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.     

Farmers’ Supply Response, Price of Corn Residue, and Its Economic Viability as an Energy Feedstock

Previous economic analyses of energy from corn stover assumed yield reductions from residue removal (without nutrient replacement) and limited or no supply response by farmers to changes in the price of stover. We exploit agronomic and cost information from a randomized block design experiment to model and quantify farmers’ supply response to changes in relative prices of corn stover, corn grain, and soybean. We then couple this supply response with a model of a cost-minimizing processing plant. Results suggest that stover-based energy may be closer to economic viability than previously found. In addition, in areas where reductions in corn yield due to corn monoculture are small, processing plants may find optimal to pay a higher price for stover to induce farmers to adopt continuous corn because it reduces transportation cost. This suggests that such areas may experience changes in their land cover configuration if stover-based energy does become commercially viable.     

Life Cycle Performance of Cellulosic Ethanol and Corn Ethanol from a Retrofitted Dry Mill Corn Ethanol Plant

This study conducts a life cycle assessment of a simulated dry mill corn ethanol facility in California’s Central Valley retrofitted to also produce ethanol from corn stover, a cellulosic feedstock. The assessment examines three facility designs, all producing corn ethanol and wet distiller’s grains and solubles as a co-product: a baseline facility with no cellulosic retrofit, a facility retrofitted with a small capacity for stover feedstock, and a facility retrofitted for a large capacity of stover feedstock. Corn grain is supplied by rail from the Midwest, while stover is sourced from in-state farms and delivered by truck. Two stover feedstock supply scenarios are considered, testing harvest rates at 25 or 40 % of stover mass. Allocation is required to separate impacts attributable to co-products. Additional scenarios are explored to assess the effect of co-product allocation methods on life cycle assessment results for the two fuel products, corn ethanol and stover ethanol. The assessment tracks greenhouse gas (GHG) emissions, energy consumption, criteria air pollutants, and direct water consumption. The GHG intensity of corn ethanol produced from the three facility designs range between 61.3 and 68.9 g CO₂e/MJ, which includes 19.8 g CO₂e/MJ from indirect land use change for Midwestern corn grain. The GHG intensity of cellulosic ethanol varies from 44.1 to 109.2 g CO₂e/MJ, and 14.6 to 32.1 g CO₂e/MJ in the low and high stover capacity cases, respectively. Total energy input ranges between 0.60 and 0.71 MJ/MJ for corn ethanol and 0.13 to 2.29 MJ/MJ for stover ethanol. This variability is the result of the stover supply scenarios (a function of harvest rate) and co-product allocation decisions.     

Trade‐offs among agronomic,energetic, and environmental performance characteristics of corn and prairie bioenergy cropping systems

Cellulosic bioenergy production provides opportunities to utilize a range of cropping systems that can enhance the multifunctionality of agricultural landscapes. In a 9‐ha field experiment located on fertile land in Boone County, IA, USA, we directly compared a corn‐soybean rotation harvested for grain, continuous corn harvested for grain and stover, continuous corn harvested for grain and stover with a rye cover crop, newly reconstructed prairie harvested for biomass and fertilized with nitrogen, and unfertilized newly reconstructed prairie harvested for biomass. Comparisons were made using four performance indicators: harvestable yield, net energy balance (NEB), root production, and nutrient balances. We found trade‐offs among systems in terms of the measured performance indicators. Continuous corn systems were the highest yielding, averaging 13 Mg ha^?1 of harvested biomass (grain plus stover), whereas fertilized and unfertilized prairies produced the least harvested biomass at 8.8 and 6.5 Mg ha^?1, respectively. Mean NEBs were highest in continuous corn systems at 45.1 GJ ha^?1, intermediate in the corn‐soybean rotation at 28.6 GJ ha^?1, and lowest in fertilized and unfertilized prairies at 11.4 and 10.5 GJ ha^?1, respectively. Concomitant with the high yields of the continuous corn systems were the large nutrient requirements of these systems compared to the prairie systems. Continuous corn with rye required three times more nitrogen inputs than fertilized prairie. Root production, on the other hand, was on average seven times greater in the prairie systems than the annual crop systems. On highly fertile soils, corn‐based cropping systems are likely to play an important role in maintaining the high productivity of agricultural landscapes, but alternative cropping systems, such as prairies used for bioenergy production, can produce substantial yield, require minimal externally derived inputs, and can be incorporated into the landscape at strategic locations to maximize the production of other ecosystem services.     

