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UNIVERSITY OF KENTUCKY COLLEGE OF AGRICULTURE COLLEGE OF ENGINEERING

UNIVERSITY OF KENTUCKY COLLEGE OF AGRICULTURE COLLEGE OF ENGINEERING BIOSYSTEMS & AGRICUTURAL ENGINEERING DEPARTMENT. Biosystems & Agricultural Engineering. Dr. Scott Shearer Department Chairman. Biosystems and Agricultural Engineering Department. ANR Agent Training Dec. 10, 2007.

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UNIVERSITY OF KENTUCKY COLLEGE OF AGRICULTURE COLLEGE OF ENGINEERING

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  1. UNIVERSITY OF KENTUCKY COLLEGE OF AGRICULTURE COLLEGE OF ENGINEERING BIOSYSTEMS & AGRICUTURAL ENGINEERING DEPARTMENT

  2. Biosystems & Agricultural Engineering Dr. Scott Shearer Department Chairman Biosystems and Agricultural Engineering Department

  3. ANR Agent Training Dec. 10, 2007 The 25 x `25 Energy Challenge Sam McNeill – Extension Ag. Engineer, UKREC Mike Montross – UK BAE, Lexington

  4. National Energy Initiatives • 25 x ’25 (USDA-DOE) • 25% of all energy from renewable fuels by 2025 (geothermal, solar, wind, biofuels, etc.) • Bush’s 2007 SOTU • 20 in 10 = 20 % reduction in gasoline consumption by 2017 (higher fuel-economy standards and alt fuel vehicles) • 35 by ’17 = 35 B gal/yr of alt fuels by 2017 • 15 x ’15 • 15 billion gallons of ETOH by 2015 • National Corn Growers Assoc.

  5. NREL & USDA-DOE Initiatives • NREL - 30 x `30 30% of gasoline consumption in 2004 replaced by ethanol in 2030 • USDA-DOE Billion Ton Study

  6. http://www.eia.doe.gov/

  7. U.S. Energy Flows(quadrillion Btu) Energy Information Administration

  8. U.S. Petroleum Flows(million barrels/day) Energy Information Administration

  9. U.S. Primary Energy Consumption by Fuel 1960-2030 (quadrillion Btu) History Projections Liquid Fuels Coal Natural Gas Nuclear Renewables EIA: Annual Energy Outlook 2007

  10. U.S. Liquid Fuels and Other Petroleum Supply, Consumption, and Net Imports, 1960-2030 (million barrels per day) History Projections Consumption 61% Net Imports 60% Domestic Supply EIA: Annual Energy Outlook 2007

  11. ? ?

  12. World Liquids Production, 2004-2030(million barrels per day oil equivalent) 118 Total Non-OPEC (Conventional) 53 54 OPEC (Conventional) Unconventional 10 EIA: International Energy Outlook 2007

  13. Top Oil Producing Countries(Q4 `05 to Q3 `06)

  14. World Oil Reserves, 2006 BAE

  15. BAE

  16. Gasoline vs Oil Prices BAE

  17. 2010 – 2015 Hybrid cars and small trucks 40 – 60 mpg Popular U.S. Vehicles 2001 - 2004SUV’s, trucks, vans and cars17 – 28 mpg

  18. How to Save Petroleum Fuels • Carpool / combine/ reduce trips • Inflate tires to proper pressure • Regular engine tune-ups • Avoid rapid starts/stops • Keep speed constant • Hybrid vehicles • Biofuels • Fill gap between fuel demand and petroleum supplies in near term • Coupled with energy savings extend supply

  19. Feasibility of Replacing All Energy with Renewable? • Land in farms - 940 million acres • About half is in cropland • Additional 740 million acres in forest • 100 quads of energy • Require 3.4 DRY ton/ac of material • No processing

  20. Corn Sources for Biofuels • Largest US corn crop - 13.1 billion bu (2007) • 2.7 gal ethanol/bu @ 76,000 Btu/gal • US consumed 140 billion gallons of gasoline in 2005 • All the corn could displace 20% of gasoline on energy basis

  21. Economics of Corn Grain to Ethanol • Anyone interested in ethanol when corn is $4.00/bu? • Corn represents $1.48/gal • Accounting for DDGS at $120/ton, ethanol is $1.07/gal • Equivalent energy cost = $1.60/gal • Road taxes are another $0.50/gal • Neglects plant cost utilities, enzymes, yeast, labor, etc.

  22. Effect of Hybrid on Ethanol Production • Samples from UK corn hybrid trials

  23. Ethanol Production From Hybrids

  24. Overall Ethanol Production

  25. Grain Endosperm 2005 2010 2015 2020 150 180 200 250 Bu/Ac 2.5 2.7 2.8 2.8 Gal/Bu 390 486 560 700 Gal/Ac Grain Pericarp 0 .45 .500 .625 Ton/Ac 0 40 60 90 Gal/Ton 0 18 30 56 Gal/Ac Stover 0 2.5 2.75 3 Ton/Ac 0 40 60 90 Gal/Ton 0 100 165 270 Gal/Ac Gallons / Acre 1,000 gallons / acre by 2020? Corn Has Significant Potential for Biofuels Ethanol Productivity Potential 435 Gal/Acre @ 150 bu/ac grain yield Endosperm 18 Gal/Acre (2010) Pericarp 100 Gal/Acre (2010) Stover

