Processing Methods to Improve the Feed Value of Perennial Grasses

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Vincent Bishop
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1 Processing Methods to Improve the Feed Value of Perennial Grasses Michael Cecava, Director of Feed Technology Research Archer Daniels Midland Company GLBW Bioenergy and Sustainable Agriculture Workshop: Perennial Biomass Crops for Multiple Benefits November 18 20, 2014, Decatur, Illinois ARCHER DANIELS MIDLAND COMPANY 1

2 Vision for Biomass Corn fiber Corn stover Energy crops Wood Sugarcane Sugars Hydrocarbon fuels Chemicals Feed Food Cellulosic products from a variety of feedstocks ARCHER DANIELS MIDLAND COMPANY 2

3 Carbohydrate and lignin composition of herbaceous biomass An abundant source of carbohydrates and lignin Lignin inversely related to animal feed value Cellulose (Percent) Hemi cellulose (Percent) Lignin (Percent) Corn stover Sweet sorghum Switchgrass Miscanthus Giant Reed Source: Oak Ridge National Laboratory, Bioenergy Feedstock Development Program ARCHER DANIELS MIDLAND COMPANY 3

difficult to convert - as nature intended.

4 Biomass to carbohydrate Difficult conversion, difficult purification Protein Oil 4% 3% Ash 6% Other 2% Cellulose 38% Lignin 18% Hemicellulose 25% The stability of structural materials in plants make them difficult to convert - as nature intended. Depolymerizing and purifying biomass have become the Holy Grail of major segments of the renewable industry..is there a solution? ARCHER DANIELS MIDLAND COMPANY 4

5 The original biomass bio converter Ruminant Bioreactor: Biomass Input ~ 26 Lb/Day Rumen capacity per cow ~ 40 Gal Fermenter ARCHER DANIELS MIDLAND COMPANY 5

6 Processing methods to improve biomass digestion by animals ARCHER DANIELS MIDLAND COMPANY 6

7 Alkaline treatment Alkali treatment processes: NaOH (caustic soda) NaOH + CaO or CaOH 2 (lime) Ammonia Advantages of lime treatment Handling & Safety (less caustic than NaOH) Environmental (Ca has less impact on soils than Na) ARCHER DANIELS MIDLAND COMPANY 7

8 Calcium hydroxide disrupts structure and enables enzyme accessibility Electron micrographs courtesy of MS Lime ARCHER DANIELS MIDLAND COMPANY 8

Reducing particle size increases reactive

50 (varies) (moisture and equipment affect

9 Reducing particle size increases reactive surface area For animal feed applications Preferred size of screen in grinder: 3 to 5 Mean particle size: ~ 0.50 (varies) (moisture and equipment affect size) Finer is better to a point ARCHER DANIELS MIDLAND COMPANY 9

10 Ground biomass can be treated in feed wagon Biomass should be hydrated to ~ 50% moisture before treatment Ground biomass Load into feed mixer Add water Add hydrated lime Store Discharge from mixer 5 to 10 minutes mixing Feed Grill ARCHER DANIELS MIDLAND COMPANY 10

11 Estimated costs to treat biomass DIY on farm process Biomass* $60 per dry ton Grinding (contract) $25 per dry ton (if grinding cost is $450/hr) Treatment + Storage $45 per dry ton (if lime costs $370/ton) TOTAL $130 per dry ton * fertilizer value + collection cost + transportation to feedlot ARCHER DANIELS MIDLAND COMPANY 11

12 Commercial scale alkaline processing Feasible to treat 20 to 60 dry tons per hour in continuous process ADM Research Demonstration with Corn Stover and Wheat Straw (Oregon, June, 2012) Bulk lime added to water Lime suspension applied Lime pumped to grinder Treated stover pile ARCHER DANIELS MIDLAND COMPANY 12

Commercial scale alkaline processing of biomass Value proposition for end user The actual treatment for continuous on farm processing averages about $36 per dry matter ton for grinding + chemicals

13 Commercial scale alkaline processing of biomass Value proposition for end user The actual treatment for continuous on farm processing averages about $36 per dry matter ton for grinding + chemicals The amount of total savings swings depending on commodity prices, but ADM estimates savings of $13.5 per finished beef animal Substitute corn silage Substitute hay Potentially replace corn Commercial processing contact: John Klein ADM Alliance Nutrition, Inc. Forage Products Business Manager Cell Fax john.klein@adm.com ARCHER DANIELS MIDLAND COMPANY 13

