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Waste B iomass Based Biorefinery

Waste B iomass Based Biorefinery. Shihwu Sung. Department of Civil, Construction & Environmental Engineering Iowa State University. Biorefinery Concepts. Trees Grassess Agricultural Crops Agricultural Residues Animal Wastes Municipal Waste Sludge. USES Fuels -Ethanol

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Waste B iomass Based Biorefinery

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  1. Waste Biomass Based Biorefinery Shihwu Sung Department of Civil, Construction & Environmental Engineering Iowa State University

  2. Biorefinery Concepts • Trees • Grassess • Agricultural Crops • Agricultural Residues • Animal Wastes • Municipal Waste Sludge USES Fuels -Ethanol -Renewable Diesel Power -Electricity -Power Chemicals -Plastics -Solvents -Chemical Intermediates -Phenolic -Adhesives -Furfural -Fatty Acids -Acetic Acid -Carbon Black -Paints -Dyes, Pigments and Ink -Detergents -Etc. Food and Feed Biomass Feedstock Conversion Process • Enzymatic Fermentation • Gas/Liquid Fermentation • Acid Hydrolysis • Gasification • Combustion • Co-firing www.bioproducts-bioenergy.gov

  3. Biorefinery Research ISU Environmental Engineering Program

  4. Anaerobic Digestion (1) Complex Organics Carbohydrates Proteins Lipids 1. Hydrolysis Simple Organics (2) Volatile Organic Acids Propionate, Butyrate, etc. 2. Acidogenesis Acetate H2 + CO2 (3) 3. Methanogenesis CH4 + CO2

  5. Anaerobic Biotechnologies • Covered Anaerobic Lagoon (CAL) • Complete Mix Anaerobic Digester (CMAD) • Plug Flow Anaerobic Digester (PFAD) • Upflow Anaerobic Sludge Blanket Reactor (UASB) • Anaerobic Filter (AF) • Anaerobic Sequencing Batch Reactor (ASBR) • Temperature Phased Anaerobic Digester(TPAD)

  6. Household Swine Waste Anaerobic Digester, Morelia, Mexico

  7. Ambient Temperature Covered Anaerobic Lagoon

  8. Covered Anaerobic Lagoon

  9. Complete Mix Digester Colorado Pork

  10. Complete Mix Digester Colorado Pork

  11. Complete Mix Anaerobic Digester - Swine Waste

  12. CSTR Anaerobic Digester - DairyWaste

  13. 40kW Skid Mounted Generator

  14. Plug Flow Anaerobic Digester AA Dairy, Candor, NY TS content: 11 – 13%

  15. Animal Waste-to-Biodiesel Plant Smithfield Foods, Inc.

  16. Anaerobic Sequencing Batch reactor (earthen dikes with membrane cover) Settling Tanks (solid/liquid separation)

  17. Methane-to-Methanol Production Smithfield Foods, Inc.

  18. Methanol-to-Biodiesel Production Smithfield Bioenergy, Inc.

  19. O O || || CH - O - C - R CH - O - C - R 2 1 3 1 | | O O CH - OH 2 | || || | CH - O - C - R + 3 CH OH  CH - O - C - R + CH - OH 2 3 3 2 | (KOH) | | O O CH - OH 2 | || || CH - O - C - R CH - O - C - R 2 3 3 3 Triglyceride (oil & fat) methanol mixture of fatty esters glycerin Transesterification Biodiesel

  20. Tallow, edible, Corn, 2,453 , 10% 2,075 , 8% Cottonseed, 725 , 3% Sunflower, 320 , 1% Lard, 1,075 , 4% Canola, 541 , 2% Safflower, 89 , 0% Soybean, 18,435 , 72% Feedstock Availability in US Unit: cents/pound Unit: million lb • Fats and oils was 26 billion lb in 2002 (~3.5 billion gallons of biodiesel) • Soybean oil is dominant and relatively cheap material

  21. Smithfield Bioenergy Utah Plant • Swine Waste • Average 50,000 lb/d Pig Manure (~144,000 pigs) • Supplemented with 6,000 lb/d Glycerin • Biogas Production • 400,000- 500,000 cuft/d from Pig Manure • 1,000,000 cuft/d with Glycerin • Products • Every 1,000 cuft biogas could produce one gallon of methanol • 500,000 cuft Biogas => 5,000 gallon Methanol 1,000,000 cuft => 10,000 gallon Methanol per day

  22. Biodiesel Yield at Smithfield Energy 100 lb oil + 21.71 lb methanol → 100.45 lb biodiesel + 10.40 lb glycerol + 10.86 lb XS methanol 100 gal of oil + 24.65 gal methanol → 103.3 gal biodiesel + 7.42 gal glycerol + 12.33 gal XS methanol Typical proportions for the chemicals used: Reactants • Fat or oil (e.g. 100 lb soybean oil) • Primary alcohols (e.g. 10 lb methanol) Catalyst • Mineral base (e.g. 0.3 lb sodium hydroxide)