Selenium concentrations in crops grown on low-selenium soils as affected by fly-ash amendment

Summary Studies were conducted under greenhouse and field conditions to evaluate the feasibility of using fly-ash amendments to produce selenium-adequate crops (0.10 to 0.30 ppm Se) on low-Se soils without adversely affecting either the crops or the soils. Two soils, a fine-loamy Alfisol belonging to the Honeoye series and a coarse-loamy Inceptisol belonging to the Mardin series were used to make 3 soil treatments thus: Honeoye, limed Mardin and unlimed Mardin. Fly-ash was mixed with the soils at rates of 0, 2500, 5000, 5000, 10000, 25000 and 50000 ppm. In the greenhouse studies the test crops were corn (Zea mays L.), alfalfa (Medicago sativa), birdsfoot trefoil (Loitus corniculatus) and dry beans (Phaseolus vulgaris L.). There were no yield differences due to fly-ash additions. The rates of 25,000 and 50,000 ppm fly-ash produced the desired Se levels in the utilizable parts of the crops. In the field studies, conducted on another fine-loamy Alfisol belonging to the Lima series and using fly-ash at the rates of 0, 11.2, 22.4 and 112.0 metric tons/ha, it was observed that the yields of corn and dry beans grown were also not influenced by the treatments. Increased levels of Se in corn grains (0.10 ppm) and stover (0.08 ppm) and dry bean seeds (0.14 ppm) were observed at the application rate of 112 metric tons per ha.The results indicate that fly-ash has a potential for producing forages and feed crops containing adequate amounts of Se to protect livestock from Se-responsive diseases.     

The production of pulp from Marsh Grass

With an adequate technology, the Romanian Government mechanically harvests 125,000 tons of dry marsh grass (Phragmites communis Trinius) annually from the vast reedlands of the Danube Delta which, when processed, yield up to 60% in unbleached pulp. The reed pulp is mixed with wood pulp in the production of fabricated paper. At $85.00 per ton of reed raw material, the reed pulp industry amounts to over $10 million annual revenue.     

Supply of cellulosic biomass in Illinois and implications for the Conservation Reserve Program

We developed a mathematical programming model to estimate the supply of cellulosic biomass in Illinois at various biomass prices and examine the implications of biomass production for the maintenance costs of the Conservation Reserve Program (CRP). We find that Illinois has the potential to produce about 38.4–54.5 million dry metric tons (MT) of biomass in 2020 at a biomass price of $150/MT, depending on the production costs of cellulosic feedstocks, residue collection technology, and rates of yield increases of conventional crops. Corn stover will account for more than 65% of the total biomass production across biomass prices and the scenarios considered, while the roles of wheat straw and energy crops are quite limited. Given biomass prices of $50/MT‐$150/MT, many landowners would convert their expiring CRP lands to croplands. To maintain the size of the CRP during the 2007–2020 period at the 2007 levels in Illinois, total program maintenance costs would be $104.6–176.5 million at a biomass price of $50/MT, depending on biomass production conditions and crop yields on CRP lands. This would increase to $155.2–245.4 million at a biomass price of $150/MT.     

Modeling the effects of pelleting on the logistics of distillers grains shipping

The energy security needs of energy importing nations continue to escalate. It is clear that biofuels can help meet some of the increasing need for energy. Theoretically, these can be produced from a variety of biological materials, including agricultural residues (such as corn stover and wheat straw), perennial grasses, legumes, algae, and other biological materials. Currently, however, the most heavily utilized material is corn starch. Industrial fuel ethanol production in the US primarily uses corn, because it is readily converted into fuel at a relatively low cost compared to other biomass sources. The production of corn-based ethanol in the US is dramatically increasing. As the industry continues to grow, the amount of byproducts and coproducts also increases. At the moment, the nonfermentable residues (which are dried and sold as distillers dried grains with solubles – DDGS) are utilized only as livestock feed. The sale of coproducts provides ethanol processors with a substantial revenue source and significantly increases the profitability of the production process. Even though these materials are used to feed animals in local markets, as the size and scope of the industry continues to grow, the need to ship large quantities of coproducts grows as well. This includes both domestic as well as international transportation. Value-added processing options offer the potential to increase the sustainability of each ethanol plant, and thus the industry overall. However, implementation of new technologies will be dependent upon how their costs interact with current processing costs and the logistics of coproduct deliveries. The objective of this study was to examine some of these issues by developing a computer model to determine potential cost ramifications of using various alternative technologies during ethanol processing. This paper focuses specifically on adding a densification unit operation (i.e., pelleting) to produce value-added DDGS at a fuel ethanol manufacturing plant. We have examined the economic implications of pelleting DDGS for varying DDGS production rates (100–1000 tons/d) and pelleting rates (0–100%), for a series of DDGS sales prices ($50–$200/ton). As the proportion of pelleting increases, the cost of transporting DDGS to distant markets drastically declines, because the rail cars can be filled to capacity. For example, at a DDGS sales price of $50/ton, 100% pelleting will reduce shipping costs (both direct and indirect) by 89% compared to shipping the DDGS in bulk form (i.e., no pelleting), whereas at a DDGS sales price of $200/ton, it will reduce costs by over 96%. It is clear that the sustainability of the ethanol industry can be improved by implementing pelleting technology for the coproducts, especially at those plants that ship their DDGS via rail.     

