Feedstock Engineering

Transcription

1 Feedstock Engineering Shahab Sokhansanj and Janet Cushman Bioenergy Feedstock Development Program Oak Ridge National Laboratory December 12, 2001 Lincoln Nebraska

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3 OBJECTIVES Reduce feedstock cost by improving the existing equipment and infrastructure - short term objective. Maximize the crop value through one-step harvesting, whole crop utilization, and integration with conversion facilities - mid to long term objective. Foster collaborative research efforts among researchers, processors, and equipment manufacturers to ensure a sustainable feedstock handling and delivery system.

4 I. Improve the existing collection, densification, and transportation science and technology Feedstock characterization quantity and quality Operational parameter - rate of work, reliability, timeliness Densification compacting, cubing Moisture control and management drying and safe storage Systems modeling and optimization

5 II. Develop innovative single step harvesting, densification, and transportation concepts Develop an integrated system that harvests the whole plant and fractionates it into its valuable components: grain, stalk, cobs, and leaves. Applies adequate residue to the soil for productivity and conservation precision farming Process the valuable components for storage and transport drying and/or densification

6 III. Integrate feedstock supply systems and bioconversion processes. Corn stover is pre-treated at the farm level, the substrate (in a slurry form) is transported to a central conversion plant the dairy model, the crude oil model Paradigm shift

7 CURRENT PROJECTS Moisture control University of Tennessee, Lester Pordesimo To determine the drying rate of corn stover: cob, leaf, husk, and stalk in the field and by artificial drying

8 HIGH TEMPERATURE DRYING RATE Drying of old stover (cut into pieces) at 60 o C. Moisture content (%wb) Cob 0.40 Stalk Time (hrs)

9 DRYING RATE IN THE FIELD BEFORE HARVEST Moisture content of plant components during harvest season Moisture content (%wb) Stalk Cob Grain Husk Leaf 7-Aug 17-Aug 27-Aug 6-Sep 16-Sep Dates

10 BIOMASS ESTIMATION Typical correlationmatrix for corn plant Diam 1 Diam 2 Stalk wt Grain wt Cob wt Height Diam 1 1 Diam Stalk wt Grain wt Cob wt Height

11 CURRENT PROJECTS Innovation in corn stover harvesting CEA and University of Wisconsin, Jim Hettenhaus and Kevin Shinners To evaluate innovative corn stover collection techniques and recommend feasible technologies Harvest, handling and densification for commercial processing of biomass feedstock Iowa State University, Graeme Quick To design and build one pass combine harvester for corn grain and stover at any moisture content

12 Combined Systems Developed International Harvester 1460 Axial Flow Combine with Row Bean Head Collects the Whole Plant Harvests and Separates Grain From Stover Stover Conveyed to Hesston Stakhand 10 Density of Stover Increased Dirt Free Collection

13 CURRENT PROJECTS Sensitivity analysis on the cost of stover collection BFDP ORNL, Anthony Turhollow, Robert Perlack, Shahab Sokhansanj To quantify the magnitude of change in the collection cost of stover due to change in operational variables (yield, density, hours of operation, speed)

14 Sensitivity of collection (windrow, bale, load, transport for 5 miles, stack) costs to operational variables Worst Base Best Yield, ton/ac $/ton Density, lb/ft 3 $/ton Operating hours $/ton 50% % % Combinations*, $/ton

15 CURRENT PROJECTS Field characterization of corn stover University of Kentucky, Mike Montrose, Sam McNeil, Scott Shearer, Tim Stombaugh, To quantify the amount and quality of corn stover that can be collected using the existing collection equipment

16 Yield Map 36 acres

17 Grid Data of Stover Distribution Stover to grain mass ratio 1:1

18 CURRENT PROJECTS Application analysis of commercial forage processing to feedstock processing for bioenergy BFDP ORNL, Anthony Turhollow, Robert Perlack, Mark Downing, Shahab Sokhansanj To investigate the current logistics of harvesting and processing operations for high density forage products as potential models for feedstock supply logistics

19 Alliances with Farm Equipment Industry Equipment Manufacturers Institute Farm Equipment Manufacturers Association John Deere Vermeer AGCO Case New Holland (with INEEL, ADM, U of Idaho) Farm equipment manufacturers are interested

20 PLANNED PROJECTS Densification technologies RFP To develop innovative technologies (sceince and engineering) for low cost densification of biomass Operational research data and modeling RFP to develop engineering management data (performance, service, timeliness) for field operations and for off the field operations applied to feedstock handling

21 PLANNED PROJECTS Measure of Performance for Engineering Projects (Feedstock) BFDP ORNL/NREL, Shahab Sokhansanj To develop indicators and baseline on which the progress in feedstock supply projects can be measured during Stage Gate reviews Bio-feedstock and equipment industry BFDP ORNL, Shahab Sokhansanj To development of a paper on the impact of feedstock collection and delivery system on manufacturing and related industries