The greenhouse gas emissions performance of cellulosic ethanol supply chains in Europe

Background  

The production of fuel-grade ethanol from lignocellulosic biomass resources has the potential to increase biofuel production capacity whilst minimising the negative environmental impacts. These benefits will only be realised if lignocellulosic ethanol production can compete on price with conventional fossil fuels and if it can be produced commercially at scale. This paper focuses on lignocellulosic ethanol production in Europe. The hypothesis is that the eventual cost of production will be determined not only by the performance of the conversion process but by the performance of the entire supply-chain from feedstock production to consumption. To test this, a model for supply-chain cost comparison is developed, the components of representative ethanol supply-chains are described, the factors that are most important in determining the cost and profitability of ethanol production are identified, and a detailed sensitivity analysis is conducted.     

Life cycle cost analysis of fuel ethanol produced from cassava in Thailand

Background, aim, and scope

As a net oil importer, Thailand has a special interest in the development of biofuels, especially ethanol. At present, ethanol in the country is mainly a fermentation/distillery product of cane molasses, but cassava holds superior potential for the fuel. This study aims to assess the economics of cassava-based ethanol as an alternative transportation fuel in Thailand. The scope of the study includes the cassava cultivation/processing, the conversion to ethanol, the distribution of the fuel, and all transportation activities taking place within the system boundary.

Materials and methods

The life cycle cost assessment carried out follows three interrelated phases: data inventory, data analysis, and interpretation. The functional unit for the comparison between ethanol and gasoline is the specific distance that a car can travel on 1 L ethanol in the form of E10, a 10% ethanol blend in gasoline.

Results

The results of the analysis show, despite low raw material cost compared to molasses and cane-based ethanol, that cassava ethanol is still more costly than gasoline. This high cost has put an economic barrier to commercial application, leading to different opinions about government support for ethanol in the forms of tax incentives and subsidies.

Discussion

Overall, feedstock cost tends to govern ethanol’s production cost, thus, making itself and its 10% blend in gasoline less competitive than gasoline for the specific conditions considered. However, this situation can also be improved by appropriate measures, as discussed later.

Conclusions

To make ethanol cost-competitive with gasoline, the first possible measure is a combination of increasing crop yield and decreasing farming costs (chemical purchase and application, planting, and land preparation) so as to make a 47% reduction in the cost per tonne of cassava. This is modeled by a sensitivity analysis for the cost in the farming phase. In the industrial phase of the fuel production cycle, utilization of co-products and substitution of rice husk for bunker oil as process energy tend to reduce 62% of the price gap between ethanol and gasoline. The remaining 38% price gap can be eliminated with a 16% cut of raw material (cassava) cost, which is more practical than a 47% where no savings options in ethanol conversion phase are taken into account.

Recommendations and perspectives

The life cycle cost analysis helps identify the key areas in the ethanol production cycle where changes are required to improve cost performance. Including social aspects in an LCC analysis may make the results more favorable for ethanol.     

Techno-economic evaluation of 2nd generation bioethanol production from sugar cane bagasse and leaves integrated with the sugar-based ethanol process

Background

Bioethanol produced from the lignocellulosic fractions of sugar cane (bagasse and leaves), i.e. second generation (2G) bioethanol, has a promising market potential as an automotive fuel; however, the process is still under investigation on pilot/demonstration scale. From a process perspective, improvements in plant design can lower the production cost, providing better profitability and competitiveness if the conversion of the whole sugar cane is considered. Simulations have been performed with AspenPlus to investigate how process integration can affect the minimum ethanol selling price of this 2G process (MESP-2G), as well as improve the plant energy efficiency. This is achieved by integrating the well-established sucrose-to-bioethanol process with the enzymatic process for lignocellulosic materials. Bagasse and leaves were steam pretreated using H₃PO₄ as catalyst and separately hydrolysed and fermented.

