Policy Implications of Allocation Methods in the Life Cycle Analysis of Integrated Corn and Corn Stover Ethanol Production

A biorefinery may produce multiple fuels from more than one feedstock. The ability of these fuels to qualify as one of the four types of biofuels under the US Renewable Fuel Standard and to achieve a low carbon intensity score under California’s Low Carbon Fuel Standard can be strongly influenced by the approach taken to their life cycle analysis (LCA). For example, in facilities that may co-produce corn grain and corn stover ethanol, the ethanol production processes can share the combined heat and power (CHP) that is produced from the lignin and liquid residues from stover ethanol production. We examine different LCA approaches to corn grain and stover ethanol production considering different approaches to CHP treatment. In the baseline scenario, CHP meets the energy demands of stover ethanol production first, with additional heat and electricity generated sent to grain ethanol production. The resulting greenhouse gas (GHG) emissions for grain and stover ethanol are 57 and 25 g-CO₂eq/MJ, respectively, corresponding to a 40 and 74 % reduction compared to the GHG emissions of gasoline. We illustrate that emissions depend on allocation of burdens of CHP production and corn farming, along with the facility capacities. Co-product handling techniques can strongly influence LCA results and should therefore be transparently documented.     

Life cycle analysis of biochemical cellulosic ethanol under multiple scenarios

Cellulosic ethanol is widely believed to offer substantial environmental advantages over petroleum fuels and grain‐based ethanol, particularly in reducing greenhouse gas emissions from transportation. The environmental impacts of biofuels are largely caused by precombustion activities, feedstock production and conversion facility operations. Life cycle analysis (LCA) is required to understand these impacts. This article describes a field‐to‐blending terminal LCA of cellulosic ethanol produced by biochemical conversion (hydrolysis and fermentation) using corn stover or switchgrass as feedstock. This LCA develops unique models for most elements of the biofuel production process and assigns environmental impact to different phases of production. More than 30 scenarios are evaluated, reflecting a range of feedstock, technology and scale options for near‐term and future facilities. Cellulosic ethanol, as modeled here, has the potential to significantly reduce greenhouse gas (GHG) emissions compared to petroleum‐based liquid transportation fuels, though substantial uncertainty exists. Most of the conservative scenarios estimate GHG emissions of approximately 45–60 g carbon dioxide equivalent per MJ of delivered fuel (g CO₂e MJ^?1) without credit for coproducts, and 20–30 g CO₂e MJ^?1 when coproducts are considered. Under most scenarios, feedstock production, grinding and transport dominate the total GHG footprint. The most optimistic scenarios include sequestration of carbon in soil and have GHG emissions below zero g CO₂e MJ^?1, while the most pessimistic have life‐cycle GHG emissions higher than petroleum gasoline. Soil carbon changes are the greatest source of uncertainty, dominating all other sources of GHG emissions at the upper bound of their uncertainty. Many LCAs of biofuels are narrowly constrained to GHG emissions and energy; however, these narrow assessments may miss important environmental impacts. To ensure a more holistic assessment of environmental performance, a complete life cycle inventory, with over 1100 tracked material and energy flows for each scenario is provided in the online supplementary material for this article.     

Spatially Explicit Life Cycle Analysis of Cellulosic Ethanol Production Scenarios in Southwestern Michigan

Modeling the life cycle of fuel pathways for cellulosic ethanol (CE) can help identify logistical barriers and anticipated impacts for the emerging commercial CE industry. Such models contain high amounts of variability, primarily due to the varying nature of agricultural production but also because of limitations in the availability of data at the local scale, resulting in the typical practice of using average values. In this study, 12 spatially explicit, cradle-to-refinery gate CE pathways were developed that vary by feedstock (corn stover, switchgrass, and Miscanthus), nitrogen application rate (higher, lower), pretreatment method (ammonia fiber expansion [AFEX], dilute acid), and co-product treatment method (mass allocation, sub-division), in which feedstock production was modeled at the watershed scale over a nine-county area in Southwestern Michigan. When comparing feedstocks, the model showed that corn stover yielded higher global warming potential (GWP), acidification potential (AP), and eutrophication potential (EP) than the perennial feedstocks of switchgrass and Miscanthus, on an average per area basis. Full life cycle results per MJ of produced ethanol demonstrated more mixed results, with corn stover-derived CE scenarios that use sub-division as a co-product treatment method yielding similarly favorable outcomes as switchgrass- and Miscanthus-derived CE scenarios. Variability was found to be greater between feedstocks than watersheds. Additionally, scenarios using dilute acid pretreatment had more favorable results than those using AFEX pretreatment.     