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.     

A continuous, farm-scale, solid-phase fermentation process for fuel ethanol and protein feed production from fodder beets

Fuel ethanol (95%) was produced from fodder beets in two farm-scale processes. In the first process, involving conventional submerged fermentation of the fodder beets in a mash, ethanol and a feed (PF) rich in protein, fat, and fiber were produced. Ethanol yields of 70 L/metric ton (7 gal/ton) were obtained; however, resulting beers had low ethanol concentrations [3-5% (v/v)]. The high viscosity of medium and low sugar, beet mashes caused mixing problems which prevented any further increase of beet sugar in the mash. The severely limited the maximum attainable ethanol concentration during fermentation, thereby making the beer costly to distill into fuel ethanol and the process energy inefficient. In order to achieve distillably worthwhile ethanol concentrations of 8-10% (v/v), we developed and tested a solid-phase fermentation process (continuous). In preliminary trials, this system produced fermented pulp with over 8% (v/v) ethanol corresponding to an ethanol yield of 87 L/metric ton (21 gal/ton). Production costs with this novel process are $0.47/L ($1.77/gal) and the energy balance is 2.11. These preliminary cost estimates indicate that fodder beets are potentially competitive with corn as an ethanol feedstock. Additional research, however, is warranted to more precisely refine individual costs, energy balances and the actual value of the PF.     

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.     

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.     

Vertical Distribution of Corn Stover Dry Mass Grown at Several US Locations

Corn (Zea mays L.) stover was identified as a renewable non-food agricultural feedstock for production of liquid fuels, biopower, and other bioproducts, but it is also needed for erosion control, carbon sequestration, and nutrient cycling. To help balance these multiple demands, our objectives were to (1) determine height distribution of corn stover biomass, (2) quantify the percentage of stover that is corn cob, and (3) develop a general relationship between plant harvest height and stover remaining in the field for a broad range of growing conditions, soil types, and hybrids in different regions. Plant height, dry grain, stover, and cob yield data were collected at eight US locations. Overall, stover yield increased about 0.85 Mg ha^-1 and cob yield increased about 0.10 Mg ha^-1 for each 1.0 Mg ha^-1 increase in dry grain yield. At grain harvest, the stover-to-grain ratio ranged from 0.64 to 0.96 and cob-to-grain ratio ranged from 0.11 to 0.19. A strong nearly 1:1 linear (r ²?=?0.93) relationship between the relative cutting height and relative biomass remaining in the field was observed across all sites. These data were requested by the US Department of Agriculture-Natural Resource Conservation Service to help improve version 2 of the Revised Universal Soil Loss Equation (RUSLE2) and Wind Erosion Prediction System and better estimate corn stover harvest rates based on cutting height or selective organ harvest (e.g., grain and cob only). This information will improve the capacity of RUSLE2 and similar models to predict the erosion risk associated with harvesting corn residues.     

