Final Technical Report

Abstract

The two main objectives of this project were: 1) to develop and test technologies to harvest, transport, store, and separate corn stover to supply a clean raw material to the bioproducts industry, and 2) engineer fermentation systems to meet performance targets for lactic acid and ethanol manufacturers. Significant progress was made in testing methods to harvest corn stover in a “single pass” harvest mode (collect corn grain and stover at the same time). This is technically feasible on small scale, but additional equipment refinements will be needed to facilitate cost effective harvest on a larger scale. Transportation models were developed, which indicate that at a corn stover yield of 2.8 tons/acre and purchase price of $35/ton stover, it would be unprofitable to transport stover more than about 25 miles; thus suggesting the development of many regional collection centers. Therefore, collection centers should be located within about 30 miles of the farm, to keep transportation costs to an acceptable level. These collection centers could then potentially do some preprocessing (to fractionate or increase bulk density) and/or ship the biomass by rail or barge to the final customers. Wet storage of stover via ensilage was tested, but no clear economic advantages were evident. Wet storage eliminates fire risk, but increases the complexity of component separation and may result in a small loss of carbohydrate content (fermentation potential). A study of possible supplier-producer relationships, concluded that a “quasi-vertical” integration model would be best suited for new bioproducts industries based on stover. In this model, the relationship would involve a multiyear supply contract (processor with purchase guarantees, producer group with supply guarantees). Price will likely be fixed or calculated based on some formula (possibly a cost plus). Initial quality requirements will be specified (but subject to refinement).Producers would invest in harvest/storage/transportation equipment and the processor would build and operate the plant. Pilot fermentation studies demonstrated dramatic improvements in yields and rates with optimization of batch fermentor parameters. Demonstrated yields and rates are approaching those necessary for profitable commercial operation for production of ethanol or lactic acid. The ability of the biocatalyst to adapt to biomass hydrolysate (both biomass sugars and toxins in the hydrolysate) was demonstrated and points towards ultimate successful commercialization of the technology. However, some of this work will need to be repeated and possibly extended to adapt the final selected biocatalyst for the specific commercial hydrolysate composition. The path from corn stover in the farm field to final products, involves a number of steps. Each of these steps has options, problems, and uncertainties; thus creating a very complex multidimensional obstacle to successful commercial development. Through the tasks of this project, the technical and commercial uncertainties of many of these steps have been addressed; thus providing for a clearer understanding of paths forward and commercial viability of a corn stover-based biorefinery.