Influence of spatially dependent,modeled soil carbon emission factors on life‐cycle greenhouse gas emissions of corn and cellulosic ethanol

Converting land to biofuel feedstock production incurs changes in soil organic carbon (SOC) that can influence biofuel life‐cycle greenhouse gas (GHG) emissions. Estimates of these land use change (LUC) and life‐cycle GHG emissions affect biofuels' attractiveness and eligibility under a number of renewable fuel policies in the USA and abroad. Modeling was used to refine the spatial resolution and depth extent of domestic estimates of SOC change for land (cropland, cropland pasture, grassland, and forest) conversion scenarios to biofuel crops (corn, corn stover, switchgrass, Miscanthus, poplar, and willow) at the county level in the USA. Results show that in most regions, conversions from cropland and cropland pasture to biofuel crops led to neutral or small levels of SOC sequestration, while conversion of grassland and forest generally caused net SOC loss. SOC change results were incorporated into the Greenhouse Gases, Regulated Emissions, and Energy use in Transportation (GREET) model to assess their influence on life‐cycle GHG emissions of corn and cellulosic ethanol. Total LUC GHG emissions (g CO₂eq MJ^?1) were 2.1–9.3 for corn‐, ?0.7 for corn stover‐, ?3.4 to 12.9 for switchgrass‐, and ?20.1 to ?6.2 for Miscanthus ethanol; these varied with SOC modeling assumptions applied. Extending the soil depth from 30 to 100 cm affected spatially explicit SOC change and overall LUC GHG emissions; however, the influence on LUC GHG emission estimates was less significant in corn and corn stover than cellulosic feedstocks. Total life‐cycle GHG emissions (g CO₂eq MJ^?1, 100 cm) were estimated to be 59–66 for corn ethanol, 14 for stover ethanol, 18–26 for switchgrass ethanol, and ?7 to ?0.6 for Miscanthus ethanol. The LUC GHG emissions associated with poplar‐ and willow‐derived ethanol may be higher than that for switchgrass ethanol due to lower biomass yield.     

Soil Greenhouse Gas Emissions in Response to Corn Stover Removal and Tillage Management Across the US Corn Belt

In-field measurements of direct soil greenhouse gas (GHG) emissions provide critical data for quantifying the net energy efficiency and economic feasibility of crop residue-based bioenergy production systems. A major challenge to such assessments has been the paucity of field studies addressing the effects of crop residue removal and associated best practices for soil management (i.e., conservation tillage) on soil emissions of carbon dioxide (CO₂), nitrous oxide (N₂O), and methane (CH₄). This regional survey summarizes soil GHG emissions from nine maize production systems evaluating different levels of corn stover removal under conventional or conservation tillage management across the US Corn Belt. Cumulative growing season soil emissions of CO₂, N₂O, and/or CH₄ were measured for 2–5 years (2008–2012) at these various sites using a standardized static vented chamber technique as part of the USDA-ARS’s Resilient Economic Agricultural Practices (REAP) regional partnership. Cumulative soil GHG emissions during the growing season varied widely across sites, by management, and by year. Overall, corn stover removal decreased soil total CO₂ and N₂O emissions by -4 and -7 %, respectively, relative to no removal. No management treatments affected soil CH₄ fluxes. When aggregated to total GHG emissions (Mg CO₂?eq ha^?1) across all sites and years, corn stover removal decreased growing season soil emissions by ?5?±?1 % (mean?±?se) and ranged from -36 % to 54 % (n?=?50). Lower GHG emissions in stover removal treatments were attributed to decreased C and N inputs into soils, as well as possible microclimatic differences associated with changes in soil cover. High levels of spatial and temporal variabilities in direct GHG emissions highlighted the importance of site-specific management and environmental conditions on the dynamics of GHG emissions from agricultural soils.     