The conversion of the corn/soybean ecosystem to no-till agriculture may result in a carbon sink

Mitigating or slowing an increase in atmospheric carbon dioxide concentration ([CO₂]) has been the focus of international efforts, most apparent with the development of the Kyoto Protocol. Sequestration of carbon (C) in agricultural soils is being advocated as a method to assist in meeting the demands of an international C credit system. The conversion of conventionally tilled agricultural lands to no till is widely accepted as having a large-scale sequestration potential. In this study, C flux measurements over a no-till corn/soybean agricultural ecosystem over 6 years were coupled with estimates of C release associated with agricultural practices to assess the net biome productivity (NBP) of this no-till ecosystem. Estimates of NBP were also calculated for the conventionally tilled corn/soybean ecosystem assuming net ecosystem exchange is C neutral. These measurements were scaled to the US as a whole to determine the sequestration potential of corn/soybean ecosystems, under current practices where 10% of agricultural land devoted to this ecosystem is no-tilled and under a hypothetical scenario where 100% of the land is not tilled. The estimates of this analysis show that current corn/soybean agriculture in the US releases ∼7.2 Tg C annually, with no-till sequestering ∼2.2 Tg and conventional-till releasing ∼9.4 Tg. The complete conversion of land area to no till might result in 21.7 Tg C sequestered annually, representing a net C flux difference of ∼29 Tg C. These results demonstrate that large-scale conversion to no-till practices, at least for the corn/soybean ecosystem, could potentially offset ca. 2% of annual US carbon emissions.     

Control of the Soybean Cyst Nematode by Crop Rotation in Combination with a Nematicide

An experiment to evaluate the control of soybean cyst nematodes compared 1-year, 2-year, and 3-year nonhost rotations with continuous soybeans (Glycine max) in 0.2-ha plots. In a second 1-year rotation, the plots were planted to soybean or corn (Zea mays) after fumigation in the spring with a split application of 1,3-dichloropropene (748.2 liters/ha). The effects of the nematicide were apparent the first year. Soybean yield was 1,482 kg/ha compared to 233 kg/ha in the untreated plots. In the second year, the highest yielding plants (2,035 kg/ha) were those following 1 year of corn that had been treated the previous year; plants in untreated plots yielded 288 kg/ha. Average yield of soybean following 1 year of corn was 957 kg/ha compared to 288 kg/ha for continuous soybean. In the third year, the effects of the nematicide were still evident. Soybean plants in plots treated the first year, followed by corn, then soybean, yielded 1,044 kg/ha compared to 761 kg/ ha for soybean following 1 year of corn and 991 kg/ha for soybean following 2 years of corn. Plots planted to soybean for 3 consecutive years yielded 337 kg/ha. Nematicidal effects were no longer evident during the fourth year. Yields were most improved by the greatest number of years in the nonhost crop; highest yields in descending order were from plants following 3 years of corn, 2 years of corn, and 1 year of corn. Plots planted to soybean for 4 consecutive years yielded 130 kg/ha. Highly significant negative correlations occurred each year between initial nematode population densities and seed yield.     

Modeled Impacts of Cover Crops and Vegetative Barriers on Corn Stover Availability and Soil Quality

Environmentally benign, economically viable, and socially acceptable agronomic strategies are needed to launch a sustainable lignocellulosic biofuel industry. Our objective was to demonstrate a landscape planning process that can ensure adequate supplies of corn (Zea mays L.) stover feedstock while protecting and improving soil quality. The Landscape Environmental Assessment Framework (LEAF) was used to develop land use strategies that were then scaled up for five U.S. Corn Belt states (Nebraska, Iowa, Illinois, Indiana, and Minnesota) to illustrate the impact that could be achieved. Our results show an annual sustainable stover supply of 194 million Mg without exceeding soil erosion T values or depleting soil organic carbon [i.e., soil conditioning index (SCI)?>?0] when no-till, winter cover crop, and vegetative barriers were incorporated into the landscape. A second, more rigorous conservation target was set to enhance soil quality while sustainably harvesting stover. By requiring erosion to be <1/2 T and the SCI-organic matter (OM) subfactor to be >?0, the annual sustainable quantity of harvestable stover dropped to148 million Mg. Examining removal rates by state and soil resource showed that soil capability class and slope generally determined the effectiveness of the three conservation practices and the resulting sustainable harvest rate. This emphasizes that sustainable biomass harvest must be based on subfield management decisions to ensure soil resources are conserved or enhanced, while providing sufficient biomass feedstock to support the economic growth of bioenergy enterprises.     

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%.     