  26. U.S. Corn Yield Agricultural Economics

  27. 63 Slide Title Capacity: 129% of 2006 crop Iowa corn processing & ethanol plants, current & planned, 10/26/06

  28. Corn Quality • US Grade #2 Yellow Corn - no premium for better quality or special traits • Moisture limit: 17% (a few take 18%) • Test Weight low limit: 54 lb/bu • Damage limit: 10% (discount from 5%) • Broken Corn: 12% max

  29. Corn Quality (cont.) • Starch and oil measurements are taken by 15 plants, but none use a quality spec for starch and oil • Nutrients are measured by some plants to predict levels in DGS • Mycotoxin testing done on as-needed basis by 12 plants; 10 plants test every load Note: nutrients and mycotoxins concentrate in distillers grains @ 4:1 ratio.

  30. Plants did not care about specialty grains - 100 trucks/day or 200 trucks/day - Means raising the area average and consistency will be more important Plants had absolute quality limits for US Grade factors – moisture, damage - Large change in culture for farmers - Means no leeway for storage problems, - Storing more grain longer. - Storage management will be important.

  31. Soybean Sources for Biofuels • Largest US soybean crop - 3.1 bil bu (2004) • 1.4 gal pure biodiesel/bu @ 124,000 Btu/gal • US consumed 46 billion gallons of diesel • All the soybeans would replace 9% of diesel fuel on energy basis

  32. Require Alternative Feedstocks • USDA-DOE 1 billion ton study (30% of our gasoline in 2004) • Agricultural residues • Forest residues • Energy crops (trees, grasses) • Urban wastes

  33. Sources of 1 Billion Tons/yr

  34. Relative to Existing Ag Market • Granular material – 0.5 billion ton • Hard to handle (silage, hay, etc.) – 0.3 billion ton

  35. DOE Grants Just Announced (2/28/07) • 385 million dollars in grants from DOE to build demonstration cellulosic ethanol plants • Variety of feedstocks, urban waste, corn stover, wheat straw, forest residue, and construction waste • Rated capacity of plants 101 mgpy • Still questions on feasibility

  36. Where Does UKCA Fit? • Highlights of proposed design • Plant consumes 2200 ton/day of biomass • Biomass cost $30/ton • Ethanol yield of 90 gal/ton • Capital cost 197 million, produce 69 mgpy ethanol at $1.07/gal • Operating costs (10 million in cellulase, 3.8 million in pretreatment chemicals) • Lignin utilization • Sustainability

  37. Feedstock Supply • 2,200 ton/day • Densification • 110 trucks everyday • Increase yield of feedstocks • Limited to 50 mi haul radius • Collecting 0.6 ton/ac • Feasible for KY

  38. Feedstock Cost • Collection of agricultural residues • Lower production costs for energy crops • Lower establishment costs • Less fertilizer

  39. Sustainability – Ag Residue Collection • Require residue cover • Nelson (2002) estimated ~18% of stover can be removed (~1.4 t/ha) • Perlack & Turhollow 2.5 t/ha

  40. Corn Plant • Stalks – higher lignin, more structure, slow decomposition, better sustainability • Cobs, leaves, and husks – material passing through combine • Wet vs. dry

  41. Glucose Concentration from Stover Fractions

  42. Costs of Corn Stover Collection • Investigated 4 collection treatments • Rotary mow and rake ~ $45/t • Rake only ~ $40/t • Bale only ~ $40/t • Bale behind combine with no spreader ~ $25/t

  43. Other Options • Process material on farm • Simple pretreatment and saccharification methods for farm use • Concentrate sugars for transport to central location • Ferment ethanol on farm • Final quality control and distillation at central location • Better suited crops • Miscanthus, switchgrass, poplars, sweet sorghum, etc.

  44. Switchgrass Establishment • Work by Ken Vogel, USDA-ARS • 10 growers planted 175 acres in Upper Midwest • Currently still a problem • Costs between 26 to 190 $/ton Vogel, 2006 Biotechnology for Fuels and Chemicals, neglects land costs

  45. Sweet Sorghum • Juice had sugar content of ~ 20% • Filtered and fermented to ethanol with 96% conversion • Option for producers with cattle

  46. What are Biofuels • Ethanol • Corn, Barley, Sorghum, Cheese Whey, Sugars • Cellulosic: Wood Pulp, Corn Stover, etc. • 10 % blend needs no engine modifications • E-85 (85% blend) can only be used in flex-fuel vehicles • Biodiesel • Vegetable Oils: Soybean, Sunflower, Palm, etc. • Post-Consumer Oils: Yellow Grease • Animal Fats and Wastes

  47. Benefits of Biofuels • Reduces our dependence on foreign oil (energy security) • Creates economic development in Ohio’s rural communities • Superior performance • Fights global warming (environmental) • Degrades in soil and water quickly

  48. Potential Impact in Ohio • Increased Industrial Production in Rural Areas • Most Production Facilities are Farmer-owned: • Dividends remain locally, further boosting rural economies. • Increased amount of value-add from corn & soybean processing remains in-state. • Fuel price & price volatility is lowered: • Lower transport costs • Closer supplies

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