Thermo alkaline shearing process Produces highly digestible biomass

Continuous Mixer equipped with adjustable paddles and shearing plows Corn

C to 105 C under atmospheric pressure or slightly greater Moisture content

14 Thermo alkaline shearing process Produces highly digestible biomass Littleford Continuous Mixer The Littleford KM Series Ploughshare Continuous Mixer equipped with adjustable paddles and shearing plows Corn stover, wheat straw CaO, NaOH, fibrolytic enzymes Temperature of about 80 C to 105 C under atmospheric pressure or slightly greater Moisture content of 35 to 65% in process Reaction time ~ 10 to 20 minutes ARCHER DANIELS MIDLAND COMPANY 14

Thermo alkaline extrusion processing Feasible to create highly

Grinding and shearing Residues: Corn stover, wheat straw,

Moisture: ~35% Reaction time 5 to 15 seconds Temperatures: 100

15 Thermo alkaline extrusion processing Feasible to create highly digestible biomass Readco Twin Screw Extruder Fragmentation: Grinding and shearing Residues: Corn stover, wheat straw, cottonseed hulls, switchgrass Chemicals: Ca(OH) 2, NaOH, HCl0 3 Moisture: ~35% Reaction time 5 to 15 seconds Temperatures: C. Pressure: 20 psi (estimated) ARCHER DANIELS MIDLAND COMPANY 15

16 Can alkaline treatment improved the feed value of bioenergy crops? Effect of Calcium Hydroxide Treatment on Switch Grass A.S.Leaflet R Garland Dahlke, ISU Extension and Outreach Program, Specialist Stephanie Clark, CenUSA Bioenergy Intern Meagan Van Emon, Montana State Extension Beef Cow Calf Specialist Chris Clark, ISU Extension and Outreach Beef Field Specialist Material and Methods Mature corn stalks compared to late harvest switch grass Forages ground & mixed with water to achieve 40% moisture +/ calcium hydroxide at 7% wt:wt on dry matter basis Stored anaerobically in barrels for one week or four weeks Sampled and assayed for rumen digestion in cannulated steers ARCHER DANIELS MIDLAND COMPANY 16

17 Process for research scale treatment Tub grinder Mixer wagon with load cells Water and CaOH added Hydrate Lime product sold specifically for treating crop residues (MS Lime Company) Sealed for anaerobic storage Barrel packing Sealed barrels stored ARCHER DANIELS MIDLAND COMPANY 17

18 Similar chemical profile for mature switchgrass and corn stover (before treatment) Nutrient Corn Stover Switchgrass Dry matter, % Protein, % of DM NDF, % of DM (hemicellulose, cellulose, lignin) ADF, % of DM (cellulose, lignin) Ca, % of DM P, %of DM Source: Effect of Calcium Hydroxide Treatment on Switch Grass, Garland Dahlke, ISU Extension and Outreach Program Specialist, Stephanie Clark, CenUSA Bioenergy Intern, Meagan Van Emon, Montana State Extension Beef Cow Calf Specialist, Chris Clark, ISU Extension and Outreach Beef Field Specialist ARCHER DANIELS MIDLAND COMPANY 18

19 Lime treatment improved dry matter digestibility of forages Treated switchgrass roughly equal to untreated corn stover 90 SG CS SG T CS T Corn grain Rumen dry matter digestion, % % 24 % 36 % 48 Incubation time in rumen, hours Corn silage Alfalfa hay Grass hay (poor) Oat hulls Sawdust Source: Effect of Calcium Hydroxide Treatment on Switch Grass, Garland Dahlke, ISU Extension and Outreach Program Specialist, Stephanie Clark, CenUSA Bioenergy Intern, Meagan Van Emon, Montana State Extension Beef Cow Calf Specialist, Chris Clark, ISU Extension and Outreach Beef Field Specialist ARCHER DANIELS MIDLAND COMPANY 19

20 Extended storage did not benefit dry matter digestion One week of lime tempering is sufficient Rumen dry matter digestion, % 1wk 4wk SG CS SG T CS T SG = switchgrass, not treated; CS = corn stover, not treated SG T = lime treated swithgrass; CS T = lime treated corn stover Source: Effect of Calcium Hydroxide Treatment on Switch Grass, Garland Dahlke, ISU Extension and Outreach Program Specialist, Stephanie Clark, CenUSA Bioenergy Intern, Meagan Van Emon, Montana State Extension Beef Cow Calf Specialist, Chris Clark, ISU Extension and Outreach Beef Field Specialist ARCHER DANIELS MIDLAND COMPANY 20