Results

The addition of a steam dryer, doubling of the enzyme dosage in enzymatic hydrolysis, including leaves as raw material in the 2G process, heat integration and the use of more energy-efficient equipment led to a 37 % reduction in MESP-2G compared to the Base case. Modelling showed that the MESP for 2G ethanol was 0.97 US$/L, while in the future it could be reduced to 0.78 US$/L. In this case the overall production cost of 1G + 2G ethanol would be about 0.40 US$/L with an output of 102 L/ton dry sugar cane including 50 % leaves. Sensitivity analysis of the future scenario showed that a 50 % decrease in the cost of enzymes, electricity or leaves would lower the MESP-2G by about 20%, 10% and 4.5%, respectively.

Conclusions

According to the simulations, the production of 2G bioethanol from sugar cane bagasse and leaves in Brazil is already competitive (without subsidies) with 1G starch-based bioethanol production in Europe. Moreover 2G bioethanol could be produced at a lower cost if subsidies were used to compensate for the opportunity cost from the sale of excess electricity and if the cost of enzymes continues to fall.     

Techno-Economic Evaluation of Cellulosic Ethanol Production Based on Pilot Biorefinery Data: a Case Study of Sweet Sorghum Bagasse Processed via L+SScF

Replacing fossil fuels with renewable fuels derived from lignocellulosic biomass can contribute to the mitigation of global warming and the economic development of rural communities. This will require lignocellulosic biofuels to become price competitive with fossil fuels. Techno-economic analyses can provide insights into which parts of the biofuel production process need to be optimized to reduce cost or energy use. We used data obtained from a pilot biorefinery to model a commercial-scale biorefinery that processes lignocellulosic biomass to ethanol, with a focus on the minimum ethanol selling price (MESP). The process utilizes a phosphoric acid-catalyzed pre-treatment of sweet sorghum bagasse followed by liquefaction and simultaneous saccharification and co-fermentation (L+SScF) of hexose and pentose sugars by an engineered Escherichia coli strain. After validating a techno-economic model developed with the SuperPro Designer software for the conversion of sugarcane bagasse to ethanol by comparing it to a published Aspen Plus model, six different scenarios were modeled for sweet sorghum bagasse Under the most optimistic scenario, the ethanol can be produced at a cost close to the energy-equivalent price of gasoline. Aside from an increase in the price of gasoline, the gap between ethanol and gasoline prices could also be bridged by either a decrease in the cost of cellulolytic enzymes or development of value-added products from lignin.     

Chemical and morphological characterization of sugarcane bagasse submitted to a delignification process for enhanced enzymatic digestibility

Background

While advantages of biofuel have been widely reported, studies also highlight the challenges in large scale production of biofuel. Cost of ethanol and process energy use in cellulosic ethanol plants are dependent on technologies used for conversion of feedstock. Process modeling can aid in identifying techno-economic bottlenecks in a production process. A comprehensive techno-economic analysis was performed for conversion of cellulosic feedstock to ethanol using some of the common pretreatment technologies: dilute acid, dilute alkali, hot water and steam explosion. Detailed process models incorporating feedstock handling, pretreatment, simultaneous saccharification and co-fermentation, ethanol recovery and downstream processing were developed using SuperPro Designer. Tall Fescue (Festuca arundinacea Schreb) was used as a model feedstock.

Results

Projected ethanol yields were 252.62, 255.80, 255.27 and 230.23 L/dry metric ton biomass for conversion process using dilute acid, dilute alkali, hot water and steam explosion pretreatment technologies respectively. Price of feedstock and cellulose enzymes were assumed as $50/metric ton and 0.517/kg broth (10% protein in broth, 600 FPU/g protein) respectively. Capital cost of ethanol plants processing 250,000 metric tons of feedstock/year was $1.92, $1.73, $1.72 and $1.70/L ethanol for process using dilute acid, dilute alkali, hot water and steam explosion pretreatment respectively. Ethanol production cost of $0.83, $0.88, $0.81 and $0.85/L ethanol was estimated for production process using dilute acid, dilute alkali, hot water and steam explosion pretreatment respectively. Water use in the production process using dilute acid, dilute alkali, hot water and steam explosion pretreatment was estimated 5.96, 6.07, 5.84 and 4.36 kg/L ethanol respectively.