Techno‐economic analysis for incorporating a liquid–liquid extraction system to remove acetic acid into a proposed commercial scale biorefinery

Mitigating the effect of fermentation inhibitors in bioethanol plants can have a great positive impact on the economy of this industry. Liquid–liquid extraction (LLE) using ethyl acetate is able to remove fermentation inhibitors—chiefly, acetic acid—from an aqueous solution used to produce bioethanol. The fermentation broth resulting from LLE has higher performance for ethanol yield and its production rate. Previous techno‐economic analyses focused on second‐generation biofuel production did not address the impact of removing the fermentation inhibitors on the economic performance of the biorefinery. A comprehensive analysis of applying a separation system to mitigate the fermentation inhibition effect and to provide an analysis on the economic impact of removal of acetic acid from corn stover hydrolysate on the overall revenue of the biorefinery is necessary. This study examines the pros and cons associated with implementing LLE column along with the solvent recovery system into a commercial scale bioethanol plant. Using details from the NREL‐developed model of corn stover biorefinery, the capital costs associated with the equipment and the operating cost for the use of solvent were estimated and the results were compared with the profit gain due to higher ethanol production. Results indicate that the additional capital will add 1% to the total capital and manufacturing cost will increase by 5.9%. The benefit arises from the higher ethanol production rate and yield as a consequence of inhibitor extraction and results in a $0.35 per gallon reduction in the minimum ethanol selling price (MESP). © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 32:971–977, 2016     

The Role of Calcium in Mediating Smut Disease Severity and Salt Tolerance in Corn under Chloride and Sulphate Salinity

The effect of sahne irrigation water containing NaCl or Na₂SO₄ with and without CaSO₄ application on the gram yield, smut index and plant nutrient contents of two intermediate smut-susceptible corn cultivars was investigated in cemented plots containing sandy loam soil. The plants were artificially infected and the disease severity was rated. At the end of silking stage, the leaf C1, Na and Ca contents were detected and Ca/Na ratio was calculated. At harvest, the grain yield of smut-free and smutted plants was recorded. The results showed that Na₂SO₄-treated plants had a greater yield advantage than those exposed to NaCl-treatments. The inclusion of CaSO₄ was beneficial to both salinity types and improved the yield potential. Similarly, smut susceptibility was reduced by 10.8% for the Na₂SO₄-stressed plants, compared with 22.7% for NaCl treatment. The comparable reductions in disease severity associated with Ca supply dropped to 33.0 and 17.0%, respectively, indicating the beneficial contribution of a Ca supply on the mediating disease reaction. Although the smut index was markedly decreased as the leaf C1 content increased in Ca-deficient plants subjected to saline irrigation water without Ca supply, the increase in the Ca/Na ratio in plant tissue, associated with supplemental CaSO₄ application to each salinity type, appeared to have an additive effect on smut disease control and salt tolerance.     

Economics and Energy of Ethanol Production from Alfalfa, Corn, and Switchgrass in the Upper Midwest, USA

In the USA, biomass crop systems will be needed to meet future ethanol production goals. We estimated production costs, profits, and energy budgets for three potential crop systems for the Upper Midwest: continuous corn with stover harvest, an alfalfa–corn rotation with stover harvest, and switchgrass. Production costs, profits, and on-farm energy use were greatest for continuous corn, less for alfalfa–corn, and least for switchgrass. Energy to transport crops was similar for all crop systems. Both energy used to produce ethanol and energy output in ethanol was greatest for continuous corn, less for alfalfa–corn, and least for switchgrass. Co-product energy output was 32% greater for alfalfa–corn than continuous corn and 42% greater than switchgrass. Net energy produced (outputs–inputs) was greatest for switchgrass, followed by continuous corn, and then alfalfa–corn. Efficiency of energy production (outputs/inputs) was greatest for switchgrass, followed by alfalfa–corn, and then continuous corn. Our analysis emphasizes tradeoffs among crop systems. Corn may produce high rates of ethanol and net energy, but will do so least efficiently and with the greatest erosion and N leaching. Corn may have the greatest production costs, but return the greatest profit. Comparatively, alfalfa–corn will produce less ethanol and net energy, but will do so more efficiently, and with less erosion and little N leaching. Production costs, but also profits, may be less for alfalfa–corn than continuous corn. Switchgrass may produce the most net energy and will do so most efficiently and with the least erosion, but will also yield the least ethanol. Nitrogen leaching will be less for switchgrass than corn, but greater than alfalfa–corn. Switchgrass may be the least expensive to produce, but may return a profit only if selling prices or yields are high.