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Design and Scale-Up of Corn Fiber and Corn Stover Pretreatment for Fuel Ethanol Production

Design and Scale-Up of Corn Fiber and Corn Stover Pretreatment for Fuel Ethanol Production. Nathan Mosier, Rick Hendrickson, Bruce Dien, Rich Dreschel, Gary Welch, Michael Ladisch Purdue University Williams Bio-energy USDA NCAUR. IFAFS Project Institutions. Acknowledgements.

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Design and Scale-Up of Corn Fiber and Corn Stover Pretreatment for Fuel Ethanol Production

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  1. Design and Scale-Up of Corn Fiber and Corn Stover Pretreatment for Fuel Ethanol Production Nathan Mosier, Rick Hendrickson, Bruce Dien, Rich Dreschel, Gary Welch, Michael Ladisch Purdue University Williams Bio-energy USDA NCAUR

  2. IFAFS Project Institutions

  3. Acknowledgements The material is this work was supported by: USDA Initiative for Future Agricultural and Food Systems/Cooperative State Research, Education and Extension Service Contract 00-52104-0663 NREL Subcontract ZCO-1-31023-01 Purdue University Agricultural Research Programs

  4. Acknowledgements Andy Aden Bruce Dale Tim Eggeman Rick Elander Joan Goetz Mark Holtzapple Kelly Ibsen Young Mie Kim Y.Y. Lee Charles Wyman

  5. Where does corn fiber come from?

  6. What is corn stover? Leaves Cobs Stalks Roots

  7. Typical Compositions Corn Stover Corn Fiber Glucan (cellulose) 36.2% 14.3% Glucan (starch) 0.0 23.7 Xylan 21.4 16.8 Arabinan 3.9 10.8 Protein 3.5 11.8 Lignin 22.6 8.4 Acetyl 2.3 NA Ash 6.0 0.4

  8. Pretreatment Hemicellulose Effect of Pretreatment Cellulose Lignin Amorphous Region Crystalline Region

  9. Pretreatment Modeling C k1 k4 k3 Gn G Degradation K k2 C* k2, k3, >> k1

  10. Principles of Liquid Water Pretreatment • Controlled pH • High Temperature • Liquid Water (high pressure) • Water acts as acid • kw = 10-14 to 6 • 10-12 from 20°C to 230°C.

  11. pH of Liquid Water vs Temperature

  12. Pretreatment Modeling C k1 k4 k3 Gn G Degradation K k2 C*

  13. Utilization of FiberBenefits of existing industrial infrastructure Fiber already collected: fiber packaged with corn Existing ethanol plants: handle and manage fiber streams provide utilities process fermentation ethanol market ethanol and co-products

  14. Process DescriptionPretreated Corn Fiber: Liquid Separation Pretreat Fiber Liquid Stillage Centrifuge Solids To Fermentation

  15. “Snake-coil” Plug Flow Pretreatment Reactor Williams Bioenergy Pekin, IL

  16. Process StepsLiquid / Solid Separation and SSF 1. Separate liquid from solids with centrifuge 2. Process liquid stream Add cellulase, other enzymes. Combine with liquified starch stream. Add yeast. Hydrolyze, ferment in the same tank. 3. Process solids from pretreatment Dry and sell as co-product feed.

  17. Pretreatment Conditions Fiber : Stillage Ratio wet basis = 0.39 : 1 Fiber : Water Ratio dry basis = 0.16 : 1 Temperature and Hold Time 160 C, hold for 30 min Separate liquid from solid (centrifuge) Liquid to fermentor, solid to feed drier

  18. Pretreated Corn Fiber 1 – grams of free glucose per gram of pretreated fiber 2 – based on analysis of pretreated fiber by 4% acid hydrolysis

  19. FermentabilityHydrolyzed Pretreatment Liquid Data from Nacy Ho and Miroslav Sedlak, LORRE, Purdue University Fermentability confirmed by Bruce Dien, USDA-NCAUR

  20. Corn Fiber / Stover UtilizationOpportunities Increase annual ethanol production by 100 million gal/ yr or more Introduce cellulose conversion technologies into existing corn to ethanol facilities Catalyze industry use of other cellulosics

  21. Corn Stover Pretreatment

  22. Corn Stover (1000x)

  23. Pretreated Corn Stover (1000x)

  24. Xylose Recovery pH 4.5, 50°C, Celluclast + Novozyme 188, 96 hrs

  25. Corn Stover Digestibility pH 4.5, 50°C Celluclast + Novozyme 188, 96 hrs

  26. Conclusions Conversion of Corn Fiber and Corn Stover gives fermentable sugars Pretreatment required Water is an effective pretreating agent pH control minimizes monosaccharide formation Industrial pretreatment development and pilot research being underway

  27. Fermentability Corn Steep Liquor (Control) vsPretreated Corn Fiber CO2 Produced

  28. Ethanol Animal Feed Milling Animal Feed Dryer Stillage Fiber Dryer Saccharification Pretreatment Integrated Biomass Processing Ethanol Fermentation Gluten Distillation Fiber Separation Gluten Separation Saccharification

  29. Utilization of FiberChallenges Limited markets as animal feed Relatively low price at $60 to 65 /ton Triple bioenergy production by 2010 will generate more fiber

  30. Bio-Rad HPX-87H 300mm x 7.8mm HPLC Column 5mM H2SO4 Buffer 60oC, 0.6 mL/min

  31. Composition (% dry wt) Corn Fiber Pretreatment Concentration (%w/w) Xylan 17% Xylose 0.1% Xylan 1.0% 0.6% Glucose Composition (% dry wt) Starch 24% Xylan 3% 2.6% Starch Cellulose 36% Cellulose Pretreatment Liquid 14% Protein 20% Protein 12% 19% Lignin 8% Pretreatment Solid Lignin Corn Fiber

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