Energy consumption and greenhouse gas emissions from enzyme and yeast manufacture for corn and cellulosic ethanol production

Enzymes and yeast are important ingredients in the production of ethanol, yet the energy consumption and emissions associated with their production are often excluded from life-cycle analyses of ethanol. We provide new estimates for the energy consumed and greenhouse gases (GHGs) emitted during enzyme and yeast manufacture, including contributions from key ingredients such as starch, glucose, and molasses. We incorporated these data into Argonne National Laboratory’s Greenhouse Gases, Regulated Emissions, and Energy Use in Transportation model and observed that enzymes and yeast together contribute 1.4 and 27?% of farm-to-pump GHG emissions for corn and cellulosic ethanol, respectively. Over the course of the entire corn ethanol life cycle, yeast and enzymes contribute a negligible amount of GHG emissions, but increase GHG emissions from the cellulosic ethanol life cycle by 5.6?g CO₂e/MJ.     

Soil Greenhouse Gas Emissions and Carbon Dynamics of a No-Till,Corn-Based Cellulosic Ethanol Production System

Crop residues like corn (Zea mays L.) stover perform important functions that promote soil health and provide ecosystem services that influence agricultural sustainability and global biogeochemical cycles. We evaluated the effect of corn stover removal from a no-till, corn-soybean (Glycine max (L.) Merr) rotation on soil greenhouse gas (GHG; CO₂, N₂O, CH₄) fluxes, crop yields, and soil organic carbon (SOC) dynamics. We conducted a 4-year study using replicated field plots managed with two levels of corn stover removal (none; 55 % stover removal) for four complete crop cycles prior to initiation of ground surface gas flux measurements. Corn and soybean yields were not affected by stover removal with yields averaging 7.28 Mg ha^?1 for corn and 2.64 Mg ha^?1 for soybean. Corn stover removal treatment did not affect soil GHG fluxes from the corn phase; however, the treatment did significantly increase (107 %, P?=?0.037) N₂O fluxes during the soybean phase. The plots were a net source of CH₄ (～0.5 kg CH₄-C ha^?1 year^?1 average of all treatments and crops) during the generally wet study duration. Soil organic carbon stocks increased in both treatments during the 4-year study (initiated following 8 years of stover removal), with significantly higher SOC accumulation in the control plots compared to plots with corn stover removal (0–15 cm, P?=?0.048). Non-CO₂ greenhouse gas emissions (945 kg CO₂-eq ha^?1 year^?1) were roughly half of SOC (0–30 cm) gains with corn stover removal (1.841 Mg CO₂-eq ha^?1 year^?1) indicating that no-till practices greatly improve the viability of biennial corn stover harvesting under local soil-climatic conditions. Our results also show that repeated corn stover harvesting may increase N loss (as N₂O) from fields and thereby contribute to GHG production and loss of potential plant nutrients.     

The Feasibility of Producing Adequate Feedstock for Year-Round Cellulosic Ethanol Production in an Intensive Agricultural Fuelshed

