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Fuel and chemicals from crops

Fuel and chemicals from crops. J. (Hans) van Leeuwen Professor of Environmental and Biological Engineering,. Ames, IA, August 2009. Towards a more sustainable future. Small, but growing contribution. Changing the face of Earth. Manhattan over 400 years. Sugar and starch crops.

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Fuel and chemicals from crops

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  1. Fuel and chemicals from crops J. (Hans) van Leeuwen Professor of Environmental and Biological Engineering, Ames, IA, August 2009

  2. Towards a more sustainable future Small, but growing contribution

  3. Changing the face of Earth Manhattan over 400 years

  4. Sugar and starch crops

  5. Lignocellulosics: switchgrass

  6. More lignocellulosics

  7. Ethanol conversions Photosynthesis produces sugars: 6CO2 + 6H2 O +Sunlight  C6H12O6 + 6O2 Many organisms can anaerobically ferment sugars: C6H12O6(aq) + yeasts  2 C2H5OH(aq) + 2 CO2(g) The ethanol is burned: C2H5OH + 3O2 Energy + 3 H2O + 2 CO2

  8. Biovance-Zwam, Inc. Corn-to-ethanol plant limitations Ethanol 1/3 CO2 1/3 DDG(S) 1/3 Water Stillage Heat!!! $$$$$ The solution? 13c/gal

  9. Distillation Fermentor CO2 Enzymes Milling Cooking Corn Typical corn dry-grind ethanol plant Ethanol Yeasts Water Vapor Thin stillage backset Eliminate Whole stillage Evaporator Syrup Thin stillage DDGS Distillers dried grains with solubles Centrifuge DDG Thick stillage Dryer

  10. Ethanol yield from products

  11. Fungal Production and Water Reclamation Plant Fungal inoculum Screen Blowers (Van Leeuwen et al. R&D 100 award, 2008)

  12. Biodiesel Canola

  13. Biodiesel manufacture

  14. Typical yield of biodiesel/ha

  15. Algal oil production Microalgae have much faster growth-rates than terrestrial crops. The per unit area yield of oil from algae is estimated to be from between 5,000 to 20,000 US gallons per acre per year (4,700 to 18,000 m3/km2·a);[citation needed] this is 7 to 30 times > than the next best crop, Chinese tallow (700 US gal/acre·a or 650 m3/km2·a).[19]

  16. Biobutanol Biobutanol can be produced by fermentation of biomass by the A.B.E. process. The process uses the bacteriumClostridium acetobutylicum, also known as the Weizmann organism. It was Chaim Weizmann who first used this bacteria for the production of acetone from starch (with the main use of acetone being the making of Cordite) in 1916. The butanol was a by-product of this fermentation (twice as much butanol was produced). The process also creates a recoverable amount of H2 and a number of other by-products: acetic, lactic and propionic acids, acetone, isopropanol and ethanol.

  17. Comparison of liquid fuels *Octane rating of a spark ignition engine fuel is the detonation resistance (anti-knock rating) compared to a mixture of iso-octane (2,2,4-trimethylpentane, an isomer of octane) and n-heptane. By definition, iso-octane is assigned an octane rating of 100, and heptane is assigned an octane rating of zero. An 87-octane gasoline, for example, possesses the same anti-knock rating of a mixture of 87% (by volume) iso-octane, and 13% (by volume) n-heptane.

  18. Mucor circinelloides Note oil inclusions Pellet growth makes for easy separation

  19. Lignocellulosic fungal bio-oil process (Van Leeuwen et al. R&D 100 award, 2009)

  20. Mass balance for ammonia pretreatment 100 kg corn stover - Glucan: 35.0 kg - Xylan: 23.0 kg - Other sugars 1: 6.0 kg - Lignin: 15.0 kg - Others 2: 21 kg Corn stover ~85% conversion Hydrolysate - Glucose: 33.1 kg - Xylose: 17.9 kg - Other monomeric sugars: ~4.3 kg Liquid Solid Pretreatment Enzyme hydrolysis 15 %NH3, 6-12 h, @60ºC Residualsolid 68.5 kg pretreated corn stover - Glucan: 35.0 kg - Xylan: 18.5 kg - Other sugars: 4.5 kg - Lignin: 5.0 kg - Others: 4.0 kg Washed liquid - Glucan: 5.3 kg - Xylan: 2.8 kg - Other sugars: 0.7 kg - Lignin: ~5.0 kg - Others: ~4.0 kg - Lignin: 10.0 kg - Xylan: 4.5 kg - Other sugars: 1.2 kg - Others: 17.0 kg • Other sugars include arabinan, galactan, and mannan. • Other components include protein, acetyl groups, ash, extractives (tannin, gums, ash) • Conversion from polysaccharides to monomeric sugars: 85% is assumed for both glucan and xylan.

  21. Close-up view of donut horn

  22. Ultrasonic set-up for continuous oil recovery

  23. Mucor cells bursting after ultrasonication

  24. White-rot fungus from the van Leeuwen garden

  25. Lignocellulosic bio-oil using two fungal processes (Van Leeuwen et al. R&D 100 award, 2009)

  26. Cost-benefit analysis Basis 1000 ton/day corn stover/ switchgrass feed to produce, at 10% conversion, 35,000 ton oil

  27. Operational costs

  28. Potential revenue

  29. Endorsements MycoMax Grand Prize for University Research 2008 and 2009 R&D 100, 2008 and 2009 Project Innovation Award, 2008

  30. MycoInnovations Small adjustments needed Scale-up time has arrived

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