  23. Temperature-Phased Anaerobic Digestion (TPAD) LABORATORY SETUP Gasmeter Gasmeter H2S scrubber H2S scrubber Thermophilic at 55oC Mesophilic at 35oC Feed Tank

  24. Temperature-Phased Anaerobic Digester (TPAD)

  25. Heat Exchanger Design

  26. STUDIES WITH LIVESTOCK WASTES • Substrate: Dairy Cattle Manure OBJECTIVES • Determination of optimum system loading • Production of Class A biosolids

  27. FEED COMPOSITIONS THERMOPHILIC SRT: 4 days MESOPHILIC SRT: 10 days

  28. VS REMOVALS AT DIFFERENT LOADINGS

  29. METHANE RECOVERY AT DIFFERENT LOADINGS

  30. REDUCTION OF INDICATOR ORGANISMS

  31. BIOSOLIDS meet 40 CFR Part 503 limits for pathogen reduction • VFA • Thermophilic digester 250 ~ 3,067 mg/L • Mesophilic digester 140 ~ 1,398 mg/L • Methane Content • Thermophilic digester 62 ±7% • Mesophilic digester 68 ±3%

  32. Biohydrogen Production from Renewable Organic Wastes

  33. H2 and acid production Glucose Solvent production EMP Pathway H2 Pyruvate Acetate Acetyl CoA Ethanol Acetoacetyl CoA Propanol Butyrate Butyryl CoA Butanol Dark Fermentation • Dark fermentation carried out by genus Clostridium

  34. Metabolic Pathway of Biological Hydrogen Production • Biological hydrogen production accompanied with organic acid production C6H12O6+2H2O 2CH3COOH + 2CO2 + 4H2 C6H12O6CH3CH2CH2COOH + 2CO2 + 2H2 4C6H12O6+2H2O  2CH3COOH +3CH3CH2CH2COOH + 8CO2 + 10H2

  35. Kinetic parameters of Michaelis-Menten equation NFDM: Non-fat dry milk • NFDM: 57% carbohydrate; • Food waste: 43% carbohydrate • Hydrogen production rate: lactose > sucrose (Woodward et al., 2000 )

  36. Batch Study Conclusion • The higher carbohydrate content, the higher substrate affinity • High Ks value: high substrate concentration requirement • Not appropriate to use particulate organic waste for hydrogen fermentation

  37. ASBR Study Conclusion • Effect of HRT • Optimum HRT: 16 h • At short HRT, ORP increased to hostile the survive of anaerobic microbes. • Effect of pH • The best performance: pH 4.9 Effect of substrate (sucrose) concentration • Effect of substrate concentration • The best performance: 25 g COD/L

  38. Thin Stillage from Dry Corn Milling Ethanol Plant • Anaerobic Digestion (AD) • Fungal Biomass-to-Chitin and Chitosan

  39. Ground Corn Slurry Tank Liquefaction Unit Distillation System Ethanol Fermentor DDGS DWG (10-12% H2O) DWGS (60-65% H2O) Rotary Drier #2 Rotary Drier #1 (30% H2O) Centrifuge Whole Stillage (90%) (10%) (88% H2O) Syrup Evaporator (60%H2O) (94% H2O) DWG : Distiller's Wet Grains Condensate DWGS: Distiller's Wet Grains with Solubles DDGS: Distiller's Dried Grains with Solubles Overview of Production Processes Thin Stillage

  40. AD - Methane Yield Not Steady State S C S C S C S C

  41. AD - Volatile Solids Not Steady State

  42. Stillage Digestion Corn Related Studies Thermophilic CSTR Studies

  43. Stillage Digestion • Energy Recycling (Basis: 45 Mgal/yr at MGP) • Displace 43% to 59% of natural gas usage • High: $17 million/year • Low: $7 million/year • Likely: $10 million/yr • Saving a dime per gallon

  44. Fungal biomass – major source of chitin and chitosan Applications Medicine Cosmetics and Toiletries Agriculture Biotechnology Pollution control.

  45. Growing fungus Rhizopus oligoporus on thin stillage Day 0 Day 4 Day 5 Day 8 Fungal biomass

  46. Fungal biomass with solids attached Effluent collected

  47. Nisin production from Soy Whey Nisin is an antimicrobial peptide usually produced by the certain species of Lactococcus. Nisin exhibits the broad antimicrobial activity against Gram-positive bacteria including food borne pathogens. In this study, nisin fermentation was conducted in soy whey as growth media by using the strains of Lactococcus lactis.

  48. Agar Well Diffusion Assay for nisin quantification Growth of Micrococcus luteus Zone of inhibition

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