To date, cellulosic ethanol production has not been commercialized in the United States. However, government mandates aimed at increasing second-generation biofuel production could spur exploratory development in the cellulosic ethanol industry. We conducted an in-depth analysis of the fuelshed surrounding a starch-based ethanol plant near York, Nebraska that has the potential for cellulosic ethanol production. To assess the feasibility of supplying adequate biomass for year-round cellulosic ethanol production from residual maize (Zea mays) stover and bioenergy switchgrass (Panicum virgatum) within a 40-km road network service area of the existing ethanol plant, we identified ～14,000 ha of marginally productive cropland within the service area suitable for conversion from annual rowcrops to switchgrass and ～132,000 ha of maize-enrolled cropland from which maize stover could be collected. Annual maize stover and switchgrass biomass supplies within the 40-km service area could range between 429,000 and 752,000 metric tons (mT). Approximately 140–250 million liters (l) of cellulosic ethanol could be produced, rivaling the current 208 million l annual starch-based ethanol production capacity of the plant. We conclude that sufficient quantities of biomass could be produced from maize stover and switchgrass near the plant to support year-round cellulosic ethanol production at current feedstock yields, sustainable removal rates and bioconversion efficiencies. Modifying existing starch-based ethanol plants in intensive agricultural fuelsheds could increase ethanol output, return marginally productive cropland to perennial vegetation, and remove maize stover from productive cropland to meet feedstock demand.     

Development of Sustainable Corn Stover Harvest Strategies for Cellulosic Ethanol Production

To prepare for a 2014 launch of commercial scale cellulosic ethanol production from corn/maize (Zea mays L.) stover, POET-DSM near Emmetsburg, IA has been working with farmers, researchers, and equipment dealers through “Project Liberty” on harvest, transportation, and storage logistics of corn stover for the past several years. Our objective was to evaluate seven stover harvest strategies within a 50-ha (125 acres) site on very deep, moderately well to poorly drained Mollisols, developed in calcareous glacial till. The treatments included the following: conventional grain harvest (no stover harvest), grain plus a second-pass rake and bale stover harvest, and single-pass grain plus cob-only biomass, grain plus vegetative material other than grain [(MOG) consisting of cobs, husks, and upper plant parts], grain plus all vegetative material from the ear shank upward (high cut), and all vegetative material above a 10 cm stubble height (low cut), with a John Deere 9750 STS combine, and grain plus direct baling of MOG with an AgCo harvesting system. Average grain yields were 11.4, 10.1, 9.7, and 9.5 Mg ha^?1 for 2008, 2009, 2010, and 2011, respectively. Average stover harvest ranged from 0 to 5.6 Mg ha^?1 and increased N, P, and K removal by an average of 11, 1.6, and 15 kg Mg^?1, respectively. Grain yield in 2009 showed a significant positive response to higher 2008 stover removal rates, but grain yield was not increased in 2010 or 2011 due to prior-year stover harvest. High field losses caused the direct-bale treatment to have significantly lower grain yield in 2011 because the AgCo system could not pick up the severely lodged crop. We conclude that decreases in grain yield across the 4 years were due more to seasonal weather patterns, spatial variability, and not rotating crops than to stover harvest.     

Evaluation of Simultaneous Saccharification and Ethanol Fermentation of Undetoxified Steam-Exploded Corn Stover by Saccharomyces cerevisiae Y5

Toxin-tolerant yeast strains that produce high ethanol yield are inevitably requited for cost-effective ethanol production from undetoxified steam-exploded corn stover. To verify the ethanol-producing capability of the strain Saccharomyces cerevisiae Y5 developed in our laboratory, simultaneous saccharification and fermentation of undetoxified steam-exploded corn stover with solids loading of 30 % (w/v) was carried out in different-sized flasks and an automatic fermenter. After 96 h, the ethanol concentrations had reached 50, 47.8, and 47.5 g/L in the 100-mL flask, 3,000-mL flask, and 5-L automatic fermenter, respectively. The experiment demonstrates that ethanol production from undetoxified steam-exploded corn stover using S. cerevisiae Y5 simplifies the production process, reduces equipment investment and water consumption, and generates highly concentrated ethanol. S. cerevisiae Y5 is a promising strain that could reduce the cost of producing ethanol from steam-exploded corn stover.     