Conclusions

Ethanol price and energy use were highly dependent on process conditions used in the ethanol production plant. Potential for significant ethanol cost reductions exist in increasing pentose fermentation efficiency and reducing biomass and enzyme costs. The results demonstrated the importance of addressing the tradeoffs in capital costs, pretreatment and downstream processing technologies.     

Integration options for high energy efficiency and improved economics in a wood-to-ethanol process

Background

There is currently a steady increase in the use of wood-based fuels for heat and power production in Sweden. A major proportion of these fuels could serve as feedstock for ethanol production. In this study various options for the utilization of the solid residue formed during ethanol production from spruce, such as the production of pellets, electricity and heat for district heating, were compared in terms of overall energy efficiency and production cost. The effects of changes in the process performance, such as variations in the ethanol yield and/or the energy demand, were also studied. The process was based on SO₂-catalysed steam pretreatment, which was followed by simultaneous saccharification and fermentation. A model including all the major process steps was implemented in the commercial flow-sheeting program Aspen Plus, the model input was based on data recently obtained on lab scale or in a process development unit.

Results

For the five base case scenarios presented in the paper the overall energy efficiency ranged from 53 to 92%, based on the lower heating values, and a minimum ethanol selling price from 3.87 to 4.73 Swedish kronor per litre (0.41–0.50 EUR/L); however, ethanol production was performed in essentially the same way in each base case scenario. (Highly realistic) improvements in the ethanol yield and reductions in the energy demand resulted in significantly lower production costs for all scenarios.

Conclusion

Although ethanol was shown to be the main product, i.e. yielding the major part of the income, the co-product revenue had a considerable effect on the process economics and the importance of good utilization of the entire feedstock was clearly shown. With the assumed prices of the co-products, utilization of the excess solid residue for heat and power production was highly economically favourable. The study also showed that improvements in the ethanol yield and reductions in the energy demand resulted in significant production cost reductions almost independently of each other.     

Comparative LCA of ethanol versus gasoline in Brazil using different LCIA methods

Purpose

The main objective of this study is to expand the discussion about how, and to what extent, the environmental performance is affected by the use of different life cycle impact assessment (LCIA) illustrated by the case study of the comparison between environmental impacts of gasoline and ethanol form sugarcane in Brazil.

Methods

The following LCIA methods have been considered in the evaluation: CML 2001, Impact 2002+, EDIP 2003, Eco-indicator 99, TRACI 2, ReCiPe, and Ecological Scarcity 2006. Energy allocation was used to split the environmental burdens between ethanol and surplus electricity generated at the sugarcane mill. The phases of feedstock and (bio)fuel production, distribution, and use are included in system boundaries.

Results and discussion

At the midpoint level, comparison of different LCIA methods showed that ethanol presents lower impacts than gasoline in important categories such as global warming, fossil depletion, and ozone layer depletion. However, ethanol presents higher impacts in acidification, eutrophication, photochemical oxidation, and agricultural land use categories. Regarding to single-score indicators, ethanol presented better performance than gasoline using ReCiPe Endpoint LCIA method. Using IMPACT 2002+, Eco-indicator 99, and Ecological Scarcity 2006, higher scores are verified for ethanol, mainly due to the impacts related to particulate emissions and land use impacts.

Conclusions

Although there is a relative agreement on the results regarding equivalent environmental impact categories using different LCIA methods at midpoint level, when single-score indicators are considered, use of different LCIA methods lead to different conclusions. Single-score results also limit the interpretability at endpoint level, as a consequence of small contributions of relevant environmental impact categories weighted in a single-score indicator.     

