 0-0.10, y = 0.2 and x = 0.10, y = 0.2-0.6) can be indexed to a cubic structure. Increased electrical conductivity and decreased cathode polarization resistance have been achieved by A-site deficiency. No obvious variation can be observed in TEC by A-site deficiency. The electrical conductivity and TEC of Ba_0.9Co_0.9−yFe_yNb_0.1O_3−δ decrease while the cathode polarization resistance increases with the increase in iron doping concentration. The highest conductivity of 13.9 S cm⁻¹ and the lowest cathode polarization resistance of 0.07 Ω cm² have been achieved at 700 °C for Ba_0.9Co_0.7Fe_0.2Nb_0.1O_3−δ. The composition Ba_0.9Co_0.3Fe_0.6Nb_0.1O_3−δ shows the lowest TEC value of 13.2 × 10⁻⁶ °C⁻¹ at 600 °C and can be a potential cathode material for SOFCs.     

Biomass availability, energy consumption and biochar production in rural households of Western Kenya

Pyrolytic cook stoves in smallholder farms may require different biomass supply than traditional bioenergy approaches. Therefore, we carried out an on-farm assessment of the energy consumption for food preparation, the biomass availability relevant to conventional and pyrolytic cook stoves, and the potential biochar generation in rural households of western Kenya. Biomass availability for pyrolysis varied widely from 0.7 to 12.4 Mg ha⁻¹ y⁻¹ with an average of 4.3 Mg ha⁻¹ y⁻¹, across all 50 studied farms. Farms with high soil fertility that were recently converted to agriculture from forest had the highest variability (CV = 83%), which was a result of the wide range of farm sizes and feedstock types in the farms. Biomass variability was two times lower for farms with low than high soil fertility (CV = 37%). The reduction in variability is a direct consequence of the soil quality, coupled with farm size and feedstock type. The total wood energy available in the farms (5.3 GJ capita⁻¹ y⁻¹) was not sufficient to meet the current cooking energy needs using conventional combustion stoves, but may be sufficient for improved combustion stoves depending on their energy efficiency. However, the biomass that is usable in pyrolytic cook stoves including crop residues, shrub and tree litter can provide 17.2 GJ capita⁻¹ y⁻¹ of energy for cooking, which is well above the current average cooking energy consumption of 10.5 GJ capita⁻¹ y⁻¹. The introduction of a first-generation pyrolytic cook stove reduced wood energy consumption by 27% while producing an average of 0.46 Mg ha⁻¹ y⁻¹ of biochar.     

Water use impact of ethanol at a gasoline substitution ratio of 5% from cassava in Nigeria

The process of fuel ethanol production from cassava root is connected to a chain of impacts on the water resource of the country where the cassava plant is grown and the root processed into fuel ethanol. The paper assesses the impact of the domestic production of 5 per cent ethanol (E5) needed under the Nigerian biofuel programme from cassava root on the water resource of Nigeria. Using the 2007 Premium Motor Spirit (PMS) consumption as the baseline, Nigeria will require about 0.49 hm³ of ethanol to blend 9.32 hm³ of PMS to arrive at the 2007 consumption estimates. The impact of the domestic production of this ethanol requirement translates to about 6.0 km³ of water; out of which about 48 per cent is green and about 52 per cent is blue. Addressing future impact typical of a developing economy like Nigeria, a three-scenario analysis was adopted to examine the impact of future growth in cassava-fuel ethanol requirement on the water resource of Nigeria, and also, the impact of improved water use on the future water footprint of E5. The projected water impact of cassava-ethanol production into the future ranges from 6.02 to 7.28 km³, while improved water use could lower these values by about 0.04–2.35 km³ for the same period, 2010 to 2020, under the projection assumptions made.     

Pd-Ni electrocatalysts for efficient ethanol oxidation reaction in alkaline electrolyte

Pd_xNi_y/C catalysts with high ethanol oxidation reaction (EOR) activity in alkaline solution have been prepared through a solution phase-based nanocapsule method. XRD and TEM show Pd_xNi_y nanoparticles with a small average diameter (2.4-3.2 nm) and narrow size distribution (1-6 nm) were homogeneously dispersed on carbon black XC-72 support. The EOR onset potential on Pd₄Ni₅/C (−801 mV vs. Hg/HgO) was observed shifted 180 mV more negative than that of Pd/C. Its exchange current density was 33 times higher than that of Pd/C (41.3 × 10⁻⁷ A/cm²vs. 1.24 × 10⁻⁷ A/cm²). After a 10,000-s chronoamperometry test at −0.5 V (vs Hg/HgO), the EOR mass activity of Pd₂Ni₃/C survived at 1.71 mA/mg, while that of Pd/C had dropped to 0, indicating Pd_xNi_y/C catalysts have a better ’detoxification’ ability for EOR than Pd/C. We propose that surface Ni could promote refreshing Pd active sites, thus enhancing the overall ethanol oxidation kinetics. The nanocapsule method is able to not only control over the diameter and size distribution of Pd-Ni particles, but also facilitate the formation of more efficient contacts between Pd and Ni on the catalyst surface, which is the key to improving the EOR activity.