Variation due to Growth Environment in Alfalfa Yield, Cellulosic Ethanol Traits, and Paper Pulp Characteristics

Alfalfa (Medicago sativa L.) is a promising bioenergy and bioproduct feedstock because of its high yield, N-fixation capacity, potential for planting in rotation with corn (Zea mays L.), and valuable protein co-product (leaf meal). Our objective was to examine the effect of growth environment on biomass yield, cellulosic ethanol traits, and paper pulp fiber characteristics of alfalfa stems. Landscape position (summit and mild slope), season of harvest (four harvests per season), and multiple years (2005 and 2006) provided environmental variation. Alfalfa stem samples were analyzed for cell wall carbohydrate and lignin concentration. Stems were subjected to dilute acid pre-treatment, enzymatic saccharification, and pulping processes to measure relevant cellulosic ethanol and paper production traits. Landscape position was not a significant source of variation for yield or any biomass quality trait. Yields varied among harvests in 2005 (1,410–3,265 kg ha^?1) and 2006 (1,610–3,795 kg ha^?1). All cell wall, conversion test, and paper production traits exhibited year by harvest interactions with no clear pattern. Total carbohydrates and lignin ranged from 440 to 531 g?kg^?1 DM and from 113 to 161 g?kg^-1 DM, respectively. Release of cell wall sugars by the conversion test ranged widely (419 to 962 g?kg^?1 DM). Fiber traits were similarly variable with length and fine content ranging from 1.24 to 1.59 mm and from 15.2% to 21.9%, respectively. Utilizing alfalfa biomass for cellulosic ethanol and paper pulp production will involve dealing with significant feedstock quality variation due to growth environment.     

Life cycle assessment of bio-based ethanol produced from different agricultural feedstocks

Purpose

Bio-based products are often considered sustainable due to their renewable nature. However, the environmental performance of products needs to be assessed considering a life cycle perspective to get a complete picture of potential benefits and trade-offs. We present a life cycle assessment of the global commodity ethanol, produced from different feedstock and geographical origin. The aim is to understand the main drivers for environmental impacts in the production of bio-based ethanol as well as its relative performance compared to a fossil-based alternative.

Methods

Ethanol production is assessed from cradle to gate; furthermore, end-of-life emissions are also included in order to allow a full comparison of greenhouse gas (GHG) emissions, assuming degradation of ethanol once emitted to air from household and personal care products. The functional unit is 1 kg ethanol, produced from maize grain in USA, maize stover in USA, sugarcane in North-East of Brazil and Centre-South of Brazil, and sugar beet and wheat in France. As a reference, ethanol produced from fossil ethylene in Western Europe is used. Six impact categories from the ReCiPe assessment method are considered, along with seven novel impact categories on biodiversity and ecosystem services (BES).

Results and discussion

GHG emissions per kilogram bio-based ethanol range from 0.7 to 1.5 kg CO₂ eq per kg ethanol and from 1.3 to 2 kg per kg if emissions at end-of-life are included. Fossil-based ethanol involves GHG emissions of 1.3 kg CO₂ eq per kg from cradle-to-gate and 3.7 kg CO₂ eq per kg if end-of-life is included. Maize stover in USA and sugar beet in France have the lowest impact from a GHG perspective, although when other impact categories are considered trade-offs are encountered. BES impact indicators show a clear preference for fossil-based ethanol. The sensitivity analyses showed how certain methodological choices (allocation rules, land use change accounting, land use biomes), as well as some scenario choices (sugarcane harvest method, maize drying) affect the environmental performance of bio-based ethanol. Also, the uncertainty assessment showed that results for the bio-based alternatives often overlap, making it difficult to tell whether they are significantly different.

Conclusions

Bio-based ethanol appears as a preferable option from a GHG perspective, but when other impacts are considered, especially those related to land use, fossil-based ethanol is preferable. A key methodological aspect that remains to be harmonised is the quantification of land use change, which has an outstanding influence in the results, especially on GHG emissions.     