Prospects for Cellulosic Biofuel Production in the Northeastern United States: A Scenario Analysis

Secure access to energy and food are two of the challenges facing the Northeast region of the United States. Traditional biofuel feedstocks, such as corn and oil seed, are able to satisfy energy requirements. However, they compete with food production for desirable land and water resources and, in any case, are not likely to exploit the region's current comparative advantages. This study investigates a potential solution to the energy security problem in the Northeast: biofuel from advanced feedstock in the form of net forest growth and woody wastes, of which the region has abundant endowments. The federal government has committed to requiring 79.5 billion liters (BL) of advanced biofuel production annually by 2022. We evaluate both the physical capacity for its production and its cost competitiveness using an input‐output model of consumption, production, and trade in the 13‐state region. The model minimizes resource use required to satisfy given consumer demand using alternative technological options and subject to resource constraints. We compile data from the technical literature quantifying state‐level biofuel feedstock endowments and the technological requirements for cellulosic ethanol production. We find that exploiting the region's endowment of cellulosic feedstock requires either making the price of biofuels competitive with gasoline through subsidies or restricting imports of gasoline. Based on this initial investigation, we conclude that the region can produce significant amounts of advanced biofuel, up to 20.28 BL of cellulosic ethanol per year, which could displace nearly 12.5% of the gasoline that is now devoted to motorized transport in the region.     

Life cycle assessment of potential energy uses for short rotation willow biomass in Sweden

Purpose

Two different bioenergy systems using willow chips as raw material has been assessed in detail applying life cycle assessment (LCA) methodology to compare its environmental profile with conventional alternatives based on fossil fuels and demonstrate the potential of this biomass as a lignocellulosic energy source.

Methods

Short rotation forest willow plantations dedicated to biomass chips production for energy purposes and located in Southern Sweden were considered as the agricultural case study. The bioenergy systems under assessment were based on the production and use of willow-based ethanol in a flexi fuel vehicle blended with gasoline (85 % ethanol by volume) and the direct combustion of willow chips in an industrial furnace in order to produce heat for end users. The standard framework for LCA from the International Standards Organisation was followed in this study. The environmental profiles as well as the hot spots all through the life cycles were identified.

Results and discussion

According to the results, Swedish willow biomass production is energetically efficient, and the destination of this biomass for energy purposes (independently the sort of energy) presents environmental benefits, specifically in terms of avoided greenhouse gases emissions and fossil fuels depletion. Several processes from the agricultural activities were identified as hot spots, and special considerations should be paid on them due to their contribution to the environmental impact categories under analysis. This was the case for the production and use of the nitrogen-based fertilizer, as well as the diesel used in agricultural machineries.

Conclusions

Special attention should be paid on diffuse emissions from the ethanol production plant as well as on the control system of the combustion emissions from the boiler.     

High throughput screening of hydrolytic enzymes from termites using a natural substrate derived from sugarcane bagasse

Background

Short rotation coppice willow is a potential lignocellulosic feedstock in the United Kingdom and elsewhere; however, research on optimising willow specifically for bioethanol production has started developing only recently. We have used the feedstock Salix viminalis × Salix schwerinii cultivar 'Olof' in a three-month pot experiment with the aim of modifying cell wall composition and structure within the stem to the benefit of bioethanol production. Trees were treated for 26 or 43 days with tension wood induction and/or with an application of the cellulose synthesis inhibitor 2,6-dichlorobenzonitrile that is specific to secondary cell walls. Reaction wood (tension and opposite wood) was isolated from material that had received the 43-day tension wood induction treatment.

Results

Glucan content, lignin content and enzymatically released glucose were assayed. All measured parameters were altered without loss of total stem biomass yield, indicating that enzymatic saccharification yield can be enhanced by both alterations to cell wall structure and alterations to absolute contents of either glucan or lignin.

Conclusions

Final glucose yields can be improved by the induction of tension wood without a detrimental impact on biomass yield. The increase in glucan accessibility to cell wall degrading enzymes could help contribute to reducing the energy and environmental impacts of the lignocellulosic bioethanol production process.     

Cross-reactions between engineered xylose and galactose pathways in recombinant Saccharomyces cerevisiae

Background

Bioethanol can be produced from sugar-rich, starch-rich (first generation; 1G) or lignocellulosic (second generation; 2G) raw materials. Integration of 2G ethanol with 1G could facilitate the introduction of the 2G technology. The capital cost per ton of fuel produced would be diminished and better utilization of the biomass can be achieved. It would, furthermore, decrease the energy demand of 2G ethanol production and also provide both 1G and 2G plants with heat and electricity. In the current study, steam-pretreated wheat straw (SPWS) was mixed with presaccharified wheat meal (PWM) and converted to ethanol in simultaneous saccharification and fermentation (SSF).