21 Forage Quality of Miscanthus at Different Cutting Times N. Reitz, E. Sacks, and T.L. Felix Department of Animal Science & Department of Crop Science, College of ACES, University of Illinois at Urbana Champaign 3 Genotypes: M. xgiganteus Illinois M. sacchariflorus Blumel M. sinensis Emerald Shadow Effect of time and variety on NDF content Illinois Emerald Blumel 4 plot replications per genotype Samples taken every two weeks Total of 5 time points Time point 1 occurred May 21 st, 2013 NDF, % of DM Tp1 Tp2 Tp3 Tp4 Tp5 Time Point ARCHER DANIELS MIDLAND COMPANY 21

22 Miscanthus digestible fiber content declined over time Varieties exhibited different rate of decline N. Reitz, E. Sacks, and T.L. Felix Department of Animal Science & Department of Crop Science, College of ACES, University of Illinois at Urbana Champaign Effect of time and variety on rumen NDF digestion 70 Illinois Emerald Blumel 60 NDF Disappearance (%) Tp2 Tp3 Tp4 Tp5 Time Point ARCHER DANIELS MIDLAND COMPANY 22

23 Early harvest Miscanthus can be quality animal feed High amounts of protein and digestible dry matter (may not require pre treatment) Stage Date DM, % Protein, % Cell Walls, % Lignin, % In Vitro DM dig, % Immature June Immature June Prebloom June Prebloom July Prebloom July Early bloom July Mid bloom August Full bloom August Source: Bae et al Quality of forage from Miscanthesis senensis. J. Dairy Sci. 66: ARCHER DANIELS MIDLAND COMPANY 23

Corn processing coproducts are cost effective

Germ Meal Wet Distillers Grains (WDGS) & Modified

Grains with Solubles (DDGS) Golden Gluten Wet

24 Corn processing coproducts are cost effective complements to biomass Supply protein and energy in the ration Condensed Fermented Corn Extractives (Steep water) Corn Gluten Meal Corn Germ Meal Wet Distillers Grains (WDGS) & Modified Wet Distillers Grains (MWDGS) Distillers Dried Grains with Solubles (DDGS) Golden Gluten Wet Corn Gluten Feed Dry Gluten Feed Pellets ARCHER DANIELS MIDLAND COMPANY 24

25 Opportunity for biomass as animal feed Localized and low cost processing schemes are available today Advanced processing schemes for depot processing appear feasible On farm storage processing can be varied depending on moisture content and rations can be adjusted to account for variation Ash and mineral can be managed by feed formulation Foreign material (rocks, metal) may be unavoidable but probably will be worse for equipment than livestock Molds and mycotoxins are a problem especially for young stock and reproducing female stock, can technologies reduce microbial growth? Perennial biomasses can substitute roughages and potentially some amount of cereal grains depending on availability, quality and price ARCHER DANIELS MIDLAND COMPANY 25

26 Near term opportunity for lignocellulosicbiomass: The original biomass bio converter ARCHER DANIELS MIDLAND COMPANY 26

27 Providing ecosystem services Deere ADM Monsanto Corn stover storage trial 12 January 2010 ARCHER DANIELS MIDLAND COMPANY 27

28 Thank You! Questions? ARCHER DANIELS MIDLAND COMPANY 28

29 Processing Methods to Improve the Feed Value of Perennial Grasses Michael Cecava, Director of Feed Technology Research Archer Daniels Midland Company GLBW Bioenergy and Sustainable Agriculture Workshop: Perennial Biomass Crops for Multiple Benefits November 18 20, 2014, Decatur, Illinois ARCHER DANIELS MIDLAND COMPANY 29

Biomass Collection: A Challenge for Cellulosic Ethanol Production NSF FEW Nexus Workshop José Leboreiro, Ph.D. Rapid City October 19, 2015

Biomass Collection: A Challenge for Cellulosic Ethanol Production 2015 NSF FEW Nexus Workshop José Leboreiro, Ph.D. Rapid City October 19, 2015 Outline Introduction ADM Overview Biofuels Perspective on