Multilocation Corn Stover Harvest Effects on Crop Yields and Nutrient Removal

Corn (Zea mays L.) stover was identified as an important feedstock for cellulosic bioenergy production because of the extensive area upon which the crop is already grown. This report summarizes 239 site-years of field research examining effects of zero, moderate, and high stover removal rates at 36 sites in seven different states. Grain and stover yields from all sites as well as N, P, and K removal from 28 sites are summarized for nine longitude and six latitude bands, two tillage practices (conventional vs no tillage), two stover-harvest methods (machine vs calculated), and two crop rotations {continuous corn (maize) vs corn/soybean [Glycine max (L.) Merr.]}. Mean grain yields ranged from 5.0 to 12.0 Mg ha^?1 (80 to 192 bu ac^?1). Harvesting an average of 3.9 or 7.2 Mg ha^?1 (1.7 or 3.2 tons ac^?1) of the corn stover resulted in a slight increase in grain yield at 57 and 51 % of the sites, respectively. Average no-till grain yields were significantly lower than with conventional tillage when stover was not harvested, but not when it was collected. Plant samples collected between physiological maturity and combine harvest showed that compared to not harvesting stover, N, P, and K removal was increased by 24, 2.7, and 31 kg ha^?1, respectively, with moderate (3.9 Mg ha^?1) harvest and by 47, 5.5, and 62 kg ha^?1, respectively, with high (7.2 Mg ha^?1) removal. This data will be useful for verifying simulation models and available corn stover feedstock projections, but is too variable for planning site-specific stover harvest.     

Influence of Corn Residue Harvest Management on Grain,Stover, and Energy Yields

Economic, environmental, and energy independence issues are contributing to rising fossil fuel prices, petroleum supply concerns, and a growing interest in biomass feedstocks as renewable energy sources. Potential feedstocks include perennial grasses, timber, and annual grain crops with our focus being on corn (Zea mays L.) stover. A plot-scale study evaluating stover removal was initiated in 2008 on a South Carolina Coastal Plain Coxville/Rains–Goldsboro–Lynchburg soil association site. In addition to grain and stover yields, carbon balance, greenhouse gas (GHG) emissions and soil quality impact reported elsewhere in this issue, variation in gross energy distribution within various plant fractions — whole plant, below ear shank (bottom), above ear shank (top), cob, as well as leaves and stems of the bottom and top portions (n _{(part, year)}?=?20) was measured with an isoperibol calorimeter. Stalks from above the ear shank were the most energy dense, averaging 18.8 MJ/kg db, and when combined with other plant parts from above the ear shank, the entire top half was more energy dense than the bottom half — 18.4 versus 18.2 MJ/kg db. Gross energy content of the whole plant, including the cob, averaged 18.28?±?0.76 MJ/kg db. Over the 4 years, partial to total removal (i.e., 25 % to 100 %) of above-ground plant biomass could supply between 30 and 168 GJ/ha depending upon annual rainfall. At 168 GJ/ha, the quantity of corn stover biomass (whole plant) available in a 3,254-km² area (32 km radius) around the study site could potentially support a 500-MW power plant.     

Climate change impacts on life cycle greenhouse gas (GHG) emissions savings of biomethanol from corn and soybean

Purpose

The purpose of this study is to assess and calculate the potential impacts of climate change on the greenhouse gas (GHG) emissions reduction potentials of combined production of whole corn bioethanol and stover biomethanol, and whole soybean biodiesel and stalk biomethanol. Both fuels are used as substitutes to conventional fossil-based fuels. The product system includes energy crop (feedstock) production and transportation, biofuels processing, and biofuels distribution to service station.

Methods

The methodology is underpinned by life cycle thinking. Crop system model and life cycle assessment (LCA) model are linked in the analysis. The Decision Support System for Agrotechnology Transfer – crop system model (DSSAT-CSM) is used to simulate biomass and grain yield under different future climate scenarios generated using a combination of temperature, precipitation, and atmospheric CO₂. Historical weather data for Gainesville, Florida, are obtained for the baseline period (1981–1990). Daily minimum and maximum air temperatures are projected to increase by +2.0, +3.0, +4.0, and +5.0 °C, precipitation is projected to change by ±20, 10, and 5 %, and atmospheric CO₂ concentration is projected to increase by +70, +210, and +350 ppm. All projections are made throughout the growing season. GaBi 4.4 is used as primary LCA modelling software using crop yield data inputs from the DSSAT-CSM software. The models representation of the physical processes inventory (background unit processes) is constructed using the ecoinvent life cycle inventory database v2.0.