Results

Both the ethanol concentration and the ethanol yield increased with increasing amounts of PWM in mixtures with SPWS. The maximum ethanol yield (99% of the theoretical yield, based on the available C6 sugars) was obtained with a mixture of SPWS containing 2.5% water-insoluble solids (WIS) and PWM containing 2.5% WIS, resulting in an ethanol concentration of 56.5 g/L. This yield was higher than those obtained with SSF of either SPWS (68%) or PWM alone (91%).

Conclusions

Mixing wheat straw with wheat meal would be beneficial for both 1G and 2G ethanol production. However, increasing the proportion of WIS as wheat straw and the possibility of consuming the xylose fraction with a pentose-fermenting yeast should be further investigated.     

Life cycle assessment of fuel ethanol from cane molasses in Thailand

Background, aim and scope

After China and India, Thailand is considered another emerging market for fuel ethanol in Asia. At present, ethanol in the country is mainly a fermentation/distillery product of cane molasses, although cassava and cane juice are considered other potential raw materials for the fuel. This study aims to evaluate the environmental impacts of substituting conventional gasoline (CG) with molasses-based gasohol in Thailand.

Materials and methods

The life cycle assessment (LCA) procedure carried out follows three interrelated phases: inventory analysis, characterization and interpretation. The functional unit for the comparison is 1 l gasoline equivalent consumed by a new passenger car to travel a specific distance.

Results

The results of the study show that molasses-based ethanol (MoE) in the form of 10% blend with gasoline (E10), along its whole life cycle, consumes less fossil energy (5.3%), less petroleum (8.1%) and provides a similar impact on acidification compared to CG. The fuel, however, has inferior performance in other categories (e.g. global warming potential, nutrient enrichment and photochemical ozone creation potential) indicated by increased impacts over CG.

Discussion

In most cases, higher impacts from the upstream of molasses-based ethanol tend to govern its net life cycle impacts relative to CG. This makes the fuel blend less environmentally friendly than CG for the specific conditions considered. However, as discussed later, this situation can be improved by appropriate changes in energy carriers.

Conclusions

The LCA procedure helps identify the key areas in the MoE production cycle where changes are required to improve environmental performance. Specifically, they are: (1) use of coal as energy source for ethanol conversion, (2) discharge of distillery spent wash into an anaerobic pond, and (3) open burning of cane trash in sugar cane production.

Recommendations and perspectives

Measures to improve the overall life cycle energy and environmental impacts of MoE are: (1) substituting biomass for fossil fuels in ethanol conversion, (2) capturing CH₄ from distillery spent wash and using it as an energy supply, and (3) utilizing cane trash for energy instead of open burning in fields.     

Techno-economic potential of bioethanol from bamboo in China

Background

Bamboo is potentially an interesting feedstock for advanced bioethanol production in China due to its natural abundance, rapid growth, perennial nature and low management requirements. Liquid hot water (LHW) pretreatment was selected as a promising technology to enhance sugar release from bamboo lignocellulose whilst keeping economic and environmental costs to a minimum. The present research was conducted to assess: 1) by how much LHW pretreatment can enhance sugar yields in bamboo, and 2) whether this process has the potential to be economically feasible for biofuel use at the commercial scale. Pretreatments were performed at temperatures of 170-190°C for 10–30 minutes, followed by enzymatic saccharification with a commercial enzyme cocktail at various loadings. These data were then used as inputs to a techno-economic model using AspenPlus? to determine the production cost of bioethanol from bamboo in China.

