ALFALFA AS BIOMASS FEEEDSTOCK: ENGINEERING PERSPECTIVES. Increasing Alfalfa in Corn Belt. Increasing Local Markets. Commercial Hay Production

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1 ALFALFA AS BIOMASS FEEEDSTOCK: ENGINEERING PERSPECTIVES Increasing Alfalfa in Corn Belt Increase local market move dairies Develop commercial hay businesses 29 and 30 June, 2010 Alfalfa/Corn Rotations for Sustainable Cellulosic Biofuels Production Johnston, IA Dr. Kevin Shinners University of Wisconsin Madison Create value added products for new markets Exploiting compositional differences Increasing Local Markets Shifting dairy industry is difficult : Capital intensive Lacking local infrastructure Commercial Hay Production Commercial hay has good potential: Market already exists Shipping distance shorter LSB low labor requirements Compared to corn: Profit potential greater 1

2 Creating Value Added Products Dual use alfalfa for feed and biomass feedstock. Exploit fractional compositional differences: Dry, wet or harvest fractionation Cut & Swath Field Cure & Rake Bale Store Load Gather & Unload Unload Convey Dehydrate Remove Twine Initial Screening Decompose Bale Collection Hammermill Final Screening Pelletization Cubing ALM Storage Storage 2

3 Positive Attributes of : Year around operation! Can fine tune composition Maturity less of concern Dry product & marketing Negative Attributes of : ALM market only as feed Weather losses Many non value added steps Energy & capital intensive Negative Attributes of : Bales should be covered: LRB variable moisture & composition, losses LSB no outdoor storage Assumptions: 4 ton/h; 10,000 ton/year Values adjusted for inflation Capital ~$600k Fixed Costs $15/ton Variable Costs $45/ton Total Cost $60/ton After Gray and Kaan,

4 Unknown Attributes of : Will ALM be competitive with SBOM? Alfalfa 17% protein $195/ton Direct Cut Macerate Express Juice 47% protein $290/ton Juice ~ 25% of DM Cake ~ 75% of DM Press Cake (60 65% MC) Juice Direct Ensile Process On-Farm Animal Feed Protein Coagulation Protein Coagulation Cellulosic Feedstock Protein Brown Juice Separation Brown Juice Process Protein Fertilizer Purify, Dry Pocess 4

5 Positive Attributes of : Weather independence Many high value products Ensiled system: Year round operation 5

6 Negative Attributes of : Seasonal operation Many technologies required High moisture Preservation 6

7 ALM Source: (Preston, 2006) Positive Attributes of : Components never co mingled ation costs may be reduced Single day harvesting possible Less weather risks Fewer issues w/ maturity Negative Attributes of : Leaves are very wet Preservation direct ensile at < 25% DM (Muck et al., 2010) What is market for wet leaves? Custom blended rations possible 7

8 Potential Research Needs : Develop on farm fractionation technology: Potential Research Needs : Fast drying schemes maceration/mat formation Using leaf stripper concepts but after field wilting Potential Research Needs : Develop cost effective on farm processing systems Alternative Value Added Scheme Harvest Fractionation Combine with harvest fractionation : Develop scaled direct ensiling systems More fully develop stripping technology Leaves Stems 8

9 Alternative Value Added Scheme Alternative Value Added Scheme Stems Moisture.. % w.b. Fraction of DM.. % Juice Solids Wilt Field Dry Initial Final Press Cake Juice % DM WP - Macerated Chop Bale Leaf Macerated Ensile Store Leaf - Unmacerated Animal Roughage Biomass Feedstock Alternative Value Added Scheme Leaves ALFALFA AS BIOMASS FEEEDSTOCK: ENGINEERING PERSPECTIVES Express Juice Leaf Press Cake (60 65% MC) Protein Coagulation Direct Ensile Protein Process Protein Brown Juice Fertilizer Animal Feed Biomass Feedstock 29 and 30 June, 2010 Alfalfa/Corn Rotations for Sustainable Cellulosic Biofuels Production Johnston, IA Dr. Kevin Shinners University of Wisconsin Madison 9