Results and discussion

Under current baseline climate condition, net greenhouse gas (GHG) emissions savings per hectare from corn-integrated biomethanol synthesis (CIBM) and soybean-integrated biomethanol synthesis (SIBM) were calculated as ?8,573.31 and ?3,441 kg CO₂-eq. ha^?1 yr^?1, respectively. However, models predictions suggest that these potential GHG emissions savings would be impacted by changing climate ranging from negative to positive depending on the crop and biofuel type, and climate scenario. Increased atmospheric level of CO₂ tends to minimise the negative impacts of increased temperature.

Conclusions

While policy measures are being put in place for the use of renewable biofuels driven by the desire to reduce GHG emissions from the use of conventional fossil fuels, climate change would also have impacts on the potential GHG emissions reductions resulting from the use of these renewable biofuels. However, the magnitude of the impact largely depends on the biofuel processing technology and the energy crop (feedstock) type.     

Concentrated HCl Catalyzed 5-(Chloromethyl)furfural Production from Corn Stover of Varying Particle Sizes

5-(Chloromethyl) Furfural (CMF) is a potential chemical building block for replacing petroleum-derived chemicals derived from lignocellulosic feedstocks. In this study, hand harvested corn stover and mechanically forage chopped corn stover was processed in a 1 L hydrolysis reactor to produce CMF in a biphasic, two solvent system. Both 1,2 dichloroethane (DCE) and dichloromethane (DCM) were tested as organic solvents. The results showed that DCE performed better than DCM due to temperature and pressure limitations of the reactor system. Using DCE as the extracting solvent, the effects of solids loading, particle size, and moisture content of the corn stover on the hydrolysis efficiency were determined. One liter acid hydrolysis reactor provides consistent and reproducible yields of 63% CMF from hand harvested corn stover as feedstock at solid loading of 10% wt/v, 100C for 1 h. For the forage chopped corn stover, increasing particle size brings an increase in the feedstock sugar content. Foraged chopped corn stover (FCCS) particle sizes larger than 19 mm (0.75 in.) results in significant reduction in CMF yield from 43 to 35%.     

Simultaneous Saccharification and Ethanol Fermentation of Corn Stover at High Temperature and High Solids Loading by a Thermotolerant Strain Saccharomyces cerevisiae DQ1

The thermotolerant strain Saccharomyces cerevisiae DQ1 was applied to the simultaneous saccharification and fermentation (SSF) at high temperature and high solids loading of the dilute acid-pretreated corn stover in the present study. The SSF using S. cerevisiae DQ1 was operated at 30?% solids loading of the pretreated corn stover with three-step SSF mode and achieved up to ethanol titer of 48?g/L and yield of 65.6?%. S. cerevisiae DQ1 showed strong thermotolerance in both the regular one-step SSF and the three-step SSF with changing temperature in each step. The three-step SSF at 40°C using S. cerevisiae DQ1 tolerated the greater cellulase dosage and solids loading of the pretreated corn stover and resulted in increased ethanol production. The present study provided a practical potential for the future SSF of lignocellulose feedstock at high temperature to reach high ethanol titer.     