Results

At the selected LHW pretreatment of 190°C for 10 minutes, 69% of the initial sugars were released under a standardised enzyme loading; this varied between 59-76% when 10–140 FPU/g glucan of commercial enzyme Cellic CTec2 was applied. Although the lowest enzyme loading yielded the least amount of bioethanol, the techno-economic evaluation revealed it to be the most economically viable scenario with a production cost of $0.484 per litre (with tax exemption and a $0.16/litre subsidy). The supply-chain analysis demonstrated that bioethanol could be economically competitive with petrol at the pump at enzyme loadings up to 60 FPU/g glucan. However, in a prospective scenario with reduced government support, this enzyme loading threshold would be reduced to 30 FPU/g glucan.

Conclusions

Bioethanol from bamboo is shown to be both technically and economically feasible, as well as competitive with petrol in China. Alternative approaches to reduce bioethanol production costs are still needed however, to ensure its competitiveness in a possible future scenario where neither tax exemptions nor subsidies are granted to producers. These measures may include improving sugar release with more effective pretreatments and reduced enzyme usage, accessing low cost bamboo feedstock or selecting feedstocks with higher/more accessible cellulose.

     

Allocation issues in LCA methodology: a case study of corn stover-based fuel ethanol

Background, aim, and scope

Facing the threat of oil depletion and climate change, a shift from fossil resources to renewables is ongoing to secure long-term low carbon energy supplies. In view of the carbon dioxide reduction targets agreed upon in the Kyoto protocol, bioethanol has become an attractive option for one energy application, as transport fuel. Many studies on the LCA of fuel ethanol have been conducted, and the results vary to a large extent. In most of these studies, only one type of allocation is applied. However, the effect of allocation on outcomes is of crucial importance to LCA as a decision supporting tool. This is only addressed in a few studies to a limited extent. Moreover, most of the studies mainly focus on fossil energy use and GHG emissions. In this paper, a case study is presented wherein a more complete set of impact categories is used. Land use has been left out of account as only hectare data would be given which is obviously dominated by agriculture. Moreover, different allocation methods are applied to assess the sensitivity of the outcomes for allocation choices.

Materials and methods

This study focuses on the comparison of LCA results from the application of different allocation methods by presenting an LCA of gasoline and ethanol as fuels and with two types of blends of gasoline with ethanol, all used in a midsize car. As a main second-generation application growing fast in the USA, corn stover-based ethanol is chosen as a case study. The life cycles of the fuels include gasoline production, corn and stover agriculture, cellulosic ethanol production, blending ethanol with gasoline to produce E10 (10% of ethanol) and E85 (85% of ethanol), and finally the use of gasoline, E10, E85, and ethanol. In this study, a substantially broader set of eight environmental impacts is covered.

Results

LCA results appear to be largely dependent on the allocation methods rendered. The level of abiotic depletion and ozone layer depletion decrease when replacing gasoline by ethanol fuels, irrespective of the allocation method applied, while the rest of the impacts except global warming potential are larger. The results show a reduction of global warming potential when mass/energy allocation is applied; in the case of economic allocation, it gives contrary results. In the expanded systems, global warming potential is significantly reduced comparing to the ones from the allocated systems. A contribution analysis shows that car driving, electricity use for cellulase enzyme production, and ethanol conversion contribute largely to global warming potential from the life cycle of ethanol fuels.

Discussion

The reason why the results of global warming potential show a reverse trend is that the corn/stover allocation ratio shifts from 7.5 to 1.7 when shifting from economic allocation to mass/energy allocation. When mass/energy allocation is applied, both more credits (CO₂ uptake) and more penalties (N₂O emission) in agriculture are allocated to stover compared to the case of economic allocation. However, more CO₂ is taken up than N₂O (in CO₂ eq.) emitted. Hence, the smaller the allocation ratio is between corn and stover, the lower the share of the overall global warming emissions being allocated to ethanol will be. In the system expansion approach, global warming potentials are significantly reduced, resulting in the negative values in all cases. This implies that the system expansion results are comparable to one another because they make the same cutoffs but not really to the results related to mass, energy, and economic value-based allocated systems.

Conclusions

The choice of the allocation methods is essential for the outcomes, especially for global warming potential in this case. The application of economic allocation leads to increased GWP when replacing gasoline by ethanol fuels, while reduction of GWP is achieved when mass/energy allocation is used as well as in the system where biogenic CO₂ is excluded. Ethanol fuels are better options than gasoline when abiotic depletion and ozone layer depletion are concerned. In terms of other environmental impacts, gasoline is a better option, mainly due to the emissions of nutrients and toxic substances connected with agriculture. A clear shift of problems can be detected: saving fossil fuels at the expense of emissions related to agriculture, with GHG benefits depending on allocation choices. The overall evaluation of these fuel options, therefore, depends very much on the importance attached to each impact category.

Recommendations and perspectives

This study focuses only on corn stover-based ethanol as one case. Further studies may include other types of cellulosic feedstocks (i.e., switchgrass or wood), which require less intensive agricultural practice and may lead to better environmental performance of fuel ethanol. Furthermore, this study shows that widely used but different allocation methods determine outcomes of LCA studies on biofuels. This is an unacceptable situation from a societal point of view and a challenge from a scientific point of view. The results from applying just one allocation method are not sufficient for decision making. Comparison of different allocation methods is certainly of crucial importance. A broader approach beyond LCA for the analysis of biorefinery systems with regard to energy conservation, environmental impact, and cost–benefit will provide general indications on the sustainability of bio-based productions.     

Development of a fluorescence-based method for monitoring glucose catabolism and its potential use in a biomass hydrolysis assay

Background  

The availability and low cost of lignocellulosic biomass has caused tremendous interest in the bioconversion of this feedstock into liquid fuels. One measure of the economic viability of the bioconversion process is the ease with which a particular feedstock is hydrolyzed and fermented. Because monitoring the analytes in hydrolysis and fermentation experiments is time consuming, the objective of this study was to develop a rapid fluorescence-based method to monitor sugar production during biomass hydrolysis, and to demonstrate its application in monitoring corn stover hydrolysis.     

The challenge of enzyme cost in the production of lignocellulosic biofuels

With the aim of understanding the contribution of enzymes to the cost of lignocellulosic biofuels, we constructed a techno-economic model for the production of fungal cellulases. We found that the cost of producing enzymes was much higher than that commonly assumed in the literature. For example, the cost contribution of enzymes to ethanol produced by the conversion of corn stover was found to be $0.68/gal if the sugars in the biomass could be converted at maximum theoretical yields, and $1.47/gal if the yields were based on saccharification and fermentation yields that have been previously reported in the scientific literature. We performed a sensitivity analysis to study the effect of feedstock prices and fermentation times on the cost contribution of enzymes to ethanol price. We conclude that a significant effort is still required to lower the contribution of enzymes to biofuel production costs.     

Techno-economic analysis of biomass to fuel conversion via the MixAlco process

MixAlco is a robust process that converts biomass to fuels and chemicals. A key feature of the MixAlco process is the fermentation, which employs a mixed culture of acid-forming microorganisms to convert biomass components (carbohydrates, proteins, and fats) to carboxylate salts. Subsequently, these intermediate salts are chemically converted to hydrocarbon fuels (gasoline, jet fuel, and diesel). This work focuses on process synthesis, simulation, integration, and cost estimation of the MixAlco process. For the base-case capacity of 40 dry tonne feedstock per hour, the total capital investment is US $5.54/annual gallon of hydrocarbon fuels (US $5.54/annual gallon of hydrocarbon fuels (US 3.79/annual gallon of ethanol equivalent), and the minimum selling price [with 10% return on investment (ROI), internal hydrogen production, and US $60/tonne biomass] is US $60/tonne biomass] is US 2.56/gal hydrocarbon, which is equivalent to US $1.75/gal ethanol. If plant capacity is increased to 400 tph, the minimum selling price of biomass-derived hydrocarbon fuels is US $1.75/gal ethanol. If plant capacity is increased to 400 tph, the minimum selling price of biomass-derived hydrocarbon fuels is US 1.76/gal hydrocarbon (US $1.20/gal ethanol equivalent), which can compete without subsidies with petroleum-derived hydrocarbons when crude oil sells for about US $1.20/gal ethanol equivalent), which can compete without subsidies with petroleum-derived hydrocarbons when crude oil sells for about US 65/bbl. At 40 tph, using the average tipping fee for municipal solid waste (US $45/dry tonne) and current price of external hydrogen (US $45/dry tonne) and current price of external hydrogen (US 1/kg), the minimum selling price is only US $1.24/gal hydrocarbon (US $1.24/gal hydrocarbon (US 0.85/gal ethanol equivalent).     