Modeling Water Quality Impacts of Cellulosic Biofuel Production from Corn Silage

The growing interest in the use of alternative biomass products for fuel production requires a thorough understanding of the environmental impacts associated with the production of these bioenergy crops. Corn silage is a potential bioenergy feedstock; however, water quality implications for its utilization as a biofeedstock are not understood. The objective of this work was to evaluate water quality impacts associated with corn silage production. The GLEAMS-NAPRA model was used to quantify runoff, percolation, erosion, nitrate-nitrogen, total phosphorus, and pesticide losses attributed to the production of corn silage with and without winter cover crops for two tillage options (conventional tillage and no till) on three Indiana soils. Results revealed that corn silage would generate greater annual surface runoff (1 to 6 mm) and percolation (1 to 20 mm) compared with corn grain and grain plus stover cropping systems. Silage/winter cereal rye cover crop reduced annual surface runoff and percolation and was strongly influenced by increases in evapotranspiration, when compared with continuous silage production. Silage managed with winter cereal rye cover crop influenced water quality by reducing annual nitrate losses with runoff from a low of 14 % to a high of 27 %, with relatively no effect because of tillage management. No-till practice on silage system produced significantly greater phosphorus losses (7.46 to 18.07 kg/ha) in comparison to silage/cereal rye, corn grain, and grain plus stover harvest (p?<?0.05). For every 1,000 l of ethanol produced from corn silage, erosion losses ranged from 0.07 to 0.95 t/ha for conventional tillage practices and from 0.06 to 0.83 t/ha for no-till practices. The feasibility of cropping systems such as corn silage/cereal rye could contribute to large-scale biomass production but should be further investigated.     

Nutrient Removal as a Function of Corn Stover Cutting Height and Cob Harvest

One-pass harvest equipment has been developed to collect corn (Zea mays L.) grain, stover, and cobs that can be used as bioenergy feedstock. Nutrients removed in these feedstocks have soil fertility implication and affect feedstock quality. The study objectives were to quantify nutrient concentrations and potential removal as a function of cutting height, plant organ, and physiological stage. Plant samples were collected in 10-cm increments at seven diverse geographic locations at two maturities and analyzed for multiple elements. At grain harvest, nutrient concentration averaged 5.5 g?N kg^?1, 0.5 g?P kg^?1, and 6.2 g?K kg^?1 in cobs, 7.5 g?N kg^?1, 1.2 g?P kg^?1, and 8.7 g?K kg^?1 in the above-ear stover fraction, and 6.4 g?N kg^?1, 1.0 g?P kg^?1, and 10.7 g?K kg^?1 in the below-ear stover fraction (stover fractions exclude cobs). The average collective cost to replace N, P, and K was $11.66 Mg^?1 for cobs, $17.59 Mg^?1 for above-ear stover, and $18.11 Mg^?1 for below-ear stover. If 3 Mg ha^?1 of above-ear stover fraction plus 1 Mg of cobs are harvested, an average N, P, and K replacement cost was estimated at $64 ha^?1. Collecting cobs or above-ear stover fraction may provide a higher quality feedstock while removing fewer nutrients compared to whole stover removal. This information will enable producers to balance soil fertility by adjusting fertilizer rates and to sustain soil quality by predicting C removal for different harvest scenarios. It also provides elemental information to the bioenergy industry.     

The Economics of Biomass Collection and Transportation and Its Supply to Indiana Cellulosic and Electric Utility Facilities

With cellulosic energy production from biomass becoming popular in renewable energy research, agricultural producers may be called upon to plant and collect corn stover or harvest switchgrass to supply feedstocks to nearby facilities. Determining the production and transportation cost to the producer of corn stover or switchgrass and the amount available within a given distance from the plant will result in a per metric ton cost the plant will need to pay producers in order to receive sufficient quantities of biomass. This research computes up-to-date biomass production costs using recent prices for all important cost components including seed, fertilizer, herbicide, mowing/shredding, raking, baling, storage, handling, and transportation. The cost estimates also include nutrient replacement for corn stover. The total per metric ton cost is a combination of these cost components depending on whether equipment is owned or custom hired, what baling options are used, the size of the farm, and the transport distance. Total costs per dry metric ton for biomass with a transportation distance of 60 km ranges between $63 and $75 for corn stover and $80 and $96 for switchgrass. Using the county quantity data and this cost information, we then estimate biomass supply curves for three Indiana coal-fired electric utilities. This supply framework can be applied to plants of any size, location, and type, such as future cellulosic ethanol plants. Finally, greenhouse gas emissions reductions are estimated from using biomass instead of coal for part of the utility energy and also the carbon tax required to make the biomass and coal costs equivalent. Depending on the assumed CO₂ price, the use of biomass instead of coal is found to decrease overall costs in most cases.