Second generation ethanol in Brazil: can it compete with electricity production?

Much of the controversy surrounding second generation ethanol production arises from the assumed competition with first generation ethanol production; however, in Brazil, where bioethanol is produced from sugarcane, sugarcane bagasse and trash will be used as feedstock for second generation ethanol production. Thus, second generation ethanol production may be primarily in competition with electricity production from the lignocellulosic fraction of sugarcane. A preliminary technical and economic analysis of the integrated production of first and second generation ethanol from sugarcane in Brazil is presented and different technological scenarios are evaluated. The analysis showed the importance of the integrated use of sugarcane including the biomass represented by surplus bagasse and trash that can be taken from the field. Second generation ethanol may favorably compete with bioelectricity production when sugarcane trash is used and when low cost enzyme and improved technologies become commercially available.     

Synergistic effects of mixing hybrid poplar and wheat straw biomass for bioconversion processes

Background

Low cost of raw materials and good process yields are necessary for future lignocellulosic biomass biorefineries to be sustainable and profitable. A low cost feedstock will be diverse, changing as a function of seasonality and price and will most likely be available from multiple sources to the biorefinery. The efficacy of the bioconversion process using mixed biomass, however, has not been thoroughly investigated. Considering the seasonal availability of wheat straw and the year round availability of hybrid poplar in the Pacific Northwest, this study aims to determine the impact of mixing wheat straw and hybrid poplar biomass on the overall sugar production via steam pretreatment and enzymatic saccharification.

Results

Steam pretreatment proved to be effective for processing different mixtures of hybrid poplar and wheat straw. Following SO₂-catalyzed steam explosion pretreatment, on average 22 % more sugar monomers were recovered using mixed feedstock than either single biomass. Improved sugar recovery with mixtures of poplar and wheat straw continued through enzymatic hydrolysis. After steam pretreatment and saccharification, the mixtures showed 20 % higher sugar yields than that produced from hybrid poplar and wheat straw alone.

Conclusions

Blending hybrid poplar and wheat straw resulted in more monomeric sugar recovery and less sugar degradation. This synergistic effect is attributable to interaction of hybrid poplar’s high acetic acid content and the presence of ash supplied by wheat straw. As a consequence on average 20 % more sugar was yielded by using the different biomass mixtures. Combining hybrid poplar and wheat straw enables sourcing of the lowest cost biomass, reduces seasonal dependency, and results in increasing biofuels and chemicals productivity in a cellulosic biorefinery.

     

An Olive Tree Pruning Biorefinery for Co-Producing High Value-Added Bioproducts and Biofuels: Economic and Energy Efficiency Analysis

This work presents a conceptual design of an integrated biorefinery using olive tree pruning as feedstock. The biorefinery combines a state-of-the-art thermochemical technology for producing high value-added antioxidants with an energy self-sufficient biochemical platform for lignocellulosic ethanol production. These plants are integrated by exchanging energy and feedstock. The process and design parameters employed in the plant designs are based on the authors’ own lab and pilot-scale data. The paper discusses the economic dilemma of using this feedstock for producing high value-added products in small amounts versus producing large amounts of low-profit biofuels. The feasibility of this production strategy at medium scale is demonstrated via a techno-economic analysis based on total production cost for each co-product. Each plant is energy integrated, and the energy performance of the bioethanol plant is assessed by calculating the end-use-energy ratio. Both analyses are parameterized with respect to plant capacity (100–1500 t dry weight (dw)/day) and raw material price (20–100 €/ton dry weight).